Airworthiness Directives; Honeywell International Inc. ALF502L Series and ALF502R Series Turbofan Engines

[Federal Register Volume 71, Number 89 (Tuesday, May 9, 2006)]
[Rules and Regulations]
[Pages 26823-26826]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 06-4193]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 92-ANE-34-AD; Amendment 39-14584; AD 2006-09-13]
RIN 2120-AA64


Airworthiness Directives; Honeywell International Inc. ALF502L 
Series and ALF502R Series Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for Honeywell International Inc. ALF502L series and ALF502R series 
turbofan engines. That AD currently establishes stress rupture 
retirement life limits for certain third stage turbine discs used in 
conjunction with certain third stage turbine nozzles. This AD brings 
requirements forward and unchanged, from the previous AD for ALF502R 
series turbofan engines. Also, this AD establishes new reduced stress 
rupture retirement life limits for certain part numbers (P/Ns) of third 
stage turbine disc and shaft assemblies installed in ALF502L series 
turbofan engines. This AD also requires removing those same parts from 
service using a drawdown schedule. This AD results from a report of 
failure of a third stage turbine disc and shaft assembly, leading to 
turbine blade release and separation of the exhaust nozzle. We are 
issuing this AD to prevent total loss of engine power, in-flight engine 
shutdown, release of turbine blades, separation of the exhaust nozzle, 
and possible damage to the airplane.

DATES: This AD becomes effective June 13, 2006. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of June 13, 2006.

ADDRESSES: Contact Honeywell Engines, Systems & Services, Customer 
Support Center, M/S 26-06/2102-323, P.O. Box 29003, Phoenix, AZ 85038-
9003; telephone (800) 601-3099, for the service bulletins identified in 
this AD.
    You may examine the AD docket at the FAA, New England Region, 
Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA. You may examine the service bulletins, at the FAA, New 
England Region, Office of the Regional Counsel, 12 New England 
Executive Park, Burlington, MA.

FOR FURTHER INFORMATION CONTACT: Robert Baitoo, Aerospace Engineer, Los 
Angeles Aircraft Certification Office,

[[Page 26824]]

FAA, Transport Airplane Directorate, 3960 Paramount Blvd., Lakewood, CA 
90712-4137; telephone: (562) 627-5245, fax: (562) 627-5210.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR Part 39 
with a proposed airworthiness directive (AD). The proposed AD applies 
to Honeywell International Inc. ALF502L series and ALF502R series 
turbofan engines. We published the proposed AD in the Federal Register 
on November 2, 2005 (70 FR 66302). That action proposed to bring 
requirements forward and unchanged, from the previous AD for ALF502R 
series turbofan engines. Also, that action proposed to establish new 
reduced stress rupture retirement life limits for certain P/Ns of third 
stage turbine disc and shaft assemblies installed in ALF502L series 
turbofan engines. That action also proposed to require removing those 
same parts from service using a drawdown schedule.

Examining the AD Docket

    You may examine the AD Docket (including any comments and service 
information), by appointment, between 8 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. See ADDRESSES for the 
location.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We received no comments on the proposal or on 
the determination of the cost to the public.

Conclusion

    We have carefully reviewed the available data and determined that 
air safety and the public interest require adopting the AD as proposed.

Costs of Compliance

    There are about 180 Honeywell International, Inc. ALF502L, ALF502L-
2, ALF502L-2A, ALF502L-2C, ALF502L-3, and ALF502R series turbofan 
engines of the affected design in the worldwide fleet. We estimate the 
AD will affect 170 engines installed on airplanes of U.S. registry. We 
also estimate that it will take about 14 workhours per engine to 
perform the actions, and that the average labor rate is $65 per 
workhour. The prorated cost of a replacement third stage turbine disc 
and shaft assembly is estimated to be $40,000. Based on these figures, 
we estimate the total parts and labor cost of the AD on U.S. operators 
to be $6,954,700.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, Section 106, describes the 
authority of the FAA Administrator. Subtitle VII, Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    We are issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701, ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
rulemaking action.

Regulatory Findings

    We have determined that this AD will not have federalism 
implications under Executive Order 13132. This AD will not have a 
substantial direct effect on the States, on the relationship between 
the national government and the States, or on the distribution of power 
and responsibilities among the various levels of government.
    For the reasons discussed above, I certify that this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866;
    (2) Is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979); and
    (3) Will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared a summary of the costs to comply with this AD and 
placed it in the AD Docket. You may get a copy of this summary by 
sending a request to us at the address listed under ADDRESSES. Include 
``AD Docket No. 92-ANE-34-AD'' in your request.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the Federal Aviation Administration amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by removing Amendment 39-9163 (60 FR 
11621, April 3, 1995) and by adding a new airworthiness directive, 
Amendment 39-14584, to read as follows:

2006-09-13 Honeywell International Inc. (formerly AlliedSignal, Inc. 
and Textron Lycoming): Amendment 39-14584. Docket No. 92-ANE-34-AD.

Effective Date

    (a) This AD becomes effective June 13, 2006.

Affected ADs

    (b) This AD supersedes AD 95-04-11.

Applicability

    (c) This AD applies to Honeywell International Inc. (formerly 
AlliedSignal, Inc. and Textron Lycoming) ALF502L, ALF502L-2, 
ALF502L-2A, ALF502L-2C, and ALF502L-3 series turbofan engines with 
third stage turbine disc and shaft assemblies that have operated in 
the Honeywell Pre SB No. ALF502L 72-232 configuration. This AD also 
applies to ALF502R series engines. These engines are installed on, 
but not limited to, BAe Systems AVRO 146 and Bombardier (Canadair) 
CL600-1A11 series airplanes.

Unsafe Condition

    (d) This AD results from a report of failure of a third stage 
turbine disc and shaft assembly, leading to turbine blade release 
and separation of the exhaust nozzle. We are issuing this AD to 
prevent total loss of engine power, in-flight engine shutdown, 
release of turbine blades, separation of the exhaust nozzle, and 
possible damage to the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.

ALF502L Series Turbofan Engines

Determination of Third Stage Turbine Disc and Shaft Assembly Drawdown 
Schedule

    (f) For ALF502L series turbofan engines, determine if the third 
stage turbine disc and shaft assembly is currently operating in the 
Pre SB No. ALF502L 72-232 configuration as follows:
    (1) If a third stage turbine nozzle assembly, part number (P/N) 
2-141-120R56/-57 is installed, then Honeywell SB No. ALF502L 72-232 
has been complied with. Proceed to the drawdown schedule in 
paragraph (h) of this AD.
    (2) If any other third stage turbine nozzle assembly is 
installed, then the engine is in the Pre SB No. ALF502L 72-232 
configuration. Proceed to the drawdown schedule in paragraph (g) of 
this AD.

[[Page 26825]]

Drawdown Schedule for Third Stage Turbine Disc and Shaft Assemblies 
That Are Operating in the Pre SB No. ALF502L 72-232 Configuration

    (g) For ALF502L series turbofan engines, use the drawdown 
schedule described in the following Table 1, and replace with 
serviceable parts:

   Table 1.--Drawdown Schedule for Third Stage Turbine Disc and Shaft
            Assemblies in Pre SB ALF502L 72-232 Configuration
------------------------------------------------------------------------
                                     If hours-in-
For third stage turbine disc and   service (HIS) on
      shaft assembly P/Ns:        the effective date     Then remove:
                                    of this AD are:
------------------------------------------------------------------------
2-143-030-05, 2-143-030-08, 2-    (1) 5,200 or more   Within 50
 143-030-14, 2-143-030R21, 2-143-  HIS..               additional HIS.
 030-22, 2-143-030-23.            (2) 5,001 to 5,199  Before reaching
                                   HIS..               5,250 HIS.
                                  (3) 2,551 to 5,000  Within 250
                                   HIS..               additional HIS.
                                  (4) 2,550 or fewer  Before reaching
                                   HIS..               2,800 HIS.
------------------------------------------------------------------------

Determination of Drawdown Schedule for Third Stage Turbine Disc and 
Shaft Assemblies That Have Operated in Pre and Post SB No. ALF502L 72-
232 Configurations

    (h) For ALF502L series turbofan engines, with third stage 
turbine disc and shaft assemblies converted from Pre SB No. ALF502L 
72-232 configuration to Post SB No. ALF502L 72-232 configuration, do 
the following:
    (1) Determine the total HIS accumulated on the third stage 
turbine disc and shaft assembly at time of installation of third 
stage turbine nozzle assembly, P/N 2-141-120-R56/-57.
    (2) If the total is 2,800 HIS or more, use the drawdown schedule 
in Table 1 of this AD to remove the assembly from service.
    (3) If the total is fewer than 2,800 HIS, calculate the 
remaining service life using paragraphs 2.A. through 2.B.(4)(i) of 
the Accomplishment Instructions of Honeywell SB No. ALF502 72-0004, 
Revision 17, dated January 16, 2005.
    (i) For ALF502L series turbofan engines, use the drawdown 
schedule described in the following Table 2 to remove the assembly 
from service:

   Table 2.--Drawdown Schedule for Third Stage Turbine Disc and Shaft
 Assemblies Operated In Pre and Post SB No. ALF502L 72-232 Configuration
------------------------------------------------------------------------
                                     If HIS on the
For third stage turbine disc and   effective date of         Then:
  shaft assembly part numbers:       this AD are:
------------------------------------------------------------------------
(1) 2-143-030-05, 2-143-030-08,   (i) 30,000 or more  Remove within 50
 2-143-030-14.                     HIS..               additional HIS.
                                  (ii) 27,250 to      Remove within 250
                                   29,999 HIS..        additional HIS.
                                  (iii) Fewer than    Remove using
                                   27,250 HIS..        Tables 1 through
                                                       5 of Honeywell SB
                                                       No. ALF502 72-
                                                       0004, Revision
                                                       17, dated January
                                                       16, 2005.
(2) 2-143-030R21, 2-143-030-23..  (i) 24,650 or more  Remove within 50
                                   HIS..               additional HIS.
                                  (ii) 22,150 to      Remove within 250
                                   24,649 HIS..        additional HIS.
                                  (iii) Fewer than    Remove using
                                   22,150 HIS..        Tables 1 through
                                                       5 of Honeywell SB
                                                       No. ALF502 72-
                                                       0004, Revision
                                                       17, dated January
                                                       16, 2005.
(3) 2-143-030-22................  (i) 50,000 or more  Remove within 50
                                   HIS..               additional HIS.
                                  (ii) 49,750 to      Remove within 250
                                   49,999 HIS..        additional HIS.
                                  (iii) Fewer than    Remove using
                                   49,750 HIS..        Tables 1 through
                                                       5 of Honeywell SB
                                                       No. ALF502 72-
                                                       0004, Revision
                                                       17, dated January
                                                       16, 2005.
------------------------------------------------------------------------

ALF502R Series Turbofan Engines

Requirements Brought Forward, and Unchanged From AD 95-04-11

    (j) For ALF502R series turbofan engines, remove from service and 
replace with a serviceable part third stage turbine disks, P/Ns 2-
143-030-05, 2-143-030-08, and 2-143-030-14, as follows:
    (1) For disks that have been installed only with third stage 
turbine nozzles P/Ns 2-141-130-52 or 2-141-120-53, remove from 
service as follows:
    (i) For disks that have accumulated 13,220 or more hours time in 
service (TIS) since new on April 13, 1995 (the effective date of AD 
95-04-11), within the next 80 hours TIS after December 11, 1990, but 
not to exceed the existing cyclic life limit.
    (ii) For disks that have accumulated less than 13,220 hours TIS 
since new on April 13, 1995, before accumulating more than 13,300 
hours TIS since new, but not to exceed the existing cyclic life 
limit.
    (iii) Thereafter, remove disks before accumulating more than 
13,300 hours TIS since new, but not to exceed the existing cyclic 
life limit.
    (2) For disks that have been installed only with third stage 
turbine nozzles, P/Ns 2-141-120-57 or 2-141-120-R56, remove from 
service as follows:
    (i) For disks that have accumulated 27,420 or more hours TIS 
since new on April 13, 1995, within 80 hours TIS after April 13, 
1995, but not to exceed the existing cyclic life limit.
    (ii) For disks that have accumulated less than 27,420 hours TIS 
since new on April 13, 1995, before accumulating more than 27,500 
hours TIS since new, but not to exceed the existing cyclic life 
limit.
    (iii) Thereafter, remove disks before accumulating more than 
27,500 hours TIS since new, but not to exceed the existing cyclic 
life limit.
    (3) For disks that have been installed with both third stage 
turbine nozzles, P/Ns 2-141-120-52 or 2-141-120-120-53, and third 
stage turbine nozzles P/Ns 2-141-120-57 or 2-141-120-R56, remove 
from service as follows:
    (i) Determine the prorated hourly life limit using the procedure 
defined in the Accomplishment Instructions, Section 2.B.(2) of 
Textron Lycoming SB No. ALF 502 72-0002, Revision 22, dated December 
23, 1992. From this prorated hourly life limit, subtract 80 hours 
TIS to determine the compliance threshold.
    (ii) For disks that have equaled or exceeded the compliance 
threshold on April 13, 1995,

[[Page 26826]]

within the next 80 hours TIS, but not to exceed the existing cyclic 
life limit.
    (iii) For disks that have accumulated fewer than the compliance 
threshold on April 13, 1995, before accumulating more than the 
calculated prorated hourly life limit.
    (iv) Thereafter, remove disks at or before accumulating the 
prorated hourly life limit, but not to exceed the existing cyclic 
life limit.

Alternative Methods of Compliance

    (k) The Manager, Los Angeles Aircraft Certification Office, has 
the authority to approve alternative methods of compliance for this 
AD if requested using the procedures found in 14 CFR 39.19.

Special Flight Permits

    (l) Under 14 CFR part 39.23, we are limiting the special flight 
permits for this AD by allowing a onetime special flight if the disc 
life limit has been reached.

Related Information

    (m) Honeywell SB No. ALF/LF A72-1085, Revision 1, dated January 
16, 2005, pertains to the subject of this AD.

Material Incorporated by Reference

    (n) You must use the service bulletins listed in Table 3 of this 
AD to perform the inspections required by this AD. The Director of 
the Federal Register approved the incorporation by reference of this 
service bulletin in accordance with 5 U.S.C. 552(a) and 1 CFR part 
51. Contact Rolls-Royce plc, P.O. Box 31, Derby, DE248BJ; UK, 
telephone: 011-44-1332-242424; fax: 011-44-1332-249936, for a copy 
of this service information. You can review copies at the FAA, New 
England Region, Office of the Regional Counsel, 12 New England 
Executive Park, Burlington, MA; or at the National Archives and 
Records Administration (NARA). For information on the availability 
of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

                                      Table 3.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
        Service bulletin (SB) No.             Pages       Revision                       Date
----------------------------------------------------------------------------------------------------------------
Textron Lycoming SB No. ALF 502 72-0002..          1-2           22  December 23, 1992.
 Total Pages: 27
                                                     3           18  December 21, 1989.
                                                   4-7           22  December 23, 1992.
                                                     8           21  September 25, 1992.
                                                  9-10           22  December 23, 1992.
                                                    11           21  September 25, 1992.
                                                 12-26           22  December 23, 1992.
                                                    27           21  September 25, 1992.
Honeywell SB No. ALF502 72-0004..........            1           17  January 16, 2005.
 Total Pages: 30
                                                     2           16  November 7, 2003.
                                                     3           17  January 16, 2005.
                                                     4           16  November 7, 2003.
                                                  5-30           17  January 16, 2003.
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    Issued in Burlington, Massachusetts, on April 26, 2006.
Francis A. Favara,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 06-4193 Filed 5-8-06; 8:45 am]
BILLING CODE 4910-13-P

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