Airworthiness Directives; Rolls-Royce Corporation Turbofan Engines

[Federal Register Volume 79, Number 2 (Friday, January 3, 2014)]
[Rules and Regulations]
[Pages 344-346]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2013-30734]



[[Page 344]]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0811; Directorate Identifier 2008-NE-41-AD; 
Amendment 39-17715; AD 2013-26-06]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce Corporation Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are superseding airworthiness directive (AD) 2010-19-01 for 
certain Rolls-Royce Corporation (RRC) AE 3007A series turbofan engines. 
AD 2010-19-01 required removing certain high-pressure turbine (HPT) 
stage 2 wheels, or performing inspections on them, and reduced their 
approved life limits. This new AD clarifies the AE 3007A turbofan 
engine model applicability, further reduces the approved life limits of 
affected HPT stage 2 wheels, and eliminates the inspections required by 
the existing AD. This AD was prompted by additional analysis that 
concluded that lower life limits for the affected HPT stage 2 wheels 
are necessary. We are issuing this AD to prevent uncontained failure of 
the HPT stage 2 wheel, damage to the engine, and damage to the 
airplane.

DATES: This AD is effective February 7, 2014.

ADDRESSES: For service information identified in this AD, contact 
Rolls-Royce Corporation, 450 South Meridian Street, Mail Code NB-01-06, 
Indianapolis, IN 46225, phone: 317-230-1667; email: royce.com">CMSEindyOSD@rolls-royce.com; Internet: www.rolls-royce.com. You may view this service 
information at the FAA, Engine & Propeller Directorate, 12 New England 
Executive Park, Burlington, MA. For information on the availability of 
this material at the FAA, call 781-238-7125.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2009-
0811; or in person at the Docket Management Facility between 9 a.m. and 
5 p.m., Monday through Friday, except Federal holidays. The AD docket 
contains this AD, the regulatory evaluation, any comments received, and 
other information. The address for the Docket Office (phone: 800-647-
5527) is Document Management Facility, U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE., Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Kyri Zaroyiannis, Aerospace Engineer, 
Chicago Aircraft Certification Office, Small Airplane Directorate, FAA, 
2300 E. Devon Ave., Des Plaines, IL 60018; phone: 847-294-7836; fax: 
847-294-7834; email: [email protected].

SUPPLEMENTARY INFORMATION:

Discussion

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 to supersede AD 2010-19-01, Amendment 39-16429 (75 FR 57660, 
September 22, 2010), (``AD 2010-19-01''). AD 2010-19-01 applied to the 
specified products. The NPRM published in the Federal Register on 
August 8, 2013 (78 FR 48339). The NPRM proposed to clarify the AE 3007A 
turbofan engine model applicability, further reduce the approved life 
limits of affected HPT stage 2 wheels, and eliminate the inspections 
required by the existing AD.

Comments

    We gave the public the opportunity to participate in developing 
this AD. The following presents the comments received on the proposal 
and the FAA's response to each comment.

Request To Clarify Applicability

    One commenter indicated that the compliance section may lead the 
operator to remove all engines with HPT stage 2 wheels, part number (P/
N) 23074462, while only a few engines are affected. He noted that 
compliance paragraphs in previous ADs on HPT stage 2 wheels used tables 
to identify affected and non-affected wheels.
    We do not agree. The applicability section of this AD states that 
the AD applies to RRC AE 3007A, A1, A1/1, A1/2, A1/3, A1P, A1E, and A3 
turbofan engines with an installed HPT stage 2 wheel, P/N 23084520 or 
P/N 23069438, 23069592, 23074462, 23074644, or 23075345, except for the 
HPT stage 2 wheel serial numbers listed in Table 2 through Table 5 of 
RRC Alert Service Bulletin (ASB) No. AE 3007A-A-72-414, Revision 1, 
dated December 5, 2012. Therefore, as noted in the AD, operators do not 
need to remove engines with HPT stage 2 wheels, P/N 23074462 with the 
serial numbers listed in Table 2 through Table 5 of this ASB. We did 
not change this AD.

Request Not To Reduce Life Limits

    One commenter indicated that eddy current inspections (ECIs) or 
surface wave ultrasonic test (SWUT) inspections of the HPT stage 2 
wheels have proven satisfactory to this point as there have been no 
failures of engines in service worldwide. The commenter noted that 
reducing the life limit for these HPT stage 2 wheels is not justified.
    We do not agree. Per FAA risk guidelines as published in Advisory 
Circular (AC) No. 39-8 ``Continued Airworthiness Assessments Of 
Powerplant And Auxiliary Power Unit Installations Of Transport Category 
Airplanes,'' dated September 8, 2003 (online at http://www.faa.gov/documentLibrary/media/Advisory_Circular/AC39-8.pdf), we do not rely on 
recurring inspections to serve as a final corrective action unless 
there is no practicable alternative. In this case, analysis and testing 
performed on the affected wheels by RRC has shown that the life limit 
for the affected wheels must be reduced. We did not change this AD.

Request Not To Issue AD

    The same commenter noted that reduced life limits are already 
required based on an ASB published by RRC and incorporation of these 
life limits in the new RRC Engine Maintenance Manual (EMM), dated 
January 20, 2013. Operators have to consider these updates in their own 
maintenance programs. Therefore, an AD is not necessary.
    We do not agree. Companies cannot mandate that operators follow new 
life limits. AD compliance is mandatory. We did not change this AD.

Request To Revise the Cost of Compliance Estimate

    The same commenter requested that the FAA include the number of 
aircraft affected worldwide in its cost of compliance estimate. He also 
indicated that cost of compliance should include an estimated labor 
cost of $250 per engine for each HPT stage 2 wheel change.
    We do not agree. First, our ADs apply only to U.S. registered or 
operated products, not to products registered elsewhere. Therefore, 
costs to operators registered elsewhere are speculative.
    Second, our cost estimate in this AD is based on the pro-rated cost 
of the reduction in life to the wheel. The labor cost of replacing the 
wheel is the same as it would be if the life of the wheel had not been 
changed. We did not change this AD.

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Request To Continue Inspections and Related Compliance Issues

    The same commenter suggested revising the compliance section of 
this AD by continuing with ECIs and/or SWUT inspections at the interval 
required by AD 2010-19-01 (75 FR 57660, September 22, 2010) or if the 
inspections are not performed at the required interval, then (1) the 
new life limit published in the RRC EMM, dated January 20, 2013, shall 
be considered; (2) at the next engine shop visit or when the life limit 
is reached, the affected parts will be changed; and (3) no engine can 
be released from an engine shop with life limits that exceed those 
published in the RRC EMM, dated January 20, 2013.
    The commenter asked that if this change cannot be accepted, then 
RRC should be required to lend an engine to the operator free of charge 
and change the HPT wheels free of charge.
    The commenter also indicated that providing a grace period of 15 
cycles in service before removal of the engine for an issue that has 
been known and managed for the last 5 years without incident is not 
justified.
    We do not agree. Repetitive inspection of the affected HPT wheels 
is not a replacement for reduction in their life limit. As stated 
above, based on FAA risk guidelines as published in AC 39-8, we do not 
rely on recurring inspections to serve as a final corrective action 
unless there is no practicable alternative. In the case of these 
affected wheels, analysis has shown that the life of these wheels must 
be reduced. Second, requests for warranty support, i.e., that RRC 
provide a free lease engine and free replacement HPT stage 2 wheel are 
economic issues between the operator and the original equipment 
manufacturer. Third, successful performance of a part has no effect on 
the need to remove that part once it has reached its life limit. 
However, we are providing a 15-cycle allowance to minimize disruptions 
to operators. This grace period is supported by our risk assessment. We 
did not change this AD.

Conclusion

    We reviewed the relevant data, considered the comments received, 
and determined that air safety and the public interest require adopting 
this AD as proposed.

Costs of Compliance

    We estimate that this AD affects 18 engines installed on airplanes 
of U.S. registry. We also estimate that a replacement HPT stage 2 wheel 
costs about $145,524, and that it will be replaced during an engine 
shop visit at no additional labor cost. Based on these figures, we 
estimate the total cost of the AD to U.S. operators to be $2,619,432.

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),
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction, and
    (4) 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.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA 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 airworthiness directive (AD) 
2010-19-01, Amendment 39-16429 (75 FR 57660, September 22, 2010) and 
adding the following new AD:

2013-26-06 Rolls-Royce Corporation (Formerly Allison Engine 
Company): Amendment 39-17715; Docket No. FAA-2009-0811; Directorate 
Identifier 2008-NE-41-AD.

(a) Effective Date

    This AD is effective February 7, 2014.

(b) Affected ADs

    This AD supersedes AD 2010-19-01, Amendment 39-16429 (75 FR 
57660, September 22, 2010).

(c) Applicability

    This AD applies to the following Rolls-Royce Corporation (RRC) 
AE 3007A, A1, A1/1, A1/2, A1/3, A1P, A1E, and A3 turbofan engines:
    (1) With an installed high-pressure turbine (HPT) stage 2 wheel, 
part number (P/N) 23084520, or
    (2) With an installed HPT stage 2 wheel, P/N 23069438, 23069592, 
23074462, 23074644, or 23075345, except for the HPT stage 2 wheel 
serial numbers listed in Table 2 through Table 5 of RRC Alert 
Service Bulletin (ASB) No. AE 3007A-A-72-414, Revision 1, dated 
December 5, 2012. Those HPT stage 2 wheels maintain their existing 
approved life limits.

(d) Unsafe Condition

    This AD was prompted by additional analysis that concluded that 
lower life limits for the affected HPT stage 2 wheels are necessary. 
We are issuing this AD to prevent uncontained failure of the HPT 
stage 2 wheel, damage to the engine, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.
    (1) For HPT stage 2 wheels, P/N 23069438 and P/N 23069592, do 
the following:
    (i) For HPT stage 2 wheels that have 9,500 cycles since new 
(CSN) or more on the effective date of this AD, remove the HPT stage 
2 wheel from service within 15 cycles-in-service (CIS) after the 
effective date of this AD.
    (ii) After the effective date of this AD, do not approve for 
return to service any engine with an HPT stage 2 wheel, P/N 23069438 
or P/N 23069592, that exceeds the new life limit of 9,500 CSN.
    (2) For HPT stage 2 wheels, P/N 23074462, do the following:
    (i) For AE 3007A1E turbofan engines with HPT stage 2 wheels 
installed that have 7,500

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CSN or more on the effective date of this AD, and for the AE 3007A, 
A1, A1/1, A1/2, A1/3, A1P, and A3 turbofan engines with HPT stage 2 
wheels installed that have 9,500 CSN or more on the effective date 
of this AD, remove the wheel from service within 15 CIS after the 
effective date of this AD.
    (ii) Thereafter:
    (A) Do not approve for return to service any AE 3007A1E turbofan 
engine with an HPT stage 2 wheel, P/N 23074462, installed, that 
exceeds the new life limit of 7,500 CSN; and
    (B) Do not approve for return to service any AE 3007A, A1, A1/1, 
A1/2, A1/3, A1P, and A3 turbofan engines with an HPT stage 2 wheel, 
P/N 23074462, installed, that exceeds the new life limit of 9,500 
CSN.
    (C) Throughout the life of the HPT stage 2 wheel, always use the 
lowest life limit applicable to any engine model in which the part 
was used in service. If life usage records are not sufficient to 
identify all engine models in which the part has been flown, the 
lowest life applicable to any engine model for which the part is 
eligible must be used.
    (3) For HPT stage 2 wheels, P/N 23074644 and P/N 23075345, do 
the following:
    (i) For HPT stage 2 wheels that have 9,500 CSN or more on the 
effective date of this AD, remove the HPT stage 2 wheel from service 
within 15 CIS after the effective date of this AD.
    (ii) Thereafter, do not approve for return to service any engine 
with an HPT stage 2 wheel, P/N 23074644 or P/N 23075345, installed, 
that exceeds the new life limit of 9,500 CSN.
    (4) For HPT stage 2 wheels, P/N 23084520, do the following:
    (i) For HPT stage 2 wheels that have 23,000 CSN or more on the 
effective date of this AD, remove the HPT stage 2 wheel from service 
before the next flight after the effective date of this AD.
    (ii) Thereafter, do not approve for return to service any engine 
with an HPT stage 2 wheel, P/N 23084520, installed, that exceeds the 
new life limit of 23,000 CSN.

(f) Alternative Methods of Compliance

    The Manager, Chicago Aircraft Certification Office, may approve 
alternative methods of compliance for this AD. Use the procedures 14 
CFR 39.19 to make your request.

(g) Related Information

    (1) For more information about this AD, contact Kyri 
Zaroyiannis, Aerospace Engineer, Chicago Aircraft Certification 
Office, Small Airplane Directorate, FAA, 2300 E. Devon Ave., Des 
Plaines, IL 60018; phone: 847-294-7836; fax: 847-294-7834; email: 
[email protected].
    (2) RRC ASB No. AE 3007A-A-72-414, Revision 1, dated December 5, 
2012, which is not incorporated by reference in this AD, can be 
obtained from RRC, using the contact information in paragraph (g)(3) 
of this AD.
    (3) For service information identified in this AD, contact 
Rolls-Royce Corporation, 450 South Meridian Street, Mail Code NB-01-
06, Indianapolis, IN 46225, phone: 317-230-1667; email: 
royce.com">CMSEindyOSD@rolls-royce.com; Internet: www.rolls-royce.com.
    (4) You may view this service information at the FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, 
MA. For information on the availability of this material at the FAA, 
call 781-238-7125.

(h) Material Incorporated by Reference

    None.

    Issued in Burlington, Massachusetts, on December 17, 2013.
Colleen M. D'Alessandro,
Assistant Directorate Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2013-30734 Filed 1-2-14; 8:45 am]
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