Airworthiness Directives; The Boeing Company Airplanes

[Federal Register Volume 81, Number 53 (Friday, March 18, 2016)]
[Rules and Regulations]
[Pages 14704-14707]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2016-06117]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2016-4227; Directorate Identifier 2016-NM-025-AD; 
Amendment 39-18439; AD 2016-06-08]
RIN 2120-AA64


Airworthiness Directives; The Boeing Company Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

[[Page 14705]]


ACTION: Final rule; request for comments.

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SUMMARY: We are adopting a new airworthiness directive (AD) for The 
Boeing Company Model 787-8 and 787-9 airplanes powered by GE GEnx 
engines. This AD requires revising the airplane flight manual to 
provide the flight crew a new fan ice removal procedure to reduce the 
likelihood of engine damage due to fan ice shedding. This AD also 
requires, for certain airplanes, reworking the fan stator module 
assembly on GE GEnx-1B Performance Improvement Program (PIP) 2 engines. 
This AD was prompted by a recent engine fan blade rub event that caused 
an in-flight non-restartable power loss. We are issuing this AD to 
prevent reduced fan tip clearance, which could result in engine damage 
and a possible in-flight non-restartable power loss of one or both 
engines.

DATES: This AD is effective March 18, 2016.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of March 18, 
2016.
    We must receive comments on this AD by May 2, 2016.

ADDRESSES: You may send comments, using the procedures found in 14 CFR 
11.43 and 11.45, by any of the following methods:
    <bullet> Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
    <bullet> Fax: 202-493-2251.
    <bullet> Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
    <bullet> Hand Delivery: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590, between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays.
    For service information identified in this final rule, contact 
General Electric Company, GE Aviation, Room 285, 1 Neumann Way, 
Cincinnati, OH 45215; phone: 513-552-3272; email: [email protected]. You 
may view this referenced service information at the FAA, Transport 
Airplane Directorate, 1601 Lind Avenue SW., Renton, WA. For information 
on the availability of this material at the FAA, call 425-227-1221. It 
is also available on the Internet at http://www.regulations.gov by 
searching for and locating Docket No. FAA-2016-4227.

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-2016-
4227; 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 street address for the Docket Office (phone: 
800-647-5527) is in the ADDRESSES section. Comments will be available 
in the AD docket shortly after receipt.

FOR FURTHER INFORMATION CONTACT: Sue Lucier, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification Office 
(ACO), 1601 Lind Avenue SW., Renton, WA 98057-3356; phone: 425-917-
6438; fax: 425-917-6590; email: [email protected].

SUPPLEMENTARY INFORMATION:

Discussion

    We received a report of a significant GE GEnx-1B PIP2 engine fan 
rub event, apparently caused by partial fan ice shedding and a 
resulting fan imbalance that in turn caused substantial damage to the 
engine and an in-flight non-restartable power loss. We continue to 
investigate this issue with Boeing and GE; however, the engine damage 
appears to be a result of reduced fan tip clearances common to the 
GEnx-1B PIP2 engine. The other engine on the event airplane was a GEnx-
1B PIP1 configuration that incurred expected wear and minor damage 
during the icing event and continued to operate normally. The event 
occurred in icing conditions at an altitude of 20,000 feet. Reduced fan 
tip clearance, if not corrected, could result in engine damage and a 
possible in-flight non-restartable power loss of one or both engines. 
We are issuing this AD to correct the unsafe condition on these 
products.

Related Service Information Under 1 CFR Part 51

    We reviewed GE GEnx-1B Service Bulletin 72-0309 R00, dated March 
11, 2016, which describes procedures for reworking the fan stator 
module assembly on GEnx-1B PIP2 engines. This service information is 
reasonably available because the interested parties have access to it 
through their normal course of business or by the means identified in 
the ADDRESSES section.

FAA's Determination

    We are issuing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design.

AD Requirements

    This AD requires accomplishing the actions specified in the GE 
service information described previously. This AD also requires 
revising the airplane flight manual (AFM) to provide the flight crew a 
new fan ice removal procedure to reduce the likelihood of engine damage 
due to fan ice shedding.

Interim Action

    We consider this AD interim action. The engine manufacturer is 
currently developing a modification that will address the unsafe 
condition identified in this AD. Once this modification is developed, 
approved, and available, we may consider additional rulemaking.

FAA's Justification and Determination of the Effective Date

    An unsafe condition exists that requires the immediate adoption of 
this AD. The FAA has found that the risk to the flying public justifies 
waiving notice and comment prior to adoption of this rule because 
reduced fan tip clearance could result in engine damage and a possible 
in-flight non-restartable power loss of one or both engines. Therefore, 
we find that notice and opportunity for prior public comment are 
impracticable and that good cause exists for making this amendment 
effective in less than 30 days.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment. However, we invite you to send any written data, views, or 
arguments about this AD. Send your comments to an address listed under 
the ADDRESSES section. Include the docket number FAA-2016-4227 and 
Directorate Identifier 2016-NM-025-AD at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this AD. We will 
consider all comments received by the closing date and may amend this 
AD because of those comments.
    We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact we 
receive about this AD.

[[Page 14706]]

Costs of Compliance

    We estimate that this AD affects 34 airplanes of U.S. registry. We 
estimate the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                              Cost per          Cost on U.S.
              Action                     Labor cost          Parts cost        product           operators
----------------------------------------------------------------------------------------------------------------
AFM revision.....................  1 work-hour x $85 per               $0             $85  $2,890.
                                    hour = $85.
Rework...........................  40 work-hours x $85                  0           3,400  3,400 (1 affected
                                    per hour = $3,400.                                      airplane).
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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

    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, 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 adding the following new airworthiness 
directive (AD):

2016-06-08 The Boeing Company: Amendment 39-18439; Docket No. FAA-
2016-4227; Directorate Identifier 2016-NM-025-AD.

(a) Effective Date

    This AD is effective March 18, 2016.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to The Boeing Company Model 787-8 and 787-9 
airplanes, certificated in any category, powered by General Electric 
(GE) GEnx engines.

(d) Subject

    Air Transport Association (ATA) of America Code 72, Engines.

(e) Unsafe Condition

    This AD was prompted by a recent engine fan blade rub event that 
caused an in-flight non-restartable power loss. We are issuing this 
AD to prevent reduced fan tip clearance, which could result in 
engine damage and a possible in-flight non-restartable power loss of 
one or both engines.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Revision of Airplane Flight Manual (AFM): Certificate Limitations

    Within 7 days after the effective date of this AD, revise the 
Certificate Limitations chapter of the applicable Boeing 787 AFM to 
include the statement provided in figure 1 to paragraph (g) of this 
AD. This may be done by inserting a copy of this AD into the AFM.

                  Figure 1 to Paragraph (g) of This AD
------------------------------------------------------------------------
 
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Engine Operational Limits
 
Cold Weather Operations Fan Ice Removal
 
In order to avoid possible fan damage and engine failure, when in icing
 conditions above 12,500 feet MSL, the flight crew must comply with the
 Cold Weather Operations Additional Fan Ice Removal procedure contained
 in the Operating Procedures chapter of this manual.
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(h) AFM Revision: Operating Procedures

    Within 7 days after the effective date of this AD, revise the 
Operating Procedures chapter of the Boeing 787 AFM to include the 
statement provided in figure 2 to paragraph (h) of this AD. This may 
be done by inserting a copy of this AD into the AFM.

                  Figure 2 to Paragraph (h) of This AD
------------------------------------------------------------------------
 
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Cold Weather Operations
Additional Fan Ice Removal Procedure
 
This procedure is required when in icing conditions above 12,500 feet
 MSL, by the Engine Operational Limits Cold Weather Operations Fan Ice
 Removal limitation contained in the Certificate Limitations chapter of
 this manual. The language below shall not be modified.
 
During flight in icing conditions (EAI EICAS indication showing) with N1
 settings below 85%, or when fan icing is suspected due to high engine
 vibration, the fan blades must be cleared of any ice. Do the following
 procedure every 5 minutes on both engines, one engine at a time:
 Increase to a minimum of 85% N1 momentarily, then resume normal
 operation.
------------------------------------------------------------------------

(i) Rework

    For airplanes with two engines with engine serial numbers listed 
in paragraph 1.A., ``Effectivity,'' of GE GEnx-1B Service Bulletin 
72-0309 R00, dated March 11, 2016: On or before March 25, 2016, 
rework the fan stator module assembly of one of the engines, in 
accordance with paragraphs 3.A.(1)(b), 3.B., or 3.C. of the 
Accomplishment Instructions of GE GEnx-1B Service Bulletin 72-0309 
R00, dated March 11, 2016.

(j) Parts Installation Limitation

    As of March 25, 2016, no person may operate an airplane that has 
two engines with engine serial numbers listed in paragraph

[[Page 14707]]

1.A., ``Effectivity,'' of GE GEnx-1B Service Bulletin 72-0309 R00, 
dated March 11, 2016, unless at least one engine has been reworked 
in accordance with paragraph 3.A.(1)(b), 3.B., or 3.C. of the 
Accomplishment Instructions of GE GEnx-1B Service Bulletin 72-0309 
R00, dated March 11, 2016.

(k) Reporting Provisions

    Although GE GEnx Service Bulletin GEnx-1B 72-0309 R00, dated 
March 11, 2016, specifies reporting certain tip clearance 
measurements to GE, this AD does not require any report.

(l) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle Aircraft Certification Office (ACO), 
FAA, has the authority to approve AMOCs for this AD, if requested 
using the procedures found in 14 CFR 39.19. In accordance with 14 
CFR 39.19, send your request to your principal inspector or local 
Flight Standards District Office, as appropriate. If sending 
information directly to the manager of the ACO, send it to the 
attention of the person identified in paragraph (m) of this AD. 
Information may be emailed to: [email protected].
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any repair, modification, or alteration required by this AD 
if it is approved by the Boeing Commercial Airplanes Organization 
Designation Authorization (ODA) that has been authorized by the 
Manager, Seattle ACO, to make those findings. To be approved, the 
repair method, modification deviation, or alteration deviation must 
meet the certification basis of the airplane, and the approval must 
specifically refer to this AD.

(m) Related Information

    For more information about this AD, contact Sue Lucier, 
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle ACO, 
1601 Lind Avenue SW., Renton, WA 98057-3356; phone: 425-917-6438; 
fax: 425-917-6590; email: [email protected].

(n) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) GE GEnx-1B Service Bulletin 72-0309 R00, dated March 11, 
2016.
    (ii) Reserved.
    (3) For service information identified in this AD, contact 
General Electric Company, GE Aviation, Room 285, 1 Neumann Way, 
Cincinnati, OH 45215; phone: 513-552-3272; email: [email protected].
    (4) You may view this service information at the FAA, Transport 
Airplane Directorate, 1601 Lind Avenue SW., Renton, WA. For 
information on the availability of this material at the FAA, call 
425-227-1221.
    (5) You may view this service information that is incorporated 
by reference 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.


    Issued in Renton, Washington, on March 14, 2016.
Michael Kaszycki,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2016-06117 Filed 3-17-16; 8:45 am]
 BILLING CODE 4910-13-P

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