Airworthiness Directives; Engine Alliance Turbofan Engines

[Federal Register Volume 84, Number 185 (Tuesday, September 24, 2019)]
[Rules and Regulations]
[Pages 49944-49947]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2019-20599]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2019-0692; Product Identifier 2018-NE-19-AD; Amendment 
39-19735; AD 2019-18-08]
RIN 2120-AA64


Airworthiness Directives; Engine Alliance Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is superseding Airworthiness Directive (AD) 2019-16-04 
for all Engine Alliance (EA) GP7270 and GP7277 model turbofan engines. 
AD 2019-16-04 required a visual inspection of the 1st-stage low-
pressure compressor (LPC) rotor assembly, referred to after this as the 
``engine fan hub assembly,'' for damage, a one-time eddy current 
inspection (ECI) of the engine fan hub blade slot bottom and blade slot 
front edge for cracks; and removal of parts if damage or defects are 
found. AD 2019-16-04 also required replacement of the engine fan hub 
blade lock assembly for certain GP7270 and GP7277 model turbofan 
engines. This AD, for certain GP7270 and GP7277 model turbofan engines, 
reduces the compliance time for the initial ECI and requires repetitive 
ECIs of the engine fan hub blade slot bottom and blade slot front edge 
for cracks. This AD also retains the visual inspection requirements of 
the engine fan hub assembly for all GP7270 and GP7277 model turbofan 
engines. This AD was prompted by an uncontained failure of the engine 
fan hub. The FAA is issuing this AD to address the unsafe condition on 
these products.

DATES: This AD is effective October 9, 2019.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of October 9, 
2019.
    The FAA must receive any comments on this AD by November 8, 2019.

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 
Engine Alliance, 411 Silver Lane, East Hartford, CT 06118; phone: 800-
565-0140; email: [email protected]; website: 
www.engineallianceportal.com. You may view this service information at 
the FAA, Engine and Propeller Standards Branch, 1200 District Avenue, 
Burlington, MA 01803. For information on the availability of this 
material at the FAA, call 781-238-7759. It is also available on the 
internet at http://www.regulations.gov by searching for and locating 
Docket No. FAA-2019-0692.

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-2019-
0692; or in person at Docket Operations between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays. The AD docket contains 
this final rule, the regulatory evaluation, any comments received, and 
other information. The street address for Docket Operations is listed 
above. Comments will be available in the AD docket shortly after 
receipt.

FOR FURTHER INFORMATION CONTACT: Matthew Smith, Aerospace Engineer, ECO 
Branch, FAA, 1200 District Avenue, Burlington, MA 01803; phone: 781-
238-7735; fax: 781-238-7199; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    The FAA issued AD 2019-16-04, Amendment 39-19707 (84 FR 41617, 
August 15, 2019), (``AD 2019-16-04''), for all EA GP7270 and GP7277 
model turbofan engines. AD 2019-16-04 required a visual inspection of 
the engine fan hub assembly for damage, a one-time ECI of the engine 
fan hub blade slot bottom and blade slot front edge for cracks, and 
removal of parts if damage or defects are found that are outside 
serviceable limits. AD 2019-16-04 required an independent inspection of 
the engine fan hub assembly prior to reassembly of the engine fan hub 
blade lock assembly. AD 2019-16-04 also required replacement of the 
engine fan hub blade lock assembly for certain serial-numbered GP7270 
and GP7277 model turbofan engines. AD 2019-16-04 resulted from the 
manufacturer's determination that an independent inspection of the fan 
hub assembly for damage was necessary prior to the reassembly of the 
engine fan hub blade lock assembly for all EA GP7270 and GP7277 model 
turbofan engines. The FAA issued AD 2019-16-04 to detect defects, 
damage, and cracks that could result in an uncontained failure of the 
engine fan hub assembly.

[[Page 49945]]

Actions Since AD 2019-16-04 Was Issued

    Since the FAA issued AD 2019-16-04, the manufacturer identified a 
fatigue crack originating inboard of a blade slot after the 
manufacturer performed a metallurgical examination of the engine fan 
hub that was recovered, related to the September 30, 2017 event. After 
performing a risk assessment, the manufacturer determined the need to 
reduce the compliance time for the initial ECI and add a repetitive 
ECI. The FAA is issuing this AD to address the unsafe condition on 
these products.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed EA Alert Service Bulletin (ASB) EAGP7-A72-389, 
Revision No. 5, dated August 23, 2019. The ASB describes procedures for 
ECI of the EA GP7270 and GP7277 model turbofan engines fan hub 
assembly. 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.

Other Related Service Information

    The FAA reviewed EA ASB EAGP7-A72-418, Revision No. 1, dated 
January 11, 2019. The ASB provides guidance on replacement or 
modification of the engine fan hub blade lock assembly.
    The FAA also reviewed the following service information:
    Subtask 72-31-42-210-001-A, of Task 72-31-42-000-802-A, from the 
A380 Aircraft Maintenance Manual (AMM). This subtask describes an on-
wing visual inspection that is to be performed after removal of the 
engine fan hub blade lock assembly.
    Figure 405 of Task 72-00-31-420-004 of the EA GP7000 Series Engine 
Manual (EM). This figure and task describe a visual inspection that is 
to be performed after removal of the engine fan hub blade lock assembly 
when the engine is in the shop.
    Subtask 72-00-00-210-012-A, of Task 72-00-00-210-806-A, from the 
A380 Aircraft Maintenance Manual (AMM). This subtask describes an on-
wing visual inspection that is to be performed after reassembly of the 
engine fan hub blade lock assembly.
    Task 72-00-31-420-004, Paragraph 1.E.(13), of the GP7000 Series EM 
describes a visual inspection that is to be performed after reassembly 
of the engine fan hub blade lock assembly when the engine is in the 
shop.
    Table 601 in Subtask 72-00-00-210-012-A, Task 72-00-00-210-806, 
from the A380 AMM or Task 72-00-31-220-010 of the EA GP7000 Series EM. 
Table 601 and Task 72-00-31-220-010 provide guidance on acceptable 
damage service limits.

FAA's Determination

    The FAA is issuing this AD because all the relevant information was 
evaluated and the FAA 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, for certain GP7270 and GP7277 model turbofan 
engines, an initial and repetitive ECI of the engine fan hub blade slot 
bottom and blade slot front edge for cracks. For all GP7270 and GP7277 
model turbofan engines, this AD also requires an independent inspection 
of the engine fan hub assembly prior to the reassembly of the engine 
fan hub blade lock assembly and a visual inspection of the engine fan 
hub assembly for damage. For certain serial-numbered GP7270 and GP7277 
model turbofan engines, this AD requires replacement of the engine fan 
hub blade lock assembly with a part eligible for installation.

FAA's Justification and Determination of the Effective Date

    No domestic operators use this product. Therefore, the FAA finds 
good cause that notice and opportunity for prior public comment are 
unnecessary. In addition, for the reason stated above, the FAA finds 
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 the FAA did not provide you with notice and an opportunity 
to provide your comments before it becomes effective. However, the FAA 
invites you to send any written data, views, or arguments about this 
final rule. Send your comments to an address listed under the ADDRESSES 
section. Include the docket number FAA-2019-0692 and product identifier 
2018-NE-19-AD at the beginning of your comments. The FAA specifically 
invites comments on the overall regulatory, economic, environmental, 
and energy aspects of this final rule. The FAA will consider all 
comments received by the closing date and may amend this final rule 
because of those comments.
    The FAA will post all comments received, without change, to http://www.regulations.gov, including any personal information you provide. 
The FAA will also post a report summarizing each substantive verbal 
contact received about this final rule.

Regulatory Flexibility Act

    The requirements of the Regulatory Flexibility Act (RFA) do not 
apply when an agency finds good cause pursuant to 5 U.S.C. 553 to adopt 
a rule without prior notice and comment. Because FAA has determined 
that it has good cause to adopt this rule without notice and comment, 
RFA analysis is not required.

Costs of Compliance

    The FAA estimates that this AD affects zero engines installed on 
airplanes of U.S. registry. We have revised the estimate of work hours 
to complete the ECI based on updated service information.
    The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
ECI...................................  20 work-hours x $85 per               $0          $1,700              $0
                                         hour = $1,700.
Visual inspection.....................  1 work-hour x $85 per                  0              85               0
                                         hour = $85.
Replace fan hub blade lock assembly...  25 work-hours x $85 per           28,000          30,125               0
                                         hour = $2,125.
----------------------------------------------------------------------------------------------------------------

    The FAA estimates the following costs to do any necessary 
replacements that would be required based on the results of the 
inspection. The FAA has no way of determining the number of engines 
that might need these replacements:

[[Page 49946]]



                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                    Action                                 Labor cost               Parts cost        product
----------------------------------------------------------------------------------------------------------------
Replace engine fan hub assembly...............  50 work-hours x $85 per hour =          $790,500        $794,750
                                                 $4,250.
----------------------------------------------------------------------------------------------------------------

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.
    The FAA is 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.
    This AD is issued in accordance with authority delegated by the 
Executive Director, Aircraft Certification Service, as authorized by 
FAA Order 8000.51C. In accordance with that order, issuance of ADs is 
normally a function of the Compliance and Airworthiness Division, but 
during this transition period, the Executive Director has delegated the 
authority to issue ADs applicable to engines, propellers, and 
associated appliances to the Manager, Engine and Propeller Standards 
Branch, Policy and Innovation Division.

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, and
    (2) Will not affect intrastate aviation in Alaska.

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 part 39 of the Federal Aviation 
Regulations (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) 
AD 2019-16-04, Amendment 39-19707 (84 FR 41617, August 15, 2019), and 
adding the following new AD:

2019-18-08 Engine Alliance: Amendment 39-19735; Docket No. FAA-2019-
0692; Product Identifier 2018-NE-19-AD.

(a) Effective Date

    This AD is effective October 9, 2019.

(b) Affected ADs

    This AD replaces AD 2019-16-04, Amendment 39-19707 (84 FR 41617, 
August 15, 2019) (``AD 2019-16-04'').

(c) Applicability

    This AD applies to all Engine Alliance (EA) GP7270 and GP7277 
model turbofan engines.

(d) Subject

    Joint Aircraft System Component (JASC) Code 7230, Turbine Engine 
Compressor Section.

(e) Unsafe Condition

    This AD was prompted by an uncontained failure of the engine fan 
hub. The FAA is issuing this AD to detect defects, damage, and 
cracks that could result in an uncontained failure of the engine fan 
hub assembly. The unsafe condition, if not addressed, could result 
in uncontained failure of the engine fan hub assembly, damage to the 
engine, and damage to the airplane.

(f) Compliance

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

(g) Required Actions

    (1) For EA GP7270 and GP7277 model turbofan engines with engine 
fan hub assembly part numbers (P/Ns) 5760221 or 5760321, within 
1,700 cycles since new, or within 150 flight cycles (FCs) after the 
effective date of this AD, or within 330 FCs since an eddy current 
inspection (ECI) was performed in accordance with the Accomplishment 
Instructions, For Fan Hubs at LPC Module Assembly Level, paragraphs 
2.A and 2.B, of EA ASB EAGP7-A72-389, Revision No. 4, dated June 14, 
2019, or earlier versions of that ASB; or within 330 FCs since 
overhaul, whichever occurs later:
    (i) For engine fan hub assemblies at the low-pressure compressor 
(LPC) module assembly level, perform an ECI of the engine fan hub 
blade slot bottoms and front edges in accordance with the 
Accomplishment Instructions, For Fan Hubs at LPC Module Assembly 
Level, paragraphs 1.B. and 1.C., of EA ASB EAGP7-A72-389, Revision 
No. 5, dated August 23, 2019.
    (ii) For engine fan hub assemblies at the piece part level, 
perform an ECI of the engine fan hub blade slot bottoms and front 
edges, in accordance with the Accomplishment Instructions, For Fan 
Hubs at Piece Part Level, paragraphs 1.A. and 1.B., of EA ASB EAGP7-
A72-389, Revision No. 5, dated August 23, 2019.
    (iii) For engine fan hub assemblies installed in an engine (on-
wing or off-wing), perform an ECI of the engine fan hub blade slot 
bottoms and front edges, in accordance with the Accomplishment 
Instructions, For Fan Hubs Installed in an Engine, paragraphs 3.B. 
and 3.C., of EA ASB EAGP7-A72-389, Revision No. 5, dated August 23, 
2019.
    (iv) Thereafter, repeat the ECI of the engine fan hub blade slot 
bottoms and front edges at intervals not exceeding 330 FCs since the 
previous ECI required by paragraphs (g)(1)(i) through (iii) of this 
AD, as applicable.
    (v) If any ECI of the engine fan hub assembly results in a 
rejectable indication per the Appendix, Added Data, of EA ASB EAGP7-
A72-389, Revision No. 5, dated August 23, 2019, remove the engine 
fan hub assembly from service and, before further flight, replace 
with a part that is eligible for installation.
    (2) For all GP7270 and GP7277 model turbofan engines, after the 
effective date of this AD:
    (i) At the next disassembly of the engine fan hub blade lock 
assembly, visually inspect the following areas for damage:
    (A) The fan hub blade lock retention hooks (also known as lock 
ring contact area); and
    (B) The fan hub rim face.
    (ii) At the next reassembly of the fan hub blade lock assembly, 
visually inspect the following areas of the engine fan hub for 
damage:
    (A) The fan hub scallop areas;
    (B) The fan hub bore area behind the balance flange;
    (C) The fan hub fan blade lock retention hooks;
    (D) The fan hub rim face; and
    (E) The clinch nut holes.
    (iii) After any reassembly per paragraph (g)(2)(ii), before 
further flight, perform an

[[Page 49947]]

independent inspection of all areas of the engine fan hub referenced 
in paragraph (g)(2)(ii) of this AD for damage.
    (iv) Thereafter, repeat the inspections required by paragraphs 
(g)(2)(i) through (iii) of this AD at each disassembly and 
reassembly of the engine fan hub blade lock assembly.
    (v) As an optional terminating action to the inspection 
requirements and independent inspection requirements of paragraph 
(g)(2)(i) through (iii) of this AD, insert the requirements for the 
visual inspections and independent inspections required by these 
paragraphs as Required Inspection Items in the approved continuous 
airworthiness maintenance program for the airplane.
    (vi) If damage is found outside serviceable limits during the 
inspections required by (g)(2)(i) through (iii) of this AD, before 
further flight, remove the engine fan hub assembly from service and 
replace it with a part eligible for installation.
    (3) For GP7270 and GP7277 model turbofan engines with engine 
serial numbers P550101 through P550706, remove the engine fan hub 
blade lock assembly, P/N 5700451, by September 1, 2020, and replace 
with a part eligible for installation. Refer to EA ASB EAGP7-A72-
418, Revision No. 1, dated January 11, 2019, for guidance on 
replacement of the engine fan hub blade lock assembly.

(h) Credit for Previous Actions

    You may take credit for the inspections required by paragraph 
(g)(1)(i) through (iii) of this AD if you performed the inspections 
before the effective date of this AD using EA ASB EAGP7-A72-389, 
Revision No. 4, dated June 14, 2019, or an earlier version.

(i) Definitions

    (1) For the purpose of this AD, a part eligible for installation 
for replacement of the engine fan hub blade lock assembly is:
    (i) A part that is not P/N 5700451, or
    (ii) An engine fan hub blade lock assembly that has been 
modified in accordance with EA ASB EAGP7-A72-418, Revision No. 1, 
dated January 11, 2019, or EA ASB EAGP7-A72-418, Revision No. 0, 
dated December 7, 2018.
    (2) For the purpose of this AD, an independent inspection is a 
second visual inspection performed by an individual qualified to 
perform inspections who was not involved in the original inspection 
of the engine fan hub assembly following disassembly and reassembly 
of the engine fan hub blade lock assembly.

(j) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, ECO Branch, 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 
certification office, send it to the attention of the person 
identified in paragraph (k) of this AD. You may email your request 
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) AMOCs approved for AD 2019-16-04, AD 2018-11-16 (83 FR 
27891, June 15, 2018), and AD 2019-03-04 (84 FR 4694, February 19, 
2019) are approved as AMOCs for the corresponding provisions of this 
AD.

(k) Related Information

    For more information about this AD, contact Matthew Smith, 
Aerospace Engineer, ECO Branch, FAA, 1200 District Avenue, 
Burlington, MA 01803; phone: 781-238-7735; fax: 781-238-7199; email: 
[email protected].

(l) 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) Engine Alliance (EA) Alert Service Bulletin EAGP7-A72-389, 
Revision No. 5, dated August 23, 2019.
    (ii) [Reserved]
    (3) For EA service information identified in this AD, contact 
Engine Alliance, 411 Silver Lane, East Hartford, CT 06118; phone: 
800-565-0140; email: [email protected]; website: 
www.engineallianceportal.com.
    (4) You may view this service information at the FAA, Engine & 
Propeller Standards Branch, 1200 District Avenue, Burlington, MA 
01803. For information on the availability of this material at the 
FAA, call 781-238-7759.
    (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, email: [email protected], or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued in Burlington, Massachusetts, on September 18, 2019.
Karen M. Grant,
Acting Manager, Engine & Propeller Standards Branch, Aircraft 
Certification Service.
[FR Doc. 2019-20599 Filed 9-23-19; 8:45 am]
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