Airworthiness Directives; International Aero Engines AG Turbofan Engines

[Federal Register Volume 86, Number 108 (Tuesday, June 8, 2021)]
[Rules and Regulations]
[Pages 30380-30383]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2021-11960]



[[Page 30380]]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2021-0129; Project Identifier AD-2020-01597-E; 
Amendment 39-21577; AD 2021-11-15]
RIN 2120-AA64


Airworthiness Directives; International Aero Engines AG Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain International Aero Engines AG (IAE) V2500 model turbofan 
engines. This AD was prompted by an analysis performed by the 
manufacturer after an event involving an uncontained failure of a high-
pressure turbine (HPT) 1st-stage disk that resulted in high-energy 
debris penetrating the engine cowling. This AD requires the performance 
of an ultrasonic inspection (USI) of the HPT 1st-stage disk and HPT 
2nd-stage disk and, depending on the results of the inspections, 
replacement of the HPT 1st-stage disk or HPT 2nd-stage disk. The FAA is 
issuing this AD to address the unsafe condition on these products.

DATES: This AD is effective July 13, 2021.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in this AD as of July 13, 
2021.

ADDRESSES: For service information identified in this final rule, 
contact International Aero Engines AG, 400 Main Street, East Hartford, 
CT 06118; phone: (800) 565-0140; email: [email protected]; website: 
http://fleetcare.pw.utc.com. You may view this service information at 
the FAA, Airworthiness Products Section, Operational Safety 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 at https://www.regulations.gov by searching for and 
locating Docket No. FAA-2021-0129.

Examining the AD Docket

    You may examine the AD docket at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2021-0129; 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, any 
comments received, and other information. The address for Docket 
Operations is 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: Nicholas Paine, Aviation Safety 
Engineer, ECO Branch, FAA, 1200 District Avenue, Burlington, MA 01803; 
phone: (781) 238-7742; fax: (781) 238-7199; email: 
[email protected].

SUPPLEMENTARY INFORMATION:

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to certain IAE V2522-A5, 
V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, 
V2531-E5, and V2533-A5 model turbofan engines. The NPRM published in 
the Federal Register on March 8, 2021 (86 FR 13225). The NPRM was 
prompted by an event involving an uncontained failure of an HPT 1st-
stage disk that resulted in high-energy debris penetrating the engine 
cowling. On March 18, 2020, an Airbus Model A321-231 airplane, powered 
by IAE V2533-A5 model turbofan engines, experienced an uncontained HPT 
1st-stage disk failure that resulted in an aborted takeoff. The 
uncontained failure of the HPT 1st-stage disk resulted in high-energy 
debris penetrating the engine cowling. The FAA published Emergency AD 
2020-07-51 on March 21, 2020 (followed by publication in the Federal 
Register on April 13, 2020, as a Final Rule, Request for Comments (85 
FR 20402)) and AD 2021-01-03 on January 6, 2021 (86 FR 458), to remove 
from service HPT 1st-stage and HPT 2nd-stage disks identified as having 
the highest risk of failure. Based on the root cause analysis performed 
since that event, the manufacturer identified a population of HPT 1st-
stage disks and HPT 2nd-stage disks that require inspection and 
possible removal from service. In the NPRM, the FAA proposed to require 
the performance of a USI of the HPT 1st-stage disk and HPT 2nd-stage 
disk and, depending on the results of the inspections, replacement of 
the HPT 1st-stage disk or HPT 2nd-stage disk. The FAA is issuing this 
AD to address the unsafe condition on these products.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from three commenters. The commenters 
were Cathay Pacific Airways (Cathay), IAE, and an individual commenter. 
One commenter requested clarification on the compliance time for 
inspection. Another commenter requested clarification regarding 
additional inspections that are needed when parts are removed for piece 
part inspections. One commenter requested clarification regarding the 
definition of a part eligible for installation as well as the 
installation prohibition. An individual commenter supported the 
proposal without change. The following presents the comments received 
on the NPRM and the FAA's response to each comment.

Request To Clarify USI Interval for Different Thrust Ratings

    Cathay asked for clarification of the interval for performing the 
USI for any HPT 1st-stage disk or HPT 2nd-stage disk that has operated 
in different thrust ratings, such as from 27K to 33K, or 33K to 27K. 
Cathay reasoned that during the IAE V2500 Customer Council Call in 
December 2020, IAE used thrust ratings to indicate when to perform the 
inspections of the HPT 1st-stage disk or HPT 2nd-stage disk.
    The FAA reviewed IAE Non-Modification Service Bulletin (NMSB) No. 
V2500-ENG-72-0713, Revision 1, dated January 26, 2021 (IAE NMSB V2500-
ENG-72-0713, Revision 1). This revised NMSB was published after the IAE 
V2500 Customer Council Call in December 2020. The revised NMSB removed 
references to thrust ratings in the Compliance section. Therefore, this 
AD does not distinguish inspection intervals based on thrust ratings.

Request To Clarify Piece-Part Opportunity Inspection Requirements

    IAE requested clarification on whether an HPT 1st-stage disk and 
HPT 2nd-stage disk with fewer than 100 flight cycles (FCs) since the 
last piece-part fluorescent penetrant inspection (FPI) need to undergo 
another FPI if the same parts were removed for the piece-part 
opportunity USI in accordance with IAE NMSB V2500-ENG-72-0713, Revision 
1. IAE reasoned that the V2500 Maintenance Scheduling section of the 
Airworthiness Limitations Section (ALS) requires an FPI at each piece-
part opportunity.
    The FAA clarifies that when an HPT 1st-stage disk or an HPT 2nd-
stage disk is removed for piece-part inspection, the ALS of the 
manufacturer's Instructions for Continued Airworthiness may require 
additional inspections not required by this AD. The FAA refers the 
commenter to the ALS, which indicates that additional inspections are 
not required unless the part has more than

[[Page 30381]]

100 FCs since the last piece-part opportunity inspection, is damaged, 
or is the cause for the removal of the engine. Engine removal for the 
purposes of complying with this AD is not ``cause'' for engine removal 
as stated in the ALS. The FAA added a note to paragraph (g)(1) of this 
AD to clarify piece-part inspection requirements.

Request To Define Part Eligible for Installation

    Cathay requested that the FAA define ``part eligible for 
installation'' in this AD.
    The FAA agrees and added a definition of a ``part eligible for 
installation'' in this AD.

Request To Clarify Prohibition on Installation of Parts

    Cathay asked if there is a prohibition on the installation of parts 
in this AD.
    The FAA notes that if a HPT 1st-stage disk or HPT 2nd-stage disk 
does not pass the inspection required by paragraphs (g)(1) through (6) 
of this AD, the HPT 1st-stage disk or 2nd-stage disk, as applicable, 
must be removed from service. Any HPT 1st-stage disk or 2nd-stage disk 
that passes the inspection is eligible for installation. As noted in an 
earlier comment response, the FAA added the definition of a ``part 
eligible for installation'' in this AD, which includes this 
clarification.

Support for the AD

    An individual commenter expressed support for the AD as written.

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting this AD as 
proposed. Accordingly, the FAA is issuing this AD to address the unsafe 
condition on these products. Except for minor editorial changes and any 
other changes described previously, this AD is adopted as proposed in 
the NPRM. None of the changes will increase the economic burden on any 
operator.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed IAE NMSB No. V2500-ENG-72-0713, Revision 1, dated 
January 26, 2021. The NMSB identifies the affected HPT 1st-stage disks 
and HPT 2nd-stage disks on IAE V2522-A5, V2524-A5, V2525-D5, V2527-A5, 
V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, and V2533-A5 model turbofan 
engines and specifies procedures for a USI of the HPT 1st-stage disk 
and HPT 2nd-stage disk.
    The FAA also reviewed IAE NMSB No. V2500-E5-72-0015, dated December 
15, 2020. The NMSB identifies the affected HPT 1st-stage disks and HPT 
2nd-stage disks on IAE V2531-E5 model turbofan engines and specifies 
procedures for a USI of the HPT 1st-stage disk and HPT 2nd-stage disk.
    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 ADDRESSES.

Costs of Compliance

    The FAA estimates that this AD affects 1,100 engines installed on 
airplanes of U.S. registry.
    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
----------------------------------------------------------------------------------------------------------------
USI the HPT 1st-stage disk and HPT 2nd- 20 work-hours x $85 per               $0          $1,700      $1,870,000
 stage disk.                             hour = $1,700.
----------------------------------------------------------------------------------------------------------------

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

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                    Action                                 Labor cost               Parts cost        product
----------------------------------------------------------------------------------------------------------------
Replace the HPT 1st-stage disk or HPT 2nd-      0 work-hours x $85 per hour = $0        $300,000        $300,000
 stage disk.
----------------------------------------------------------------------------------------------------------------

    The FAA has included all known costs in its cost estimate. 
According to the manufacturer, however, some of the costs of this AD 
may be covered under warranty, thereby reducing the cost impact on 
affected individuals.

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.

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) Will not affect intrastate aviation in Alaska, and

[[Page 30382]]

    (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.

List of Subjects in 14 CFR Part 39

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

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:

2021-11-15 International Aero Engines AG: Amendment 39-21577; Docket 
No. FAA-2021-0129; Project Identifier AD-2020-01597-E.

(a) Effective Date

    This airworthiness directive (AD) is effective July 13, 2021.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to International Aero Engines AG (IAE) V2522-A5, 
V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-
A5, V2531-E5, and V2533-A5 model turbofan engines with an installed:
    (1) High-pressure turbine (HPT) 1st-stage disk, part number (P/
N) 2A5001, with a serial number (S/N) listed in Appendix A, Table 1, 
of IAE Non-Modification Service Bulletin (NMSB) No. V2500-ENG-72-
0713, Revision 1, dated January 26, 2021 (IAE NMSB V2500-ENG-72-
0713, Revision 1) or IAE NMSB No. V2500-E5-72-0015, dated December 
15, 2020 (IAE NMSB V2500-E5-72-0015); and/or
    (2) HPT 2nd-stage disk, P/N 2A4802, with an S/N listed in 
Appendix A, Table 2, of IAE NMSB V2500-ENG-72-0713, Revision 1, or 
IAE NMSB V2500-E5-72-0015.

(d) Subject

    Joint Aircraft System Component (JASC) Code 7250, Turbine 
Section.

(e) Unsafe Condition

    This AD was prompted by an analysis performed by the 
manufacturer after an event involving an uncontained failure of a 
HPT 1st-stage disk that resulted in high-energy debris penetrating 
the engine cowling. The FAA is issuing this AD to prevent failure of 
the HPT 1st-stage disk and HPT 2nd-stage disk. The unsafe condition, 
if not addressed, could result in uncontained HPT disk failure, 
damage to the engine, damage to the airplane, and loss of the 
airplane.

(f) Compliance

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

(g) Required Actions

    (1) For IAE V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, and V2533-
A5 model turbofan engines with an HPT 1st-stage disk, P/N 2A5001, 
with an S/N listed in Appendix A, Table 1, of IAE NMSB V2500-ENG-72-
0713, Revision 1, at the next engine shop visit after the effective 
date of this AD or before the HPT 1st-stage disk has accumulated 
3,200 flight cycles (FCs) since the effective date of this AD, 
whichever occurs first, perform an ultrasonic inspection (USI) of 
the HPT 1st-stage disk using the Accomplishment Instructions, 
paragraph 6, of IAE NMSB V2500-ENG-72-0713, Revision 1.

    Note 1 to paragraph (g)(1): The USI required by paragraphs 
(g)(1) through (6) of this AD requires the HPT 1st-stage disk and 
HPT 2nd-stage disks to be removed from the engine allowing piece-
part opportunity inspections. Per the Airworthiness Limitations 
Section of the manufacturer's Instructions for Continued 
Airworthiness (ICAs), the additional inspections are not required 
unless the part has more than 100 FCs since the last piece-part 
opportunity inspection, is damaged, or is the cause for the removal 
of the engine. Engine removal for the purposes of complying with 
this AD is not ``cause'' for removal as stated in the ALS.

    (2) For IAE V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, and V2533-
A5 model turbofan engines with an HPT 2nd-stage disk, P/N 2A4802, 
with an S/N listed in Appendix A, Table 2, of IAE NMSB V2500-ENG-72-
0713, Revision 1, at the next engine shop visit after the effective 
date of this AD or before the HPT 2nd-stage disk has accumulated 
3,200 FCs since the effective date of this AD, whichever occurs 
first, perform a USI of the HPT 2nd-stage disk using the 
Accomplishment Instructions, paragraph 7, of IAE NMSB V2500-ENG-72-
0713, Revision 1.
    (3) For IAE V2522-A5, V2524-A5, V2525-D5, and V2527-A5 model 
turbofan engines with an HPT 1st-stage disk, P/N 2A5001, with an S/N 
listed in Appendix A, Table 1, of IAE NMSB V2500-ENG-72-0713, 
Revision 1, at the next HPT rotor and stator assembly (HPT module) 
removal or before the HPT 1st-stage disk has accumulated 6,700 FCs 
since the effective date of this AD, whichever occurs first, perform 
a USI of the HPT 1st-stage disk using the Accomplishment 
Instructions, paragraph 6, of IAE NMSB V2500-ENG-72-0713, Revision 
1.
    (4) For IAE V2522-A5, V2524-A5, V2525-D5, and V2527-A5 model 
turbofan engines with an HPT 2nd-stage disk, P/N 2A4802, with an S/N 
listed in Appendix A, Table 2, of IAE NMSB V2500-ENG-72-0713, 
Revision 1, at the next HPT module removal or before the HPT 2nd-
stage disk has accumulated 6,700 FCs since the effective date of 
this AD, whichever occurs first, perform a USI of the HPT 2nd-stage 
disk using the Accomplishment Instructions, paragraph 7, of IAE NMSB 
V2500-ENG-72-0713, Revision 1.
    (5) For IAE V2531-E5 model turbofan engines with an HPT 1st-
stage disk, P/N 2A5001, with an S/N listed in Appendix A, Table 1, 
of IAE NMSB V2500-E5-72-0015, at the next engine shop visit or 
before the HPT 1st-stage disk has accumulated 3,200 FCs since the 
effective date of this AD, whichever occurs first, perform a USI of 
the HPT 1st-stage disk using the Accomplishment Instructions, 
paragraph 6, of IAE NMSB V2500-E5-72-0015.
    (6) For IAE V2531-E5 model turbofan engines with an HPT 2nd-
stage disk, P/N 2A4802, with an S/N listed in Appendix A, Table 2, 
of IAE NMSB V2500-E5-72-0015, at the next engine shop visit or 
before the HPT 2nd-stage disk has accumulated 3,200 FCs since the 
effective date of this AD, whichever occurs first, perform a USI of 
the HPT 2nd-stage disk using the Accomplishment Instructions, 
paragraph 7, of IAE NMSB V2500-E5-72-0015.
    (7) If, during the USI required by paragraphs (g)(1) through (6) 
of this AD, a HPT 1st-stage disk or HPT 2nd-stage disk does not pass 
the inspection as specified in the Accomplishment Instructions, 
paragraph 8., of IAE NMSB V2500-ENG-72-0713, Revision 1, or IAE NMSB 
V2500-E5-72-0015, as applicable, before further flight, remove the 
HPT 1st-stage disk or 2nd-stage disk, as applicable, from service 
and replace with a part eligible for installation.

(h) Definition

    (1) For the purpose of this AD, an ``engine shop visit'' is the 
induction of an engine into the shop for maintenance involving the 
separation of pairs of major mating engine flanges, H-P, except for 
the following situations, which do not constitute an engine shop 
visit.
    (i) Separation of engine flanges solely for the purposes of 
transportation without subsequent engine maintenance.
    (ii) Engine removal for the purpose of performing field 
maintenance activities at a maintenance facility in lieu of 
performing them on-wing.
    (2) For the purpose for this AD, a ``part eligible for 
installation'' is:
    (i) An HPT 1st-stage disk or HPT 2nd-stage disk listed in 
Appendix A, Tables 1 and 2, of IAE NMSB V2500-ENG-72-0713, Revision 
1, or Appendix A, Tables 1 and 2, of IAE NMSB V2500-E5-72-0015, that 
passed the USI required by paragraphs (g)(1) through (6) of this AD; 
or
    (ii) An HPT 1st-stage disk or HPT 2nd-stage disk that is not 
listed in Appendix A, Tables 1 and 2, of IAE NMSB V2500-ENG-72-0713, 
Revision 1, or Appendix A, Tables 1 and 2, of IAE NMSB V2500-E5-72-
0015.

(i) 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,

[[Page 30383]]

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 Related Information. 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.

(j) Related Information

    For more information about this AD, contact Nicholas Paine, 
Aviation Safety Engineer, ECO Branch, FAA, 1200 District Avenue, 
Burlington, MA 01803; phone: (781) 238-7742; fax: (781) 238-7199; 
email: [email protected].

(k) 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) International Aero Engines (IAE) Non-Modification Service 
Bulletin (NMSB) No. V2500-ENG-72-0713, Revision 1, dated January 26, 
2021.
    (ii) IAE NMSB No. V2500-E5-72-0015, dated December 15, 2020.
    (3) For IAE service information identified in this AD, contact 
International Aero Engines AG, 400 Main Street, East Hartford, CT 
06118; phone: (800) 565-0140; email: [email protected]; website: 
http://fleetcare.pw.utc.com.
    (4) You may view this service information at FAA, Airworthiness 
Products Section, Operational Safety 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: https://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued on May 19, 2021.
Lance T. Gant,
Director, Compliance & Airworthiness Division, Aircraft Certification 
Service.
[FR Doc. 2021-11960 Filed 6-7-21; 8:45 am]
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