Airworthiness Directives; Pratt & Whitney Division Turbofan Engines

[Federal Register Volume 87, Number 73 (Friday, April 15, 2022)]
[Rules and Regulations]
[Pages 22441-22444]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2022-08045]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2022-0386; Project Identifier AD-2022-00336-E; 
Amendment 39-22001; AD 2022-07-13]
RIN 2120-AA64


Airworthiness Directives; Pratt & Whitney Division Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for all 
Pratt & Whitney Division (PW) PW4074, PW4074D, PW4077, PW4077D, 
PW4084D, PW4090, and PW4090-3 model turbofan engines. This AD was 
prompted by an in-flight shutdown (IFSD) of an engine due to an air/oil 
heat exchanger leak caused by corrosion and subsequent investigation by 
the manufacturer that revealed additional air/oil heat exchanger leaks. 
This AD requires an inspection of the air/oil heat exchanger and, 
depending on the results of the inspection, replacement of the air/oil 
heat exchanger. This AD also provides instructions for storing an air/
oil heat exchanger after inspection. The FAA is issuing this AD to 
address the unsafe condition on these products.

DATES: This AD is effective May 2, 2022.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of May 2, 2022.
    The FAA must receive comments on this AD by May 31, 2022.

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 https://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: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this final rule, contact 
Pratt & Whitney Division, 400 Main Street, East Hartford, CT 06118; 
phone: (860) 565-0140; email: [email protected]; website: https://connect.prattwhitney.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 (817) 222-5110. It is 
also available at https://www.regulations.gov by searching for and 
locating Docket No. FAA-2022-0386.

Examining the AD Docket

    You may examine the AD docket at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2022-0386; 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 street address for the 
Docket Operations is listed above.

FOR FURTHER INFORMATION CONTACT: Carol Nguyen, Aviation Safety 
Engineer, ECO Branch, FAA, 1200 District Avenue, Burlington, MA 01803; 
phone: (781) 238-7655; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Background

    On November 9, 2021, a Boeing Model 777 airplane, powered by PW 
PW4077 engines, on a ferry flight from San Francisco, CA to Honolulu, 
HI, experienced an oil leak on the number 1 engine that resulted in an 
IFSD and air turnback to San Francisco, CA. A post-flight inspection 
revealed that the oil leak was from the air/oil heat exchanger. After 
this event, on December 19, 2021, the manufacturer was made aware of 
another oil leak related to the air/oil heat exchanger that was 
discovered during a post-flight inspection after the first flight out 
of storage. Subsequent investigation revealed 19 air/oil heat exchanger 
leaks occurred on the affected engines during the past year, which is 
significantly higher than the three to four air/oil heat exchanger 
leaks typically occurring each year. After

[[Page 22442]]

further investigation, the manufacturer determined that the air/oil 
heat exchanger leak was due to corrosion. The manufacturer published 
Pratt & Whitney Special Instruction No. 255F-21A, dated February 15, 
2022, which provides instructions for performing an inspection of the 
air/oil heat exchanger and, depending on the results of the inspection, 
replacement of the air/oil heat exchanger. This special instruction 
also provides instructions for storing an air/oil heat exchanger after 
the inspection. This condition, if not addressed, could result in low 
oil pressure, failure of one or more engines, IFSD, loss of engine 
thrust control, reduced control of the airplane, and loss of the 
airplane. The FAA is issuing this AD to address the unsafe condition on 
these products.

FAA's Determination

    The FAA is issuing this AD because the agency has determined the 
unsafe condition described previously is likely to exist or develop in 
other products of the same type design.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed Pratt & Whitney Special Instruction No. 255F-21A, 
dated February 15, 2022. This special instruction specifies procedures 
for performing an inspection of the air/oil heat exchanger and, 
depending on the results of the inspection, replacement of the air/oil 
heat exchanger. This special instruction also specifies procedures for 
storing an air/oil heat exchanger after the inspection. 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.

Other Related Service Information

    The FAA reviewed Pratt & Whitney Special Instruction No. 255F-21, 
dated December 22, 2021. This special instruction describes procedures 
for performing an inspection of the air/oil heat exchanger and, 
depending on the results of the inspection, replacement of the air/oil 
heat exchanger.

AD Requirements

    This AD requires an inspection of the air/oil heat exchanger within 
30 days prior to the first flight after the effective date of this AD. 
Depending on the results of the inspection, this AD may require 
replacement of the air/oil heat exchanger. The air/oil heat exchanger 
may be inspected more than 30 days prior to the first flight after the 
effective date of this AD if the air/oil heat exchanger is subsequently 
stored in accordance with procedures from the manufacturer.

Interim Action

    The FAA considers this AD to be an interim action. If final action 
is later identified, the FAA might consider additional rulemaking.

Justification for Immediate Adoption and Determination of the Effective 
Date

    Section 553(b)(3)(B) of the Administrative Procedure Act (APA) (5 
U.S.C. 551 et seq.) authorizes agencies to dispense with notice and 
comment procedures for rules when the agency, for ``good cause,'' finds 
that those procedures are ``impracticable, unnecessary, or contrary to 
the public interest.'' Under this section, an agency, upon finding good 
cause, may issue a final rule without providing notice and seeking 
comment prior to issuance. Further, section 553(d) of the APA 
authorizes agencies to make rules effective in less than thirty days, 
upon a finding of good cause.
    An unsafe condition exists that requires the immediate adoption of 
this AD without providing an opportunity for public comments prior to 
adoption. The FAA has found that the risk to the flying public 
justifies foregoing notice and comment prior to adoption of this rule. 
The Boeing Model 777 fleet with affected engines installed has been 
grounded after a fan blade-out event that occurred on February 20, 
2021. According to the manufacturer, the lack of operation may have 
exacerbated corrosion on the air/oil heat exchanger. Both engines 
installed on the airplane may develop leaks on the air/oil heat 
exchangers. Since the Boeing Model 777 fleet will start to return to 
service soon, there is an increased risk that these leaks will occur 
during the first flight out of storage, and there is a risk of a dual-
engine IFSD and loss of the airplane. The FAA considers inspection of 
the air/oil heat exchanger for leaks to be an urgent safety issue. 
Accordingly, notice and opportunity for prior public comment are 
impracticable and contrary to the public interest pursuant to 5 U.S.C. 
553(b)(3)(B).
    In addition, the FAA finds that good cause exists pursuant to 5 
U.S.C. 553(d) for making this amendment effective in less than 30 days, 
for the same reasons the FAA found good cause to forego notice and 
comment.

Comments Invited

    The FAA invites you to send any written data, views, or arguments 
about this final rule. Send your comments to an address listed under 
ADDRESSES. Include ``FAA-2022-0386 and Project Identifier AD-2022-
00336-E'' at the beginning of your comments. The most helpful comments 
reference a specific portion of the final rule, explain the reason for 
any recommended change, and include supporting data. The FAA will 
consider all comments received by the closing date and may amend this 
final rule because of those comments.
    Except for Confidential Business Information (CBI) as described in 
the following paragraph, and other information as described in 14 CFR 
11.35, the FAA will post all comments received, without change, to 
https://www.regulations.gov, including any personal information you 
provide. The agency will also post a report summarizing each 
substantive verbal contact received about this final rule.

Confidential Business Information

    CBI is commercial or financial information that is both customarily 
and actually treated as private by its owner. Under the Freedom of 
Information Act (FOIA) (5 U.S.C. 552), CBI is exempt from public 
disclosure. If your comments responsive to this AD contain commercial 
or financial information that is customarily treated as private, that 
you actually treat as private, and that is relevant or responsive to 
this AD, it is important that you clearly designate the submitted 
comments as CBI. Please mark each page of your submission containing 
CBI as ``PROPIN.'' The FAA will treat such marked submissions as 
confidential under the FOIA, and they will not be placed in the public 
docket of this AD. Submissions containing CBI should be sent to Carol 
Nguyen, Aviation Safety Engineer, ECO Branch, FAA, 1200 District 
Avenue, Burlington, MA 01803. Any commentary that the FAA receives 
which is not specifically designated as CBI will be placed in the 
public docket for this rulemaking.

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 prior notice and 
comment, RFA analysis is not required.

Costs of Compliance

    The FAA estimates that this AD affects 108 engines installed on 
airplanes of U.S. registry.
    The FAA estimates the following costs to comply with this AD:

[[Page 22443]]



                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
Inspect air/oil heat exchanger........  2 work-hours x $85 per                $0            $170         $18,360
                                         hour = $170.
----------------------------------------------------------------------------------------------------------------

    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 air/oil heat exchanger.............  0 work-hours x $85 per hour = $0...         $12,000         $12,000
----------------------------------------------------------------------------------------------------------------

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, 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.

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:

2022-07-13 Pratt & Whitney Division: Amendment 39-22001; Docket No. 
FAA-2022-0386; Project Identifier AD-2022-00336-E.

(a) Effective Date

    This airworthiness directive (AD) is effective May 2, 2022.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to Pratt & Whitney Division PW4074, PW4074D, 
PW4077, PW4077D, PW4084D, PW4090, and PW4090-3 model turbofan 
engines, with an installed air/oil heat exchanger that has 
accumulated any number of cycles since new (CSN) or cycles since 
last overhaul.

(d) Subject

    Joint Aircraft System Component (JASC) Code 7921, Engine Oil 
Cooler.

(e) Unsafe Condition

    This AD was prompted by an in-flight shutdown (IFSD) of an 
engine due to an air/oil heat exchanger leak caused by corrosion and 
subsequent investigation by the manufacturer that revealed 
additional air/oil heat exchanger leaks on the affected engines. The 
FAA is issuing this AD to prevent leaks in the air/oil heat 
exchanger. The unsafe condition, if not addressed, could result in 
low oil pressure, failure of one or more engines, IFSD, loss of 
engine thrust control, reduced control of 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) Within 30 days prior to the first flight after the effective 
date of this AD, perform an inspection for leaks of the air/oil heat 
exchanger in accordance with the Accomplishment Instructions, 
paragraph 3., of Pratt & Whitney Special Instruction No. 255F-21A, 
dated February 15, 2022.
    (2) If any air/oil heat exchanger fails the inspection required 
by paragraph (g)(1) of this AD, before further flight, remove the 
air/oil heat exchanger and replace with a part eligible for 
installation.

(h) Definition

    For the purpose of this AD, a ``part eligible for installation'' 
is:
    (1) A new air/oil heat exchanger with zero CSN, or
    (2) An overhauled air/oil heat exchanger with zero cycles since 
last overhaul, or
    (3) An air/oil heat exchanger that has passed the inspection 
required by paragraph (g)(1) of this AD.

(i) Effect of Storage on Compliance Time

    For performance of the inspection for leaks required by 
paragraph (g)(1) of this AD, the air/oil heat exchanger may be 
inspected more than 30 days prior to the first flight after the 
effective date of this AD if, after performing said inspection, the 
following are accomplished:
    (1) The air/oil heat exchanger is stored in accordance with the 
Accomplishment Instructions, paragraph 6., of Pratt & Whitney 
Special Instruction No. 255F-21A, dated February 15, 2022; and
    (2) The cumulative time between performance of the inspection 
and the first flight minus the time stored in accordance with 
paragraph (i)(1) of this AD does not exceed 30 days.

[[Page 22444]]

(j) Credit for Previous Actions

    You make take credit for the actions required by paragraph 
(g)(1) of this AD if the inspection for leaks was performed before 
the effective date of this AD using the Accomplishment Instructions, 
paragraph 3., of Pratt & Whitney Special Instruction No. 255F-21, 
dated December 22, 2021.

(k) Special Flight Permit

    Special flight permits, as described in 14 CFR 21.197 and 
21.199, are permitted prior to compliance with paragraph (g)(1) of 
this AD, provided that the air/oil heat exchanger has first passed 
an inspection, performed within 60 days of the flight, performed in 
accordance with:
    (1) The Accomplishment Instructions, paragraph 3., of Pratt & 
Whitney Special Instruction No. 255F-21, dated December 22, 2021, 
before the effective date of this AD, or
    (2) The Accomplishment Instructions, paragraph 3., of Pratt & 
Whitney Special Instruction No. 255F-21A, dated February 15, 2022.

(l) 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 (m) of this AD and email 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.

(m) Related Information

    For more information about this AD, contact Carol Nguyen, 
Aviation Safety Engineer, ECO Branch, FAA, 1200 District Avenue, 
Burlington, MA 01803; phone: (781) 238-7655; 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) Pratt & Whitney Special Instruction No. 255F-21A, dated 
February 15, 2022.
    (ii) [Reserved]
    (3) For service information identified in this AD, contact Pratt 
& Whitney Division, 400 Main Street, East Hartford, CT 06118; phone: 
(860) 565-0140; email: [email protected]; website: https://connect.prattwhitney.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 (817) 222-5110.
    (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 March 31, 2022.
Derek Morgan,
Acting Director, Compliance & Airworthiness Division, Aircraft 
Certification Service.
[FR Doc. 2022-08045 Filed 4-14-22; 8:45 am]
BILLING CODE 4910-13-P

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