Airworthiness Directives; Rolls-Royce Corporation Turboshaft Engines

[Federal Register Volume 87, Number 100 (Tuesday, May 24, 2022)]
[Rules and Regulations]
[Pages 31384-31386]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2022-11084]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2021-1071; Project Identifier AD-2021-01055-E; 
Amendment 39-22044; AD 2022-10-06]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce Corporation Turboshaft 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is superseding Airworthiness Directive (AD) 2017-18-
14, which applied to certain Rolls-Royce Corporation (RRC) 250 model 
turboshaft engines. AD 2017-18-14 required repetitive visual 
inspections and fluorescent penetrant inspections (FPIs) of the 3rd-
stage turbine wheel and removal from service of the 4th-stage turbine 
wheel. This AD was prompted by in-service turbine blade failures that 
resulted in the loss of power and engine in-flight shutdowns. This AD 
requires replacement of the 3rd-stage and 4th-stage turbine wheels. 
This AD also revises the applicability to include an additional 
turboshaft engine model. The FAA is issuing this AD to address the 
unsafe condition on these products.

DATES: This AD is effective June 28, 2022.

ADDRESSES: For service information identified in this final rule, 
contact Rolls-Royce Corporation, 450 South Meridian Street, Mail Code 
NB-01-06, Indianapolis, IN 46225; phone: (317) 230-2720; email: 
Royce.com">HelicoptCustSupp@Rolls-Royce.com; website: www.rolls-royce.com. You may 
view this service information at the Airworthiness Products Section, 
Operational Safety Branch, FAA, 1200 District Avenue, Burlington, MA 
01803. For information on the availability of this material at the FAA, 
call (817) 222-5110.

Examining the AD Docket

    You may examine the AD docket at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2021-1071; 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: John Tallarovic, Aviation Safety 
Engineer, Chicago ACO, FAA, 2300 E Devon Avenue, Des Plaines, IL 60018; 
phone: (847) 294-8180; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 to supersede AD 2017-18-14, Amendment 39-19023 (82 FR 
42443, September 8, 2017), (AD 2017-18-14). AD 2017-18-14 applied to 
certain RRC 250-C20, -C20B, -C20F, -C20J, -C20R, -C20R/1, -C20R/2, -
C20R/4, -C20W, -C300/A1, and -C300/B1 turboshaft engines with either a 
3rd-stage turbine wheel, part number (P/N) 23065818, or a 4th-stage 
turbine wheel, P/N 23055944 or RR30000240, installed. The NPRM 
published in the Federal Register on January 14, 2022 (87 FR 2365). The 
NPRM was prompted by in-service turbine blade failures that resulted in 
the loss of power and engine in-flight shutdowns. Since the FAA issued 
AD 2017-18-14, the manufacturer redesigned the 3rd-stage turbine wheel. 
The manufacturer published Rolls-Royce Alert Commercial Engine Bulletin 
(CEB) CEB A-1428/CEB A-72-4111 (single document), which describes 
procedures for replacement of the 3rd-stage turbine wheel, P/N 
23065818, with the new increased blade fillet 3rd-stage turbine wheel, 
P/N M250-10473. Additionally, the FAA determined that the RRC 250-C20C 
(T63-A-720) model turboshaft engine is also susceptible to the unsafe 
condition. In the NPRM, the FAA proposed to require replacement of the 
3rd-stage and 4th-stage turbine

[[Page 31385]]

wheels. 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 two commenters. The commenters were 
an anonymous commenter and RRC. The following presents the comments 
received on the NPRM and the FAA's response to each comment.

Comments on Part Availability and Costs

    The anonymous commenter stated that RRC does not have the inventory 
to supply engine shops with the 3rd-stage and 4th-stage turbine wheels 
proposed for replacement in the NPRM. The commenter requested that RRC 
provide credit to its customers for unused time on 3rd-stage and 4th-
stage turbine wheels and reasoned that customers paid for the full life 
of the 3rd-stage and 4th-stage turbine wheels, not a partial life, 
which now requires replacement at full price. The commenter also stated 
that the part cost estimates in the NPRM for the 3rd-stage and 4th-
stage turbine wheels are inaccurate and should indicate an estimated 
cost of $22,929.15 and $18,926.59 to reflect Aviall and Boeing's 
prices, respectively. The commenter noted that they have found 
performing FPIs on the 3rd-stage and 4th-stage turbine wheels result in 
serviceable conditions compared to the previous configurations that 
were beyond serviceable. The commenter expressed that the proposed 
requirements in the NPRM would be a financial burden on RRC's 
customers, considering the current market instability.
    The FAA disagrees that the manufacturer will not have sufficient 
inventory, which would prevent compliance with this AD. Prior to 
publishing the NPRM, the FAA confirmed with RRC that there would be 
adequate inventory for operators to replace the 3rd-stage and 4th-stage 
turbine wheels. In response to this comment, the FAA confirmed with RRC 
that the 3rd-stage and 4th-stage turbine wheels are available at a 50% 
discounted price. Additionally, RRC indicated that suppliers will also 
provide the discounted price. The FPI of 3rd-stage turbine wheels was 
an interim action until redesigned parts became available. While FPI 
reduces the risk of a blade failure, the unsafe condition is addressed 
by replacing the 3rd-stage turbine wheel with the revised design. The 
FAA did not change this AD as a result of the comments.

Request To Update Service Information

    RRC requested that the FAA revise the Related Service Information 
paragraph of this AD to reference Rolls-Royce Alert CEB CEB A-1428/CEB 
A-72-4111 (single document), Revision 2, dated December 8, 2021. RRC 
reasoned that since the three Rolls-Royce bulletins were submitted to 
the FAA in support of the NPRM, Rolls-Royce has published Revision 2 of 
Rolls-Royce Alert CEB CEB A-1428/CEB A-72-4111 (single document).
    The FAA agrees. The FAA has updated the Related Service Information 
paragraph of this AD to reference Rolls-Royce Alert CEB CEB A-1428/CEB 
A-72-4111 (single document), Revision 2, dated December 8, 2021.

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting the 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

    The FAA reviewed Rolls-Royce Alert CEB CEB A-1428/CEB A-72-4111 
(single document), Revision 2, dated December 8, 2021. This Alert CEB 
describes procedures for replacing the 3rd-stage turbine wheel, P/N 
23065818, with the new increased blade fillet 3rd-stage turbine wheel, 
P/N M250-10473.
    The FAA reviewed Rolls-Royce Alert CEB CEB-A-1422/CEB-A-72-4108 
(single document), Original Issue, dated September 13, 2017. This Alert 
CEB describes procedures for replacing 4th-stage turbine wheel, P/N 
23055944, with the new increased blade fillet 4th-stage turbine wheel, 
P/N M250-10445.
    The FAA also reviewed Rolls-Royce Alert Service Bulletin (SB) 
RR300-A-72-024, Original Issue, dated September 13, 2017. This Alert SB 
describes procedures for replacing the 4th-stage turbine wheel, P/N 
RR30000240, with the new increased blade fillet 4th-stage turbine 
wheel, P/N RR30000494.

Costs of Compliance

    The FAA estimates that this AD affects 3,769 engines installed on 
helicopters of U.S. registry. The FAA estimates that 3,041 3rd-stage 
turbine wheels and 3,769 4th-stage turbine wheels will require 
replacement.
    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
----------------------------------------------------------------------------------------------------------------
Replace 3rd-stage turbine wheel, P/ 3 work-hours x $85            $11,170         $11,425  $34,743,425 (3,041
 N 23065818.                         per hour = $255.                                       engines).
Replace 4th-stage turbine wheel, P/ 3 work-hours x $85              8,928           9,183  $34,610,727 (3,769
 N 23055944 or RR30000240.           per hour = $255.                                       engines).
----------------------------------------------------------------------------------------------------------------

    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 operators.

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

[[Page 31386]]

develop on products identified in this rulemaking action.

Regulatory Findings

    The FAA has 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) Will not affect intrastate aviation in Alaska, and
    (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:
0
a. Removing Airworthiness Directive 2017-18-14, Amendment 39-19023 (82 
FR 42443, September 8, 2017); and
0
b. Adding the following new airworthiness directive:

2022-10-06 Rolls-Royce Corporation: Amendment 39-22044; Docket No. 
FAA-2021-1071; Project Identifier AD-2021-01055-E.

(a) Effective Date

    This airworthiness directive (AD) is effective June 28, 2022.

(b) Affected ADs

    This AD replaces AD 2017-18-14, Amendment 39-19023 (82 FR 42443, 
September 8, 2017).

(c) Applicability

    This AD applies to Rolls-Royce Corporation (RRC) 250-C20, 250-
C20B, 250-C20C (T63-A-720), 250-C20F, 250-C20J, 250-C20R, 250-C20R/
1, 250-C20R/2, 250-C20R/4, 250-C20W, 250-C300/A1, and 250-C300/B1 
model turboshaft engines with either a 3rd-stage turbine wheel, part 
number (P/N) 23065818, or a 4th-stage turbine wheel, P/N 23055944 or 
RR30000240, installed.

(d) Subject

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

(e) Unsafe Condition

    This AD was prompted by in-service turbine blade failures that 
resulted in the loss of power and engine in-flight shutdowns. The 
FAA is issuing this AD to prevent failure of the 3rd-stage and 4th-
stage turbine blades. The unsafe condition, if not addressed, could 
result in damage to the engine and damage to the aircraft.

(f) Compliance

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

(g) Required Actions

    (1) Within 1,775 hours since last visual inspection and 
fluorescent penetrant inspection (FPI), or at the next engine shop 
visit, whichever occurs first after the effective date of this AD, 
remove:
    (i) 3rd-stage turbine wheel, P/N 23065818, and replace with a 
part eligible for installation.
    (ii) 4th-stage turbine wheel, P/N 23055944, and replace with a 
part eligible for installation.
    (2) Within 2,025 hours since last visual inspection and FPI, or 
at the next engine shop visit, whichever occurs first after the 
effective date of this AD, remove 4th-stage turbine wheel, P/N 
RR30000240, and replace with a part eligible for installation.

(h) Definitions

    (1) For this purpose of this AD, an ``engine shop visit'' is the 
induction of an engine into the shop for maintenance in which the 
turbine module is separated from the exhaust collector, the gas-
producer-support is separated from the power-turbine-support, or 
there is separation of pairs of major mating engine flanges, except 
that the separation of engine flanges solely for the purposes of 
transportation without subsequent engine maintenance does not 
constitute an engine shop visit.
    (2) For the purpose of this AD, a ``part eligible for 
installation'' is a 3rd-stage turbine wheel or 4th-stage turbine 
wheel that does not have a P/N listed in the Applicability, 
paragraph (c), of this AD.

(i) Special Flight Permit

    A special flight permit may be issued in accordance with 14 CFR 
21.197 and 21.199 to permit a one-time non-revenue ferry flight to 
operate the airplane to a maintenance facility where the engine can 
be removed from service. This ferry flight must be performed with 
only essential flight crew.

(j) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Chicago 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 
certification office, send it to the attention of the person 
identified in paragraph (k) of this AD.
    (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.

(k) Related Information

    For more information about this AD, contact John Tallarovic, 
Aviation Safety Engineer, Chicago ACO, FAA, 2300 E Devon Avenue, Des 
Plaines, IL 60018; phone: (847) 294-8180; email: 
[email protected].

(l) Material Incorporated by Reference

    None.

    Issued on May 3, 2022.
Lance T. Gant,
Director, Compliance & Airworthiness Division, Aircraft Certification 
Service.
[FR Doc. 2022-11084 Filed 5-23-22; 8:45 am]
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