2011-22-03: Low-cycle fatigue cracks

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): 2011-22-03 Rolls-Royce Corporation (Formerly Allison Engine Company): Amendment 39-16845; Docket No. FAA-2011-0273; Directorate Identifier 2011-NE-08-AD. (a) Effective Date This AD is effective November 17, 2011. [[Page 67593]] (b) Affected ADs None. (c) Applicability This AD applies to Rolls-Royce Corporation (RRC) AE 3007A, AE 3007A1/1, AE 3007A1, AE 3007A1/3, AE 3007A1E, AE 3007A1P, and AE 3007A3 turbofan engines, with any of the 6th-through-13th stage compressor wheel part numbers (P/Ns) in Table 1 of this AD installed. Table 1--6th-Through-13th Stage Compressor Wheel P/Ns Affected by This AD ---------------------------------------------------------------------------------------------------------------- Wheel P/Ns with chrome- Compressor wheel stage carbide coated knife Wheel P/Ns with uncoated knife seals seals ---------------------------------------------------------------------------------------------------------------- 6th................................................ 23074717 23062666, 23071261, 23071396 7th................................................ 23074719, 23074217 23062667, 23071262, 23071397 8th................................................ 23074721 23061628, 23071263 9th................................................ 23074722 23061629, 23071264 10th............................................... 23074723 23061630, 23071265 11th............................................... 23074724 23061631, 23066231 12th............................................... 23074725 23061632, 23071267 13th............................................... 23074213, 23074726 23061633, 23071268 ---------------------------------------------------------------------------------------------------------------- (d) Unsafe Condition This AD was prompted by reports of low-cycle fatigue cracks found during shop visits, in the 6th-through-13th stage compressor wheels having chrome-carbide coated or uncoated knife edge seals. We are issuing this AD to prevent uncontained failure of the 6th- through-13th stage compressor wheel, leading to damage to the airplane. (e) Compliance Comply with this AD within the compliance times specified, unless already done. (f) Initial Inspection The initial inspection compliance times for the 6th-through-13th stage compressor wheels are based on cycles-since-new (CSN) and cycles-in-service (CIS) of their 12th and 13th stage compressor wheels. For engines that one or both 12th and 13th stage compressor wheels have chrome-carbide coated knife edge seals, use the compliance times listed in Table 2 of this AD. For engines that both 12th and 13th stage compressor wheels do not have chrome-carbide coated knife edge seals, use the compliance times listed in Table 3 of this AD. (1) Perform a one-time comprehensive eddy current inspection (ECI) of the 6th-through-13th stage compressor wheel knife edge seals for cracks, using paragraph 2, Accomplishment Instructions, of RRC Alert Service Bulletin (ASB) No. AE 3007A-A-72-386, Revision 4, dated June 27, 2011 (Completion of this one-time comprehensive ECI relieves you thereafter of the repetitive inspection requirements of this AD); or (2) Perform an initial ECI of the 6th-through-13thstage compressor wheel outer circumferences for cracks, using paragraph 2, Accomplishment Instructions, of RRC ASB No. AE 3007A-A-72-390, Revision 3, dated June 27, 2011. Table 2--Initial Inspection Compliance Times for Engines, That One or Both 12th and 13th Stage Compressor Wheels Have Chrome-Carbide Coated Knife Edge Seals ------------------------------------------------------------------------ For 12th and or 13th stage compressor wheels with the Initially inspect after the following CSN on the effective effective date of this AD date of this AD ------------------------------------------------------------------------ (i) 18,185 or more CSN............ Within 15 CIS. (ii) 16,700 to 18,184 CSN......... Before accumulating 18,200 CSN. (iii) 16,000 to 16,699 CSN........ Within 1,500 CIS. (iv) 15,100 to 15,999 CSN......... Within 2,000 CIS. (v) 14,300 to 15,099 CSN.......... Within 2,800 CIS. (vi) 13,000 to 14,299 CSN......... Within 3,400 CIS. (vii) 12,300 to 12,999 CSN........ Within 4,000 CIS. (viii) 11,200 to 12,299 CSN....... Within 4,600 CIS. (ix) 9,700 to 11,199 CSN.......... Within 5,300 CIS. (x) Fewer than 9,700 CSN.......... Before accumulating 15,000 CSN or at the next shop visit when the engine has more than 7,000 cycles, whichever occurs first. ------------------------------------------------------------------------ Table 3--Initial Inspection Compliance Times for Engines, That Both 12th and 13th Stage Compressor Wheels Do Not Have Chrome-Carbide Coated Knife Edge Seals ------------------------------------------------------------------------ For 12th and or 13th stage compressor wheels with the Initially inspect after the following CSN on the effective effective date of this AD: date of this AD: ------------------------------------------------------------------------ (i) 18,300 or more CSN............ Within 200 CIS. (ii) 16,000 to 18,299 CSN......... Within 1,500 CIS. (iii) 15,100 to 15,999 CSN........ Within 2,000 CIS. (iv) 14,300 to 15,099 CSN......... Within 2,800 CIS. (v) 13,000 to 14,299 CSN.......... Within 3,400 CIS. (vi) 12,300 to 12,999 CSN......... Within 4,000 CIS. (vii) 11,200 to 12,299 CSN........ Within 4,600 CIS. (viii) 9,700 to 11,199 CSN........ Within 5,300 CIS. [[Page 67594]] (ix) Fewer than 9,700 CSN......... Before accumulating 15,000 CSN or at the next shop visit when the engine has more than 7,000 cycles, whichever occurs first. ------------------------------------------------------------------------ (g) Repetitive Inspections (1) After passing the initial inspection, perform repetitive ECIs of the compressor wheel outer circumference, for cracks, within every 5,000 cycles-since-last-inspection (CSLI), using paragraph 2, Accomplishment Instructions, of RRC ASB No. AE 3007A-A-72-390, Revision 3, dated June 27, 2011; or (2) Perform a one-time comprehensive ECI of the6th-through-13th stage compressor wheel knife edge seals for cracks, within 5,000 CSLI using paragraph 2, Accomplishment Instructions, of RRC ASB No. AE 3007A-A-72-386, Revision 4, dated June 27, 2011. Completion of this one-time ECI comprehensive inspection relieves you thereafter of the repetitive inspection requirements of this AD. (h) 6th-Through-13th Stage Compressor Wheels Found Cracked Remove from service before further flight 6th-through-13th stage compressor wheels that are found cracked. (i) Special Flight Permits Special Flight Permits are limited to essential flight crew only. (j) Reporting Requirements Report all inspection results within 10 days, to AE Service Data, Rolls-Royce Corporation, Attn: AE Service Data Manager, P.O. Box 420, Speed Code U17, Indianapolis, IN 46206-0420, email: royce.com">cra.rel.data@rolls-royce.com. Use the reporting instructions in: (1) Paragraph 2.D. of ASB No. AE 3007A-A-72-386, Revision 4, dated June 27,2011. (2) Service Bulletin Compliance Form of RRC ASB No. AE 3007A-A- 72-390, Revision 3, dated June 27, 2011. (k) Paperwork Reduction Act Burden Statement A federal agency may not conduct or sponsor, and a person is not required to respond to, nor shall a person be subject to a penalty for failure to comply with a collection of information subject to the requirements of the Paperwork Reduction Act unless that collection of information displays a current valid OMB Control Number. The OMB Control Number for this information collection is 2120-0056. Public reporting for this collection of information is estimated to be approximately 5 minutes per response, including the time for reviewing instructions, completing and reviewing the collection of information. All responses to this collection of information are mandatory. Comments concerning the accuracy of this burden and suggestions for reducing the burden should be directed to the FAA at: 800 Independence Ave. SW., Washington, DC 20591, Attn: Information Collection Clearance Officer, AES-200. (l) Previous Inspection Credit (1) If you previously performed an ECI of the 6th-through-13th stage compressor wheels using RRC ASB No. AE 3007A-A-390, Revision 1, dated February 14, 2011 or Revision 2, dated June 10, 2011, or Revision 3, dated June 27, 2011, you met the initial inspection requirements of this AD. (2) If you previously performed a one-time comprehensive ECI of the 6th-through-13th stage compressor wheel knife edge seals, using RRC ASB No. AE 3007A-A-72-386, dated October 20, 2010, or Revision 1, dated December 17, 2010, or Revision 2 dated January 10, 2011, or Revision 3, dated June 10, 2011, you met the initial inspection requirements of paragraph (f) of this AD. Completion of this one- time comprehensive inspection relieves you of the repetitive inspection requirements of this AD. (3) If you previously performed an ultrasonic inspection of the compressor wheel knife edge seals, using RRC Service Bulletin No. AE 3007A-72-382, dated April 6, 2010, prior to publication of RRC ASB No. AE 3007A-A-72-386, dated October 20, 2010, you met the initial inspection requirements of this AD. Completion of this one-time ultrasonic inspection relieves you of the repetitive inspection requirements of this AD. (m) Alternative Methods of Compliance (AMOCs) The Manager, Chicago Aircraft Certification Office, may approve AMOCs for this AD. Use the procedures found in 14 CFR 39.19 to make your request. (n) Related Information For more information about this AD, contact Kyri Zaroyiannis, Aerospace Engineer, Chicago Aircraft Certification Office, Small Airplane Directorate, FAA, 2300 E. Devon Ave., Des Plaines, IL 60018; phone: (847) 294-7836; fax: (847) 294-7834; email: kyri.zaroyiannis@faa.gov. (o) Material Incorporated by Reference You must use the following service information to do the actions required by this AD, unless the AD specifies otherwise. The Director of the Federal Register approved the incorporation by reference (IBR) under 5 U.S.C. 552(a) and 1 CFR part 51 of the following service information on the date specified: (1) Rolls-Royce Corporation Alert Service Bulletin No. AE 3007A- A-72-386, Revision 4, dated June 27, 2011, approved for IBR November 17, 2011. (2) Rolls-Royce Corporation Alert Service Bulletin No. AE 3007A- A-72-390, Revision 3, dated June 27, 2011, approved for IBR November 17, 2011. (3) For service information identified in this AD, contact Rolls-Royce Corporation, P.O. Box 420, Indianapolis, IN 46206; phone: (317) 230-3774; fax: (317) 230-6084; email: royce.com">indy.pubs.services@rolls-royce.com. (4) You may review copies of the service information at the FAA, Engine & Propeller Directorate, 12 New England Executive Park, Burlington, MA. For information on the availability of this material at the FAA, call (781) 238-7125. (5) You may also review copies of the service information thatis incorporated by reference at the National Archives and Records Administration (NARA). For information on the availability of this material at an NARA facility, call (202) 741-6030, or go to http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.