2015-10-04: HPC stage 3 to 8 drum

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 removing Airworthiness Directive (AD) 2012-09-09, Amendment 39-17044 (77 FR 30371, May 23, 2012), and adding the following new AD: 2015-10-04 International Aero Engines AG: Amendment 39-18159 Docket No. FAA-2009-1100; Directorate Identifier 2009-NE-37-AD. (a) Effective Date This AD is effective July 1, 2015. (b) Affected ADs This AD replaces AD 2012-09-09, Amendment 39-17044 (77 FR 30371, May 23, 2012). (c) Applicability This AD applies to: (1) All International Aero Engines AG (IAE) V2500-A1 turbofan engines; and (2) All IAE V2525-D5 and V2528-D5 turbofan engines; and(3) IAE V2522-A5, V2524-A5, V2527-A5, V2527E-A5, V2527M-A5, V2530-A5, and V2533-A5 turbofan engines with serial numbers (S/Ns) V10001 through V13190, and V15001 through V16728, excluding V16707. [[Page 30143]] (d) Unsafe Condition This AD was prompted by the discovery that additional attachment nuts for certain high-pressure compressor (HPC) stage 3 to 8 drums cause the drum to corrode and crack. We are issuing this AD to prevent failure of the HPC stage 3 to 8 drum, which could result in uncontained drum failure, damage to the engine, and damage to the airplane. (e) Compliance Comply with this AD within the compliance times specified, unless already done. You may use the inspections listed in paragraph (h)(3) of this AD instead of an ultrasonic inspection (USI) for the initial inspection required by paragraphs (e)(1) through (e)(5). If cracks are found during any of the inspections required by this AD, remove the drum from service before further flight. (1) Initial USI of the HPC Stage 3 to 8 Drum--Group ``A'' and Group ``B'' For IAE V2500-A1 turbofan engines with S/Ns listed in ``Group A'' or ``Group B'' in paragraph 1.E. in IAE Alert Non-Mandatory Service Bulletin (NMSB) No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014, perform an initial USI of the HPC stage 3 to 8 drum within 200 cycles of the drum accumulating 8,000 cycles or within 200 cycles from the effective date of this AD, whichever occurs later. (2) Initial USI of the HPC Stage 3 to 8 Drum--Group ``C'' For IAE V2500-A5 turbofan engines with S/Ns listed in ``Group C'' in paragraph 1.E. in IAE Alert NMSB No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014, perform an initial USI of the HPC stage 3 to 8 drum within 200 cycles of the drum accumulating 6,250 cycles or within 200 cycles from the effective date of this AD, whichever occurs later. (3) Initial USI of the HPC Stage 3 to 8 Drum--Group ``D'' For IAE V2500-A5 turbofan engines with S/Ns listed in ``Group D'' in paragraph 1.E. in IAE Alert NMSB No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014, perform an initial USI of the HPC stage 3 to 8 drum within 200 cycles of the drum accumulating 3,750 cycles or within 200 cycles from the effective date of this AD, whichever occurs later. (4) Initial USI of the HPC Stage 3 to 8 Drum--Group ``E'' For IAE V2500-A1, -A5, and -D5 turbofan engines not listed in ``Group A,'' ``Group B,'' ``Group C,'' or ``Group D,'' and with drum assembly part numbers (P/Ns) listed in ``Group E'' in paragraph 1.E. in IAE Alert NMSB No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014, perform an initial USI of the HPC stage 3 to 8 drum within 200 cycles of the drum accumulating 12,500 cycles or within 200 cycles from the effective date of this AD, whichever occurs later. (5) Initial USI of the HPC Stage 3 to 8 Drum--Group ``F'' For IAE V2500-A1, -A5, and -D5 turbofan engines not listed in ``Group A,'' ``Group B,'' ``Group C,'' or ``Group D,'' and with drum assembly P/Ns listed in ``Group F'' in paragraph 1.E. in IAE Alert NMSB No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014, perform an initial USI of the HPC stage 3 to 8 drum within 200 cycles of the drum accumulating 9,000 cycles or within 200 cycles from the effective date of this AD, whichever occurs later. (f) Repetitive USIs of the HPC Stage 3 to 8 Drum (1) For engines included in ``Group A,'' ``Group B,'' ``Group C,'' ``Group E,'' or ``Group F,'' as defined in paragraph (e) of this AD, perform repetitive USIs of the HPC stage 3 to 8 drum within every 750 cycles of the last USI after the initial inspection required by paragraph (e) of this AD. (2) For engines included in ``Group D,'' as defined in paragraph (e) of this AD, perform repetitive USIs of the HPC stage 3 to 8 drum within every 500 cycles of the last USI after the initial inspection required by paragraph (e) of this AD. (3) If you inspect the HPC stage 3 to 8 drum at piece-part exposure, you may delay the next USI as shown in the ``Grace Periods Table'' for each compliance group listed in paragraph 1.E. in IAE Alert NMSB No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014. (g) USI Procedure for the Inspection of the HPC Stage 3 to 8 Drum For the USI inspections required by this AD, do the following. Inspect the stage 8 disk of the HPC stage 3 to 8 drum on the outer diameter adjacent to the stage 7 to 8 electron beam weld land using ultrasonic probe manipulator assembly P/N IAE2R19865 for IAE V2500- A1 engines, P/N IAE2R19852 or IAE2R19879 for IAE V2500-A5 engines, and P/N IAE2R19874 for IAE V2500-D5 engines. Inspect the stage 8 disk of the HPC stage 3 to 8 drum on the inner diameter at the inner radius position using ultrasonic probe manipulator assembly P/N IAE2R19870 for IAE V2500-A1 engines, P/N IAE2R19859 or IAE2R19880 for IAE V2500-A5 engines, and P/N IAE2R19876 for IAE V2500-D5 engines. Inspect the full circumference of both the inner and outer diameters. If the entire circumference cannot be inspected, remove the drum from the engine before further flight. (1) Calibrate the ultrasonic equipment using the following parameters and the acceptance criteria listed in paragraph 3.A.(1)(a) of IAE Alert NMSB No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014. Use working standard P/N IAE2R19854 for outer diameter inspection and working standard P/N IAE2R19860 for inner diameter inspection: (i) Set Frequency to 5 Mhz. (ii) Set Rectify to Full Wave. (iii) Set Pulser to Single Crystal. (iv) Maximize the signal response to achieve 70 percent full screen height. (v) Adjust the range control to position the target signal at 5.0 time base position based on ten division time base. (vi) For outer diameter inspection, set Gate Position to 3.5-7.0 time base position based on ten division time base. (vii) For inner diameter inspection, set Gate Position to 3.0- 8.0 time base position based on ten division time base. (2) Inspect the HPC stage 3 to 8 drum using the acceptance criteria listed in paragraph 3.A.(1)(a) of IAE Alert NMSB No. V2500- ENG-72-A0615, Revision 6, dated September 4, 2014. (3) After completing the inspection of each feature, verify the calibration of the ultrasonic equipment. If the calibration is under sensitivity by more than 3db, then repeat the calibration and inspection of the feature. (h) Removal of Silver-Plated Nuts At the next piece-part exposure of the HPC stage 3 to 8 drum after the effective date of this AD, do the following before returning any HPC stage 3 to 8 drum to service: (1) Remove from service all silver-plated nuts (fully or partially-plated), P/Ns AS44862 or AS64367, that attach the HPC stage 3 to 8 drum to the HPC stage 9 to 12 drum. (2) Clean the HPC stage 3 to 8 drum to remove the silver residue. (3) Inspect the HPC stage 3 to 8 drum using at least one of the followingmethods: (i) Fluorescent penetrant inspection (FPI) of the HPC stage 3 to 8 drum for cracks, or (ii) Eddy current inspection (ECI) of the HPC stage 3 to 8 drum for cracks. (i) Installation Prohibition After the effective date of this AD, do not install any silver- plated nuts, P/N AS44862 or AS64367, into any engine. (j) Mandatory Terminating Action Within 9,450 cycles after the effective date of this AD, but not later than December 31, 2025, install: (1) An HPC stage 3 to 8 drum that has never operated with silver-plated nuts (fully or partially plated) to attach the HPC stage 3 to 8 drum to the HPC stage 9 to 12 drum, with (2) silver-free nuts to attach the HPC stage 3 to 8 drum to the HPC stage 9 to 12 drum. (k) Definition For the purpose of this AD, ``piece-part exposure'' is removal of the HPC stage 3 to 8 drum from the engine, removal of all blades from the drum, and separation of the HPC stage 3 to 8 drum from the stage 9 to 12 drum.(l) Credit for Previous Actions If you performed an inspection of the HPC stage 3 to 8 drum before the effective date of this AD using one of the following IAE NMSBs, you met the initial inspection requirement of paragraph (e) of this AD: (i) IAE NMSB No. V2500-ENG-72-0608, Revision 3, dated September 20, 2011. (ii) IAE NMSB No. V2500-ENG-72-0615, Revision 3, dated September 20, 2011; IAE Alert NMSB No. V2500-ENG-72-0615, Revision 4, dated May 2, 2013; and IAE Alert NMSB No. V2500-ENG-72-0615, Revision 5, dated August 5, 2014. (iii) IAE NMSB No. V2500-ENG-72-0638, dated April 11, 2013. [[Page 30144]] (m) Alternative Methods of Compliance (AMOCs) The Manager, Engine Certification Office, FAA, may approve AMOCs for this AD. Use the procedures found in 14 CFR 39.19 to make your request. You may email your request to: ANE-AD-AMOC@faa.gov. (n) Related Information (1) For more information about this AD, contact Martin Adler, Aerospace Engineer,Engine Certification Office, FAA, Engine & Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; phone: 781-238-7157; fax: 781-238-7199; email: martin.adler@faa.gov. (2) IAE NMSB No. V2500-ENG-72-0638, dated April 11, 2013; IAE NMSB No. V2500-ENG-72-0637, dated May 2, 2013; IAE NMSB No. V2500- ENG-72-0625, dated October 8, 2014; IAE EM Task 72-41-11-200-001; and IAE EM Task 72-41-11-110-001, which are not incorporated by reference in this AD, can be obtained from IAE, using the contact information in paragraph (o)(3) of this AD. IAE NMSB No. V2500-ENG- 72-0638, dated April 11, 2013 provides guidance on performing the USI. IAE NMSB No. V2500-ENG-72-0637 and IAE EM Task 72-41-11-200-001 provide guidance on performing the FPI. Guidance on performing the ECI can be found in IAE NMSB No. V2500-ENG-72-0625. IAE Engine Manual Task 72-41-11-110-001 provides guidance on cleaning the HPC stage 3 to 8 drum. (o) 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 Alert Non-Modification Service Bulletin No. V2500-ENG-72-A0615, Revision 6, dated September 4, 2014. (ii) Reserved. (3) For IAE service information identified in this AD, contact International Aero Engines AG, 400 Main Street, East Hartford, CT 06118; phone: 860-368-3700; fax: 860-368-4600; email: iaeinfo@iaev2500.com; Internet: https://www.iaeworld.com. (4) You may view this 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 view this service information at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.