2024-05-11: Turbine Engine Compressor Section; Turbine Section

1. The authority citation for part 39 continues to read as follows: Authority: 49 U.S.C. 106(g), 40113, 44701. 2. The FAA amends § 39.13 by: a. Removing Airworthiness Directive 2022-19-15, Amendment 39-22184 (87 FR 59660, October 3, 2022; corrected October 24, 2022 (87 FR 64156)); and Airworthiness Directive 2023-16-07, Amendment 39-22526 (88 FR 56999, August 22, 2023); and b. Adding the following new airworthiness directive: 2024-05-11 International Aero Engines, LLC: Amendment 39-22703; Docket No. FAA-2023-2401; Project Identifier AD-2023-01278-E. (a) Effective Date This airworthiness directive (AD) is effective April 11, 2024. (b) Affected ADs (1) This AD replaces AD 2022-19-15, Amendment 39-22184 (87 FR 59660, October 3, 2022; corrected October 24, 2022 (87 FR 64156)). (2) This AD replaces AD 2023-16-07, Amendment 39-22526 (88 FR 56999, August 22, 2023) (AD 2023-16-07). (c) Applicability (1) This AD applies to International Aero Engines, LLC (IAE LLC) Model PW1122G-JM, PW1124G1-JM, PW1124G-JM, PW1127G-JM, PW1127G1-JM, PW1127G1A-JM, PW1127G1B-JM, PW1127GA-JM, PW1129G-JM, PW1130G-JM, PW1133G-JM, PW1133GA-JM, PW1428G-JM, PW1428GA-JM, PW1428GH-JM, PW1431G-JM, PW1431GA-JM, and PW1431GH-JM engines with an installed: (i) High-pressure compressor (HPC) 7th-stage integrally bladed rotor (IBR-7) having part number (P/N) 30G2307 or 30G4407; (ii) HPC 8th-stage integrally bladed rotor (IBR-8) having P/N 30G5608, 30G5908, or 30G8908; (iii) HPC rear hub having P/N 30G4008 or 30G8208; (iv) High-pressure turbine (HPT) 1st-stage hub having P/N 30G4201, 30G6201, or 30G7301; or (v) HPT 2nd-stage hub having P/N 30G3902, 30G5502, or 30G6602. (2) This AD does not apply to parts identified in paragraphs (c)(1)(i) through (v) of this AD if those parts were manufactured from powdered metal material produced prior to November 1, 2015, or after September 1, 2021, as identified by part serial number in Tables 1, 2, and 3 of PW Special Instruction (SI) No. 222F-23, Revision B, dated March 1, 2024 (PW SI No. 222F-23, Revision B) or in the original manufacturing records for the part. (3) If the original manufacturing records do not identify the production date of the powdered metal used to make the parts identified in paragraphs (c)(1)(i) through (v) of this AD, and the part serial number is not listed in Tables 1, 2, and 3 of PW SI No. 222F-23, Revision B, then the part is subject to the requirements of this AD. (d) Subject Joint Aircraft System Component (JASC) Code 7230, Turbine Engine Compressor Section; 7250, Turbine Section. (e) Unsafe Condition This AD was prompted by an analysis of an event involving an IAE LLC Model PW1127GA-JM engine, which experienced failure of an HPC IBR-7 that resulted in an engine shutdown and aborted takeoff. The FAA is issuing this AD to prevent failure of the HPT 1st-stage hub, HPT 2nd-stage hub, HPC IBR-7, and HPC IBR-8. The unsafe condition, if not addressed, could result in uncontained hub failure, release of high-energy debris, 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) Retained Inspections From AD 2023-16-07, With No Changes (1) This paragraph restates the requirements of paragraph (g)(1) of AD 2023-16-07. For Group 1 and Group 2 engines with an installed HPT 1st-stage hub having part number (P/N) 30G7301 and a serial number (S/N) listed in Tables 1, 2, 3, or 4 of PW Special Instruction (SI) No. 149F-23, dated August 4, 2023 (PW SI No. 149F-23), within 30 days after August 28, 2023 (the effective date of AD 2023-16-07), perform an AUSI of the HPT 1st-stage hubs for cracks in accordance with the Accomplishment Instructions, paragraph 9.A. or 9.B., as applicable, of Pratt & Whitney (PW) Service Bulletin PW1000G-C-72-00-0188-00A-930A-D, Issue No: 002, dated July 8, 2022 (PW1000G-C-72-00-0188-00A-930A-D, Issue No: 002). (2) This paragraph restates the requirements of paragraph (g)(2) of AD 2023-16-07. For Group 1 and Group 2 engines with an installed HPT 2nd-stage hub having P/N 30G6602 and an S/N listed in Tables 1, 2, 3, or 4 of PW SI No. 149F-23, within 30 days after August 28, 2023 (the effective date of AD 2023-16-07), perform an AUSI of the HPT 2nd-stage hubs for cracks in accordance with the Accomplishment Instructions, paragraph 9.C. or 9.D., as applicable, of PW1000G-C-72-00-0188-00A-930A-D, Issue No: 002. (h) New Required Actions (1) For Group 1 and Group 2 engines with an affected HPC IBR-7 having P/N 30G2307 or 30G4407, or an affected HPC IBR-8 having P/N 30G5608, 30G5908, or 30G8908, at the next HPC engine shop visit and thereafter at every HPC engine shop visit, perform an angled ultrasonic scan inspection (AUSI) of the affected HPC IBR-7 or HPC IBR-8, as applicable, for cracks in accordance with the Accomplishment Instructions, paragraph 4.E.(1) or 4.E.(2), of PW Alert Service Bulletin (ASB) PW1000G-C-72-00-0224-00A-930A-D, Issue No: 001, dated November 3, 2023 (PW ASB PW1000G-C-72-00-0224-00A-930A-D, Issue No: 001). (2) For Group 1 and Group 2 engines with an affected HPT 1st-stage hub having P/N 30G7301 or an HPT 2nd-stage hub having P/N 30G6602, before exceeding the applicable compliance time in Table 1 to paragraph (h)(2) of this AD, except as required by paragraphs (g)(1) and (2) and paragraph (h)(7) of this AD, perform an AUSI of the affected HPT 1st-stage hub or HPT 2nd-stage hub, as applicable, for cracks in accordance with the Accomplishment Instructions, paragraph 1.D.(7)(a) or 1.D.(7)(b) of PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002, dated December 12, 2023 (PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002). Thereafter, repeat the AUSI at the applicable interval in Table 1 to paragraph (h)(2) of this AD. Table 1 to Paragraph (h)(2) -AUSI Compliance Times Engine group AUSI performed prior to effective date of this AD Compliance time Repetitive interval 1 No Before accumulating 3,800 cycles since new (CSN) or within 100 flight cycles (FCs) after the effective date of this AD, whichever occurs later Thereafter at each HPT engine shop visit or before exceeding 3,800 FCs from the last AUSI of the affected hub, whichever occurs first. 1 Yes At the next HPT engine shop visit, not to exceed 3,800 FCs since the previous AUSI, or within 100 FCs after the effective date of this AD, whichever occurs later Thereafter at each HPT engine shop visit or before exceeding 3,800 FCs from the last AUSI of the affected hub, whichever occurs first. 2 No Before accumulating 2,800 CSN or within 100 FCs after the effective date of this AD, whichever occurs later Thereafter at each HPT engine shop visit or before exceeding 2,800 FCs from the last angled AUSI of the affected hub, whichever occurs first. 2 Yes At the next HPT engine shop visit, not to exceed 2,800 FCs since the previous AUSI, or within 100 FCs after the effective date of this AD, whichever occurs later Thereafter at each HPT engine shop visit or before exceeding 2,800 FCs from the last AUSI of the affected hub, whichever occurs first. (3) For Group 1 and Group 2 engines with an affected part listed in Table 2 to paragraph (h)(3) of this AD, at the next HPT engine shop visit not to exceed the applicable cyclic limit specified in Table 2 to paragraph (h)(3) of this AD, or 100 FCs after the effective date of the AD, whichever occurs later, except as required by paragraphs (h)(6) and (8) of this AD, remove the affected part from service and replace with a part eligible for installation. Table 2 to Paragraph (h)(3) -Part Replacement Compliance Times Engine group AUSI performed prior to effective date of this AD Part name Part No. Cyclic limit 1 Yes HPT 1st-stage hub 30G4201 or 30G6201 3,800 FCs since last AUSI. 1 No HPT 1st-stage hub 30G4201 or 30G6201 3,800 CSN. 1 Yes HPT 2nd-stage hub 30G3902 or 30G5502 3,800 FCs since last AUSI or 7,000 CSN, whichever comes first. 1 No HPT 2nd-stage hub 30G3902 or 30G5502 3,800 CSN. 2 Yes HPT 1st-stage hub 30G4201 or 30G6201 2,800 FCs since last AUSI. 2 No HPT 1st-stage hub 30G4201 or 30G6201 2,800 CSN. 2 Yes HPT 2nd-stage hub 30G3902 or 30G5502 2,800 FCs since last AUSI or 5,000 CSN, whichever comes first. 2 No HPT 2nd-stage hub 30G3902 or 30G5502 2,800 CSN. (4) For Group 1 and Group 2 engines with an affected part listed in Table 3 to paragraph (h)(4) of this AD, before exceeding the applicable compliance times specified in Table 3 to paragraph (h)(4) of this AD, remove the affected part from service and replace with a part eligible for installation. Table 3 to Paragraph (h)(4) -Part Replacement Compliance Times Engine group Part name Part No. Compliance time 1 and 2 HPC rear hub 30G4008 At the next HPC shop visit or HPT shop visit, whichever occurs first after the effective date of this AD. 1 HPC rear hub 30G8208 Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 1 HPC IBR-7 30G2307 or 30G4407 Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 1 HPC IBR-8 30G5608 or 30G5908 or 30G8908 Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 1 HPT 1st-stage hub 30G7301 Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 1 HPT 2nd-stage hub 30G6602 Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 2 HPC rear hub 30G8208 Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 2 HPC IBR-7 30G2307 or 30G4407 Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 2 HPC IBR-8 30G5608 or 30G5908 or 30G8908 Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 2 HPT 1st-stage hub 30G7301 Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. 2 HPT 2nd-stage hub 30G6602 Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. (5) For affected parts that have been operated in a Group 1 and Group 2 configuration, calculate part replacement and AUSI times required by paragraphs (h)(2) through (4) using the note to Table 3 of the compliance paragraph of PW ASB PW1000G-C-72-00-0224-00A-930A-D, Issue No: 001 or PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002, as applicable, which addresses calculating mixed model cycles. (6) For Group 1 and Group 2 engines with an installed HPT 1st-stage hub having P/N 30G6201 or an HPT 2nd-stage hub having P/N 30G5502 and an S/N listed in Tables 1, 2, 3, or 4 of PW SI No. 149F-23 that has not had an AUSI performed before the effective date of this AD, before further flight, remove the affected hub from service. (7) For Group 1 and Group 2 engines with an installed HPT 1st-stage hub having P/N 30G7301 or an HPT 2nd-stage hub having P/N 30G6602 with an S/N listed in Tables 1, 2, 3, or 4 of PW SI No. 198F-23, dated November 3, 2023 (PW SI No. 198F-23), within 100 FC after the effective date of this AD, perform an AUSI of the affected hub for cracks in accordance with the Accomplishment Instructions, paragraph 1.D.(7)(a) or 1.D.(7)(b) of PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002. (8) For Group 1 and Group 2 engines with an installed HPT 1st-stage hub having P/N 30G6201 or an HPT 2nd-stage hub having P/N 30G5502 with an S/N listed in Tables 1, 2, 3, or 4 of PW SI No. 198F-23, within 100 FC after the effective date of this AD, remove the hub from service and replace with a part eligible for installation. (9) If any crack indication is found during any AUSI required by this AD, before further flight, remove the affected part from service and replace with a part eligible for installation. (10) If an affected part has accumulated 100 FCs or less since the last AUSI, reinspection is not required provided that the part was not damaged during removal from the engine. (i) Definitions (1) For the purposes of this AD, "Group 1 engines" are IAE LLC Model PW1122G-JM, PW1124G1-JM, PW1124G-JM, PW1127G-JM, PW1127G1-JM, PW1127G1A-JM, PW1127G1B-JM, and PW1127GA-JM engines. (2) For the purposes of this AD, "Group 2 engines" are IAE LLC Model PW1129G-JM, PW1130G-JM, PW1133G-JM, PW1133GA-JM, PW1428G-JM, PW1428GA-JM, PW1428GH-JM, PW1431G-JM, PW1431GA-JM, and PW1431GH-JM engines. (3) For the purposes of this AD, an "HPC engine shop visit" is the induction of an engine into the shop for maintenance involving the separation of the H-flange. (4) For the purposes of this AD, an "HPT engine shop visit" is the induction of an engine into the shop for maintenance involving the separation of the M-flange. (5) For the purposes of this AD, a "part eligible for installation" is: (i) An HPC IBR-7 having P/N 30G2307 or 30G4407 that has passed the AUSI required by paragraph (h)(1) of this AD or is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N. (ii) An HPC IBR-8 having P/N 30G5608, 30G5908, or 30G8908 that has passed the AUSI required by paragraph (h)(1) of this AD or is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N. (iii) An HPT 1st-stage hub having P/N 30G7301 that has passed the AUSI required by paragraph (h)(2) of this AD or is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N. (iv) An HPT 2nd-stage hub having P/N 30G6602 that has passed the AUSI required by paragraph (h)(2) of this AD or is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N. (v) An HPC rear hub having P/N 30G8208 and is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N. (j) Credit for Previous Actions (1) This paragraph provides credit for the actions specified in paragraph (g)(1) and (2) of this AD, if those actions were performed before the effective date of this AD using PW Service Bulletin PW1000G-C-72-00-0188-00A-930A-D, Issue No: 001, dated September 13, 2021. This service information is not incorporated by reference in this AD. (2) This paragraph provides credit for the actions specified in paragraph (h)(2) and (6) of this AD, if those actions were performed before the effective date of this AD using PW Alert Service Bulletin PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 001, dated November 3, 2023. This service information is not incorporated by reference in this AD. (k) Alternative Methods of Compliance (AMOCs) (1) The Manager, AIR-520 Continued Operational Safety 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 AIR-520 Continued Operational Safety Branch, send it to the attention of the person identified in paragraph (l)(1) 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. (l) Additional Information (1) For more information about this AD, contact Carol Nguyen, Aviation Safety Engineer, FAA, 2200 South 216th Street, Des Moines, WA 98198; phone: (781) 238-7655; email: carol.nguyen@faa.gov. (2) Service information identified in this AD that is not incorporated by reference is available at the address specified in paragraph (m)(6) of this AD. (m) 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. (3) The following service information was approved for IBR on April 11, 2024. (i) Pratt & Whitney Alert Service Bulletin PW1000G-C-72-00-0224-00A-930A-D, Issue No: 001, dated November 3, 2023. (ii) Pratt & Whitney Alert Service Bulletin PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002, dated December 12, 2023. (iii) Pratt & Whitney Special Instruction No. 198F-23, dated November 3, 2023. (iv) Pratt & Whitney Special Instruction No. 222F-23, Revision B, dated March 1, 2024. (4) The following service information was approved for IBR on August 28, 2023 (88 FR 56999, August 22, 2023). (i) Pratt & Whitney Special Instruction No. 149F-23, dated August 4, 2023. (ii) [Reserved] (5) The following service information was approved for IBR on November 7, 2022 (87 FR 59660, October 3, 2022; corrected October 24, 2022 (87 FR 64156)). (i) Pratt & Whitney Service Bulletin PW1000G-C-72-00-0188-00A-930A-D, Issue No: 002, dated July 8, 2022. (ii) [Reserved] (6) For Pratt & Whitney service information that is incorporated by reference, contact International Aero Engines, LLC, 400 Main Street, East Hartford, CT 06118; phone: (860) 565-0140; email: help24@pw.utc.com; website: connect.prattwhitney.com. (7) You may view this service information that is incorporated by reference 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. (8) You may view this material at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, visit www.archives.gov/federal-register/cfr/ibr-locations or email fr.inspection@nara.gov. Issued on March 8, 2024. Victor Wicklund, Deputy Director, Compliance & Airworthiness Division, Aircraft Certification Service. [FR Doc. 2024-06419 Filed 3-22-24; 11:15 am]BILLING CODE 4910-13-P