Airworthiness Directives; Pratt & Whitney Turbofan Engines

Citation86 FR 36061
Record Number2021-13873
Published date08 July 2021
SectionRules and Regulations
CourtFederal Aviation Administration
Federal Register, Volume 86 Issue 128 (Thursday, July 8, 2021)
[Federal Register Volume 86, Number 128 (Thursday, July 8, 2021)]
                [Rules and Regulations]
                [Pages 36061-36064]
                From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
                [FR Doc No: 2021-13873]
                ========================================================================
                Rules and Regulations
                 Federal Register
                ________________________________________________________________________
                This section of the FEDERAL REGISTER contains regulatory documents
                having general applicability and legal effect, most of which are keyed
                to and codified in the Code of Federal Regulations, which is published
                under 50 titles pursuant to 44 U.S.C. 1510.
                The Code of Federal Regulations is sold by the Superintendent of Documents.
                ========================================================================
                Federal Register / Vol. 86, No. 128 / Thursday, July 8, 2021 / Rules
                and Regulations
                [[Page 36061]]
                DEPARTMENT OF TRANSPORTATION
                Federal Aviation Administration
                14 CFR Part 39
                [Docket No. FAA-2021-0191; Project Identifier AD-2020-01492-E;
                Amendment 39-21633; AD 2021-14-06]
                RIN 2120-AA64
                Airworthiness Directives; Pratt & Whitney Turbofan Engines
                AGENCY: Federal Aviation Administration (FAA), DOT.
                ACTION: Final rule.
                -----------------------------------------------------------------------
                SUMMARY: The FAA is superseding Airworthiness Directive (AD) 2019-21-11
                and AD 2020-07-02. AD 2019-21-11 applied to all Pratt & Whitney (PW)
                PW1519G, PW1521G, PW1521G-3, PW1521GA, PW1524G, PW1524G-3, PW1525G,
                PW1525G-3, PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A model
                turbofan engines. AD 2020-07-02 applied to all PW PW1519G, PW1521G,
                PW1521G-3, PW1521GA, PW1524G, PW1524G-3, PW1525G, and PW1525G-3 model
                turbofan engines. AD 2019-21-11 required initial and repetitive
                borescope inspections (BSIs) of the low-pressure compressor (LPC) rotor
                1 (R1) and, depending on the results of the inspections, replacement of
                the LPC. AD 2020-07-02 required the removal from service of certain
                electronic engine control (EEC) full authority digital electronic
                control (FADEC) software and the installation of a software version
                eligible for installation. This AD continues to require repetitive BSIs
                of certain LPC R1s until replacement of EEC FADEC software with the
                updated software. This AD also requires a BSI after installation of the
                updated EEC FADEC software if certain Onboard Maintenance Message fault
                codes are displayed and meet specified criteria. The FAA is issuing
                this AD to address the unsafe condition on these products.
                DATES: This AD is effective August 12, 2021.
                ADDRESSES: For service information identified in this final rule,
                contact Pratt & Whitney, 400 Main Street, East Hartford, CT 06118;
                phone: (800) 565-0140; email: [email protected]; website: http://fleetcare.pw.utc.com. You may view this service information at the
                Airworthiness Products Section, FAA, 1200 District Avenue, Burlington,
                MA 01803. For information on the availability of this material at the
                FAA, call (781) 238-7759. It is also available at https://www.regulations.gov by searching for and locating Docket No. FAA-2021-
                0191.
                Examining the AD Docket
                 You may examine the AD docket at https://www.regulations.gov by
                searching for and locating Docket No. FAA-2021-0191; 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: Nicholas Paine, Aviation Safety
                Engineer, ECO Branch, FAA, 1200 District Avenue, Burlington, MA 01803;
                phone: (781) 238-7116; fax: (781) 238-7199; email:
                [email protected].
                SUPPLEMENTARY INFORMATION:
                Background
                 The FAA issued a notice of proposed rulemaking (NPRM) to amend 14
                CFR part 39 to supersede AD 2019-21-11, Amendment 39-19777 (84 FR
                57813, October 29, 2019), (AD 2019-21-11) and AD 2020-07-02, Amendment
                39-21106 (85 FR 17742, March 31, 2020), (AD 2020-07-02). AD 2019-21-11
                applied to certain PW PW1519G, PW1521G, PW1521GA, PW1524G, PW1525G,
                PW1521G-3, PW1524G-3, PW1525G-3, PW1919G, PW1921G, PW1922G, PW1923G,
                and PW1923G-A model turbofan engines. AD 2020-07-02 applied to all PW
                PW1519G, PW1521G, PW1521G-3, PW1521GA, PW1524G, PW1524G33, PW1525G, and
                PW1525G33 model turbofan engines.
                 The NPRM published in the Federal Register on March 26, 2021 (86 FR
                16137). The NPRM was prompted by reports of in-flight shutdowns due to
                failure of the LPC R1 and by subsequent findings of cracked LPC R1s
                during inspection. Additionally, the manufacturer performed further
                root cause analysis of the LPC R1 failures and determined the need to
                update the EEC FADEC software to automate rotor speed management and
                limit the maximum climb and maximum continuous thrust ratings. In the
                NPRM, the FAA proposed to retain certain requirements of AD 2019-21-11
                and none of the requirements of AD 2020-07-02. In the NPRM, the FAA
                proposed to continue to require a BSI of certain LPC R1s for damage and
                cracks and, depending on the results of the BSI, replacement of the LPC
                R1. In the NPRM, the FAA proposed to continue to require repetitive
                BSIs of certain LPC R1s until replacement of the EEC FADEC software
                with the updated software. In the NPRM, the FAA also proposed to
                require a BSI of the LPC R1 after installation of the updated EEC FADEC
                software if certain Onboard Maintenance Message fault codes are
                displayed and meet specified criteria.
                Discussion of Final Airworthiness Directive
                Comments
                 The FAA received comments from two commenters. The commenters were
                Air Line Pilots Association, International (ALPA) and Delta Air Lines,
                Inc. (DAL). ALPA supported the proposal without change. DAL supported
                the proposal but recommended certain changes. The following presents
                the comments received on the NPRM and the FAA's response to each
                comment.
                Request To Correct the Effective Date of AD 2019-19-11
                 DAL requested that the FAA correct the reference to the effective
                date of AD 2019-19-11, in paragraph (g)(1)(i) of this AD from October
                29, 2019, to September 26, 2019 (the effective date of AD 2019-19-11).
                 The FAA agrees and has revised paragraph (g)(1)(i) of this AD as
                requested. This change adds no additional burden on any operator who is
                required to comply with this AD.
                [[Page 36062]]
                Request To Allow Use of Later Revisions of Service Information
                 DAL requested that the FAA add the phrase ``or later'' after PW
                Section PW1000G-A-72-00-00-02A-0B5A-A of PW Engine Maintenance Manual
                (EMM), Issue No. 016, dated January 15, 2021, and PW Section PW1000G-A-
                72-31-00-00A-312A-D of PW EMM, Issue No. 016, dated January 11, 2021,
                referenced in Notes 2 and 3 to paragraph (g)(6) of this AD. DAL stated
                that if a maintenance technician were troubleshooting Onboard
                Maintenance Message fault code 7100F0029 or 7100F0030, the maintenance
                technician would be guided to the latest issue of the publication.
                 The FAA disagrees to add the phrase ``or later'' to the required
                actions section as requested by DAL. Notes 2 and 3 to paragraph (g)(6)
                of this AD, which contain references to the sections of the EMM
                specified by DAL, provide guidance for both determining the N1
                Exceedance duration and for performing the BSI. This AD does not
                mandate the use of specific manual revisions for purposes of compliance
                with the required actions.
                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 Pratt & Whitney Service Bulletin (SB) PW1000G-A-
                72-00-0125-00A-930A-D, Issue No. 002, dated October 24, 2019; Pratt &
                Whitney SB PW1000G-A-72-00-0075-00B-930A-D, Issue No. 003, dated
                October 24, 2019; Pratt & Whitney SB PW1000G-A-73-00-0044-00A-930A-D,
                Issue No. 004, dated February 23, 2021; and Pratt & Whitney SB PW1000G-
                A-73-00-0023-00B-930A-D, Issue No. 002, dated February 22, 2021. The
                FAA also reviewed Section PW1000G-A-72-00-00-02A-0B5A-A of Pratt &
                Whitney EMM, Issue No. 016, dated January 15, 2021; and Section
                PW1000G-A-72-31-00-00A-312A-D of Pratt & Whitney EMM, Issue No. 016,
                dated January 11, 2021.
                 Pratt & Whitney SBs PW1000G-A-72-00-0125-00A-930A-D, Issue No. 002,
                dated October 24, 2019, and PW1000G-A-72-00-0075-00B-930A-D, Issue No.
                003, dated October 24, 2019, describe procedures for performing initial
                and repetitive BSI of certain LPC R1s. Pratt & Whitney SB PW1000G-A-73-
                00-0044-00A-930A-D, Issue No. 004, dated February 23, 2021, describes
                procedures for replacing or modifying the EEC to incorporate EEC FADEC
                software version V2.11.10.4. Pratt & Whitney SB PW1000G-A-73-00-0023-
                00B-930A-D, Issue No. 002, dated February 22, 2021, describes
                procedures for replacing or modifying the EEC to incorporate EEC FADEC
                software version V9.5.6.7.
                 Section PW1000G-A-72-00-00-02A-0B5A-A of Pratt & Whitney EMM, Issue
                No. 016, dated January 15, 2021, describes procedures for inspecting
                the engine for possible engine damage after receiving notification of
                an N1 or N2 overspeed operation. Section PW1000G-A-72-31-00-00A-312A-D
                of Pratt & Whitney EMM, Issue No. 016, dated January 11, 2021,
                describes procedures for performing a BSI of the LPC.
                Interim Action
                 The FAA considers this AD to be an interim action. If final
                corrective action is later identified, the FAA might consider
                additional rulemaking.
                Costs of Compliance
                 The FAA estimates that this AD affects 94 engines installed on
                airplanes of U.S. registry.
                 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 EEC FADEC software............ 2 work-hours x $85 per $0 $170 $15,980
                 hour = $170.
                BSI per inspection cycle.............. 2 work-hours x $85 per 0 170 15,980
                 hour = $170.
                ----------------------------------------------------------------------------------------------------------------
                 The FAA estimates the following costs to do any necessary
                replacements 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 LPC R1................................ 40 work-hours x $85 per hour = $156,000 $159,400
                 $3,400.
                BSI of the LPC R1 if Onboard Maintenance 2 work-hours x $85 per hour = 0 170
                 Message fault codes are displayed. $170.
                ----------------------------------------------------------------------------------------------------------------
                 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 individuals.
                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
                [[Page 36063]]
                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
                 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 AD 2019-21-11, Amendment 39-19777
                (84 FR 57813, October 29, 2019); and AD 2020-07-02, Amendment 39-21106
                (85 FR 17742, March 31, 2020); and
                0
                b. Adding the following new airworthiness directive:
                2021-14-06 Pratt & Whitney: Amendment 39-21633; Docket No. FAA-2021-
                0191; Project Identifier AD-2020-01492-E.
                (a) Effective Date
                 This airworthiness directive (AD) is effective August 12, 2021.
                (b) Affected ADs
                 This AD replaces AD 2019-21-11, Amendment 39-19777 (84 FR 57813,
                October 29, 2019); and AD 2020-07-02, Amendment 39-21106 (85 FR
                17742, March 31, 2020).
                (c) Applicability
                 This AD applies to Pratt & Whitney (PW) PW1519G, PW1521G,
                PW1521G-3, PW1521GA, PW1524G, PW1524G-3, PW1525G, PW1525G-3,
                PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A model turbofan
                engines.
                (d) Subject
                 Joint Aircraft System Component (JASC) Code 7230, Turbine Engine
                Compressor Section.
                (e) Unsafe Condition
                 This AD was prompted by reports of in-flight shutdowns due to
                failure of the low-pressure compressor (LPC) rotor 1 (R1) and by
                subsequent findings of cracked LPC R1s during inspection. The FAA is
                issuing this AD to prevent failure of the LPC R1. The unsafe
                condition, if not addressed, could result in uncontained release of
                the LPC R1, damage to the engine, damage to the airplane, and loss
                of control of the airplane.
                (f) Compliance
                 Comply with this AD within the compliance times specified,
                unless already done.
                 (g) Required Actions
                 (1) Except for those model turbofan engines identified in
                paragraph (g)(2) of this AD, perform a borescope inspection (BSI) of
                the LPC R1 for damage and cracks as follows:
                 (i) For engines that have accumulated fewer than 300 flight
                cycles since new (CSN), perform a BSI within 50 flight cycles (FCs)
                from September 26, 2019 (the effective date of AD 2019-19-11), or
                before further flight, whichever occurs later.
                 (ii) For engines that have accumulated fewer than 300 FCs since
                installation of V2.11.7 or V2.11.8 electronic engine control (EEC)
                full authority digital electronic control (FADEC) software, perform
                a BSI within 50 FCs from October 29, 2019 (the effective date of AD
                2019-21-11), or before further flight, whichever occurs later.
                 (iii) Thereafter, at intervals not to exceed 50 FCs until the
                engine accumulates 300 flight CSN or accumulates 300 FCs since the
                installation of V2.11.7 or V2.11.8 EEC FADEC software, whichever
                occurs later, repeat the BSI for damage and cracks.
                 (iv) Perform the BSI required by paragraphs (g)(1)(i) through
                (iii) of this AD at the following LPC R1 locations:
                 (A) The blade tip;
                 (B) The leading edge;
                 (C) The leading edge fillet to rotor platform radius; and
                 (D) The airfoil convex side root fillet to rotor platform
                radius.
                 (2) For any affected PW model turbofan engine installed as a
                ``zero time spare,'' except for PW1519G, PW1521GA, PW1919G, and
                PW1922G model turbofan engines, within 15 FCs from the effective
                date of this AD, and thereafter at intervals not to exceed 15 FCs
                until the engine accumulates 300 flight CSN, perform a BSI of the
                LPC R1 for damage and cracks at the locations in paragraph
                (g)(1)(iv) of this AD.
                 (3) Based on the results of the BSIs required by paragraphs
                (g)(1) and (2) of this AD, before further flight, remove and replace
                the LPC R1 if:
                 (i) There is damage on an LPC R1 that exceeds serviceable
                limits; or
                 (ii) Any crack in the LPC R1 exists.
                 Note 1 to paragraph (g)(3): Guidance on determining the
                serviceable limits in paragraph (g)(3) of this AD can be found in PW
                Service Bulletin (SB) PW1000G-A-72-00-0125-00A-930A-D, Issue No.
                002, dated October 24, 2019, and PW SB PW1000G-A-72-00-0075-00B-
                930A-D, Issue No. 003, dated October 24, 2019.
                 (4) For PW PW1519G, PW1521G, PW1521G-3, PW1521GA, PW1524G,
                PW1524G-3, PW1525G, and PW1525G-3 model turbofan engines, within 120
                days from the effective date of this AD, remove the EEC FADEC
                software if the version is earlier than EEC FADEC software version
                V2.11.10.4 and install EEC FADEC software that is eligible for
                installation.
                 (5) For PW PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A
                model turbofan engines, within 120 days of the effective date of
                this AD, remove the EEC FADEC software if the version is earlier
                than EEC FADEC software version V9.5.6.7 and install EEC FADEC
                software that is eligible for installation.
                 (6) For PW PW1519G, PW1521G, PW1521G-3, PW1521GA, PW1524G,
                PW1524G-3, PW1525G, and PW1525G-3 model turbofan engines with EEC
                FADEC software version V2.11.10.4 or later installed, within 15 FCs
                after receipt of Onboard Maintenance Message fault code 7100F0029 or
                7100F0030, perform a BSI of the LPC R1 for damage and cracks at the
                locations in paragraph (g)(1)(iv) of this AD if the fault code is
                displayed on the ``Active Failure Messages'' and meets the following
                criteria:
                 (i) N1 Exceedance is above 95.2%;
                 (ii) N1 Exceedance occurred above 29,100 feet; and
                 (iii) N1 Exceedance occurs for a duration of 40 seconds (15
                seconds of cockpit display) or more during any flight.
                 Note 2 to paragraph (g)(6): Guidance on determining the N1
                Exceedance duration can be found in PW Section PW1000G-A-72-00-00-
                02A-0B5A-A of PW Engine Maintenance Manual (EMM), Issue No. 016,
                dated January 15, 2021.
                 Note 3 to paragraph (g)(6): Guidance on performing the BSI can
                be found in PW Section PW1000G-A-72-31-00-00A-312A-D of PW EMM,
                Issue No. 016, dated January 11, 2021.
                 (7) As the result of the BSI of the LPC R1 required by paragraph
                (g)(6) of this AD, before further flight, remove and replace the LPC
                R1 if:
                 (i) There is damage on an LPC R1 that exceeds serviceable
                limits; or
                 (ii) Any crack in the LPC R1 exists.
                 (h) Terminating Actions
                 (1) For PW1519G, PW1521G, PW1521G-3, PW1521GA, PW1524G, PW1524G-
                3, PW1525G, and PW1525G-3 model turbofan engines, the installation
                of EEC FADEC software required by paragraph (g)(4) of this AD
                terminates the repetitive BSI requirements of paragraphs (g)(1) and
                (2) of this AD.
                [[Page 36064]]
                 (2) For PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A model
                turbofan engines, the installation of EEC FADEC software required by
                paragraph (g)(5) of this AD terminates the repetitive BSI
                requirements of paragraphs (g)(1) and (2) of this AD.
                 (i) Installation Prohibition
                 After the effective date of this AD, do not install EEC FADEC
                software earlier than version V2.11.10.4 or version V9.5.6.7 onto
                any engine identified in paragraph (c) of this AD.
                 (j) Definitions
                 (1) For the purpose of this AD, a ``zero time spare'' is an
                engine that had zero flight hours time-in-service when it was
                installed on an airplane after the airplane had entered service.
                 (2) For the purpose of this AD, ``EEC FADEC software that is
                eligible for installation'' is EEC FADEC software version V2.11.10.4
                or later for PW1519G, PW1521G, PW1521G-3, PW1521GA, PW1524G,
                PW1524G-3, PW1525G, PW1525G-3 model turbofan engines and EEC FADEC
                software version V9.5.6.7 or later for PW1919G, PW1921G, PW1922G,
                PW1923G, and PW1923G-A model turbofan engines.
                (k) 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 Related Information. You may email your request 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.
                 (3) AMOCs approved for AD 2019-21-11 (84 FR 57813, October 29,
                2019) are approved as AMOCs for the corresponding provisions of this
                AD except for paragraphs (g)(1)(i) through (iv) and (g)(3)(i) and
                (ii) of this AD.
                (l) Related Information
                 For more information about this AD, contact Nicholas Paine,
                Aviation Safety Engineer, ECO Branch, FAA, 1200 District Avenue,
                Burlington, MA 01803; phone: (781) 238-7116; fax: (781) 238-7199;
                email: [email protected].
                (m) Material Incorporated by Reference
                 None.
                 Issued on June 23, 2021.
                Lance T. Gant,
                Director, Compliance & Airworthiness Division, Aircraft Certification
                Service.
                [FR Doc. 2021-13873 Filed 7-7-21; 8:45 am]
                BILLING CODE 4910-13-P
                

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