AD 2005-18-02

[Federal Register Volume 70, Number 169 (Thursday, September 1, 2005)]
[Rules and Regulations]
[Pages 52004-52006]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 05-17319]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 98-ANE-43-AD; Amendment 39-14242; AD 2005-18-02]
RIN 2120-AA64


Airworthiness Directives; Pratt & Whitney JT8D-209, -217, -217A, 
-217C, and -219 Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

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SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for Pratt & Whitney (PW) JT8D-209, -217, -217A, -217C, and -219 
turbofan engines. That AD currently requires revisions to the engine 
manufacturer's time limits section (TLS) to include enhanced inspection 
of selected critical life-limited parts at each piece-part opportunity. 
This AD requires modifying the airworthiness limitations section of the 
manufacturer's manual and an air carrier's approved continuous 
airworthiness maintenance program to incorporate additional inspection 
requirements. An FAA study of in-service events involving uncontained 
failures of critical rotating engine parts has indicated the need for 
mandatory inspections. The mandatory inspections are needed to identify 
those critical rotating parts with conditions, which if allowed to 
continue in service, could result in uncontained failures. We are 
issuing this AD to prevent critical life-limited rotating engine part 
failure, which could result in an uncontained engine failure and damage 
to the airplane.

DATES: This AD becomes effective February 28, 2006.

ADDRESSES: You may examine the AD docket at the FAA, New England 
Region, Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA.

FOR FURTHER INFORMATION CONTACT: Keith Lardie, Aerospace Engineer, 
Engine Certification Office, FAA, Engine and Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803-5299; telephone (781) 
238-7189, fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39 
with a proposed AD. The proposed AD applies to PW JT8D-209, -217, -
217A, -217C, and -219 turbofan engines. We published the proposed AD in 
the Federal Register on August 18, 2004 (69 FR 51196). That action 
proposed to require modifying the time limitations section of the 
manufacturer's manual and an air carrier's approved continuous 
airworthiness maintenance program to incorporate additional inspection 
requirements.

Examining the AD Docket

    You may examine the AD Docket (including any comments and service 
information), by appointment, between 8 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. See ADDRESSES for the 
location.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comments received.

Request To Increase the Costs of Compliance

    Two commenters ask us to reconsider the necessary equipment and 
cost to do the automated eddy current inspections and to revise the 
Costs of Compliance to include the necessary tooling. The commenters 
suggest the notice of proposed rulemaking (NPRM) fails to recognize the 
large investment to get the equipment needed for the eddy current 
inspection. We don't agree. The AD doesn't require air carriers to 
invest in tooling and equipment or hire more personnel to comply with 
the proposed AD. The AD requires adding the new eddy current inspection 
to the TLS of the engine manufacturer's manual, and to the air 
carriers' approved maintenance manuals. Operators can choose to buy 
equipment to perform the inspection, or they may send the disk to an 
approved service provider.

Request for an Annual Cost for the Recurring Inspections

    One commenter states the NPRM implies a onetime cost for the 
inspection, but that it is a recurring cost. We don't agree. The Costs 
of Compliance section of the NPRM states the estimated cost for each 
inspection on each engine. We used the current shop visit rate for the 
JT8D engine to calculate the yearly recurring cost for each engine. The 
air carriers can use their own specific costs for their individual JT8D 
fleet to calculate their inspection cost.

Question About the Cost for the Inspection

    One commenter states the costs for the inspections are 
significantly different from the costs we specified in the NPRM. We 
don't agree. We based

[[Page 52005]]

our cost estimate on inspection times provided by the engine 
manufacturer. We understand that cost estimates can vary depending on 
the service provider. However, we consider basing our cost estimate on 
inspection times provided by the engine manufacturer to be the most 
accurate approach to estimating the cost to comply with the AD.

Concern About Increased Inventory Levels for Parts Not Reflected in the 
Cost Estimate

    The same commenter suggests that quoted turnaround time for the 
inspection will make air carriers increase inventory levels for the 
affected parts. The commenter also suggests the cost estimate doesn't 
reflect the cost of the increased inventory. We don't agree. The AD 
requires adding the new eddy current inspection to the TLS of the 
engine manufacturer's manual, and to the air carrier's approved 
maintenance manuals. The AD doesn't require air carriers to increase 
spare parts inventory levels or specify the logistics of performing the 
inspections.

Requests To Allow Operators To Use Equivalent Equipment To Perform the 
Inspections

    Three commenters ask that we allow them to use equipment that 
equals the inspection equipment specified by the engine manufacturer. 
The commenters ask us to allow them to use equipment they already use 
for other mandated inspections. The commenters suggest that using the 
single-source equipment specified by the manufacturer will cause an 
undue burden. We don't agree. We don't intend that this proposed AD 
specify only one method, or limit the inspection to one method of 
inspection. This AD requires the operators to revise the TLS to include 
a mandatory opportunistic inspection. The engine manufacturer developed 
a validated inspection procedure using specific tooling and equipment 
that provides an acceptable inspection technique. However, operators 
may still seek approval from the manufacturer to use alternative tools 
or methods of inspections other than those specified in the engine 
manual. Providing flexibility for the engine manufacturers to revise 
their engine manuals as they fine-tuned their inspection methods and 
developed alternatives is part of the outcome of working with the Air 
Transportation Association, operators, and manufacturers.

Question About the Completeness of Paragraph (i) of the Proposed AD

    One commenter states the last sentence in paragraph (i), under 
``Maintaining Records of the Mandatory Inspections'' does not seem 
complete. The commenter states the current sentence reads: ``For air 
carriers operating under part 121, you may use either the system 
established to comply with the compliance times unless specified unless 
the actions have already been done.'' We don't agree the sentence is 
incomplete. The sentence reads ``For air carriers operating under part 
121, you may use either the system established to comply with section 
121.369 or use an alternative system that your principal maintenance 
inspector has accepted if that alternative system''.

Request To Extend the Compliance Time of the Final Rule

    Two commenters ask that we extend the effective date of the AD to 
allow an additional six to eight months. The commenters suggest the 
extension is necessary to procure the eddy current inspection 
equipment, train personnel, and to allow PW to revise their engine 
manuals to define clearly the approval procedure for alternate 
equipment. We agree. We changed the effective date from 30 days after 
publication in the Federal Register to 180 days after publication in 
the Federal Register.

Conclusion

    We have carefully reviewed the available data, including the 
comments received, and determined that air safety and the public 
interest require adopting the AD with the changes described previously. 
We have determined that these changes will neither increase the 
economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

    There are about 2,345 Pratt & Whitney JT8D-209, -217, -217A, -217C, 
and -219 turbofan engines of the affected design in the worldwide 
fleet. We estimate that this AD will affect 1,143 engines installed on 
airplanes of U.S. registry. We also estimate that it will take about 8 
work hours per engine to perform the proposed inspections, and that the 
average labor rate is $65 per work hour. Since this is an added 
inspection requirement, included as part of the normal maintenance 
cycle, no additional part costs are involved. Based on these figures, 
we estimate the total cost of the AD to U.S. operators to be $594,360.

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.
    We are 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 develop on products identified in this 
rulemaking action.

Regulatory Findings

    We have determined that this proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would 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 proposed 
regulation:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979); and
    3. Would not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared a summary of the costs to comply with this proposal and 
placed it in the AD Docket. You may get a copy of this summary by 
sending a request to us at the address listed under ADDRESSES. Include 
``AD Docket No. 98-ANE-43-AD'' in your request.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the Federal Aviation Administration 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.

[[Page 52006]]

Sec.  39.13  [Amended]

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2. The FAA amends Sec.  39.13 by removing Amendment 39-12797 (67 FR 
44527, July 3, 2002) and by adding a new airworthiness directive, 
Amendment 39-14242, to read as follows:

2005-18-02 Pratt & Whitney: Amendment 39-14242. Docket No. 98-ANE-
43-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective February 
28, 2006.

Affected ADs

    (b) This AD supersedes AD 2002-13-09.

Applicability

    (c) This AD applies to Pratt & Whitney (PW) JT8D-209, -217, -
217A, -217C, and -219 turbofan engines. These engines are installed 
on, but not limited to Boeing 727 and McDonnell Douglas MD-80 series 
airplanes.

Unsafe Condition

    (d) This AD results from the need to require enhanced inspection 
of selected critical life-limited parts of JT8D-209, -217, -217A, -
217C, and ``219 turbofan engines. We are issuing this AD to prevent 
critical life-limited rotating engine part failure, which could 
result in an uncontained engine failure and damage to the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.
    (f) Within the next 30 days after the effective date of this AD, 
(1) revise the Time Limits section (TLS) of the manufacturer's 
Engine Manual, Part Number 773128, as appropriate for PW JT8D-209, -
217, -217A, -217C, and -219 turbofan engines, and (2) for air 
carriers, revise the approved mandatory inspections section of the 
continuous airworthiness maintenance program, by adding the 
following:

``Critical Life Limited Part Inspection

    A. Inspection Requirements:
    (1) This section contains the definitions for individual engine 
piece-parts and the inspection procedures, which are necessary, when 
these parts are removed from the engine.
    (2) It is necessary to do the inspection procedures of the 
piece-parts in Paragraph B when:
    (a) The part is removed from the engine and disassembled to the 
level specified in paragraph B and
    (b) The part has accumulated more than 100 cycles since the last 
piece part inspection, provided that the part is not damaged or 
related to the cause of its removal from the engine.
    (3) The inspections specified in this section do not replace or 
make unnecessary other recommended inspections for these parts or 
other parts.

B. Parts Requiring Inspection.

    Note: Piece part is defined as any of the listed parts with all 
the blades removed.


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               Description                    Section     Inspection No.
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Hub (Disk), 1st Stage Compressor:
    Hub Detail--All P/Ns................        72-33-31   -02, -03, -04
    Hub Assembly--All P/Ns..............        72-33-31   -02, -03, -04
Disk, 13th Stage Compressor--All P/Ns...        72-36-47             -02
HP Turbine, First Stage:
    Rotor Assembly--All P/Ns............        72-52-02             -04
    Disk--All P/Ns......................        72-52-02             -03
Disk, 2nd Stage Turbine--All P/Ns.......        72-53-16             -02
Disk, 3rd Stage Turbine--All P/Ns.......        72-53-17             -02
Disk, 4th Stage Turbine--All P/Ns.......        72-53-18             -02
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Alternative Methods of Compliance

    (g) You must perform these mandatory inspections using the TLS 
and the applicable Engine Manual unless you receive approval to use 
an alternative method of compliance under paragraph (h) of this AD. 
Section 43.16 of the Federal Aviation Regulations (14 CFR 43.16) may 
not be used to approve alternative methods of compliance or 
adjustments to the times in which these inspections must be 
performed.
    (h) The Manager, Engine Certification Office, has the authority 
to approve alternative methods of compliance for this AD if 
requested using the procedures found in 14 CFR 39.19.

Maintaining Records of the Mandatory Inspections

    (i) You have met the requirements of this AD by using a TLS of 
the manufacturer's engine manual changed as specified in paragraph 
(f) of this AD, and, for air carriers operating under part 121 of 
the Federal Aviation Regulations (14 CFR part 121), by modifying 
your continuous airworthiness maintenance plan to reflect those 
changes. You must maintain records of the mandatory inspections that 
result from those changes to the TLS according to the regulations 
governing your operation. You do not need to record each piece-part 
inspection as compliance to this AD. For air carriers operating 
under part 121, you may use either the system established to comply 
with section 121.369 or use an alternative system that your 
principal maintenance inspector has accepted if that alternative 
system:
    (1) Includes a method for preserving and retrieving the records 
of the inspections resulting from this AD; and
    (2) Meets the requirements of section 121.369(c); and
    (3) Maintains the records either indefinitely or until the work 
is repeated.
    (j) These record keeping requirements apply only to the records 
used to document the mandatory inspections required as a result of 
revising the TLS as specified in paragraph (f) of this AD, and do 
not alter or amend the record keeping requirements for any other AD 
or regulatory requirement.

Related Information

    (k) None.

    Issued in Burlington, Massachusetts, on August 24, 2005.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 05-17319 Filed 8-31-05; 8:45 am]
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