2001-25-11 Pratt and Whitney: Amendment 39-12564. Docket No. 2000-NE-47-AD. Supersedes AD 2001-15-12, Amendment 39-12346, and AD 99-17-16, Amendment 39-11263.
Applicability: This airworthiness directive (AD) is applicable to Pratt and Whitney (PW) model PW4050, PW4052, PW4056, PW4060, PW4060A, PW4060C, PW4062, PW4152, PW4156, PW4156A, PW4158, PW4160, PW4460, PW4462, and PW4650 turbofan engines. These engines are installed on, but not limited to, certain models of Airbus Industrie A300, Airbus Industrie A310, Boeing 747, Boeing 767, and McDonnell Douglas MD-11 series airplanes.
Note 1: This AD applies to each engine identified in the preceding applicability provision, regardless of whether it has been modified, altered, or repaired in the area subject to the requirements of this AD. For engines that have been modified, altered, or repaired so that the performance of the requirements of this AD is affected, the owner/operator must request approval for an alternative method ofcompliance in accordance with paragraph (o) of this AD. The request should include an assessment of the effect of the modification, alteration, or repair on the unsafe condition addressed by this AD; and, if the unsafe condition has not been eliminated, the request should include specific proposed actions to address it.
Compliance: Compliance with this AD is required as indicated, unless already done.
To prevent engine power losses due to high pressure compressor (HPC) surge, do the following:
(a) When complying with this AD, determine the configuration and category of each engine on each airplane as follows:
(1) Use the following table 1 to determine the configuration of the engine:
Table 1.--Engine Configuration Listing
Configuration
Configuration
designator
Description
(i) Phase 1 without high pressure turbine (HPT) 1st turbine vane cut back (1TVCB).
A
Engines that did not incorporate the Phase 3 configuration at the time they were originally manufactured, or have not been converted to Phase 3 configuration; and have not incorporated HPT 1TVCB using any revision of SB PW4ENG 72-514.
(ii) Phase 1 with 1TVCB
B
Same as configuration (1) except that HPT 1TVCB has been incorporated using any revision of SB PW4ENG 72-514.
(iii) Phase 3, 2nd Run
C
Engines that incorporated the Phase 3 configuration at the time they were originally manufactured, or have been converted to the Phase 3 configuration during service; and that have had at least one HPC overhaul since new.
(iv) Phase 3, 1st Run
D
Same as configuration (3) except that the engine has not had an HPC overhaul since new.
(v) HPC Cutback Stator Configuration Engines.
E
Engines that currently incorporate any revision of SB's PW4ENG72-706, PW4ENG72-704, or PW4ENG72-711
(vi) Engines that have passed Testing-21.
F
Engines which have successfully passed Testing-21 performed in accordance with paragraph (h)(1) of this AD. Once an engine has passed a Testing-21, it will remain a Configuration F engine until the HPC is overhauled, or is replaced with a new or overhauled HPC.
(2) Use the following Table 2 to determine the category of Airbus engines:
Table 2.--Airbus Airplane Engine Category Listing
Engine model
Category
Engine serial number (SN)
(i) PW4156, PW4156A, and PW4158 engines.
1
717201, 717205, 717702,
717703, 717710, 717752,
717788, 717798, 717799,
724023, 724026, 724027,
724033, 724034, 724036,
724037, 724040, 724041,
724044, 724045, 724048,
724049, 724050, 724051,
724052, 724055, 724056,
724059, 724061, 724062,
724063, 724065, 724067,
724073, 724074, 724075,
724079, 724088, 724089,
724090, 724091, 724094,
724095, 724551, 724552,
724555, 724556, 724557,
724558, 724561, 724562,
724563, 724564, 724567,
724568, 724569, 724570,
724571, 724572, 724573,
724574, 724575, 724576,
724577, 724578, 724640,
724806, 724807, 724808,
724809, 724811, 724820,
724821, 724827, 724833,
724835, 724836, 724840,
724841, 724848, 724849,
724855, 724857, 724858,
724861, 724862, 724865,
724866, 724868, 724909,
724910, 724913, 724914,
724924, 724925, 724926,
724927, 727912, 728519,
728520, 728521, 728522,
728523, 728524, 728525,
728526, 728527, 728528,
728534, 728535, 728536,
728537, 728538, 728539,
728540, 728541, 728542,
728543, 728544, 728545,
728546, 728547, 728548,
728549, 728550, 728551,
728552, 728553, 728554,
728557, 728558, 728559,
728560, 728561, 728562,
728563, 728564.
(ii) PW4158 engines
2
717704, 724001, 724002,
724004, 724005, 724006,
724007, 724008, 724009,
724010, 724011, 724019,
724020, 724031, 724035,
724038, 724039, 724042,
724043, 724047, 724068,
724069, 724071, 724076,
724077, 724080, 724085,
724086, 724087, 724092,
724093, 724096, 724097,
724801, 724802, 724803,
724804, 724805, 724813,
724814, 724819, 724823,
724824, 724825,724826,
724828, 724831, 724832,
724843, 724846, 724847,
724851, 724852, 724853,
724854, 724859, 724860,
724863, 724864, 724867,
724869, 724870, 724871,
724872, 724873, 724874,
724875, 724876, 724880,
724881, 724882, 724883,
724884, 724885, 724886,
724887, 724888, 724889,
724890, 724892, 724893,
724894, 724895, 724896,
724897, 724898, 724899,
724900, 724932, 727315,
727436, 728501, 728502,
728503, 728504, 728505,
728506, 728507, 728508,
728509, 728510, 728511,
728515, 728518, 728531,
728532, 728533.
(iii) PW4156, PW4156A, and PW4158
3
All others not listed by SN in this Table.
Engines Used on Boeing Airplanes
(b) Except as provided in paragraph (g) of this AD, within 50 airplane cycles after the effective date of this AD, limit the number of engines that exceed the engine cycles-since-new (CSN), engine cycles-since-overhaul (CSO), or engine cycles since passing Testing-21 (CST) limits listed in the following Table 3, to:
(1) No more than one engine per airplane for dual-engine airplanes.
(2) No more than two engines per airplane for three-engine airplanes.
(3) No more than three engines per airplane for four-engine airplanes:
Table 3.--Engine Stagger Limits for Boeing Airplanes
Configuration
designator
B747-PW4056
B767-PW4052
B767-PW4056
B767-PW4060/
PW4060A/
PW4060C/
PW4062
MD-11 PW4460/
PW4462
A
1,400 CSN or CSO
3,000 CSN or CSO
1,600 CSN or CSO
900 CSN or CSO
800 CSN or CSO
B
2,100 CSN or CSO
4,400 CSN or CSO
2,800 CSN or CSO
2,000 CSN or CSO
1,200 CSN or CSO
C
2,100 CSN or CSO
4,400 CSN or CSO
2,800 CSN or CSO
2,000 CSN or CSO
1,300 CSN or CSO
D
2,600 CSN or CSO
4,400 CSN or CSO
3,000 CSN or CSO
2,200 CSN or CSO
2,000 CSN or CSO
E
750 CSN or CSO
750 CSN or CSO
750 CSN or CSO
750 CSN or CSO
750 CSN or CSO
F
800 CST
800 CST
800 CST
800 CST
800 CST
(c) Except as provided in paragraph (g) of this AD, within 100 airplane cycles after the effective date of this AD, limit the number of engines that exceed the CSN, CSO, or CST limits listed in Table 3, to:
(1) No more than one engine per airplane for three-engine airplanes.
(2) No more than two engines per airplane for four-engine airplanes.
(d) Within 200 airplane cycles after the effective date of this AD, limit the number of engines that, exceed the CSN, CSO, or CST limits listed in Table 3, to no more than one engine per airplane for four-engine airplanes.
(e) Thereafter, ensure that no more than one engine per airplane exceeds the CSN, CSO, or CST limit listed in Table 3.
Engines Used on Airbus Airplanes
(f) For engines installed on Airbus airplanes, do the following:
(1) Within 50 airplane cycles after the effective date of this AD, limit the number of engines that exceed, the CSN, CSO, or CST limits listed in the following Table 4, to no more than one engine per airplane:
Table 4.--Engine Stagger Limitsfor Airbus Airplanes
Configuration
designator
A310 PW4156 and PW4156A and A300 PW4158 Category 1
A300 PW4158
Category 2
A310 PW4156 and
PW4156A and A300
PW4158 Category 3
A310 PW4152
A
900 CSN or CSO
1,850 CSN or CSO
500 CSN or CSO
1,050 CSN or CSO
B
2,200 CSN or CSO
4,400 CSN or CSO
1,600 CSN or CSO
4,000 CSN or CSO
C
2,200 CSN or CSO
4,400 CSN or CSO
1,600 CSN or CSO
4,000 CSN or CSO
D
4,400 CSN or CSO
4,400 CSN or CSO
4,400 CSN or CSO
4,400 CSN or CSO
E
750 CSN or CSO
750 CSN or CSO
750 CSN or CSO
750 CSN or CSO
F
800 CST
800 CST
800 CST
800 CST
(2) Thereafter, ensure that no more than one engine per airplane, that exceeds the CSN, CSO, or CST limit listed in Table 4.
Configuration E Engines
(g) For all configuration E engines, do the following:
(1) Before further flight, limit the number of engines with configuration E from Table 1 of this AD to one on each airplane.
(2) Remove all engines with configuration E from service before accumulating 1,300 CSN or cycles-since-conversion to configuration E, whichever is later.
Stability Testing Requirement
(h) Engines removed from service in accordance with paragraphs (b), (c), (d) or (f) of this AD may be returned to service under the following conditions:
(l) After passing a cool-engine fuel spike stability test (Testing-21) that has been done in accordance with one of the following PW4000 Engine Manual (EM) Temporary Revisions (TR's) as applicable, except for engines configured with Configuration E, or engines that have experienced a Group 3 takeoff surge:
(i) PW4000 PW EM 50A443, Temporary Revision No. 71-0026, dated November 14, 2001.
(ii) PW EM 50A822, Temporary Revision No. 71-0018, dated November 14, 2001.
(iii) PW EM 50A605, Temporary Revision No. 71-0035, dated November 14, 2001.
(iv) Engines tested before the effective date in accordance with PW IEN 96KC973D, dated October 12, 2001, meets the requirements of Testing-21, or
(2) The HPC was replaced with an HPC that is new from production with no time in service, or
(3) An engine whose HPC has been overhauled, or replaced with an overhauled HPC.
Minimum Build Standard
(i) For any engine that undergoes an HPC overhaul after the effective date of this AD, do the following:
(1) Inspect the HPC mid-hook and rear-hook of the HPC inner case for wear in accordance with PW4000 Clean, Inspect and Repair (CIR) Manual PN 51A357, Section 72-35-68 Inspection/Check-04, Indexes 8-11, revised September 15, 2001. If the HPC rear hook is worn beyond serviceable limits, replace the HPC inner case rear hook with an improved durability hook in accordance with PW SB PW4ENG72-714, issued June 27, 2000. If the HPC inner case mid hook is worn beyond serviceable limits, repair the HPC inner case mid hook in accordance with any revision of PW4000 CIR PN 51A357 Section 72-35-68, Repair-16, issued June 15, 1996.(2) After the effective date of this AD, any engine that undergoes an HPC overhaul may not be returned to service unless it meets the build standard of the following PW SB's: PW4ENG 72-484, PW4ENG 72-486, PW4ENG 72-514, and PW4ENG 72-575. Engines that incorporate the Phase 3 configuration already meet the build standard defined by PW SB PW4ENG 72-514.
(j) After the effective date of this AD, any engine that undergoes separation of the HPC and HPT modules must not be installed on an airplane unless it meets the build standard of PW SB PW4ENG 72-514. Engines that incorporate the Phase 3 configuration already meet the build standard defined by PW SB PW4ENG 72-514.
(k) After the effective date of this AD, Testing-21 must be performed in accordance with paragraph (h) of this AD, before an engine can be returned to service after having undergone maintenance in the shop, except under any of the following conditions;
(1) The HPC was overhauled, or replaced with an overhauled HPC, or
(2) The HPC was replaced with an HPC that is new from production with no time in service, or
(3) The shop visit did not result in the separation of a major engine flange, with the exception of the "A" flange or "T" flange.
(l) When a thrust rating change has been made by using the Electronic Engine Control (EEC) programming plug, or an installation change has been made, during an HPC overhaul period, use the lowest cyclic limit associated with any configuration used during that overhaul period.
(m) For engines that experience a surge, do the following:
(1) For engines that experience a Group 3 takeoff surge, remove the engine from service and perform an HPC overhaul.
(2) For engines that experience a surge at Engine Pressure Ratios (EPR's) greater than 1.25, remove the engine from service within 25 cycles and perform Testing-21.
Definitions
(n) For the purposes of this AD, the following definitions apply:
(1) An HPC overhaul is defined as restoration of the HPC stages 5 through 15 blade tip clearances to the limits specified in the applicable fits and clearances section of the engine manual.
(2) A Phase 3 engine is identified by a (-3) suffix after the engine model number on the data plate if incorporated at original manufacture, or a "CN" suffix after the engine serial number if the engine was converted using PW SB's PW4ENG 72-490, PW4ENG 72-504, or PW4ENG 72-572 after original manufacture.
(3) A Group 3 takeoff surge is defined as the occurrence of any of the following engine symptoms during takeoff operation (either at reduced, derated or full rated takeoff power setting) after takeoff power set, which can be attributed to no specific and correctable fault condition after following aircraft level surge-during-forward-thrust troubleshooting procedures:
(i) Engine noises, including rumblings and loud "bang(s)."
(ii) Unstable engine parameters (EPR, N1, N2, and fuel flow) at a fixed thrust setting.
(iii) Exhaust gas temperature (EGT) increase.
(iv) Flames from the inlet, the exhaust, or both.
Alternative Methods of Compliance
(o) An alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Manager, Engine Certification Office (ECO). Operators must submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, ECO.
Note 2: Information concerning the existence of approved alternative methods of compliance with this airworthiness directive, if any, may be obtained from the ECO.
Special Flight Permits
(p) Special flight permits may be issued in accordance with Secs. 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the airplane to a location where the requirements of this AD can be done.
Testing-21 Reports
(q) Report the results of the cool engine fuel spike stability assessment tests (Testing-21) to the ANE-142 Branch Manager, Engine Certification Office, 12 New England Executive Park, Burlington, MA 01803-5299, or by electronic mail to 9-ane-surge-ad-reporting@faa.gov. The following data must be reported:
(1) Engine serial number.
(2) Engine configuration designation per Table 1.
(3) Date of the cool engine fuel spike stability test.
(4) HPC Serial Number, and HPC time and cycles since new and since compressor overhaul at the time of the test.
(5) Results of the test (Pass/Fail).
Documents That Have Been Incorporated by Reference
(r) The inspection shall be done in accordance with the following Pratt & Whitney service bulletin (SB), Internal Engineering Notice (IEN), Temporary Revisions (TR's), Clean, Inspection, and Repair Manual (CIR) repair procedures:
Document No.
Pages
Revision
Date
PW SB PW4ENG72-714
Total pages: 12.
1-2
3
4
5-12
1Original
1
Original
November 8, 2001
June 27, 2000
November 8, 2001
June 27, 2000
PW IEN 96KC973D
Total pages: 19.
All
Original
October 12, 2001
PW TR 71-0026
Total pages: 24.
All
Original
November 14, 2001
PW TR 71-0018
Total pages: 24.
All
Original
November 14, 2001.
PW TR 71-0035
Total pages: 24.
All
Original
November 14, 2001.
PW CIR 51A357, Section 72-35-68, Inspection/Check-04, Indexes 8-11.
Total pages: 5.
All
Original
September 15, 2001.
PW CIR 51A357, Section 72-35-68, Repair 16.
Total pages: 1.
All
Original
June 15, 1996.
This incorporation by reference was approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from Pratt & Whitney, 400 Main St., East Hartford, CT 06108, (860)565-6600, fax (860)565-4503. Copies may be inspected at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA; or at the Officeof the Federal Register, 800 North Capitol Street, NW, suite 700, Washington, DC.
Effective Date
(s) This amendment becomes effective on January 17, 2002.