AD 86-09-02 R2 ACTIVE

86-09-02 R2 Pratt & Whitney: Amendment 39-9385. Docket 85-ANE-34. Revises AD 86-09-02 R1, Amendment 39-5372.

Applicability: Pratt & Whitney (PW) JT8D-1,-1A, -1B, -7, -7A, -7B, -9, -9A, -11, -15, -15A, -17, -17A, -17R, and -17AR turbofan engines that do not have low emission combustion chamber assemblies, Part Number (P/N) 5001958-02, -022, and 5001959-02, -022 installed. These engines are installed on but not limited to Boeing 727, 737, and McDonnell Douglas DC-9 series aircraft. NOTE: This airworthiness directive (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 use the authority provided in paragraph (h) to request approval from the Federal Aviation Administration (FAA). Thisapproval may address either no action, if the current configuration eliminates the unsafe condition, or different actions necessary to address the unsafe condition described in this AD. Such a request should include an assessment of the effect of the changed configuration on the unsafe condition addressed by this AD. In no case does the presence of any modification, alteration, or repair remove any engine from the applicability of this AD.

Compliance: Required as indicated, unless accomplished previously.

(a) Perform an initial borescope, visual, or radiographic inspection of the combustion chamber liners for cracking or other types of distress in accordance with the inspection procedures of paragraph 2.C.(1) and (2), and Table 1 or 1A, and the inspection techniques of paragraph B, whichever is applicable, of PW Alert Service Bulletin (ASB) No. 5639, Revision 10, dated July 7, 1995. Determine reinspection interval or engine removal requirements in accordance with paragraph 2.C.(3), (4), (5), or (6), whichever is applicable, of PW ASB No. 5639, Revision 10, dated July 7, 1995.

(b) Reinspect combustion chamber liners for cracking or other types of distress in accordance with the inspection procedures of paragraph 2.C.(3) through (7), and the inspection techniques of paragraph B, whichever is applicable, of PW ASB No. 5639, Revision 10, dated July 7, 1995, as follows:

(1) For liners initially inspected by borescope or visual means, reinspect in accordance with Table 2 of PW ASB No. 5639, Revision 10, dated July 7, 1995.

(2) For liners initially inspected by radiographic means, reinspect in accordance with Table 3 of PW ASB No. 5639, Revision 10, dated July 7, 1995.

(3) Determine reinspection interval or engine removal requirements in accordance with paragraph 2.C.(3), (4), (5), or (6) whichever is applicable, of PW ASB No. 5639, Revision 10, dated July 7, 1995.

(c) For liners removed from service in accordance with paragraphs (a) or (b) of this airworthiness directive (AD), scrap or repair in accordance with paragraph 2.D of PW ASB No. 5639, Revision 10, dated July 7, 1995.

(d) For the purpose of this AD, an engine condition monitoring (ECM) program is defined as described in Appendix A of PW ASB No. 5639, Revision 10, dated July 7, 1995, of FAA-approved equivalent. Should stable cruise data be unavailable for a period exceeding 48 hours (2 calendar days), 12 cycles in service (CIS), or 14 hours time in service (TIS), whichever occurs later; and should the combustion chambers be beyond the non- ECM inspection category hour or cycles limit, the chambers must be inspected within the next 10 CIS. In the event that stable cruise data again becomes available prior to the expiration of the 10 CIS limit, return to the ECM inspection category is permitted if the following conditions are met:

(1) The period during which stable cruise data is unavailable does not include any one period of data loss that exceeds 72 hours (3 calendar days), and;

(2) One stable cruise point is recorded for each day that stable cruise data were unavailable, and that the rate of data acquisition not exceed one data point per cycle, and;

(3) No maintenance was accomplished on the fuel flow, exhaust gas temperature (EGT), or N1/N2 rotor speed engine instrumentation, and;

(4) The stable cruise data recorded in accordance with paragraph (d)(2) of this AD shall be processed by the ECM program and evaluated by a qualified analyst to confirm that no significant parameter shifts have occurred.

(e) The radiographic inspection techniques referenced in telegraphic AD T85-17-51 R1 as an approved alternative method of compliance to that telegraphic AD is not considered an alternative method of compliance with this AD.

(f) Combustion chambers that are removed from service prematurely, inspected in accordance with this AD, and that do not require repair, may be returned to service to continue their run to the appropriate initial inspection threshold or the applicable repetitive inspection interval, whichever is greater.

(g) Magnesium zirconate heat resistant coating must be applied in accordance with the PW JT8D Restructured Engine Manual, Part Number 481762, Chapter 72-41-14, Repair Number 28, or FAA-approved equivalent. To meet the requirement for magnesium zirconate in a given combustion chamber category, the coating must have been completely renewed on at least the 2 through 5 liners at that repair rather than locally patched. NOTE: PW All Operators Wire Number JT8D/72-41/PSE:JKS: 5-8-23-1, dated August 23, 1985, and Flight Operations Engineering Report Number RFT5-8-30-1, dated August 30, 1985, contain further information relevant to combustion chamber distress and the symptoms that manifest themselves as a result of excessive combustion chamber cracking and misalignment.

(h) An alternative method of compliance or adjustment of the initial compliance time that provides an acceptable level of safety may be used if approved by the Manager, Engine Certification Office. The request should be forwarded through an appropriate FAA Maintenance Inspector, who may add comments and then send it to the Manager, Engine Certification Office. NOTE: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Engine Certification Office.

(i) Special flight permits may be issued in accordance with sections 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the aircraft to a location where the requirements of this AD can be accomplished.

(j) The inspection, replacement, and repair, shall be done in accordance with the following alert service bulletin:

PW ASB No. 5639
1 and 2
10
July 7, 1995

3
1
March 21, 1986

4
10
July 7, 1995

5
2
January 16, 1987

6-26
10
July 7, 1995

Appendix
27-29
10
July 7, 1995

30
Blank

31-64
10
July 7, 1995
Total pages: 64

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, Publications Department, M/S 132-30, 400 Main St, East Hartford, CT 06108. Copies may be inspected at the FAA, New England Region, Office of the Assistant Chief Counsel, 12 New England Executive Park, Burlington, MA; or at the Office of the Federal Register, 800 North Capitol Street, NW., suite 700, Washington, DC.

(k) This amendment becomes effective on November 17, 1995.