AD 2010-19-01 Airworthiness Directives; Rolls-Royce Corporation (RRC) AE 3007A Series Turbofan Engines

This AD applies to Rolls-Royce Corporation (RRC) AE 3007A series turbofan engines with high-pressure turbine (HPT) stage 2 wheels, part numbers (P/Ns) 23069438, 23069592, 23074462, 23074644, 23075345, or 23084520 installed. These engines are installed on, but not limited to, Empresa Brasileira de Aeronautica S. A. (EMBRAER) EMB-135 and EMB-145 airplanes.

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. HPT Stage 2 Wheels Exempted From the Inspection Requirements of This AD (f) The following engines are exempt from the inspection requirements of this AD: (1) All engines with an HPT stage 2 wheel, P/N 23084520. (2) All engines with an HPT stage 2 wheel, P/N 23075345, that has a serial number (S/N) specified in Table 1 of this AD, and (3) All engines with an HPT stage 2 wheel, P/N 23074462, that has a S/N specified in Table 2 of this AD. Table 1—HPT Stage 2 Wheel, P/N 23075345 by S/N Excluded From Inspection Requirements ( g ) Through ( i ) of This AD       MM507646 MM508211 MM508319 MM508144 MM508221 MM508320 MM508153 MM508241 MM508322 MM508176 MM508248 MM508337 MM508186 MM508251 MM508338 MM508188 MM508264 MM508382 MM508205 MM508305 MM508387 MM508208 MM508311 Table 2—HPT Stage 2 Wheel, P/N 23074462 by S/N Excluded From Inspection Requirements ( g ) Through ( i ) of This AD       MM504890 MM505025 MM505054 MM504963 MM505034 MM505055 MM504990 MM505041 MM505056 MM504995 MM505045 MM505061 MM505007 MM505046 All `MM' prefix S/Ns higher than MM505061 MM505017 MM505048 All S/Ns with `MW' prefix Initial Eddy Current Inspection (ECI) or Surface Wave Ultrasonic Testing (SWUT) Inspection (g) For engines with an HPT stage 2 wheel, P/Ns 23069438, 23069592, 23074462, 23074644, or 23075345, remove the engine from service or perform an initial inspection of the wheel by the cycle limit specified in Table 3 of this AD. Use one of the following methods for the inspection: (1) For HPT stage 2 wheels that have S/Ns listed in Table 4 of this AD, use paragraphs 2.A. through 2.C.(4) of RRC Alert Service Bulletin (ASB) AE 3007A-A-72-367, Revision 2 dated June 22, 2009, to inspect the wheel. (2) For HPT stage 2 wheels that have S/Ns not listed in Table 4 of this AD, use paragraphs 2.A. through 2.C.(4) of RRC ASB AE 3007A-A-72-367, Revision 2, dated June 22, 2009, or use paragraphs 2.A. through 2.N. of RRC Service Bulletin (SB) AE 3007A-72-368, Revision 3, dated May 24, 2010; or use 2.A. through 2.V.(4) of RRC SB AE 3007A-72-369, Revision 2, dated November 5, 2009, to perform the inspections. Table 3—Compliance Times for Engine Removal or ECI or SWUT Inspection of the HPT Stage 2 Wheels by Cycles-Since-New [CSN] For HPT stage 2 wheels with the following CSN on the effective date of this AD: Remove engine from service or inspect wheel within the following cycles-in-service (CIS) after the effective date of this AD: (3) 17,500 or more CSN Remove engine from service or inspect before next flight. (4) 10,000 to 17,499 CSN 15 CIS. (5) 9,999 or fewer CSN Before accumulating 10,015 CSN. Credit for Previous Inspections (6) Inspections performed before the effective date of this AD using earlier versions of RRC ASB AE 3007A-A-72-367 or RRC SB AE 3007A-72-368 or RRC SB AE 3007A-72-369 comply with the requirements of paragraphs (g)(1) and (g)(2) of this AD. Table 4—S/Ns of HPT Stage 2 Wheels to be Inspected by SB AE 3007A-72-367 [ECI Method Only]     HPT stage 2 wheels requiring ECI method only MM119400 MM183796 MM119480 MM183808 MM119508 MM183831 MM155847 MM228730 MM155907 MM228951 MM155908 MM503748 MM183236 MM504004 MM183362 MM57188 MM183754 MM57440 MM183762 MM57480 Installation Prohibition (h) After the effective date of this AD, don't return to service, any HPT stage 2 wheel that was installed in any RRC AE 3007A series engine that has been removed as a result of the inspection requirements of this AD, unless the HPT stage 2 wheel was inspected as specified in RRC ASB AE 3007A-A-72-367, Revision 2, dated June 22, 2009; or RRC SB AE 3007A-72-368, Revision 3, dated May 24, 2010; or RRC SB AE 3007A-72-369, Revision 2, dated November 5, 2009. Repetitive Inspection (i) Thereafter, within 3,000 cycles-since-last inspection performed as a result of this AD or its predecessor ADs (Emergency ADs 2008-19-51, AD 2008-26-06, and 2009-08-51), remove the engine from service until an ECI or SWUT inspection is performed on the HPT stage 2 wheel. Use paragraphs 2.A. through 2.C.(4) of RRC ASB AE 3007A-A-72-367, Revision 2, dated June 22, 2009, or use paragraphs 2.A. through 2.N. of RRC SB AE 3007A-72-368, Revision 3, dated May 24, 2010; or use 2.A. through 2.V.(4) of RRC SB AE 3007A-72-369, Revision 2, dated November 5, 2009, to inspect the wheel. New, Reduced Engine Cycle Life Limit and Removal From Service (j) For HPT stage 2 wheels, P/N 23084520, do the following: (1) For wheels that have 22,985 CSN or more on the effective date of this AD, remove the wheel from service within 15 CIS after the effective date of this AD. (2) Thereafter, remove HPT stage 2 wheels, P/N 23084520, before exceeding the new, reduced engine cycle life limit (ECLL) of 23,000 CSN. (k) For HPT stage 2 wheels, P/N 23075345 and 23074644, do the following: (1) For wheels that have 19,985 CSN or more on the effective date of this AD, remove the wheel from service within 15 CIS after the effective date of this AD unless paragraph (k)(3) of this AD applies. (2) Thereafter, remove HPT stage 2 wheels, P/N 23075345 and 23074644, before exceeding the new, reduced ECLL of 20,000 CSN. (3) For HPT stage 2 wheels, P/N 23075345, that have a S/N listed in Table 5 of this AD and that have 22,985 CSN or more on the effective date of this AD, remove the wheel from service within 15 CIS after the effective date of this AD. (4) Thereafter, for HPT stage 2 wheels, P/N 23075345, that have a S/N listed in Table 5 of this AD, remove the wheel from service before exceeding the new, reduced ECLL of 23,000 CSN. Table 5—S/Ns of HPT Stage 2 Wheel, P/N 23075345, Eligible To Remain in Service Until 23,000 CSN         MM507646 MM508205 MM508251 MM508322 MM508144 MM508208 MM508264 MM508337 MM508153 MM508211 MM508305 MM508338 MM508176 MM508221 MM508311 MM508382 MM508186 MM508241 MM508319 MM508387 MM508188 MM508248 MM508320   (l) For wheels, P/N 23069438, in engines that have not complied with RRC SB AE 3007A-72-176, Revision 5, dated September 2, 2008, or earlier version; or SB AE 3007A-72-215, Revision 2, dated September 28, 2009, or earlier version, remove the wheel before exceeding the new, reduced ECLL of 10,000 CSN. (m) For wheels, P/N 23069438, in engines that have complied with RRC SB AE 3007A-72-176, Revision 5, dated September 2, 2008, or earlier version; or SB AE 3007A-72-215, Revision 2, dated September 28, 2009, or earlier version; do the following: (1) For wheels that have 19,985 CSN or more on the effective date of this AD, remove the wheel from service within 15 CIS after the effective date of this AD. (2) Thereafter, remove the wheel from service before exceeding the new, reduced ECLL of 20,000 CSN. Alternative Methods of

This AD results from reports of cracked HPT stage 2 wheels. We are issuing this AD to prevent uncontained failure of the HPT stage 2 wheel and damage to the airplane.