AD 2024-06-04 Airworthiness Directives; Pratt & Whitney Turbofan Engines

Models named: PW1519G, PW1521G, PW1521GA, PW1521G-3, PW1524G, PW1524G-3, PW1525G, PW1525G-3, PW1919G, PW1921G. Read the applicability below — it usually turns on serial or part numbers too.

Pratt & Whitney (PW) Model PW1519G, PW1521G, PW1521GA, PW1521G-3, PW1524G, PW1524G-3, PW1525G, PW1525G-3, PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A engines.

Comply with this AD within the compliance times specified, unless already done.

(1) For PW1500G engines with an installed HPC 8th-stage disk having part number (P/N) 30G7208, at the next HPC engine shop visit, except as required by paragraph (g)(3) of this AD, perform an angled ultrasonic inspection (AUSI) of the affected HPC 8th-stage disk for cracks in accordance with the Accomplishment Instructions, paragraph 8., of PW Alert Service Bulletin (ASB) PW1000G-A-72-00-0197-00A-930A-D, Issue No: 004, dated November 30, 2023 (PW1000G-A-72-00-0197-00A-930A-D, Issue No: 004). (2) For PW1500G engines with an installed HPT 1st-stage hub having P/N 30G8501 or an installed HPT 2nd-stage hub having P/N 30G7202, at the next engine shop visit, except as required by paragraph (g)(3) of this AD, perform an AUSI of the affected HPT 1st-stage hub or HPT 2nd-stage hub, as applicable, for cracks in accordance with the Accomplishment Instructions, paragraph 8.A. or 8.B., of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002, dated November 30, 2023 (PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002). (3) For PW1500G engines with an installed part, P/N and serial number (S/N) listed in Table 1 to paragraph (g)(3) of this AD with no AUSI performed prior to the effective date of this AD, within the applicable compliance time listed in Table 1 to paragraph (g)(3) of this AD or within 100 flight cycles (FCs) after the effective date of this AD, whichever occurs later, perform an AUSI of the affected part for cracks in accordance with the applicable service bulletin listed in Table 1 to paragraph (g)(3) of this AD. Table 1 to Paragraph (g)(3) —AUSI Compliance Times Part Applicable S/N listing Compliance time Applicable service bulletin (see paragraph (m)(2) of this AD) HPC 8th-stage disk P/N 30G7208 Table 1 of PW ASB PW1000G-A-72-00-0197-00A-930A-D, Issue No: 004 Next HPC engine shop visit not to exceed 10,000 part cycles since new (CSN) Accomplishment Instructions, paragraph 8., of PW ASB PW1000G-A-72-00-0197-00A-930A-D, Issue No: 004. HPT 1st-stage hub P/N 30G8501 Table 2 of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002 Next engine shop visit not to exceed 5,000 part CSN Accomplishment Instructions, paragraph 8.A. of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002. HPT 2nd-stage hub P/N 30G7202 Table 3 of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002 Next engine shop visit not to exceed 5,000 part CSN Accomplishment Instructions, paragraph 8.B, of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002. HPT 1st-stage hub P/N 30G8501 Table 4 of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002 Next engine shop visit not to exceed 4,000 part CSN Accomplishment Instructions, paragraph 8.A, of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002. HPT 2nd-stage hub P/N 30G7202 Table 5 of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002 Next engine shop visit not to exceed 4,000 part CSN Accomplishment Instructions, paragraph 8.B., of PW ASB PW1000G-A-72-00-0196-00A-930A-D, Issue No: 002. (4) Thereafter at each piece-part exposure of the affected part for PW1500G engines with an installed HPC 8th-stage disk having P/N 30G7208, an installed HPT 1st-stage hub having P/N 30G8501, or an installed HPT 2nd-stage hub having P/N 30G7202, do the following: (i) Perform an AUSI of the affected HPC 8th-stage disk for cracks in accordance with the Accomplishment Instructions, paragraph 5.B., PW ASB PW1000G-A-72-00-0204-00A-930A-D, Issue No: 001, dated November 30, 2023. (ii) Perform an AUSI of the affected HPT 1st-stage hub and HPT 2nd-stage hub, as applicable, for cracks in accordance with the Accomplishment Instructions, paragraph 7.A. or 7.B., of PW ASB PW1000G-A-72-00-0205-00A-930A-D, Issue No: 001, dated November 30, 2023. (5) For PW1900G engines with an installed HPC 8th-stage disk having P/N 30G7208, at the next HPC engine shop visit, except as required by paragraph (g)(7) of this AD, perform an AUSI of the affected HPC 8th-stage disk for cracks in accordance with the Accomplishment Instructions, paragraph 8., of Pratt & Whitney PW ASB PW1000G-A-72-00-0142-00B-930A-D, Issue No: 004, dated November 30, 2023 (PW1000G-A-72-00-0142-00B-930A-D, Issue No: 004). (6) For PW1900G engines with an installed HPT 1st-stage hub having P/N 30G8501 or an installed HPT 2nd-stage hub having P/N 30G7202, at the next engine shop visit, except as required by paragraph (g)(7) of this AD, perform an AUSI of the affected HPT 1st-stage hub and HPT 2nd-stage hub, as applicable, for cracks in accordance with the Accomplishment Instructions, paragraph 8.A. or 8.B., of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002, dated November 30, 2023 (PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002). (7) For PW1900G engines with an installed part, P/N and S/N listed in Table 2 to paragraph (g)(7) of this AD, with no AUSI performed prior to the effective date of this AD, within the compliance time listed in Table 2 to paragraph (g)(7) of this AD or within 100 FCs after the effective date of this AD, whichever occurs later, perform an AUSI of the affected parts for cracks in accordance with the applicable service bulletin listed in Table 2 to paragraph (g)(7) of this AD. Table 2 to Paragraph (g)(7) —AUSI Compliance Times Part Table S/N is listed in Compliance time Applicable service bulletin (see paragraph (m)(2) of this AD) HPC 8th-stage disk having P/N 30G7208 Table 1 of PW ASB PW1000G-A-72-00-0142-00B-930A-D, Issue No: 004 Next HPC engine shop visit not to exceed 10,000 part CSN Accomplishment Instructions, paragraph 8., of PW ASB PW1000G-A-72-00-0142-00B-930A-D, Issue No: 004. HPT 1st-stage hub having P/N 30G8501 Table 2 of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002 Next engine shop visit not to exceed 5,000 part CSN Accomplishment Instructions, paragraph 8.A., of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002. HPT 2nd-stage hub having P/N 30G7202 Table 3 of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002 Next engine shop visit not to exceed 5,000 part CSN Accomplishment Instructions, paragraph 8.B, of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002. HPT 1st-stage hub having P/N 30G8501 Table 4 of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002 Next engine shop visit not to exceed 4,000 part CSN Accomplishment Instructions, paragraph 8.A., of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002. HPT 2nd-stage hub having P/N 30G7202 Table 5 of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002 Next engine shop visit not to exceed 4,000 part CSN Accomplishment Instructions, paragraph 8.B., of PW ASB PW1000G-A-72-00-0141-00B-930A-D, Issue No: 002. (8) Thereafter at each piece-part exposure of the affected part for PW1900G engines with an installed HPC 8th-stage disk having P/N 30G7208, or an installed HPT 1st-stage hub having P/N 30G8501, or an installed HPT 2nd-stage hub having P/N 30G7202, do the following: (i) Perform an AUSI of the affected HPC 8th-stage disk for cracks in accordance with the Accomplishment Instructions, paragraph 5.B., of PW ASB PW1000G-A-72-00-0150-00B-930A-D, Issue No: 001, dated November 30, 2023. (ii) Perform an AUSI of the affected HPT 1st-stage hub and HPT 2nd-stage hub, as applicable, for cracks in accordance with the Accomplishment Instructions, paragraph 7.A. or 7.B., of PW ASB PW1000G-A-72-00-0151-00B-930A-D, Issue No: 001, dated November 30, 2023. (9) If any crack is found during the inspections required by paragraph (g) of this AD, before further flight, remove the affected part from service and replace with a part eligible for installation. (10) For engines with an installed part and P/N listed in Table 3 to paragraph (g)(10) of this AD having 3,300 CSN or less on the effective date of this AD, before the part accumulates 4,000 CSN or at the next engine shop visit after the effective date of this AD, whichever occurs first, remove the part from service and replace with a part eligible for installation. Table 3 to Paragraph (g)(10) —Part Numbers Part name P/N HPC 7th-stage rotor 30G3307 HPC 8th-stage disk 30G3248 HPC rear hub 30G2902 HPT 1st-stage hub 30G5701 HPT 2nd-stage hub 30G5002 HPT 1st-stage air seal 30G3132 HPT 2nd-stage air seal 30G3451 HPT 1st-stage blade retaining plate 30G1692 HPT 2nd-stage blade retaining plate 30G1698 (11) For engines with an installed part and P/N listed in Table 3 to paragraph (g)(10) of this AD having more than 3,300 CSN on the effective date of this AD, at the next engine shop visit or within 700 FCs after the effective date of this AD, whichever occurs first, remove the part from service and replace it with a part eligible for installation. (12) For engines with an installed HPT 1st-stage hub having P/N 30G8501 or an installed HPT 2nd-stage hub having P/N 30G7202 and an S/N listed in Table 1 of PW Special Instruction (SI) No. 240F-23A, dated February 7, 2024, within 100 FCs from the effective date of this AD, remove the hub from service and replace it with a part eligible for installation. (13) If an affected part has accumulated 100 FCs or less since the last AUSI, reinspection is not required provided that the part was not damaged during removal from the engine.

This AD was prompted by an updated analysis of an event involving an International Aero Engines, LLC Model PW1127GA-JM engine, which experienced a high-pressure compressor (HPC) 7th-stage integrally bladed rotor separation that resulted in an engine shutdown and aborted takeoff. The FAA is issuing this AD to prevent failure of the high-pressure turbine (HPT) 1st-stage hub, HPT 2nd-stage hub, and HPC 8th-stage disk. The unsafe condition, if not addressed, could result in uncontained hub failure, release of high-energy debris, damage to the engine, damage to the airplane, and possible loss of the airplane.

None.