AD 2024-11-03 Airworthiness Directives; International Aero Engines, AG Engines

Models named: V2522-A5, V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, V2531-E5, V2533-A5. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to International Aero Engines, AG (IAE AG) Model V2522-A5, V2524-A5, V2525-D5, V2527-A5, V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, V2531-E5, and V2533-A5 engines.

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

(1) For engines with an installed part, part number (P/N), and serial number (S/N) listed in Table 1 to paragraph (g)(1) of this AD, with no angled ultrasonic inspection (AUSI) performed, at the next engine shop visit after the effective date of this AD before exceeding the applicable cycle limit specified in Table 1 to paragraph (g)(1) of this AD, perform an AUSI of the affected parts for cracks in accordance with the applicable service information listed in Table 1 to paragraph (g)(1) of this AD. Table 1 to Paragraph ( g )(1)—AUSI Compliance Times Part Table S/N is listed in Previously operated in high-thrust model engine Flight cycle (FC) limit from the effective date of this AD Applicable service information (see paragraph (l)(2) of this AD) HPT 1st-stage hub P/N 2A5001 Table 1 of IAE AG Non-Modification Service Bulletin V2500-ENG-72-0720, dated November 20, 2023 (IAE AG NMSB V2500-ENG-72-0720) Yes 100 FCs Accomplishment Instructions, paragraph 5., of IAE AG NMSB V2500-ENG-72-0720. HPT 1st-stage hub P/N 2A5001 Table 1 of Pratt & Whitney (PW) Special Instruction No. 189F-23, dated November 20, 2023 (PW SI No. 189F-23), which only applies to the IAE AG V2531-E5 Model engine Yes 100 FCs Accomplishment Instructions, paragraph 5., of PW SI No. 189F-23, which only applies to the IAE AG V2531-E5 Model engine. HPT 1st-stage hub P/N 2A5001 Table 1 of IAE AG NMSB V2500-ENG-72-0720 No 700 FCs Accomplishment Instructions, paragraph 5., of IAE AG NMSB V2500-ENG-72-0720. HPT 2nd-stage hub P/N 2A4802 Table 2 of IAE AG NMSB V2500-ENG-72-0720 Yes 800 FCs Accomplishment Instructions, paragraph 6., of IAE AG NMSB V2500-ENG-72-0720. HPT 2nd-stage hub P/N 2A4802 Table 2 PW SI No. 189F-23, which only applies to the IAE AG V2531-E5 Model engine Yes 800 FCs Accomplishment Instructions, paragraph 6., of PW SI No. 189F-23, which only applies to the IAE AG V2531-E5 Model engine. HPT 2nd-stage hub P/N 2A4802 Table 2 of IAE AG NMSB V2500-ENG-72-0720 No 1100 FCs Accomplishment Instructions, paragraph 6., of IAE AG NMSB V2500-ENG-72-0720. (2) For parts inspected in accordance with paragraph (g)(1) of this AD, or for AUSI inspected parts installed on or after November 1, 2023, within 4,000 FCs from accomplishment of the AUSI or at the next HPT module removal after the AUSI, whichever occurs first, remove the part from service and replace with a part eligible for installation. (3) If any crack is found during the inspections required by paragraphs (g)(1) of this AD, before further flight, remove the affected part from service and replace with a part eligible for installation. (4) For engines with an AUSI inspected part installed prior to November 1, 2023, having a P/N and S/N listed in Table 2 to paragraph (g)(4) of this AD, at the next HPT module removal after the effective date of this AD, but before exceeding the applicable cycle limit specified in Table 2 to paragraph (g)(4) of this AD, remove the affected part from service and replace with a part eligible for installation. Table 2 to Paragraph ( g )(4)—Part Replacement Compliance Times Part Table S/N is listed in Previously operated in high-thrust model engine Flight cycle limit from the effective date of this AD HPT 1st-stage hub P/N 2A5001 Table 1 of IAE AG NMSB V2500-ENG-72-0720 Yes 1,800 FCs. HPT 1st-stage hub P/N 2A5001 Table 1 of PW SI No. 189F-23, which only applies to the IAE AG V2531-E5 Model engine Yes 1,800 FCs. HPT 1st-stage hub P/N 2A5001 Table 1 of IAE AG NMSB V2500-ENG-72-0720 No 2,800 FCs. HPT 2nd-stage hub P/N 2A4802 Table 2 of IAE AG NMSB V2500-ENG-72-0720 Yes 3,400 FCs. HPT 2nd-stage hub P/N 2A4802 Table 2 of PW SI No. 189F-23, which only applies to the IAE AG V2531-E5 Model engine Yes 3,400 FCs. HPT 2nd-stage hub P/N 2A4802 Table 2 of IAE AG NMSB V2500-ENG-72-0720 No 3,800 FCs. (5) For engines with an installed part that has a P/N and S/N listed in Table 3 to paragraph (g)(5) of this AD, at the next HPT module removal after the effective date of this AD, but before exceeding the applicable cycle limit specified in Table 3 to paragraph (g)(5) of this AD, remove the affected part from service and replace with a part eligible for installation. Table 3 to Paragraph ( g )(5)—Part Replacement Compliance Times Part Table S/N is listed in Previously operated in high-thrust model engine Flight cycle limit from the effective date of this AD HPT 1st-stage hub P/N 2A5001 Table 3 of IAE AG NMSB V2500-ENG-72-0720 Yes 1,800 FCs. HPT 1st-stage hub P/N 2A5001 Table 3 of IAE AG NMSB V2500-ENG-72-0720 No 2,800 FCs. HPT 2nd-stage hub P/N 2A4802 Table 4 of IAE AG NMSB V2500-ENG-72-0720 Yes 3,400 FCs. HPT 2nd-stage hub P/N 2A4802 Table 4 of IAE AG NMSB V2500-ENG-72-0720 No 3,800 FCs.

This AD was prompted by an analysis of an event involving an International Aero Engines, LLC Model PW1127GA-JM engine, which experienced failure of a high-pressure compressor 7th-stage integrally bladed rotor 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 and HPT 2nd-stage hub. 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 loss of the airplane.

This AD is related to AD 2022-02-09, Amendment 39-21906 (87 FR 7029, February 8, 2022) (AD 2022-02-09).