AD 96-18-08 Airworthiness Directives; Pratt & Whitney PW2000 Series Turbofan Engines

Pratt & Whitney Models PW2037, PW2037(M), PW2040, PW2240, and PW2337 turbofan engines, installed on but not limited to, Boeing 757 series and Ilyushin IL96 series aircraft. Note 1: 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 request approval for an alternative method of compliance 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.

Required as indicated, unless accomplished previously. To prevent high pressure turbine (HPT) or low pressure turbine (LPT) failure, which may result in an uncontained engine failure and possible damage to the aircraft, accomplish the following: (a) Remove from service 1st stage HPT disks, Part Number (P/N) 1A5301, prior to exceeding 5,000 total part cycles since new (TPC), if installed with blade retaining plate, P/N 1A6998, and replace with serviceable parts. If blade retaining plate, P/N 1A6998, [[Page 57050]] has not been installed on disk, P/N 1A5301, the disk may accumulate 15,000 TPC prior to removal from service. (b) Remove from service 1st stage HPT blade retaining plates, P/ N 1A6998, prior to exceeding 5,000 TPC, and replace with serviceable parts. If rework is accomplished prior to exceeding 5,000 TPC in accordance with the Accomplishment Instructions of PW Alert Service Bulletin (ASB) No. PW2000 A72-82, Revision 1, dated April 25, 1986; Revision 2, dated July 17, 1986; Revision 3, dated November 7, 1986; or Revision 4, dated June 18, 1987, and reidentified as assembly P/N 1B2373, the blade retaining plate may accumulate 15,000 TPC prior to removal from service. (c) Remove from service 2nd stage HPT blade retaining plates, P/ N 1B0450, prior to exceeding 7,000 TPC, and replace with serviceable parts. (d) Remove from service 2nd stage HPT blade retaining plates, P/ N 1B0945 (assembly P/N 1B0947), and replace with serviceable parts, in accordance with the Accomplishment Instructions of PW ASB No. PW2000 A72-228, Revision 2, dated May 10, 1988; Revision 3, dated August 25, 1988; or Revision 4, dated November 9, 1988, as follows: (1) Prior to exceeding 5,000 TPC, for retaining plates that have not been inspected in accordance with the Accomplishment Instructions of the above ASB prior to 3,000 TPC. (2) Prior to exceeding 8,000 TPC, for retaining plates that have been inspected in accordance with the Accomplishment Instructions of the above ASB prior to 3,000 TPC. (e) Remove from service 2nd stage HPT hubs, P/N's 1A8302, 1B1002, 1B1202, or 1B4902 prior to exceeding 7,500 TPC, and replace with serviceable hubs. Hubs may accumulate 15,000 TPC prior to removal from service if they are inspected at intervals that do not exceed 6,000 cycles in service since last inspection, in accordance with the Accomplishment Instructions of PW Service Bulletin (SB) No. PW2000 72-450, Original, dated March 13, 1992; Revision 1, dated March 26, 1992; Revision 2, dated April 7, 1992; Revision 3, dated May 29, 1992; Revision 4, dated August 28, 1992; ASB No. PW2000 72- 450, Revision 5, dated May 28, 1994; or Revision 6, dated July 9, 1996. (f) Remove from service all suspect 2nd stage HPT hubs, P/N 1B6602, prior to exceeding 7,500 TPC, and replace with serviceable hubs. The suspect hubs are identified at the assembly level, P/N 1B6232, in Section 1, Planning Information contained in PW SB No. PW2000 72-501, dated September 30, 1993. Hubs may accumulate 15,000 TPC prior to removal from service if hub assemblies are inspected prior to 7,500 TPC to verify scarf cut blades are installed and to inspect the blade platform rail fillet radii dimensions, in accordance with the Accomplishment Instructions of PW SB No. PW2000 72-501, dated September 30, 1993. Hub assemblies found with non- scarf cut blades must be reinspected at intervals not to exceed 6,000 TPC since last inspection. Blades found with under minimum rail fillet radii dimensions must be scrapped. (g) Remove from service HPT lenticular airseal, P/N 1A8209, prior to exceeding 4,000 TPC, and replace with serviceable airseals. Airseals may accumulate 15,000 TPC prior to removal from service if: (1) Inspected prior to exceeding 4,000 TPC, and thereafter inspected at intervals not to exceed 250 cycles in service since last inspection, in accordance with Compliance Paragraph E of the Accomplishment Instructions of PW ASB No. PW2000 A72-220, Revision 3, dated April 13, 1989, or Revision 4, dated September 20, 1989; or (2) The 2nd stage HPT case and vane assembly is reworked and reidentified prior to exceeding 4,000 TPC, in accordance with the Accomplishment Instructions of PW SB No. PW2000 72-233, Revision 2, dated September 27, 1988, or Revision 3, dated May 30, 1989. (h) For PW2037, PW2037(M), and PW2337 model engines, remove from service 4th stage LPT disks, P/N's 8A1024, 8A1534, or 8A2137 prior to exceeding 17,000 TPC, and replace with serviceable disks. (i) For PW2040 and PW2240 model engines, remove from service 4th stage LPT disks, P/N's 8A1534 or 8A2137, prior to exceeding 15,000 TPC, and replace with serviceable disks. (j) Remove from service 3rd stage LPT airsealing ring supports, P/N 8A1783, and replace with serviceable parts, as follows: (1) For PW2040 and PW2240 model engines, prior to exceeding 15,000 TPC. (2) For PW2037, PW2037(M), and PW2337 model engines, prior to exceeding 17,000 TPC. Airsealing ring supports may accumulate 20,000 TPC prior to removal from service if they were fluorescent penetrant inspected in accordance with Section 72-53-00 of PW2000 Engine Manual, P/N 1A6231. (k) For PW2037, PW2037(M), and PW2337 model engines, remove from service prior to exceeding 17,000 TPC, and replace with serviceable parts, as follows: (1) 4th stage LPT airseal, P/N's 8A1014 or 8A1805. (2) 5th stage LPT airseal, P/N's 8A1015 or 8A1806. (3) 7th stage LPT airseal, P/N's A8A1017, A8A1808, 8A2097, or A8A2097. (l) Parts listed in paragraph (m) of this AD may accumulate 20,000 TPC prior to removal from service if they were fluorescent penetrant inspected for cracks between 12,000 TPC and 17,000 TPC in accordance with Section 72-53-00 of PW2000 Engine Manual, P/N 1A6231. (m) For PW2040 and PW2240 model engines, remove from service prior to exceeding 15,000 TPC, and replace with serviceable parts, as follows: (1) 4th stage LPT airseal, P/N's 8A1014 or 8A1805. (2) 5th stage LPT airseal, P/N's 8A1015 or 8A1806. (3) 7th stage LPT airseal, P/N's A8A1017, A8A1808, 8A2097, or A8A2097. (n) Parts listed in paragraph (m) of this AD may accumulate the following TPC prior to removal if they were fluorescent penetrant inspected for cracks between 10,000 TPC and 15,000 TPC in accordance with Section 72-53-00 of PW2000 Engine Manual, P/N 1A6231: (1) 4th stage LPT airseal, P/N's 8A1014 or 8A1805, prior to exceeding 18,000 TPC. (2) 5th stage LPT airseal, P/N's 8A1015 or 8A1806, prior to exceeding 19,000 TPC. (3) 7th stage LPT airseal, P/N's A8A1017, A8A1808, 8A2097, or A8A2097, prior to exceeding 20,000 TPC. (o) 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. Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, Engine Certification Office. Note 2: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Engine Certification Office. (p) 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. (q) The actions required by this AD shall be done in accordance with the following PW service documents: ---------------------------------------------------------------------------------------------------------------- Document No. Pages Revision Date ---------------------------------------------------------------------------------------------------------------- ASB No. PW2000: A72-82...................... 1................... 1....................... April 25, 1986. 2-6................. Original................ June 7, 1985. 7-9................. 1....................... April 25, 1986. 10.................. Original................ June 7, 1985. 11.................. 1....................... April 25, 1986. Total Pages: 11. ASB No. PW2000: A72-82...................... 1................... 2....................... July 17, 1986. 2-6................. Original................ June 7, 1985. 7-9................. 1....................... April 25, 1986. 10.................. Original................ June 7, 1985. [[Page 57051]] 11.................. 2....................... July 17, 1986. Total Pages: 11. ASB No. PW2000: A72-82...................... 1-4................. 3....................... November 7, 1986. 5,6................. Original................ June 7, 1985. 7-14................ 3....................... November 7, 1986. Total Pages: 14. ASB No. PW2000: A72-82...................... 1................... 4....................... June 18, 1987. 2-4................. 3....................... November 7, 1986. 5,6................. Original................ June 7, 1985. 7-12................ 3....................... November 7, 1986. 13.................. 4....................... June 18, 1987. 14.................. 3....................... November 7, 1986. Total Pages: 14. ASB No. PW2000: A72-228..................... 1................... 2....................... May 10, 1988. 2................... Original................ July 6, 1987. 3................... 2....................... May 10, 1988. 4................... 1....................... March 29, 1988. 5-26................ 2....................... May 10, 1988. Total Pages: 26. ASB No. PW2000: A72-228..................... 1................... 3....................... August 25, 1988. 2................... Original................ July 6, 1987. 3................... 2....................... May 10, 1988. 4................... 3....................... August 25, 1988. 5-19................ 2....................... May 10, 1988. 20.................. 3....................... August 25, 1988. 21, 22.............. 2....................... May 10, 1988. 23.................. 3....................... August 25, 1988. 24-26............... 2....................... May 10, 1988. Total Pages: 26. ASB No. PW2000: A72-228..................... 1................... 4....................... November 9, 1988. 2................... Original................ July 6, 1987. 3................... 4....................... November 9, 1988. 4................... 3....................... August 25, 1988. 5-19................ 2....................... May 10, 1988. 20.................. 3....................... August 25, 1988. 21-22............... 2....................... May 10, 1988. 23.................. 3....................... August 25, 1988. 24-26............... 4....................... November 9, 1988. Total Pages: 26. SB No. PW2000: 72-450...................... 1-26................ Original................ March 13, 1992. Total Pages: 26. SB No. PW2000: 72-450...................... 1................... 1....................... March 26, 1992. 2-11................ Original................ March 13, 1992. 12-13............... 1....................... March 26, 1992. 14,15............... Original................ March 13, 1992. 16,17............... 1....................... March 26, 1992. 18-21............... Original................ March 13, 1992. 22,23............... 1....................... March 26, 1992. 24,25............... Original................ March 13, 1992. 26.................. 1....................... March 26, 1992. Total Pages: 26. SB No. PW2000: 72-450...................... 1................... 2....................... April 7, 1992. 2,3................. Original................ March 13, 1992 4,5................. 2....................... April 7, 1992. 2-11................ Original................ March 13, 1992. 12.................. 1....................... March 26, 1992. 13.................. 2....................... April 7, 1992. 14,15............... Original................ March 13, 1992. 16,17............... 1....................... March 26, 1992. 18-21............... Original................ March 13, 1992. 22,23............... 1....................... March 26, 1992. 24,25............... Original................ March 13, 1992. 26.................. 1....................... March 26, 1992. Total Pages: 26. SB No. PW2000: 72-450...................... 1-5................. 3....................... May 29, 1992. [[Page 57052]] 6-11................ Original................ March 13, 1992. 12.................. 1....................... March 26, 1992. 13.................. 3....................... May 29, 1992. 14.................. Original................ March 13, 1992. 15-29............... 3....................... May 29, 1992. Total Pages: 29. SB No. PW2000: 72-450...................... 1................... 4....................... August 28, 1992. 2-5................. 3....................... May 29, 1992. 6-11................ Original................ March 13, 1992. 12.................. 1....................... March 26, 1992. 13.................. 3....................... May 29, 1992. 14.................. Original................ March 13, 1992. 15.................. 4....................... August 28, 1992. 16.................. 3....................... May 29, 1992. 17.................. 4....................... August 28, 1992. 18-29............... 3....................... May 29, 1992. Total Pages: 29. ASB No. PW2000: 72-450...................... 1................... 5....................... May 28, 1994. 2................... 4....................... May 28, 1994. 3-5................. 3....................... May 29, 1992. 6-11................ Original................ March 13, 1992. 12.................. 1....................... March 26, 1992. 13.................. 3....................... May 29, 1992. 14.................. Original................ March 13, 1992. 15.................. 4....................... August 28, 1992. 16.................. 3....................... May 29, 1992. 17.................. 4....................... August 28, 1992. 18-29............... 3....................... May 29, 1992. Total Pages: 29. ASB No. PW2000: 72-450...................... 1................... 6....................... July 9, 1996. 2................... 4....................... May 28, 1994. 3-5................. 3....................... May 29, 1992. 6-11................ Original................ March 13, 1992. 12.................. 1....................... March 26, 1992. 13.................. 3....................... May 29, 1992. 14.................. Original................ March 13, 1992. 15.................. 4....................... August 28, 1992. 16.................. 3....................... May 29, 1992. 17.................. 4....................... August 28, 1992. 18-28............... 3....................... May 29, 1992. 29.................. 6....................... July 9, 1996. Total Pages: 29. ASB No. PW72-501 1-12................ Original................ September 30, 1993. Total Pages: 12. ASB No. PW2000: A72-220..................... 1................... 3....................... April 13, 1989. 2................... 1....................... July 29, 1987. 3-26................ 3....................... April 13, 1989. Total Pages: 26. ASB No. PW2000: A72-220..................... 1................... 4....................... September 20, 1989. 2................... 1....................... July 29, 1987. 3-6................. 3....................... April 13, 1989. 7-9................. 4....................... September 20, 1989. 10-16............... 3....................... April 13, 1989. 17-27............... 4....................... September 20, 1989. Total Pages: 27. SB No. PW2000: 72-233...................... 1,2................. 2....................... September 27, 1988. 3-7................. Original................ August 7, 1987. 8................... 1....................... January 22, 1988. 9,10................ 2....................... September 27, 1988. Total Pages: 10. SB No. PW2000: 72-233...................... 1-4................. 3....................... May 30, 1989. 5................... Original................ August 7, 1987. 6................... 3....................... May 30, 1989. 7................... Original................ August 7, 1987. 8................... 1....................... January 22, 1988. 9,10................ 3....................... May 30, 1989. Total Pages: 10. ---------------------------------------------------------------------------------------------------------------- [[Page 57053]] The incorporation by reference of these service documents was approved previously by the Director of the Federal Register as of November 29, 1996 (61 FR 50984, September 30, 1996). Copies may be obtained from Pratt & Whitney, Publications Department, Supervisor Technical Publications Distribution, M/S 132-30, 400 Main St., East Hartford, CT 06108; telephone (860) 565-7700, fax (860) 565-4503. Copies may be inspected at the FAA, New England Region, Office of Regional 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. (r) This amendment becomes effective on November 10, 1998. Issued in Burlington, Massachusetts, on October 19, 1998. David A. Downey, Assistant Manager, Engine and Propeller Directorate, Aircraft Certification Service. [FR Doc. 98-28534 Filed 10-23-98; 8:45 am] BILLING CODE 4910-13-U