AD 97-09-01 Airworthiness Directives; Pratt & Whitney PW2000 Series Turbofan Engines

Pratt & Whitney (PW) PW2000 series turbofan engines, installed on but not limited to Boeing 757 series, Ilyushin IL-96 series, and McDonnell Douglas Model C-17 (military) 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 (k) 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 fracture of the first stage high pressure turbine (HPT) disk, resulting in a possible uncontained engine failure and damage to the aircraft, accomplish the following: (a) Prior to further flight, for first stage HPT disks that are accessible in the shop, as defined in paragraph (j)(2) of this AD, on the effective date of this AD, perform eddy current inspections (ECI) of the first stage HPT disks for cracks in the forward face of the disk at the base of the fir tree lug at the outer diameter (OD) snap fillet radius where the side plates mate with the disk, in accordance with the Accomplishment Instructions of PW Service Bulletin (SB) No. PW2000 72-588, Revision 1, dated March 31, 1997, or Original, dated February 17, 1997. (b) For first stage HPT disks that are identified by serial number (S/N) in Table 1 of this AD, rework the forward and aft faces of the first stage HPT disk OD snap fillet radii at the base of the fir tree lug in accordance with PW Alert Service Bulletin (ASB) No. PW2000 A72-592, dated March 18, 1997, as follows: Table 1 ------------------------------------------------------------------------ ------------------------------------------------------------------------ S/N N54398 N54399 N54400 N54401 N54402 N54403 N54404 N54405 N54406 N54407 N54408 N54409 N54410 N54411 N54412 N54413 N54414 N54415 N54416 N54417 N54418 N54419 N55114 N55115 N55116 N55117 P00624 P00625 P00626 P00627 P00628 P00788 P00812 P00813 P00814 P00815 P00816 P00817 P00818 P00986 P00987 P01018 P01457 P36249 P36250 P36251 P36252 P36253 P36254 P36255 P36256 P36258 P36259 P36306 P36307 P36308 P36309 P36310 P36311 P36312 P36378 P36634 P36636 P36637 P36638 P36639 P36805 P36806 P37113 P37114 P37115 P37116 P37117 P37118 P37324 P37325 P37326 P37327 P37328 P37348 P37349 P37351 P37352 P37353 P37354 P90203 P90204 P90205 P90206 P90207 P90208 P90209 P90210 P90211 P90212 P90385 P90386 P90387 P90388 P90389 P90390 P91685 P91686 P91687 P91688 P91854 P91855 P91856 P91857 P91867 P91931 P91932 P91933 P91934 P91935 R28552 R28553 R28554 R28555 R28612 R28613 R28614 R28615 R28617 R28618 R28680 R28681 R28682 R28683 R28684 R28685 R28686 R28687 R28711 R28712 R28713 R28714 R28715 R28716 R28718 R28719 R28720 R28752 R28753 R28755 R28756 R28757 R28758 R28761 R28800 R28801 R28802 R28803 R28804 R28805 R28806 R28807 R28808 R28809 R28810 R28811 R28812 R28813 R28847 R28848 R28901 R28903 R28904 R28905 R28906 R28907 R28908 R28909 R28913 R28914 R28915 R28933 R28934 R28935 R28936 R28937 R28951 R28952 R28953 R28954 R28955 R28956 S16633 S16634 S16636 S16637 S16638 S16639 S16641 S16642 S16643 S16645 S16646 S16647 S16648 S16649 S16650 S16651 S16652 S16654 S16655 S16656 S16657 S16658 S16659 S16660 S16661 S16662 S16663 S16664 S16665 S16666 S16667 S16668 S16669 S16670 S16671 S16672 S16673 S16674 S16675 S16676 S16677 S16678 S16679 S16680 S16681 S16682 S16683 S16684 S16685 S16687 S16688 S16689 S16690 S16691 S16692 S16693 S16694 S16695 S16697 S16698 S16699 S16700 S16701 S16702 S16703 S16705 S16707 S16708 S16709 S16710 S16712 S16713 S16715 S16716 S16717 S16718 S16719 S16720 S16721 S16723 S16724 S16725 S16727 S16728 S16730 S16731 S16732 S16733 S16735 S16738 S16739 S16741 S16742 S16743 S16744 S16745 S16746 S16747 S16748 S16749 S16750 S16751 S16752 S16753 S16756 S16757 S16758 S16760 S16761 S16762 S16763 S16765 S16766 S16768 S16769 S16772 S16773 S16774 S16775 S16776 S16777 S16778 S16780 S16782 S16783 S16784 S16786 S16787 S16789 S16790 S16792 S16793 S16795 S16798 S16800 S16802 S16803 S16804 S16805 S16806 S16807 S16808 S16810 S16811 S16814 S16815 S16816 S16818 S16819 S16821 S16822 S16824 S16825 S16827 S16829 S16831 S16832 ------------------------------------------------------------------------ (1) For disks that have accumulated 10,000 or more cycles since new (CSN) on the effective date of this AD, inspect and rework within 1,600 cycles in service (CIS) after the effective date of this AD. (2) For disks that have accumulated less than 10,000 CSN on the effective date of this AD, inspect and rework at the next shop visit, or 11,600 CSN, whichever occurs first. (c) For first stage HPT disks that are identified by S/N in Table 2 of this AD, rework the forward and aft faces of the first stage HPT disk OD snap fillet radii at the base of the fir tree lug in accordance with PW ASB No. PW2000 A72-592, dated March 18, 1997, as follows: Table 2 ------------------------------------------------------------------------ ------------------------------------------------------------------------ S/N M43410 M43411 M68250 M68251 M68252 M68253 M68254 M68255 M68256 M68344 M68345 M68346 M68347 M68348 M68349 M68350 M68536 M68537 M68538 M68539 M68540 M68541 M68696 M68697 M68698 M68699 M68700 M68701 M68702 M68703 M68915 M68916 M68917 M68918 M68919 M68997 M68998 M69000 M69001 M85382 M85383 M85384 M85385 M85386 M85387 N09764 N09765 N09766 N09767 N09768 N09769 N09770 N09771 N09772 N09773 N09774 N09775 N09776 N09777 N09778 N11389 N11390 N11391 N11392 N11393 N11394 N11395 N11396 N11397 N11398 N11399 N11400 N11401 N11402 N11403 N11404 N11405 N11406 N11407 N12830 N12831 N12832 N12833 N12834 N12835 N12836 N12838 N12839 N12840 N12841 N12842 N12843 [[Page 20097]] N12844 N12845 N12846 N12847 N12848 N54390 N54391 N54392 N54393 N54395 N54396 N54397 ------------------------------------------------------------------------ (1) For disks that have accumulated 7,000 or more CSN on the effective date of this AD, inspect and rework within 800 CIS after the effective date of this AD. (2) For disks that have accumulated less than 7,000 CSN on the effective date of this AD, inspect and rework at the next shop visit, or 7,800 CSN, whichever occurs first. (d) For first stage HPT disks that are identified by S/N in Table 3 of this AD, rework the forward and aft faces of the first stage HPT disk OD snap fillet radii at the base of the fir tree lug in accordance with PW ASB No. PW2000 A72-592, dated March 18, 1997, as follows: Table 3 ------------------------------------------------------------------------ ------------------------------------------------------------------------ D301AA0002 D301AA0003 D301AA0004 D301AA0005 D301AA0006 D301AA0008 D301AA0009 D301AA0010 D301AA0011 D301AA0013 D301AA0015 D301AA0018 D301AA0019 D301AA0020 D301AA0021 D301AA0022 D301AA0023 D301AA0024 D301AA0025 D301AA0027 D301AA0028 D301AA0029 D301AA0031 D301AA0032 D301AA0033 D301AA0034 D301AA0035 D301AA0038 D301AA0039 D301AA0040 D301AA0041 D301AA0042 D301AA0044 D301AA0045 D301AA0046 D301AA0047 D301AA0048 D301AA0049 D301AA0050 D301AA0051 D301AA0052 D301AA0053 D301AA0054 D301AA0055 D301AA0056 D301AA0057 D301AA0059 D301AA0061 D301AA0062 D301AA0064 D301AA0065 D301AA0066 D301AA0067 D301AA0068 D301AA0069 D301AA0070 D301AA0071 D301AA0072 D301AA0074 D301AA0075 D301AA0077 D301AA0080 D301AA0081 D301AA0082 D301AA0083 D301AA0084 D301AA0085 D301AA0086 D301AA0087 D301AA0088 D301AA0089 D301AA0090 D301AA0091 D301AA0092 D301AA0093 D301AA0094 D301AA0095 D301AA0096 D301AA0098 D301AA0101 D301AA0102 D301AA0103 D301AA0104 D301AA0105 D301AA0106 D301AA0107 D301AA0108 D301AA0110 D301AA0111 D301AA0114 D301AA0118 D301AA0121 D301AA0123 D301AA0124 D301AA0125 D301AA0127 D301AA0129 D301AA0130 D301AA0131 D301AA0132 D301AA0133 D301AA0135 D301AA0137 D301AA0138 D301AA0140 D301AA0141 D301AA0144 D301AA0145 D301AA0146 D301AA0147 D301AA0148 D301AA0149 D301AA0150 D301AA0151 D301AA0152 D301AA0154 D301AA0156 D301AA0157 D301AA0159 D301AA0161 D301AA0163 D301AA0164 D301AA0165 D301AA0166 D301AA0167 D301AA0171 D301AA0174 D301AA0175 D301AA0177 D301AA0179 D301AA0180 D301AA0182 D301AA0187 D301AA0189 D301AA0198 D301AA0201 D301AA0205 D301AA0358 D301AA0359 D301AA0360 D301AA0361 D301AA0362 D301AA0363 D301AA0364 D301AA0367 D301AA0368 D301AA0369 D301AA0370 D301AA0371 D301AA0372 D301AA0375 D301AA0376 D301AA0377 D301AA0379 D301AA0380 D301AA0381 D301AA0382 D301AA0383 D301AA0384 D301AA0386 D301AA0387 D301AA0388 D301AA0390 D301AA0391 D301AA0392 D301AA0393 D301AA0394 D301AA0395 D301AA0396 D301AA0399 D301AA0401 D301AA0402 D301AA0403 D301AA0404 D301AA0406 D301AA0407 D301AA0408 D301AA0412 D301AA0414 D301AA0415 D301AA0416 D301AA0418 D301AA0419 D301AA0420 D301AA0421 D301AA0422 D301AA0423 D301AA0424 D301AA0425 D301AA0426 D301AA0427 D301AA0428 D301AA0431 D301AA0432 D301AA0434 D301AA0435 D301AA0437 D301AA0438 D301AA0439 D301AA0440 D301AA0443 D301AA0444 D301AA0445 D301AA0446 D301AA0447 D301AA0449 D301AA0450 DKLBA78421 DKLBA78423 DKLBA78427 DKLBA78429 DKLBA78431 DKLBA78432 DKLBA78433 DKLBA78434 DKLBA78435 DKLBA78436 DKLBA78437 DKLBA78438 DKLBA78439 DKLBA78441 DKLBA78442 DKLBA78443 DKLBA78444 DKLBA78446 DKLBA78448 DKLBA78449 DKLBA78453 DKLBA78454 DKLBA78455 DKLBA78456 DKLBA78457 DKLBA78458 DKLBA78459 DKLBA78465 DKLBA78467 DKLBA78468 DKLBA78469 DKLBA78472 DKLBA78475 DKLBA78482 DKLBA78483 DKLBA78484 DKLBA78485 DKLBA78486 DKLBA78487 DKLBA78488 DKLBA78489 DKLBA78490 DKLBA78491 DKLBA78492 DKLBA78493 DKLBA78496 DKLBA78497 DKLBA78498 DKLBA78500 DKLBA78502 DKLBA78503 DKLBA78504 DKLBA78505 DKLBA78506 DKLBA78507 DKLBA78508 DKLBA78509 DKLBA78510 DKLBA78512 DKLBA78514 DKLBA78515 DKLBA78517 DKLBA78518 DKLBA78519 DKLBA78520 DKLBA78521 DKLBA78522 DKLBA78524 DKLBA78525 DKLBA78526 DKLBA78527 DKLBA78528 DKLBA78529 DKLBA78530 DKLBA78531 DKLBA78533 DKLBA78534 DKLBA78536 DKLBA78537 DKLBA78538 DKLBA78540 DKLBA78541 DKLBA78542 DKLBA78543 DKLBA78544 DKLBA78545 DKLBA78550 DKLBA78551 DKLBA78552 DKLBA78553 DKLBA78554 DKLBA78557 DKLBA78558 DKLBA78559 DKLBA78560 DKLBA78561 DKLBA78562 DKLBA78564 DKLBA78568 DKLBA78569 DKLBA78575 DKLBA78577 DKLBA78578 DKLBA78579 DKLBA78580 DKLBA78581 DKLBA78582 DKLBA78584 DKLBA78585 DKLBA78587 DKLBA78589 DKLBA78590 DKLBA78593 DKLBA78594 DKLBA78596 DKLBA78598 DKLBA78600 DKLBA78601 DKLBA78603 DKLBA78604 DKLBA78605 DKLBA78606 DKLBA78607 DKLBA78609 DKLBA78610 DKLBA78611 DKLBA78613 DKLBA78614 DKLBA78615 DKLBA78616 DKLBA78617 DKLBA78618 DKLBA78620 DKLBA78622 DKLBA78625 DKLBA78627 DKLBA78628 DKLBA78632 DKLBA78633 DKLBA78635 DKLBA78636 DKLBA78638 DKLBA78639 DKLBA78640 DKLBA78642 DKLBA78644 DKLBA78645 DKLBA78646 DKLBA78648 DKLBA78649 DKLBA78650 DKLBA78651 DKLBA78652 DKLBA78653 DKLBA78654 DKLBA78655 DKLBA78656 DKLBA78657 DKLBA78658 DKLBA78660 DKLBA78661 DKLBAH8318 DKLBAH8319 DKLBAH8320 DKLBAH8321 DKLBAH8322 DKLBAH8323 DKLBAH8324 DKLBAH8325 DKLBAH8327 DKLBAH8328 DKLBAH8329 DKLBAH8330 DKLBAH8331 DKLBAH8332 DKLBAH8333 DKLBAH8336 DKLBAH8337 DKLBAH8339 DKLBAH8340 DKLBAH8343 DKLBAH8344 DKLBAH8346 DKLBAH8347 DKLBAH8348 DKLBAH8349 DKLBAH8350 DKLBAH8351 DKLBAH8352 DKLBAH8353 DKLBAH8354 DKLBAH8355 DKLBAH8356 DKLBAH8357 DKLBAH8360 DKLBAH8361 DKLBAH8362 DKLBAH8364 DKLBAH8365 DKLBAM0972 DKLBAM0973 L82270 L82271 L82272 L82356 L82649 L82650 L83308 L83309 L83310 L83311 L83312 M15709 M15710 M15718 M42710 M42711 M42768 M42769 M42770 M42771 M43103 M43104 M43105 M43396 M43397 M43398 M43399 M43400 M43401 M43409 ------------------------------------------------------------------------ (1) For disks that have accumulated 7,000 or more CSN on the effective date of this AD, inspect and rework within 1,100 CIS after the effective date of this AD. (2) For disks that have accumulated less than 7,000 CSN on the effective date of this AD, inspect and rework at the next shop visit, or 8,100 CSN, whichever occurs first. (e) For disks that have previously been inspected in accordance with PW SB No. PW2000 72-588, Revision 1, dated March 31, 1997, or Original, dated February 17, 1997, but not reworked in accordance with PW ASB No. PW2000 A72-592, dated March 18, 1997, rework in accordance with PW ASB No. PW2000 A72-592, dated March 18, 1997, at the next shop visit when the part is accessible, as defined in paragraph (j)(2) of this AD, or 4,000 CIS since inspection in accordance with PW SB No. PW2000 72-588, Revision 1, dated March 31, 1997, or Original, dated February 17, 1997, whichever occurs first. (f) Prior to further flight, remove and replace disks with cracks. Disks with cracks cannot be reworked. (g) If reworked, reidentify the disk in accordance with the Accomplishment Instructions of PW ASB No. PW2000 A72-592, dated March 18, 1997. (h) For all first stage HPT disks that have been reworked in accordance with PW ASB No. PW2000 A72-592, dated March 18, 1997, thereafter inspect in accordance with PW Temporary Revision 72-937, dated April 11, 1997, to Engine Manual, P/N 1A6231, Section 72-52- 02, Inspection Check 04, at each subsequent shop visit when the disk is accessible, as defined in paragraph (j)(2) of this AD, not to exceed 6,000 CIS since last inspection. (i) The following cyclic life limits apply to disks that are reworked in accordance with the Accomplishment Instructions of PW Alert Service Bulletin (ASB) No. PW2000 A72-592, dated March 18, 1997: (1) Disks that have accumulated less than 5,000 CSN upon rework may accumulate an additional 10,000 CIS following rework, and then must be retired from service. (2) Disks that have accumulated 5,000 CSN or more upon rework may remain in service to the full 15,000 CSN published life limit, and then must be retired from service. (3) Except as provided in paragraph (k) of this AD, no alternative life limits may be approved for disks reworked in accordance with PW ASB No. PW2000 A72-592, dated March 18, 1997. (j) For the purpose of this AD, the following definitions apply: (1) A shop visit is defined as an engine removal where engine maintenance, prior to reinstalling the engine, entails separation of pairs of mating major engine flanges or the removal of a disk, hub, or spool. (2) An accessible disk is defined as a disk that is in the shop, has been removed from the HPT module, separated from the rotor, and debladed. [[Page 20098]] (k) An alternative method of compliance or adjustment of the 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 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 airworthiness directive, if any, may be obtained from the Engine Certification Office. (l) 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 inspection and rework requirements of this AD can be accomplished. (m) The actions required by this AD shall be done in accordance with the following PW service documents: ---------------------------------------------------------------------------------------------------------------- Document No. Pages Revision Date ---------------------------------------------------------------------------------------------------------------- SB No. PW2000 72-588......................... 1 1................................ Mar. 31, 1997. 2 Original......................... Feb. 17, 1997. 3-12 1................................ Mar. 31, 1997. NDIP-899........................... 1-23 A................................ Mar. 25, 1997. Total Pages: 35 SB No. PW2000 72-588......................... 1-12 Original......................... Feb. 17, 1997. NDIP-899........................... 1-23 Original......................... Feb. 16, 1997. SB No. PW2000 72-588......................... 38 Original......................... Feb. 17, 1997. Total Pages: 36 ASB No. PW2000 A72-592........................ 1-16 Original......................... Mar. 18, 1997. Total Pages: 16 ---------------------------------------------------------------------------------------------------------------- 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, 400 Main St., East Hartford, CT 06108; telephone (860) 565-6600, fax (860) 565-4503. 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. (n) This amendment becomes effective on May 12, 1997. Issued in Burlington, Massachusetts, on April 17, 1997. Jay J. Pardee, Manager, Engine and Propeller Directorate, Aircraft Certification Service. [FR Doc. 97-10585 Filed 4-24-97; 8:45 am] BILLING CODE 4910-13-U