Airworthiness Directive · Amendment 39-22703 · Turbine engine compressor section
International Aero Engines, LLC Engines
(1) This AD applies to International Aero Engines, LLC (IAE LLC) Model PW1122G-JM, PW1124G1-JM, PW1124G-JM, PW1127G-JM, PW1127G1-JM, PW1127G1A-JM, PW1127G1B-JM, PW1127GA-JM, PW1129G-JM, PW1130G-JM, PW1133G-JM, PW1133GA-JM, PW1428G-JM, PW1428GA-JM, PW1428GH-JM, PW1431G-JM, PW1431GA-JM, and PW1431GH-JM engines with an installed:
(i) High-pressure compressor (HPC) 7th-stage integrally bladed rotor (IBR-7) having part number (P/N) 30G2307 or 30G4407;
(ii) HPC 8th-stage integrally bladed rotor (IBR-8) having P/N 30G5608, 30G5908, or 30G8908;
(iii) HPC rear hub having P/N 30G4008 or 30G8208;
(iv) High-pressure turbine (HPT) 1st-stage hub having P/N 30G4201, 30G6201, or 30G7301; or
(v) HPT 2nd-stage hub having P/N 30G3902, 30G5502, or 30G6602.
(2) This AD does not apply to parts identified in paragraphs (c)(1)(i) through (v) of this AD if those parts were manufactured from powdered metal material produced prior to November 1, 2015, or after September 1, 2021, as identified by part serial number in Tables 1, 2, and 3 of PW Special Instruction (SI) No. 222F-23, Revision B, dated March 1, 2024 (PW SI No. 222F-23, Revision B) or in the original manufacturing records for the part.
(3) If the original manufacturing records do not identify the production date of the powdered metal used to make the parts identified in paragraphs (c)(1)(i) through (v) of this AD, and the part serial number is not listed in Tables 1, 2, and 3 of PW SI No. 222F-23, Revision B, then the part is subject to the requirements of this AD.
The FAA is superseding Airworthiness Directive (AD) 2022-19-15 for certain International Aero Engines, LLC (IAE LLC) Model PW1100G series engines; and AD 2023-16-07 for certain IAE LLC Model PW1100G series engines and PW1400G series engines. AD 2022-19-15 required an angled ultrasonic inspection (AUSI) of the high-pressure turbine (HPT) 1st-stage disk and HPT 2nd-stage disk, and replacement, if necessary. AD 2023-16-07 required an AUSI of the HPT 1st-stage hub (also known as the HPT 1st-stage disk) and HPT 2nd-stage hub (also known as the HPT 2nd-stage disk) for cracks, and replacement, if necessary, which is terminating action for AD 2022-19-15. This AD was prompted by an investigation that determined an increased risk of powdered metal anomalies for all powdered metal parts in certain powdered metal production campaigns, which are susceptible to failure significantly earlier than previously determined. This AD retains the AUSI requirement for certain HPT 1st-stage and HPT 2nd-stage hubs from AD 2023-16-07. This AD requires performing an AUSI of the HPT 1st-stage hub, HPT 2nd-stage hub, high-pressure compressor (HPC) 7th-stage integrally bladed rotor (IBR-7), and HPC 8th-stage integrally bladed rotor (IBR-8) for cracks, and replacing if necessary. This AD also requires accelerated replacement of the HPC IBR-7, HPC IBR-8, HPC rear hub, HPT 1st-stage hub, and HPT 2nd-stage hub. The FAA is issuing this AD to address the unsafe condition on these products.
(1) This paragraph restates the requirements of paragraph (g)(1) of AD 2023-16-07. For Group 1 and Group 2 engines with an installed HPT 1st-stage hub having part number (P/N) 30G7301 and a serial number (S/N) listed in Tables 1, 2, 3, or 4 of PW Special Instruction (SI) No. 149F-23, dated August 4, 2023 (PW SI No. 149F-23), within 30 days after August 28, 2023 (the effective date of AD 2023-16-07), perform an AUSI of the HPT 1st-stage hubs for cracks in accordance with the Accomplishment Instructions, paragraph 9.A. or 9.B., as applicable, of Pratt & Whitney (PW) Service Bulletin PW1000G-C-72-00-0188-00A-930A-D, Issue No: 002, dated July 8, 2022 (PW1000G-C-72-00-0188-00A-930A-D, Issue No: 002).
(2) This paragraph restates the requirements of paragraph (g)(2) of AD 2023-16-07. For Group 1 and Group 2 engines with an installed HPT 2nd-stage hub having P/N 30G6602 and an S/N listed in Tables 1, 2, 3, or 4 of PW SI No. 149F-23, within 30 days after August 28, 2023 (the effective date of AD 2023-16-07), perform an AUSI of the HPT 2nd-stage hubs for cracks in accordance with the Accomplishment Instructions, paragraph 9.C. or 9.D., as applicable, of PW1000G-C-72-00-0188-00A-930A-D, Issue No: 002.
(1) For Group 1 and Group 2 engines with an affected HPC IBR-7 having P/N 30G2307 or 30G4407, or an affected HPC IBR-8 having P/N 30G5608, 30G5908, or 30G8908, at the next HPC engine shop visit and thereafter at every HPC engine shop visit, perform an angled ultrasonic scan inspection (AUSI) of the affected HPC IBR-7 or HPC IBR-8, as applicable, for cracks in accordance with the Accomplishment Instructions, paragraph 4.E.(1) or 4.E.(2), of PW Alert Service Bulletin (ASB) PW1000G-C-72-00-0224-00A-930A-D, Issue No: 001, dated November 3, 2023 (PW ASB PW1000G-C-72-00-0224-00A-930A-D, Issue No: 001).
(2) For Group 1 and Group 2 engines with an affected HPT 1st-stage hub having P/N 30G7301 or an HPT 2nd-stage hub having P/N 30G6602, before exceeding the applicable compliance time in Table 1 to paragraph (h)(2) of this AD, except as required by paragraphs (g)(1) and (2) and paragraph (h)(7) 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 1.D.(7)(a) or 1.D.(7)(b) of PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002, dated December 12, 2023 (PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002). Thereafter, repeat the AUSI at the applicable interval in Table 1 to paragraph (h)(2) of this AD.
| Engine group | AUSI performed prior to effective date of this AD | Compliance time | Repetitive interval |
|---|---|---|---|
| 1 | No | Before accumulating 3,800 cycles since new (CSN) or within 100 flight cycles (FCs) after the effective date of this AD, whichever occurs later | Thereafter at each HPT engine shop visit or before exceeding 3,800 FCs from the last AUSI of the affected hub, whichever occurs first. |
| 1 | Yes | At the next HPT engine shop visit, not to exceed 3,800 FCs since the previous AUSI, or within 100 FCs after the effective date of this AD, whichever occurs later | Thereafter at each HPT engine shop visit or before exceeding 3,800 FCs from the last AUSI of the affected hub, whichever occurs first. |
| 2 | No | Before accumulating 2,800 CSN or within 100 FCs after the effective date of this AD, whichever occurs later | Thereafter at each HPT engine shop visit or before exceeding 2,800 FCs from the last angled AUSI of the affected hub, whichever occurs first. |
| 2 | Yes | At the next HPT engine shop visit, not to exceed 2,800 FCs since the previous AUSI, or within 100 FCs after the effective date of this AD, whichever occurs later | Thereafter at each HPT engine shop visit or before exceeding 2,800 FCs from the last AUSI of the affected hub, whichever occurs first. |
(3) For Group 1 and Group 2 engines with an affected part listed in Table 2 to paragraph (h)(3) of this AD, at the next HPT engine shop visit not to exceed the applicable cyclic limit specified in Table 2 to paragraph (h)(3) of this AD, or 100 FCs after the effective date of the AD, whichever occurs later, except as required by paragraphs (h)(6) and (8) of this AD, remove the affected part from service and replace with a part eligible for installation.
| Engine group | AUSI performed prior to effective date of this AD | Part name | Part No. | Cyclic limit |
|---|---|---|---|---|
| 1 | Yes | HPT 1st-stage hub | 30G4201 or 30G6201 | 3,800 FCs since last AUSI. |
| 1 | No | HPT 1st-stage hub | 30G4201 or 30G6201 | 3,800 CSN. |
| 1 | Yes | HPT 2nd-stage hub | 30G3902 or 30G5502 | 3,800 FCs since last AUSI or 7,000 CSN, whichever comes first. |
| 1 | No | HPT 2nd-stage hub | 30G3902 or 30G5502 | 3,800 CSN. |
| 2 | Yes | HPT 1st-stage hub | 30G4201 or 30G6201 | 2,800 FCs since last AUSI. |
| 2 | No | HPT 1st-stage hub | 30G4201 or 30G6201 | 2,800 CSN. |
| 2 | Yes | HPT 2nd-stage hub | 30G3902 or 30G5502 | 2,800 FCs since last AUSI or 5,000 CSN, whichever comes first. |
| 2 | No | HPT 2nd-stage hub | 30G3902 or 30G5502 | 2,800 CSN. |
(4) For Group 1 and Group 2 engines with an affected part listed in Table 3 to paragraph (h)(4) of this AD, before exceeding the applicable compliance times specified in Table 3 to paragraph (h)(4) of this AD, remove the affected part from service and replace with a part eligible for installation.
| Engine group | Part name | Part No. | Compliance time |
|---|---|---|---|
| 1 and 2 | HPC rear hub | 30G4008 | At the next HPC shop visit or HPT shop visit, whichever occurs first after the effective date of this AD. |
| 1 | HPC rear hub | 30G8208 | Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 1 | HPC IBR-7 | 30G2307 or 30G4407 | Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 1 | HPC IBR-8 | 30G5608 or 30G5908 or 30G8908 | Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 1 | HPT 1st-stage hub | 30G7301 | Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 1 | HPT 2nd-stage hub | 30G6602 | Before accumulating 7,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 2 | HPC rear hub | 30G8208 | Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 2 | HPC IBR-7 | 30G2307 or 30G4407 | Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 2 | HPC IBR-8 | 30G5608 or 30G5908 or 30G8908 | Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 2 | HPT 1st-stage hub | 30G7301 | Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
| 2 | HPT 2nd-stage hub | 30G6602 | Before accumulating 5,000 CSN or within 100 FCs after the effective date of this AD, whichever occurs later. |
(5) For affected parts that have been operated in a Group 1 and Group 2 configuration, calculate part replacement and AUSI times required by paragraphs (h)(2) through (4) using the note to Table 3 of the compliance paragraph of PW ASB PW1000G-C-72-00-0224-00A-930A-D, Issue No: 001 or PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002, as applicable, which addresses calculating mixed model cycles.
(6) For Group 1 and Group 2 engines with an installed HPT 1st-stage hub having P/N 30G6201 or an HPT 2nd-stage hub having P/N 30G5502 and an S/N listed in Tables 1, 2, 3, or 4 of PW SI No. 149F-23 that has not had an AUSI performed before the effective date of this AD, before further flight, remove the affected hub from service.
(7) For Group 1 and Group 2 engines with an installed HPT 1st-stage hub having P/N 30G7301 or an HPT 2nd-stage hub having P/N 30G6602 with an S/N listed in Tables 1, 2, 3, or 4 of PW SI No. 198F-23, dated November 3, 2023 (PW SI No. 198F-23), within 100 FC after the effective date of this AD, perform an AUSI of the affected hub for cracks in accordance with the Accomplishment Instructions, paragraph 1.D.(7)(a) or 1.D.(7)(b) of PW ASB PW1000G-C-72-00-0225-00A-930A-D, Issue No: 002.
(8) For Group 1 and Group 2 engines with an installed HPT 1st-stage hub having P/N 30G6201 or an HPT 2nd-stage hub having P/N 30G5502 with an S/N listed in Tables 1, 2, 3, or 4 of PW SI No. 198F-23, within 100 FC after the effective date of this AD, remove the hub from service and replace with a part eligible for installation.
(9) If any crack indication is found during any AUSI required by this AD, before further flight, remove the affected part from service and replace with a part eligible for installation.
(10) 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.
(1) For the purposes of this AD, “Group 1 engines” are IAE LLC Model PW1122G-JM, PW1124G1-JM, PW1124G-JM, PW1127G-JM, PW1127G1-JM, PW1127G1A-JM, PW1127G1B-JM, and PW1127GA-JM engines.
(2) For the purposes of this AD, “Group 2 engines” are IAE LLC Model PW1129G-JM, PW1130G-JM, PW1133G-JM, PW1133GA-JM, PW1428G-JM, PW1428GA-JM, PW1428GH-JM, PW1431G-JM, PW1431GA-JM, and PW1431GH-JM engines.
(3) For the purposes of this AD, an “HPC engine shop visit” is the induction of an engine into the shop for maintenance involving the separation of the H-flange.
(4) For the purposes of this AD, an “HPT engine shop visit” is the induction of an engine into the shop for maintenance involving the separation of the M-flange.
(5) For the purposes of this AD, a “part eligible for installation” is:
(i) An HPC IBR-7 having P/N 30G2307 or 30G4407 that has passed the AUSI required by paragraph (h)(1) of this AD or is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N.
(ii) An HPC IBR-8 having P/N 30G5608, 30G5908, or 30G8908 that has passed the AUSI required by paragraph (h)(1) of this AD or is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N.
(iii) An HPT 1st-stage hub having P/N 30G7301 that has passed the AUSI required by paragraph (h)(2) of this AD or is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N.
(iv) An HPT 2nd-stage hub having P/N 30G6602 that has passed the AUSI required by paragraph (h)(2) of this AD or is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N.
(v) An HPC rear hub having P/N 30G8208 and is identified as not affected by this AD in paragraph (c)(2) of this AD, or later approved P/N.
