Airworthiness Directive · Amendment 39-22709 · Turbine engine compressor section
Pratt & Whitney Turbofan Engines
Pratt & Whitney (PW) Model PW1519G, PW1521G, PW1521GA, PW1521G-3, PW1524G, PW1524G-3, PW1525G, PW1525G-3, PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A engines.
The FAA is adopting a new airworthiness directive (AD) for certain Pratt & Whitney (PW) Model PW1519G, PW1521G, PW1521GA, PW1521G- 3, PW1524G, PW1524G-3, PW1525G, PW1525G-3, PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A engines. This AD was prompted by an updated analysis of an event involving an International Aero Engines, LLC (IAE LLC) Model PW1127GA-JM engine, which experienced a high-pressure compressor (HPC) 7th-stage integrally bladed rotor (IBR-7) separation that resulted in an engine shutdown and aborted takeoff. This AD requires performing an angled ultrasonic inspection (AUSI) of certain high-pressure turbine (HPT) 1st-stage hubs, HPT 2nd-stage hubs, and HPC 8th-stage disks for cracks and, depending on the results of the inspections, replacing the HPT 1st-stage hubs, HPT 2nd-stage hubs, or HPC 8th-stage disks. This AD also requires accelerated replacement of certain HPC 7th-stage rotors, HPC 8th-stage disks, HPC rear hubs, HPT 1st-stage hubs, HPT 2nd-stage hubs, HPT 1st-stage air seals, HPT 2nd- stage air seals, HPT 1st-stage blade retaining plates, and HPT 2nd- stage blade retaining plates. The FAA is issuing this AD to address the unsafe condition on these products.
(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.
| 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.
| 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.
| 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.
After the effective date of this AD, do not install an HPT 1st-stage hub having P/N 30G8501 or an HPT 2nd-stage hub having P/N 30G7202 and an S/N listed in Table 1 of PW SI No. 240F-23A, dated February 7, 2024, in any engine.
(1) For the purposes of this AD, “PW1500G” engines are PW Model PW1519G, PW1521G, PW1521GA, PW1521G-3, PW1524G, PW1524G-3, PW1525G, and PW1525G-3 engines.
(2) For the purposes of this AD, “PW1900G” engines are PW Model PW1919G, PW1921G, PW1922G, PW1923G, and PW1923G-A engines.
(3) For the purposes of this AD, a “part eligible for installation” is:
(i) Any HPC 7th-stage rotor, P/N 30G5307 or later approved P/N.
(ii) Any HPC 8th-stage disk, P/N 30G7208, that has passed the AUSI required by paragraph (g) of this AD or later approved P/N.
(iii) Any HPC rear hub, P/N 30G7308 or later approved P/N.
(iv) Any HPT 1st-stage hub, P/N 30G8501, that has passed the AUSI required by paragraph (g) of this AD or later approved P/N.
(v) Any HPT 2nd-stage hub, P/N 30G7202, that has passed the AUSI required by paragraph (g) of this AD or later approved P/N.
(vi) Any HPT 1st-stage air seal, P/N 30G5195 or later approved P/N.
(vii) Any HPT 2nd-stage air seal, P/N 30G5196 or later approved P/N.
(viii) Any HPT 1st-stage blade retaining plate, P/N 30G5193 or later approved P/N.
(ix) Any HPT 2nd-stage blade retaining plate, P/N 30G5194 or later approved P/N.
(4) For the purposes of this AD, a “piece-part exposure” is when the part is disassembled from the rotor assembly.
(5) For the purposes of this AD, an “engine shop visit” is the induction of an engine into the shop for maintenance involving the separation of pairs of major mating engine flanges, except for the following situations, which do not constitute an engine shop visit.
(i) The separation of engine flanges solely for the purposes of transportation without subsequent engine maintenance.
(ii) Fan case maintenance or replacement.
(6) For the purposes of this AD, an “HPC engine shop visit” is when the HPC rotor assembly is removed from the HPC module.
The aircraft, engines and makers this AD names, by the model designations in its text. A model listed here may still be outside the AD's serial ranges.
