Airworthiness Directive · Amendment 39-22764 · Turbine engine
International Aero Engines, AG Engines
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.
The FAA is adopting a new airworthiness directive (AD) for certain International Aero Engines, AG (IAE AG) Model V2500 engines. This AD was prompted by an 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 aborted takeoff. This AD requires performing an angled ultrasonic inspection (AUSI) of certain high-pressure turbine (HPT) 1st-stage hubs and HPT 2nd-stage hubs for cracks and replacing if necessary. This AD also requires accelerated replacement of certain HPT 1st-stage hubs and HPT 2nd-stage hubs. The FAA is issuing this AD to address the unsafe condition on these products.
(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.
| 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.
| 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.
| 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. |
(1) For the purposes of this AD, a “part eligible for installation” is an HPT 1st-stage disk or HPT 2nd-stage disk having an S/N that is not listed in IAE AG NMSB V2500-ENG-72-0720 or PW SI No. 189F-23, or an HPT 1st-stage disk or HPT 2nd-stage disk that was not removed from service per the requirements of this AD.
(2) For the purposes of this AD, an “HPT module removal” is when the HPT rotor and stator assembly are removed from the engine.
(3) For the purposes of this AD, “Previously operated in high-thrust model engine” refers to HPT 1st-stage hubs or HPT 2nd-stage hubs that have operated in an IAE AG Model V2527E-A5, V2527M-A5, V2528-D5, V2530-A5, V2531-E5, or V2533-A5 engine for any duration.
(4) 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, H-P, except for the following situations, which do not constitute an engine shop visit:
(i) Separation of engine flanges solely for the purposes of transportation without subsequent engine maintenance.
(ii) Engine removal for the purpose of performing field maintenance activities at a maintenance facility in lieu of performing them on-wing.
(5) For the purposes of this AD, the date that an AUSI inspected part was installed is the date of the authorized release certification for the shop visit at which the part was first installed after the AUSI was performed.
Compliance with paragraph (g)(1) of this AD satisfies the requirements of AD 2022-02-09.
