Airworthiness Directives; Pratt & Whitney JT8D Series Turbofan Engines

DEPARTMENT OF TRANSPORTATION

14 CFR Part 39

[Docket No. 94-ANE-27; Amendment 39-8964; AD 94-14-16]

Airworthiness Directives; Pratt & Whitney JT8D Series Turbofan

Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that

is applicable to certain Pratt & Whitney (PW) JT8D series engines. This

action requires initial and repetitive inspections of the Number 7 fuel

nozzle and support assembly, replacement of the Number 7 fuel nozzle

and support assembly with a more leak-resistant configuration, and

replacement of aluminum oil pressure and scavenge tube fittings with

steel fittings. This amendment is prompted by reports of two engine

fires initiated by fuel leakage from the Number 7 fuel nozzle and

support assembly, ignition of that fuel, melting of aluminum oil

pressure and scavenge tube fittings that are in the proximity of the

Number 7 nozzle, and augmentation of that fire with the liberated oil.

The actions specified in this AD are intended to prevent fuel leakage

from the Number 7 fuel nozzle and support assembly, ignition of that

leaking fuel, and liberation of oil from melted oil line fittings,

which can result in an uncontained engine fire and damage to the

aircraft.

DATES: Effective July 26, 1994.

The incorporation by reference of certain publications listed in

the regulations is approved by the Director of the Federal Register as

of July 26, 1994.

Comments for inclusion in the Rules Docket must be received on or

before September 9, 1994.

ADDRESSES: Submit comments in triplicate to the Federal Aviation

Administration (FAA), New England Region, Office of the Assistant Chief

Counsel, Attention: Rules Docket Number 94-ANE-27, 12 New England

Executive Park, Burlington, MA 01803-5299.

The service information referenced in this AD may be obtained from

Pratt & Whitney, Technical Publications Department, M/S 132-30, 400

Main Street, East Hartford, CT 06108. This information may be examined

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.

FOR FURTHER INFORMATION CONTACT: Mark A. Rumizen, Aerospace Engineer,

Engine Certification Office, FAA, Engine and Propeller Directorate, 12

New England Executive Park, Burlington, MA 01803-5299; telephone (617)

238-7137, fax (617) 238-7199.

SUPPLEMENTARY INFORMATION: The Federal Aviation Administration (FAA)

has received two reports of uncontained engine fires on Pratt & Whitney

(PW) JT8D series engines due to fuel leakage from the Number 7 fuel

nozzle and support assembly, ignition of that fuel, melting of aluminum

oil pressure and scavenge tube fittings that are in the proximity of

the Number 7 nozzle, and augmentation of that fire with the liberated

oil. The resulting fire burned through the engine diffuser case and fan

ducts, causing an aircraft engine cowl fire. The FAA has determined

that the fuel nozzle and support assembly is susceptible to incomplete

or improper refurbishment or repair that could result in fuel leaks

across the fuel nozzle seals, and that the aluminum oil pressure and

scavenge tube fittings have inadequate fire resistance capability.

These oil line fittings are in the path of the fuel leaking and

associated fire from the Number 7 fuel nozzle and support assembly.

Impingement of the fire on these oil fittings causes them to melt, thus

causing the oil contained in the oil tubes to escape and to augment the

fire. Therefore, this amendment will require the inspection of the

Number 7 fuel nozzle and support assembly for evidence of fuel leakage

and burning until replacement of the Number 7 fuel nozzle and support

assembly with a more leak-resistant configuration. It also requires

replacement of the aluminum oil tube fittings with steel fittings. This

condition, if not corrected, could result in fuel leakage from the

Number 7 fuel nozzle and support assembly, ignition of that leaking

fuel, and liberation of oil from melted oil line fittings, which can

result in an uncontained engine fire and damage to the aircraft.

The FAA has reviewed and approved the technical contents of PW

Alert Service Bulletin (ASB) No. A6153, Revision 1, dated June 8, 1994,

that describes procedures for initial and repetitive borescope

inspections of the Number 7 fuel nozzle and support assembly; and ASB

No. A6169, Revision 1, dated June 15, 1994, and A6170, dated May 13,

1994, that describe procedures for replacement of the Number 7 fuel

nozzle and support assembly with a more leak-resistant configuration

and replacement of the aluminum oil tube fittings with steel fittings,

respectively.

Since an unsafe condition has been identified that is likely to

exist or develop on other PW JT8D series engines of the same type

design, this AD is being issued to prevent uncontained engine fire and

damage to the aircraft. This AD requires inspection of the Number 7

fuel nozzle and support assembly for evidence of fuel leakage and

burning until replacement of the Number 7 fuel nozzle and support

assembly with an improved sealing configuration. This AD also requires

replacement of the aluminum oil tube fittings with steel fittings. The

actions are required to be accomplished in accordance with the alert

service bulletins described previously.

Since a situation exists that requires the immediate adoption of

this regulation, it is found that notice and opportunity for prior

public comment hereon are impracticable, and that good cause exists for

making this amendment effective in less than 30 days.

Comments Invited

Although this action is in the form of a final rule that involves

requirements affecting flight safety and, thus, was not preceded by

notice and an opportunity for public comment, comments are invited on

this rule. Interested persons are invited to comment on this rule by

submitting such written data, views, or arguments as they may desire.

Communications should identify the Rules Docket number and be submitted

in triplicate to the address specified under the caption ADDRESSES. All

communications received on or before the closing date for comments will

be considered, and this rule may be amended in light of the comments

received. Factual information that supports the commenter's ideas and

suggestions is extremely helpful in evaluating the effectiveness of the

AD action and determining whether additional rulemaking action would be

needed.

Comments are specifically invited on the overall regulatory,

economic, environmental, and energy aspects of the rule that might

suggest a need to modify the rule. All comments submitted will be

available, both before and after the closing date for comments, in the

Rules Docket for examination by interested persons. A report that

summarizes each FAA-public contact concerned with the substance of this

AD will be filed in the Rules Docket.

Commenters wishing the FAA to acknowledge receipt of their comments

submitted in response to this notice must submit a self-addressed,

stamped postcard on which the following statement is made: ``Comments

to Docket Number 94-ANE-27.'' The postcard will be date stamped and

returned to the commenter.

The regulations adopted herein will not have substantial direct

effects on the States, on the relationship between the national

government and the States, or on the distribution of power and

responsibilities among the various levels of government. Therefore, in

accordance with Executive Order 12612, it is determined that this final

rule does not have sufficient federalism implications to warrant the

preparation of a Federalism Assessment.

The FAA has determined that this regulation is an emergency

regulation that must be issued immediately to correct an unsafe

condition in aircraft, and is not a ``significant regulatory action''

under Executive Order 12866. It has been determined further that this

action involves an emergency regulation under DOT Regulatory Policies

and Procedures (44 FR 11034, February 26, 1979). If it is determined

that this emergency regulation otherwise would be significant under DOT

Regulatory Policies and Procedures, a final regulatory evaluation will

be prepared and placed in the Rules Docket. A copy of it, if filed, may

be obtained from the Rules Docket at the location provided under the

caption ADDRESSES.

List of Subjects in 14 CFR Part 39

Air transportation, Aircraft, Aviation safety, Incorporation by

reference, Safety.

Adoption of the Amendment

Accordingly, pursuant to the authority delegated to me by the

Administrator, the Federal Aviation Administration amends part 39 of

the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

1. The authority citation for part 39 continues to read as follows:

Authority: 49 U.S.C. App. 1354(a), 1421 and 1423; 49 U.S.C.

106(g); and 14 CFR 11.89.

Sec. 39.13 [Amended]

2. Section 39.13 is amended by adding the following new

airworthiness directive:

94-14-16 Pratt & Whitney: Amendment 39-8964. Docket 94-ANE-27.

Applicability: Pratt & Whitney (PW) Model JT8D-209, -217, -217A,

-217C, -219 turbofan engines; and JT8D-1, -1A, -1B, -7, -7A, -7B, -

9, -9A, -11, -15, -15A, -17, -17A, -17R, and -17AR turbofan engines

incorporating the original issue or any revision of Pratt & Whitney

Service Bulletin No. 5650; and any PW Model JT8D engine with low

emissions fuel nozzles, Part Numbers 775485, 809137-01, 802965, and

5004308-02 installed. These engines are installed on but not limited

to Boeing 727 and 737 series, and McDonnell Douglas DC-9 and MD-80

series aircraft.

Compliance: Required as indicated, unless accomplished

previously.

To prevent fuel leakage from the Number 7 fuel nozzle and

support assembly and melting of the oil pressure and scavenge tube

fittings, which can result in an uncontained engine fire and damage

to the aircraft, accomplish the following:

(a) Inspect Number 7 fuel nozzle and support assemblies in

accordance with PW Alert Service Bulletin (ASB) No. A6153, Revision

1, dated June 8, 1994, as follows:

(1) For Number 7 fuel nozzle and support assemblies that have

accumulated more than 2,500 hours time in service (TIS) since last

fuel nozzle and support assembly overhaul on the effective date of

this airworthiness directive (AD), initially inspect for fuel

leakage within 700 hours TIS after the effective date of this AD.

(2) For engines with Number 7 fuel nozzle and support assemblies

with 2,500 or less hours TIS since fuel nozzle and support assembly

overhaul on the effective date of this AD, initially inspect prior

to accumulating 3,200 hours TIS since overhaul.

(3) Thereafter, inspect for fuel leakage in accordance with PW

ASB A6153, Revision 1, dated June 8, 1994, at intervals not to

exceed 700 hours TIS since last inspection.

(4) Remove from service Number 7 fuel nozzle and support

assemblies that exhibit evidence of fuel leakage as described in PW

ASB No. A6153, Revision 1, dated June 8, 1994, and replace with the

improved sealing configuration nozzle in accordance with paragraph

(b) of this AD, as follows:

(i) Within 25 hours TIS, or 25 cycles in service (CIS),

whichever occurs first, after the inspection performed in paragraph

(a)(1), (a)(2), or (a)(3) for aircraft with only one engine

exhibiting Number 7 fuel nozzle and support assembly leakage.

(ii) Prior to further flight, on aircraft with two engines

exhibiting Number 7 fuel nozzle and support assembly leakage, remove

and replace at least one of the leaking Number 7 fuel nozzle and

support assemblies. The remaining Number 7 fuel nozzle and support

assembly that exhibits leakage shall be removed and replaced in

accordance with paragraph (a)(4)(i) of this AD.

(iii) Prior to further flight, on Boeing 727 aircraft, with

three engines exhibiting Number 7 fuel nozzle and support assembly

leakage, remove and replace at least two of the leaking Number 7

fuel nozzle and support assemblies. The remaining Number 7 fuel

nozzle and support assembly that exhibits leakage shall be removed

and replaced in accordance with paragraph (a)(4)(i) of this AD.

Note: Fuel nozzles that have not undergone overhaul do not

require inspection in accordance with paragraph (a) of this AD.

(b) At the next accessibility of the diffuser build group after

the effective date of this AD, but no later than July 31, 1999,

accomplish the following:

(1) Replace the Number 7 fuel nozzle and support assembly with

the improved sealing configuration in accordance with Part 1 of PW

ASB No. A6169, Revision 1, dated June 15, 1994.

(2) Replace the aluminum pressure and scavenge oil tube fittings

with steel fittings in accordance with PW ASB No. A6170, dated May

13, 1994.

Note: Replacement of the following oil tubes with corresponding

oil tubes that incorporate steel fittings constitutes compliance

with paragraph (b)(2) of this AD:

(i) Outer internal Number 4 and 5 bearing pressure tube assembly

for PW JT8D-200 series engines.

(ii) Outer internal main bearing pressure tube assembly for PW

JT8D-200 series engines.

(iii) Main bearing pressure manifold assembly for PW JT8D-200

series engines.

(iv) Front Number 4\1/2\ and 6 bearing pressure tube assembly

for all other JT8D engines.

(v) Number 4 bearing oil scavenge tube assembly for all other

JT8D engines.

(vi) Number 4 bearing oil pressure tube assembly for all other

JT8D engines.

(vii) Main bearing pressure manifold assembly for all other JT8D

engines.

(c) Incorporation of the hardware required by paragraph (b)(1)

of this AD, constitutes terminating action for the inspections

required by paragraph (a) of this AD.

(d) For the purpose of this AD, accessibility of the diffuser

build group is defined as engine maintenance that entails flange

separation of the diffuser case from the combustion chamber outer

case.

(e) For the purpose of this AD, fuel nozzle and support assembly

overhaul is defined as disassembly of the fuel nozzle from the

support assembly that entails removal of the fuel nozzle nut.

(f) For any Number 7 fuel nozzle and support assembly that is

removed for evidence of leakage in accordance with paragraph (a) of

this AD, submit the following information within 60 days after the

removal, to the Manager, Engine Certification Office, Engine and

Propeller Directorate, Aircraft Certification Service, FAA, 12 New

England Executive Park, Burlington, Massachusetts, 01803-5299; fax

(617) 238-7199:

(1) Fuel nozzle and support assembly part number and serial

number.

(2) Fuel nozzle and support assembly time and cycles since

overhaul.

(3) Description of fuel nozzle and support assembly distress.

(4) Position of distressed fuel nozzle and support assembly.

(5) Description of any other resultant engine damage.

(6) Engine serial number.

(7) Engine time and cycles since overhaul.

The reporting requirements of this AD terminate after compliance

with paragraph (b)(1) of this AD. Information collection

requirements contained in this regulation have been approved by the

Office of Management and Budget (OMB) under the provision of the

Paperwork Reduction Act of 1980 (44 U.S.C. 3501-3520) and have been

assigned OMB Control Number 2120-0056.

(g) 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: Information concerning the existence of approved

alternative methods of compliance with this airworthiness directive,

if any, may be obtained from the Engine Certification Office.

(h) Special flight permits may be issued in accordance with

Sec. Sec. 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.

(i) The inspections and modifications shall be done in

accordance with the following service documents:

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Document No. Pages Revision Date

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PW ASB No. A6153.......... 1-4 1........... June 8, 1994.

5 Original.... February 4, 1994.

6-8 1........... June 8, 1994.

9-12 Original.... February 4, 1994.

Total pages: 12.

PW ASB No. A6169.......... 1-6 1........... June 15, 1994.

7-16 Original.... April 29, 1994.

17 1........... June 15, 1994.

1-30 Original.... April 29, 1994.

Total pages: 30.

PW ASB No. A6170.......... 1-20 Original.... May 13, 1994.

Total pages: 20.

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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, Technical

Publications Department, M/S 132-30, 400 Main Street, East Hartford,

CT 06108. 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.

(j) This amendment becomes effective on July 26, 1994.

Issued in Burlington, Massachusetts, on June 29, 1994.

Jay J. Pardee,

Manager, Engine and Propeller Directorate, Aircraft Certification

Service.

[FR Doc. 94-16399 Filed 7-8-94; 8:45 am]

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