FAA Issues New Regulations for Certain Pratt & Whitney Engines

The Federal Aviation Administration (FAA) has implemented a new airworthiness directive for specific Pratt & Whitney engine models. This measure follows a 2020 incident where an engine experienced an in-flight failure, resulting in a turbine blade detachment and a titanium fire within the high-pressure compressor (HPC).

Effective August 13, the directive covers PW2037, PW2037M, and PW2040 engines equipped with certain high-pressure turbine (HPT) second-stage blade assemblies. These engines power Boeing's 757 commercial aircraft, whose production ended in late 2003, and the C-17 military transports, as stated by Pratt & Whitney.

The FAA estimates this directive will affect around 425 engines on US-registered planes, requiring 24 work hours and costing operators a total of $867,000 for compliance. Should replacement parts be necessary, additional costs could reach $473,000.

The directive stems from a September 2020 incident where a PW2037 engine on a 757 shut down mid-flight. Pratt & Whitney's investigation revealed fractures in two lugs on the turbine hub assembly, leading to the detachment of four turbine blades, further damaging the HPC and causing a titanium fire.

This incident revealed that some blade assemblies did not meet conformance standards, posing potential stress failure risks that could endanger engines and aircraft. The FAA responded with a Notice of Proposed Rulemaking (NPRM) on August 25, 2023.

Meanwhile, Pratt & Whitney is also dealing with another issue involving its PW1100G-JM engine model. A powdered metal additive used in some HPT and HPC discs was found to contain contaminants in certain cases.

As a result, the company has accelerated inspections of the geared turbofan engines powering Airbus's A320neo aircraft. Engine shop visits for the PW1100G-JM increased by 50% year-over-year in April. RTX, Pratt & Whitney's parent company, expects an average of 350 aircraft to be grounded annually from 2024 to 2026 to carry out these inspections and any necessary rework.