An applicant seeking type design approval for an engine to be installed on a two-engine airplane approved for ETOPS without the service experience specified in part 25, appendix K, K25.2.1 of this chapter, must comply with the following:
(a) The engine must be designed using a design quality process acceptable to the FAA, that ensures the design features of the engine minimize the occurrence of failures, malfunctions, defects, and maintenance errors that could result in an IFSD, loss of thrust control, or other power loss.
(b) The design features of the engine must address problems shown to result in an IFSD, loss of thrust control, or other power loss in the applicant's other relevant type designs approved within the past 10 years, to the extent that adequate service data is available within that 10-year period. An applicant without adequate service data must show experience with and knowledge of problem mitigating design practices equivalent to that gained from actual service experience in a manner acceptable to the FAA.
(c) Except as specified in paragraph (f) of this section, the applicant must conduct a simulated ETOPS mission cyclic endurance test in accordance with an approved test plan on an engine that substantially conforms to the type design. The test must:
(1) Include a minimum of 3,000 representative service start-stop mission cycles and three simulated diversion cycles at maximum continuous thrust or power for the maximum diversion time for which ETOPS eligibility is sought. Each start-stop mission cycle must include the use of take-off, climb, cruise, descent, approach, and landing thrust or power and the use of thrust reverse (if applicable). The diversions must be evenly distributed over the duration of the test. The last diversion must be conducted within 100 cycles of the completion of the test.
(2) Be performed with the high speed and low speed main engine rotors independently unbalanced to obtain a minimum of 90 percent of the recommended field service maintenance vibration levels. For engines with three main engine rotors, the intermediate speed rotor must be independently unbalanced to obtain a minimum of 90 percent of the recommended production acceptance vibration level. The required peak vibration levels must be verified during a slow acceleration and deceleration run of the test engine covering the main engine rotor operating speed ranges.
(3) Include a minimum of three million vibration cycles for each 60 rpm incremental step of the typical high-speed rotor start-stop mission cycle. The test may be conducted using any rotor speed step increment from 60 to 200 rpm provided the test encompasses the typical service start-stop cycle speed range. For incremental steps greater than 60 rpm, the minimum number of vibration cycles must be linearly increased up to ten million cycles for a 200 rpm incremental step.
(4) Include a minimum of 300,000 vibration cycles for each 60 rpm incremental step of the high-speed rotor approved operational speed range between minimum flight idle and cruise power not covered by paragraph (c)(3) of this section. The test may be conducted using any rotor speed step increment from 60 to 200 rpm provided the test encompasses the applicable speed range. For incremental steps greater than 60 rpm the minimum number of vibration cycles must be linearly increased up to 1 million for a 200 rpm incremental step.
(5) Include vibration surveys at periodic intervals throughout the test. The equivalent value of the peak vibration level observed during the surveys must meet the minimum vibration requirement of Sec. 33.201(c)(2).
(d) Prior to the test required by paragraph (c) of this section, the engine must be subjected to a calibration test to document power and thrust characteristics.
(e) At the conclusion of the testing required by paragraph (c) of this section, the engine must:
(1) Be subjected to a calibration test at sea-level conditions. Any change in power or thrust characteristics must be within approved limits.
(2) Be visually inspected in accordance with the on-wing inspection recommendations and limits contained in the Instructions for Continued Airworthiness submitted in compliance with Sec. 33.4.
(3) Be completely disassembled and inspected--
(i) In accordance with the applicable inspection recommendations and limits contained in the Instructions for Continued Airworthiness submitted in compliance with Sec. 33.4;
(ii) With consideration of the causes of IFSD, loss of thrust control, or other power loss identified by paragraph (b) of this section; and
(iii) In a manner to identify wear or distress conditions that could result in an IFSD, loss of thrust control, or other power loss not specifically identified by paragraph (b) of this section or addressed within the Instructions for Continued Airworthiness.
(4) Not show wear or distress to the extent that could result in an IFSD, loss of thrust control, or other power loss within a period of operation before the component, assembly, or system would likely have been inspected or functionally tested for integrity while in service. Such wear or distress must have corrective action implemented through a design change, a change to maintenance instructions, or operational procedures before ETOPS eligibility is granted. The type and frequency of wear and distress that occurs during the engine test must be consistent with the type and frequency of wear and distress that would be expected to occur on ETOPS eligible engines.
(f) An alternative mission cycle endurance test that provides an equivalent demonstration of the unbalance and vibration specified in paragraph (c) of this section may be used when approved by the FAA.
(g) For an applicant using the simulated ETOPS mission cyclic endurance test to comply with Sec. 33.90, the test may be interrupted so that the engine may be inspected by an on-wing or other method, using criteria acceptable to the FAA, after completion of the test cycles required to comply with Sec. 33.90(a). Following the inspection, the ETOPS test must be resumed to complete the requirements of this section.
Sec. Appendix A to Part 33--Instructions for Continued Airworthiness
a33.1 general
(a) This appendix specifies requirements for the preparation of Instructions for Continued Airworthiness as required by Sec. 33.4.
(b) The Instructions for Continued Airworthiness for each engine must include the Instructions for Continued Airworthiness for all engine parts. If Instructions for Continued Airworthiness are not supplied by the engine part manufacturer for an engine part, the Instructions for Continued Airworthiness for the engine must include the information essential to the continued airworthiness of the engine.
(c) The applicant must submit to the FAA a program to show how changes to the Instructions for Continued Airworthiness made by the applicant or by the manufacturers of engine parts will be distributed.
a33.2 format
(a) The Instructions for Continued Airworthiness must be in the form of a manual or manuals as appropriate for the quantity of data to be provided.
(b) The format of the manual or manuals must provide for a practical arrangement.
a33.3 content
The contents of the manual or manuals must be prepared in the English language. The Instructions for Continued Airworthiness must contain the following manuals or sections, as appropriate, and information:
(a) Engine Maintenance Manual or Section. (1) Introduction information that includes an explanation of the engine's features and data to the extent necessary for maintenance or preventive maintenance.
(1) Introduction information that includes an explanation of the engine's features and data to the extent necessary for maintenance or preventive maintenance.
(2) A detailed description of the engine and its components, systems, and installations.
(3) Installation instructions, including proper procedures for uncrating, deinhibiting, acceptance checking, lifting, and attaching accessories, with any necessary checks.
(4) Basic control and operating information describing how the engine components, systems, and installations operate, and information describing the methods of starting, running, testing, and stopping the engine and its parts including any special procedures and limitations that apply.
(5) Servicing information that covers details regarding servicing points, capacities of tanks, reservoirs, types of fluids to be used, pressures applicable to the various systems, locations of lubrication points, lubricants to be used, and equipment required for servicing.
(6) Scheduling information for each part of the engine that provides the recommended periods at which it should be cleaned, inspected, adjusted, tested, and lubricated, and the degree of inspection the applicable wear tolerances, and work recommended at these periods. However, the applicant may refer to an accessory, instrument, or equipment manufacturer as the source of this information if the applicant shows that the item has an exceptionally high degree of complexity requiring specialized maintenance techniques, test equipment, or expertise. The recommended overhaul periods and necessary cross references to the Airworthiness Limitations section of the manual must also be included. In addition, the applicant must include an inspection program that includes the frequency and extent of the inspections necessary to provide for the continued airworthiness of the engine.
(7) Troubleshooting information describing probable malfunctions, how to recognize those malfunctions, and the remedial action for those malfunctions.
(8) Information describing the order and method of removing the engine and its parts and replacing parts, with any necessary precautions to be taken. Instructions for proper ground handling, crating, and shipping must also be included.
(9) A list of the tools and equipment necessary for maintenance and directions as to their method of use.
(b) Engine Overhaul Manual or Section. (1) Disassembly information including the order and method of disassembly for overhaul.
(1) Disassembly information including the order and method of disassembly for overhaul.
(2) Cleaning and inspection instructions that cover the materials and apparatus to be used and methods and precautions to be taken during overhaul. Methods of overhaul inspection must also be included.
(3) Details of all fits and clearances relevant to overhaul.
(4) Details of repair methods for worn or otherwise substandard parts and components along with the information necessary to determine when replacement is necessary.
(5) The order and method of assembly at overhaul.
(6) Instructions for testing after overhaul.
(7) Instructions for storage preparation, including any storage limits.
(8) A list of tools needed for overhaul.
(c) ETOPS Requirements. For an applicant seeking eligibility for an engine to be installed on an airplane approved for ETOPS, the Instructions for Continued Airworthiness must include procedures for engine condition monitoring. The engine condition monitoring procedures must be able to determine prior to flight, whether an engine is capable of providing, within approved engine operating limits, maximum continuous power or thrust, bleed air, and power extraction required for a relevant engine inoperative diversion. For an engine to be installed on a two-engine airplane approved for ETOPS, the engine condition monitoring procedures must be validated before ETOPS eligibility is granted.
A33.4 airworthiness limitations section
The Instructions for Continued Airworthiness must contain a section titled Airworthiness Limitations that is segregated and clearly distinguishable from the rest of the manual.
(a) For all engines:
(1) The Airworthiness Limitations section must set forth each mandatory replacement time, inspection interval, and related procedure required for type certification. If the Instructions for Continued Airworthiness consist of multiple documents, the section required under this paragraph must be included in the principal manual.
(2) This section must contain a legible statement in a prominent location that reads: ``The Airworthiness Limitations section is FAA approved and specifies maintenance required under Sec. Sec. 43.16 and 91.403 of Title 14 of the Code of Federal Regulations unless an alternative program has been FAA approved.''
(b) For rotorcraft engines having 30-second OEI and 2-minute OEI ratings:
(1) The Airworthiness Limitations section must also prescribe the mandatory post-flight inspections and maintenance actions associated with any use of either 30-second OEI or 2-minute OEI ratings.
(2) The applicant must validate the adequacy of the inspections and maintenance actions required under paragraph (b)(1) of this section A33.4.
(3) The applicant must establish an in-service engine evaluation program to ensure the continued adequacy of the instructions for mandatory post-flight inspections and maintenance actions prescribed under paragraph (b)(1) of this section A33.4 and of the data for Sec. 33.5(b)(4) pertaining to power availability. The program must include service engine tests or equivalent service engine test experience on engines of similar design and evaluations of service usage of the 30-second OEI or 2-minute OEI ratings. [Amdt. 33-9, 45 FR 60181, Sept. 11, 1980, as amended by Amdt. 33-13, 54 FR 34330, Aug. 18, 1989; Amdt. 33-21, 72 FR 1878, Jan. 16, 2007; Amdt. 33-25, 73 FR 48124, Aug. 18, 2008]
Sec. Appendix B to Part 33--Certification Standard Atmospheric
Concentrations of Rain and Hail
Figure B1, Table B1, Table B2, Table B3, and Table B4 specify the atmospheric concentrations and size distributions of rain and hail for establishing certification, in accordance with the requirements of Sec. 33.78(a)(2). In conducting tests, normally by spraying liquid water to simulate rain conditions and by delivering hail fabricated from ice to simulate hail conditions, the use of water droplets and hail having shapes, sizes and distributions of sizes other than those defined in this appendix B, or the use of a single size or shape for each water droplet or hail, can be accepted, provided that applicant shows that the substitution does not reduce the severity of the test. [GRAPHIC] [TIFF OMITTED] TR26MR98.000
Table B1--Certification Standard Atmospheric Rain Concentrations------------------------------------------------------------------------
Rain water content (RWC)
Altitude (feet) (grams water/meter \3\
air)------------------------------------------------------------------------0............................................ 20.020,000....................................... 20.026,300....................................... 15.232,700....................................... 10.839,300....................................... 7.746,000....................................... 5.2------------------------------------------------------------------------RWC values at other altitudes may be determined by linear interpolation.Note: Source of data--Results of the Aerospace Industries Association
(AIA) Propulsion Committee Study, Project PC 338-1, June 1990.
Table B2--Certification Standard Atmospheric Hail Concentrations------------------------------------------------------------------------
Hail water content (HWC)
Altitude (feet) (grams water/meter \3\
air)------------------------------------------------------------------------0............................................ 6.07,300........................................ 8.98,500........................................ 9.410,000....................................... 9.912,000....................................... 10.015,000....................................... 10.016,000....................................... 8.917,700....................................... 7.819,300....................................... 6.621,500....................................... 5.624,300....................................... 4.429,000....................................... 3.346,000....................................... 0.2------------------------------------------------------------------------HWC values at other altitudes may be determined by linear interpolation.
The hail threat below 7,300 feet and above 29,000 feet is based on
linearly extrapolated data.Note: Source of data--Results of the Aerospace Industries Association
(AIA Propulsion Committee (PC) Study, Project PC 338-1, June 1990.
Table B3--Certification Standard Atmospheric Rain Droplet Size
Distribution------------------------------------------------------------------------
Contribution total RWC
Rain droplet diameter (mm) (%)------------------------------------------------------------------------0-0.49....................................... 00.50-0.99.................................... 2.251.00-1.49.................................... 8.751.50-1.99.................................... 16.252.00-2.49.................................... 19.002.50-2.99.................................... 17.753.00-3.49.................................... 13.503.50-3.99.................................... 9.504.00-4.49.................................... 6.004.50-4.99.................................... 3.005.00-5.49.................................... 2.005.50-5.99.................................... 1.256.00-6.49.................................... 0.506.50-7.00.................................... 0.25
--------------------------
Total.................................... 100.00------------------------------------------------------------------------Median diameter of rain droplets in 2.66 mmNote: Source of data--Results of the Aerospace Industries Association
(AIA Propulsion Committee (PC) Study, Project PC 338-1, June 1990.
Table B4--Certification Standard Atmospheric Hail Size Distribution------------------------------------------------------------------------
Contribution total HWC
Hail diameter (mm) (%)------------------------------------------------------------------------0-4.9........................................ 05.0-9.9...................................... 17.0010.0-14.9.................................... 25.0015.0-19.9.................................... 22.5020.0-24.9.................................... 16.0025.0-29.9.................................... 9.7530.0-34.9.................................... 4.7535.0-39.9.................................... 2.5040.0-44.9.................................... 1.5045.0-49.9.................................... 0.7550.0-55.0.................................... 0.25
--------------------------
Total.................................... 100.00------------------------------------------------------------------------Median diameter of hail is 16 mmNote: Source of data--Results of the Aerospace Industries Association
(AIA Propulsion Committee (PC) Study, Project PC 338-1, June 1990. [Doc. No. 28652, 63 FR 14799, Mar. 26, 1998]
Sec. Appendix C to Part 33--
[Reserved]
Effective Date Note: At 79 FR 65538, Nov. 4, 2014, appendix C to part 33 was added and reserved, effective Jan. 5, 2015.
Sec. Appendix D to Part 33--Mixed Phase and Ice Crystal Icing Envelope
(Deep Convective Clouds)
The ice crystal icing envelope is depicted in Figure D1 of this Appendix.[GRAPHIC] [TIFF OMITTED] TR04NO14.008
Within the envelope, total water content (TWC) in g/m\3\ has been determined based upon the adiabatic lapse defined by the convective rise of 90% relative humidity air from sea level to higher altitudes and scaled by a factor of 0.65 to a standard cloud length of 17.4 nautical miles. Figure D2 of this Appendix displays TWC for this distance over a range of ambient temperature within the boundaries of the ice crystal envelope specified in Figure D1 of this Appendix. [GRAPHIC] [TIFF OMITTED] TR04NO14.009
Ice crystal size median mass dimension (MMD) range is 50-200 microns (equivalent spherical size) based upon measurements near convective storm cores.
The TWC can be treated as completely glaciated (ice crystal) except as noted in the Table 1 of this Appendix.
Table 1--Supercooled Liquid Portion of TWC------------------------------------------------------------------------
Horizontal cloud LWC-- g/
Temperature range--deg C length--nautical miles m\3\------------------------------------------------------------------------0 to -20............................ <=50................... <=1.00 to -20............................ Indefinite............. <=0.5< -20............................... ....................... 0------------------------------------------------------------------------
The TWC levels displayed in Figure D2 of this Appendix represent TWC values for a standard exposure distance (horizontal cloud length) of 17.4 nautical miles that must be adjusted with length of icing exposure. [GRAPHIC] [TIFF OMITTED] TR04NO14.010 [79 FR 65538, Nov. 4, 2014]
Effective Date Note: At 79 FR 65538, Nov. 4, 2014, Part 33, Appendix D was added, effective Jan. 5, 2015.