The Federal Aviation Administration (FAA) has proposed new inspection requirements for Pratt & Whitney PW2000 engines, citing potential defects in high-pressure turbine components similar to those affecting the manufacturer’s troubled PW1000G series. The directive targets disks and hubs in engines powering Boeing 757 passenger jets and C-17 military transports, requiring repetitive ultrasonic checks to detect possible cracks.
Expanding Quality Concerns
The FAA’s airworthiness directive follows discoveries that certain nickel-powdered-metal parts in PW2000 engines may fail earlier than expected—a problem echoing the ongoing PW1000G recall affecting thousands of Airbus narrowbody engines. “There is an increased risk of failure for components from specific production campaigns,” the FAA stated, mandating inspections during routine maintenance without imposing new life limits or immediate groundings.
Affected Aircraft and Operators
According to Cirium data, the directive impacts 484 U.S.-registered engines, including:
- 215 PW2000s on Delta Air Lines, FedEx, and UPS Boeing 757s
- 219 F117-PW-100 variants on U.S. Air Force C-17 Globemaster III transports
Thirteen engines will require additional replacement of lenticular seal assemblies beyond the ultrasonic inspections.
Inspection Protocol
The FAA’s proposed rule requires:
- Angled-ultrasonic inspections of high-pressure turbine first-stage disks and hubs
- Crack detection procedures during every future “piece-part exposure”
- Immediate replacement of any components showing defect indications
Pratt & Whitney confirmed the measures align with existing service bulletins and will be performed during scheduled overhauls.
Industry Response
Pratt & Whitney emphasized the proactive nature of the inspections, stating: “This addresses components originally provided as spares and maintains operational continuity.” The manufacturer faces parallel challenges with its PW1000G series, where powdered-metal defects have grounded hundreds of Airbus jets globally.
Operational Impact
While no fleet groundings are anticipated, the additional maintenance requirements could strain MRO capacity. Cargo carriers FedEx and UPS—critical to global logistics—may face scheduling adjustments to accommodate inspections. The Air Force’s C-17 fleet, essential for strategic airlift, will implement checks through existing maintenance programs.
