[Federal Register: December 29, 2004 (Volume 69, Number 249)]
[Rules and Regulations]
[Page 77881-77885]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr29de04-1]
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Rules and Regulations
Federal Register
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[[Page 77881]]
DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2000-NE-62-AD; Amendment 39-13915; AD 2004-26-03]
RIN 2120-AA64
Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan
Engines
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule; request for comments.
-----------------------------------------------------------------------
SUMMARY: The FAA is superseding an existing airworthiness directive
(AD) for Rolls-Royce plc (RR) models RB211-535E4-37, RB211-535E4-B-37,
RB211-535C-37, RB211-535E4-B-75, and RB211-22B-02 turbofan engines.
That AD currently requires inspecting certain high pressure (HP)
turbine discs, manufactured between 1989 and 1999, for cracks in the
rim cooling air holes, and, if necessary, replacing the disc's
serviceable parts. This AD requires the same actions but at reduced
compliance schedules and adds the RR model RB211-535E4-C turbofan
engine to the applicability. This AD results from a report of cracks in
a model RB211-524 HP turbine disc that had propagated further than
expected. We are issuing this AD to prevent possible disc failure,
which could result in an uncontained engine failure and damage to the
airplane.
DATES: Effective January 13, 2005. The incorporation by reference of
certain publications listed in the AD is approved by the Director of
the Federal Register as of January 13, 2005.
We must receive any comments on this AD by February 28, 2005. On
December 24, 2001 (66 FR 57859, November 19, 2001), the Director of the
Federal Register approved the incorporation by reference of certain
other publications, as listed in the regulations.
ADDRESSES: Use one of the following addresses to comment on this AD:
By mail: Federal Aviation Administration (FAA), New
England Region, Office of the Regional Counsel, Attention: Rules Docket
No. 2000-NE-62-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
By fax: (781) 238-7055.
By e-mail:9-ane-adcomment@faa.gov.
You can get the service information referenced in this AD from
Rolls-Royce plc, PO Box 31, Derby, England; telephone: 011 44 1332-
249428, fax: 011 44 1332-249223.
You may examine the AD docket, by appointment, at the FAA, New
England Region, Office of the Regional Counsel, 12 New England
Executive Park, Burlington, MA.
FOR FURTHER INFORMATION CONTACT: Ian Dargin, Aerospace Engineer, Engine
Certification Office, FAA, Engine and Propeller Directorate, 12 New
England Executive Park, Burlington, MA 01803-5299; telephone (781) 238-
7178, fax (781) 238-7199.
SUPPLEMENTARY INFORMATION: On November 5, 2001, the FAA issued AD 2001-
23-02, Amendment 39-12499 (66 FR 57859, November 19, 2001), for RR
models RB211-535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-
75, and RB211-22B-02 turbofan engines. That AD requires inspecting
certain HP turbine discs, manufactured between 1989 and 1999, for
cracks in the rim cooling air holes, and, if necessary, replacing the
discs with serviceable parts. That AD resulted from reports of cracks
in rim cooling air holes in two high-life RR Trent 800 discs. That
condition, if not corrected, could result in possible disc failure,
which could result in an uncontained engine failure and damage to the
airplane.
Actions Since AD 2001-23-02 Was Issued
Since that AD was issued, the Civil Aviation Authority (CAA), which
is the airworthiness authority for the United Kingdom, recently
notified the FAA that an unsafe condition may exist on Rolls-Royce plc
models RB211-535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-
75, and RB211-535E4-C series turbofan engines. The CAA advises that
cracks in a model RB211-524 HP turbine disc had propagated further than
expected based on recent inspection findings and a re-assessment of the
disc lifing model used to define the inspection thresholds in AD 2001-
23-02. This AD requires inspection of certain HP turbine discs,
manufactured between 1989 and 1999, for cracks in the rim cooling air
holes, and, if necessary, replacement with serviceable parts. We are
reducing the inspection schedules required by AD 2001-23-02, for the
high risk discs which includes all models except for model RB211-22B-02
engines and adds the RB211-535E4-C due to manufacture at the same
facility as the Trent 800 discs using the same tooling. Discs used in
the model RB211-535 engines have a significantly higher HP turbine life
than those used in the RB211-524 and operate in a harsher environment.
Therefore, although the cracking of the rim cooling air holes will not
affect the safe operation of the RB211-524 discs, the 535 discs are at
higher risk of failure and the inspection intervals must be reduced.
This AD retains the same inspection schedules, currently required for
the model RB211-22B-02 engine, that were in AD 2001-23-02. The actions
specified in this AD are intended to prevent possible disc failure,
which could result in an uncontained engine failure and damage to the
airplane.
Bilateral Airworthiness Agreement
This engine model is manufactured in the United Kingdom and is type
certificated for operation in the United States under the provisions of
section 21.29 of the Federal Aviation Regulations (14 CFR 21.29) and
the applicable bilateral airworthiness agreement. Under this bilateral
airworthiness agreement, the CAA has kept the FAA informed of the
situation described above. We have examined the findings of the CAA,
reviewed all available information, and determined that AD action is
necessary for products of this type design that are certificated for
operation in the United States.
FAA's Determination and Requirements of This AD
The unsafe condition described previously is likely to exist or
develop on other RR models RB211-535E4-37,
[[Page 77882]]
RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4-C, and
RB211-22B-02 turbofan engines of the same type design. We are issuing
this AD to prevent possible disc failure, which could result in an
uncontained engine failure and damage to the airplane. This AD requires
inspection of certain HP turbine discs, manufactured between 1989 and
1999, for cracks in the rim cooling air holes, and, if necessary,
replacement with serviceable parts.
FAA's Determination of the Effective Date
Since an unsafe condition exists that requires the immediate
adoption of this AD, we have found that notice and opportunity for
public comment before issuing this AD are impracticable, and that good
cause exists for making this amendment effective in less than 30 days.
Comments Invited
This AD is a final rule that involves requirements affecting flight
safety and was not preceded by notice and an opportunity for public
comment; however, we invite you to make any written relevant data,
views, or arguments regarding this AD. Send your comments to an address
listed under ADDRESSES. Include ``AD Docket No. 2000-NE-62-AD'' in the
subject line of your comments. If you want us to acknowledge receipt of
your mailed comments, send us a self-addressed, stamped postcard with
the docket number written on it; we will date-stamp your postcard and
mail it back to you. We specifically invite comments on the overall
regulatory, economic, environmental, and energy aspects of the rule
that might suggest a need to modify it. If a person contacts us
verbally, and that contact relates to a substantive part of this AD, we
will summarize the contact and place the summary in the docket. We will
consider all comments received by the closing date and may amend the AD
in light of those comments.
Examining the AD Docket
You may examine the AD Docket (including any comments and service
information), by appointment, between 8 a.m. and 4:30 p.m., Monday
through Friday, except Federal holidays. See ADDRESSES for the
location.
Authority for This Rulemaking
Title 49 of the United States Code specifies the FAA's authority to
issue rules on aviation safety. Subtitle I, Section 106, describes the
authority of the FAA Administrator. Subtitle VII, Aviation Programs,
describes in more detail the scope of the Agency's authority.
We are issuing this rulemaking under the authority described in
Subtitle VII, Part A, Subpart III, Section 44701, ``General
requirements.'' Under that section, Congress charges the FAA with
promoting safe flight of civil aircraft in air commerce by prescribing
regulations for practices, methods, and procedures the Administrator
finds necessary for safety in air commerce. This regulation is within
the scope of that authority because it addresses an unsafe condition
that is likely to exist or develop on products identified in this
rulemaking action.
Regulatory Findings
We have determined that this AD will not have federalism
implications under Executive Order 13132. This AD will not have a
substantial direct effect 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.
For the reasons discussed above, I certify that the regulation:
1. Is not a ``significant regulatory action'' under Executive Order
12866;
2. Is not a ``significant rule'' under the DOT Regulatory Policies
and Procedures (44 FR 11034, February 26, 1979); and
3. Will not have a significant economic impact, positive or
negative, on a substantial number of small entities under the criteria
of the Regulatory Flexibility Act.
We prepared a summary of the costs to comply with this AD and
placed it in the AD Docket. You may get a copy of this summary by
sending a request to us at the address listed under ADDRESSES. Include
``AD Docket No. 2000-NE-62-AD'' in your request.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
Adoption of the Amendment
0
Accordingly, under 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
0
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
Sec. 39.13 [Amended]
0
2. The FAA amends Sec. 39.13 by removing Amendment 39-12499 (66 FR
57859, November 19, 2001), and by adding a new airworthiness directive,
Amendment 39-13915, to read as follows:
2004-26-03 Rolls-Royce plc: Amendment 39-13915. Docket No. 2000-NE-
62-AD. Supersedes AD 2001-23-02, Amendment 39-12499.
Effective Date
(a) This airworthiness directive (AD) becomes effective January
13, 2005.
Affected ADs
(b) This AD supersedes AD 2001-23-02, Amendment 39-12499.
Applicability
(c) This AD applies to Rolls-Royce plc (RR) models RB211-535E4-
37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4-
C, and RB211-22B-02 turbofan engines with turbine discs having part
numbers and serial numbers listed in the following Tables 1, 3, and
5 of this AD. These turbofan engines are installed on, but not
limited to, Boeing 757, Tupolev Tu204, and Lockheed L-1011 series
airplanes.
Unsafe Condition
(d) This AD results from a report of cracks, in an RB211 HP
turbine disc, that had propagated further than expected. We are
issuing this AD to prevent possible disc failure, which could result
in an uncontained engine failure and damage to the airplane.
Compliance
(e) You are responsible for having the actions required by this
AD performed within the compliance times specified unless the
actions have already been done.
Eddy Current Inspection for All Except Model RB211-22B-02
(f) For all except model RB211-22B-02 engines, do the following:
(1) Perform an eddy current inspection of the high pressure (HP)
turbine discs listed in Table 1 of this AD, for cracks in the rim
cooling air holes. Use paragraph 3. of the Accomplishment
Instructions of RR Alert SB No. RB.211-72-AE651, dated November 22,
2004, to perform the eddy current inspection.
[[Page 77883]]
Table 1--Affected HP Turbine Discs Using Compliance Schedule in Table 2
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Part No. Serial No. Part No. Serial No.
----------------------------------------------------------------------------------------------------------------
LK80623........................... CQDY6397 UL27681.............. LDRCZ12893
LK80623........................... CQDY6504 UL27681.............. LDRCZ12985
UL27680........................... CQDY6451 UL27681.............. LDRCZ13044
UL27680........................... CQDY6452 UL27681.............. LDRCZ13047
UL27680........................... CQDY6466 UL27681.............. LQDY6803
UL27680........................... CQDY6468 UL27681.............. LQDY6814
UL27680........................... CQDY6471 UL27681.............. LQDY6847
UL27680........................... CQDY6496 UL27681.............. LQDY6868
UL27680........................... CQDY6505 UL27681.............. LQDY6875
UL27680........................... CQDY6653 UL27681.............. LQDY6892
UL27680........................... CQDY6656 UL27681.............. LQDY6898
UL27680........................... CQDY6657 UL27681.............. LQDY6904
UL27680........................... CQDY6684 UL27681.............. LQDY6909
UL27680........................... CQDY6883 UL27681.............. LQDY6910
UL27681........................... CQDY6465 UL27681.............. LQDY9133
UL27681........................... LAQDY6002 UL27681.............. LQDY9574
UL27681........................... LAQDY6083 UL27681.............. LQDY9579
UL27681........................... LAQDY6087 UL27681.............. LQDY9672
UL27681........................... LDRCZ10247 UL27681.............. LQDY9770
UL27681........................... LDRCZ10277 UL27681.............. LQDY9783
UL27681........................... LDRCZ10318 UL27681.............. LQDY9786
UL27681........................... LDRCZ10335 UL27681.............. LQDY9900
UL27681........................... LDRCZ10430 UL27681.............. LQDY9902
UL27681........................... LDRCZ10531 UL27681.............. LQDY9929
UL27681........................... LDRCZ10750 UL27681.............. LQDY9957
UL27681........................... LDRCZ10899 UL27681.............. LQDY9982
UL27681........................... LDRCZ11616 UL27681.............. LQDY9992
UL27681........................... LDRCZ11720 UL27681.............. WGQDY90005
UL27681........................... LDRCZ11893 .....................
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(2) Use the compliance schedule in Table 2 of this AD.
Table 2.--Compliance Schedule for HP Turbine Discs Listed in Table 1
------------------------------------------------------------------------
If disc cycles-since-new (CSN) on
October 8, 2004 are: Then eddy current inspect:
------------------------------------------------------------------------
(1) 12,750 CSN or more................. Within 250 cycles-in-service
(CIS) from October 8, 2004 or
within 14,500 CSN, whichever
occurs first.
(2) Fewer than 12,750 CSN but 10,500 Within 500 CIS from October 8,
CSN or more. 2004.
(3) Fewer than 10,500 CSN.............. Before 11,000 CSN or at next
shop visit after the effective
date of this AD, whichever
occurs first.
------------------------------------------------------------------------
(3) On discs that pass inspection, use paragraph 3. of the
Accomplishment Instructions of RR Alert SB No. RB.211-72-AE651,
dated November 22, 2004, to permanently etch NMSB 72-AE651 onto the
disc, adjacent to the part number.
(4) Perform an eddy current inspection of the HP turbine discs
listed in Table 3 of this AD, for cracks in the rim cooling air
holes. Use paragraph 3. of the Accomplishment Instructions of RR
Alert SB No. RB.211-72-AE651, dated November 22, 2004, to perform
the eddy current inspection.
Table 3.--Affected HP Turbine Discs Using Compliance Schedule in Table 4
------------------------------------------------------------------------
Part No. Serial No.
------------------------------------------------------------------------
UL10323............................ CQDY6070 and higher.
UL27680............................ All.
UL27681............................ All.
LK80622............................ LQDY6316 and higher.
LK80623............................ CQDY5945 and higher.
UL28267............................ All.
------------------------------------------------------------------------
(5) Use the compliance schedule in Table 4 of this AD.
Table 4.--Compliance Schedule for HP Turbine Discs Listed in Table 3
------------------------------------------------------------------------
If disc cycles-since-new (CSN) on
January 29, 2001 are: Then eddy current inspect:
------------------------------------------------------------------------
(1) Fewer than 13,700 CSN.............. Before reaching 14,500 CSN, or
at the next shop visit after
the effective date of this AD,
whichever occurs first.
(2) 13,700 CSN or more................. Before reaching one of the
following, whichever occurs
first after the effective date
of this AD:
(i) 15,300 CSN.
(ii) Within 800 CIS since
January 29, 2001.
(iii) At next shop visit.
------------------------------------------------------------------------
[[Page 77884]]
(6) For discs that pass inspection, use paragraph 3. of the
Accomplishment Instructions of RR Alert SB No. RB.211-72-AE651,
dated November 22, 2004, to permanently etch NMSB 72-AE651 onto the
disc, adjacent to the part number.
Eddy Current Inspection for Model RB211-22B-02
(g) For model RB211-22B-02 engines, do the following:
(1) Perform an eddy current inspection of the HP turbine discs
listed in Table 5 of this AD, for cracks in the rim cooling air
holes. Use paragraph 3. of the Accomplishment Instructions of RR SB
No. RB.211-72-C877, Revision 1, dated March 7, 2001, to perform the
eddy current inspection.
Table 5.--Affected HP Turbine Discs in RR Model RB211-02 Series Turbofan
Engines
------------------------------------------------------------------------
Part No. Serial No.
------------------------------------------------------------------------
LK80622............................ LQDY6316 and higher.
LK80623............................ CQDY5945 and higher.
UL28267............................ All.
------------------------------------------------------------------------
(2) Use the compliance schedule in Table 6 of this AD.
Table 6.--Compliance Schedule for HP Turbine Discs Listed in Table 5
------------------------------------------------------------------------
If disc cycles-since-new (CSN) on
December 24, 2001 are: Then eddy current inspect:
------------------------------------------------------------------------
(1) 11,000 CSN or fewer................ Before exceeding 11,000 CSN, or
at the next shop visit after
the effective date of this AD,
whichever occurs first.
(2) More than 11,000 CSN............... Within 300 CIS after December
24, 2001.
------------------------------------------------------------------------
(3) For discs that pass inspection, use paragraph 3. of the
Accomplishment Instructions of RR SB No. RB.211-72-C877, Revision 1,
dated March 7, 2001, to permanently etch NMSB 72-C877 onto the disc,
adjacent to the part number.
Other Conditions for All Engines
(h) Do not perform the actions of this AD to a disc until that
disc has reached at least 1,500 CSN.
(i) Engines with an affected HP turbine disc at shop visit on
the effective date of this AD and with the HPT rotor still removed
from the combustor outer case, must have the disc eddy current
inspected before assembling the engine.
(j) Engines with an affected HP turbine disc at shop visit on
the effective date of this AD with the HPT rotor reinstalled in the
combustor case need not have the disc eddy current inspected at this
time.
(k) HP turbine discs previously eddy current inspected at fewer
than 1,500 CSN must be inspected again using this AD.
(l) Replace cracked HP turbine discs with a serviceable disc.
Definition
(m) For the purpose of this AD, next shop visit is defined as
the first shop visit opportunity when the HPT rotor is removed from
the combustion case.
(n) For the purpose of this AD, a serviceable part is one with
cyclic life remaining and either not listed in any of the preceding
tables or one listed in a preceding table, but previously eddy
current inspected and permanently etch marked with the Service
Bulletin (SB) number NMSB 72-AE651 or NMSB 72-C877 on the disc.
Previous Credit
(o) Previous credit is allowed for the actions in this AD for HP
turbine discs with 1,500 CSN or more that were eddy current
inspected using applicable RR SB No. RB.211-72-C817, Revision 2,
dated March 7, 2001, RR TSD 594-J, Overhaul Processes Manual, Task
70-00-00-200-223, or RR SB No. RB.211-72-C877, Revision 1, dated
March 7, 2001.
Reporting Requirements
(p) For all except model RB211-22B-02 engines, report findings
of the inspection using paragraph 3.E. of the Accomplishment
Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004. The
Office of Management and Budget (OMB) has approved the reporting
requirements specified in paragraph 3.E. of the Accomplishment
Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004, and
assigned OMB control number 2120-0056.
(q) For model RB211-22B-02 engines, report findings of the
inspection using paragraph 3.E. of the Accomplishment Instructions
of RR SB RB.211-72-C877, Revision 1, dated March 7, 2001. The Office
of Management and Budget (OMB) has approved the reporting
requirements specified in paragraph 3.E. of the Accomplishment
Instructions of RR SB RB.211-72-C877, Revision 1, dated March 7,
2001, and assigned OMB control number 2120-0056.
Alternative Methods of Compliance
(r) The Manager, Engine Certification Office, has the authority
to approve alternative methods of compliance for this AD if
requested using the procedures found in 14 CFR 39.19.
Material Incorporated by Reference
(s) You must use the service information specified in Table 7 of
this AD to perform the inspections required by this AD. The Director
of the Federal Register approved the incorporation by reference of
RR Alert SB No. RB.211-72-AE651, dated November 22, 2004, listed in
Table 7 of this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part
51. The incorporation by reference of RR MSB No. RB.211-72-C877,
Revision 1, dated March 7, 2001, was approved previously by the
Director of the Federal Register as of December 24, 2001 (66 FR
57859, November 19, 2001). You can get a copy from Rolls-Royce plc,
PO Box 31, Derby, England; telephone: 011 44 1332-249428, fax: 011
44 1332-249223, for a copy of this service information. You may
review copies at the FAA, New England Region, Office of the Regional
Counsel, 12 New England Executive Park, Burlington, MA; or the
National Archives and Records Administration (NARA). For information
on the availability of this material at NARA, call 202-741-6030, or
go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.
Table 7 follows:
Table 7.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
Service bulletin Page numbers Revision Date
----------------------------------------------------------------------------------------------------------------
RB.211-72-AE651................. All................ Original........... November 22, 2004.
Total Pages--7
RB.211-72-C877.................. All................ 1.................. March 7, 2001.
Total Pages--5
----------------------------------------------------------------------------------------------------------------
[[Page 77885]]
Related Information
(t) CAA airworthiness directive G-2004-0027, dated November 19,
2004, also addresses the subject of this AD.
Issued in Burlington, Massachusetts, on December 15, 2004.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft
Certification Service.
[FR Doc. 04-28144 Filed 12-28-04; 8:45 am]
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