[Federal Register: March 18, 2004 (Volume 69, Number 53)]
[Rules and Regulations]
[Page 12783-12786]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr18mr04-2]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2003-NE-56-AD; Amendment 39-13525; AD 2004-05-30]
RIN 2120-AA64
Airworthiness Directives; Rolls-Royce plc RB211 Trent 500 Series
Turbofan Engines
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule; request for comments.
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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for
Rolls-Royce plc (RR) RB211-Trent 500 series turbofan engines. This AD
requires revising the Time Limits Manual for RR RB211 Trent 500 series
turbofan engines. These revisions include required enhanced inspection
of selected critical life-limited parts at each piece-part exposure.
This AD results from the need to require enhanced inspection of
selected critical life-limited parts of RR Trent 500 series turbofan
engines. We are issuing this AD to prevent failure of critical life-
limited rotating engine parts, which could result in an uncontained
engine failure and damage to the airplane.
DATES: Effective April 2, 2004.
We must receive any comments on this AD by May 17, 2004.
ADDRESSES: Use one of the following addresses to submit comments on
this AD:
By mail: the Federal Aviation Administration
(FAA), New England Region, Office of the Regional Counsel, Attention:
Rules Docket No. 2003-NE-56-AD, 12 New England Executive Park,
Burlington, MA 01803-5299.
By fax: (781) 238-7055.
By e-mail: 9-ane-adcomment@faa.gov.
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: Christopher Spinney, Aerospace
Engineer, Engine Certification Office, FAA, Engine and Propeller
Directorate, 12 New England Executive Park, Burlington, MA 01803-5299;
telephone (781) 238-7175, fax (781) 238-7199.
SUPPLEMENTARY INFORMATION: A recent FAA study analyzing 15 years of
accident data for transport category airplanes identified several root
causes for a failure mode that can result in
[[Page 12784]]
serious safety hazards to transport category airplanes. This study
identified uncontained failure of critical life-limited rotating engine
parts as the leading engine-related safety hazard to airplanes.
Uncontained engine failures have resulted from undetected cracks in
rotating parts that started and grew to failure. Cracks can start from
causes such as unintended excessive stress from the original design, or
they may start from stresses induced from material flaws, handling, or
damage from machining operations. The failure of a rotating part can
present a significant safety hazard to the airplane by release of high-
energy fragments that could injure passengers or crew by penetration of
the cabin, damage flight control surfaces, sever flammable fluid lines,
or otherwise compromise the airworthiness of the airplane.
Based on these findings, the FAA, with the concurrence of the Civil
Aviation Authority (CAA), which is the Airworthiness Authority for the
United Kingdom (U.K.), has developed an intervention strategy to
significantly reduce uncontained engine failures. This intervention
strategy was developed after consultation with industry and will be
used as a model for future initiatives. The intervention strategy is to
conduct enhanced, nondestructive inspections of rotating parts, which
could most likely result in a safety hazard to the airplane in the
event of a part fracture. We are considering the need for additional
rulemaking. We might issue future ADs to introduce additional
intervention strategies to further reduce or eliminate uncontained
engine failures.
Properly focused enhanced inspections require identification of the
parts whose failure presents the highest safety hazard to the airplane,
identifying the most critical features to inspect on these parts, and
utilizing inspection procedures and techniques that improve crack
detection. The CAA, with close cooperation of RR, has completed a
detailed analysis that identifies the most safety significant parts and
features, and the most appropriate inspection methods.
Critical life-limited high-energy rotating parts are currently
subject to some form of recommended crack inspection when exposed
during engine maintenance or disassembly. The inspections currently
recommended by the manufacturer will become mandatory for those parts
listed in the compliance section as a result of this AD. Furthermore,
we intend that additional mandatory enhanced inspections resulting from
this AD will serve as an adjunct to the existing inspections. We have
determined that the enhanced inspections will significantly improve the
probability of crack detection on disassembled parts during
maintenance. All mandatory inspections must be conducted in accordance
with detailed inspection procedures prescribed in the manufacturer's
Engine Manual.
Additionally, this AD will:
Allow air carriers that operate under the
provisions of 14 CFR part 121 with an FAA-approved continuous
airworthiness maintenance program, and maintenance facilities to verify
completion of the enhanced inspections.
Allow the air carrier or maintenance facility to
retain the maintenance records that include the inspections resulting
from this AD, if the records include the date and signature of the
person who performed the maintenance action.
Require retaining the records with the
maintenance records of the part, engine module, or engine until the
task is repeated.
Establish a method of record preservation and
retrieval typically used in existing continuous airworthiness
maintenance programs.
Require adding instructions in an air carrier's
maintenance manual on how to implement and integrate this record
preservation and retrieval system into the air carrier's record keeping
system.
For engines or engine modules that are approved for return to
service by an authorized FAA-certificated entity, and that are acquired
by an operator after the effective date of the AD, you will not need to
perform the mandatory enhanced inspections until the next piece-part
opportunity. For example, you will not have to disassemble to piece-
part level, an engine or module returned to service by an FAA-
certificated facility simply because that engine or module was
previously operated by an entity not required to comply with this AD.
Furthermore, we intend that operators perform the enhanced inspections
of these parts at the next piece-part opportunity after the initial
acquisition, installation, and removal of the part after the effective
date of this AD. For piece parts not approved for return to service
before the effective date of this AD, the AD requires that you perform
the mandatory enhanced inspections before approval of those parts for
return to service. The AD allows installation of piece parts approved
for return to service before the effective date of this AD. However,
the AD requires an enhanced inspection at the next piece-part
opportunity.
This AD requires, within the next 40 days after the effective date
of this AD, revisions to the Time Limits Manual.
FAA's Determination and Requirements of This AD
Although no airplanes that are registered in the United States use
these engines, the possibility exists that the engines could be used on
airplanes that are registered in the United States in the future. The
unsafe condition described previously is likely to exist or develop on
other RR RB211 Trent 500 series turbofan engines of the same type
design. We are issuing this AD to prevent critical life-limited
rotating engine part failure, which could result in an uncontained
engine failure and damage to the airplane.
FAA's Determination of the Effective Date
Since there are currently no domestic operators of this engine
model, notice and opportunity for public comment before issuing this AD
are unnecessary. Therefore, a situation exists that allows the
immediate adoption of this regulation.
Changes to 14 CFR Part 39--Effect on the AD
On July 10, 2002, we issued a new version of 14 CFR part 39 (67 FR
47998, July 22, 2002), which governs our AD system. This regulation now
includes material that relates to special flight permits, alternative
methods of compliance, and altered products. This material previously
was included in each individual AD. Since this material is included in
14 CFR part 39, we will not include it in future AD actions.
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 submit any written relevant data,
views, or arguments regarding this AD. Send your comments to an address
listed under ADDRESSES. Include ``AD Docket No. 2003-NE-56-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 through
a verbal communication, and that contact relates to a substantive part
[[Page 12785]]
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.
We are reviewing the writing style we currently use in regulatory
documents. We are interested in your comments on whether the style of
this document is clear, and your suggestions to improve the clarity of
our communications with you. You may get more information about plain
language at http://www.faa.gov/language and http://www
.plainlanguage.gov.
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.
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. 2003-NE-56-AD'' in your request.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Safety.
Adoption of the Amendment
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 adding the following new airworthiness
directive:
2004-05-30 Rolls-Royce plc: Amendment 39-13525. Docket No. 2003-NE-
56-AD.
Effective Date
(a) This airworthiness directive (AD) becomes effective April 2,
2004.
Affected ADs
(b) None.
Applicability
(c) This AD applies to Rolls-Royce plc (RR) Trent 500 series
turbofan engines. These engines are installed on, but not limited
to, Airbus A340 series airplanes.
Unsafe Condition
(d) This AD results from the need to require enhanced inspection
of selected critical life-limited parts of RR Trent 500 series
turbofan engines. We are issuing this AD to prevent critical life-
limited rotating engine part 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.
(f) Within the next 40 days after the effective date of this AD,
revise the Time Limits Manual (TLM), and for air carrier operations
revise the approved continuous airworthiness maintenance program, by
adding the following:
``GROUP A PARTS MANDATORY INSPECTION
B. Inspections referred to as `Focus Inspect' in the applicable
Engine Manual inspection Task are mandatory inspections for the
components given below, when the conditions that follow are
satisfied:
(1) When the component has been completely disassembled to piece
part level as given in the applicable disassembly procedures
contained in the Engine Manual; and
(2) The part has more than 100 recorded flight cycles in
operation since the last piece part inspection; or
(3) The component removal was for damage or a cause directly
related to its removal; or
(4) Where serviceable used components, for which the inspection
history is not fully known, are to be used again.
C. The list of Group A Parts is specified below:
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Part nomenclature Part No. Inspected per overhaul manual task
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Low Pressure Compressor Rotor Disk...... All........................ 72-31-16-200-801
Low Pressure Compressor Rotor Shaft..... All........................ 72-31-20-200-801
Intermediate Pressure Compressor Rotor All........................ 72-32-31-200-801
Shaft.
Intermediate Pressure Rear Shaft........ All........................ 72-33-21-200-801
High Pressure Compressor Stage 1 to 4 All........................ 72-41-31-200-803
Rotor Disks Shaft.
High Pressure Compressor Stage 5 & 6 All........................ 72-41-31-200-801
Disks and Cone.
High Pressure Turbine Rotor Disk........ All........................ 72-41-51-200-801
High Pressure Turbine Front Coverplate.. All........................ 72-41-51-200-806
Intermediate Pressure Turbine Rotor Disk All........................ 72-51-31-200-801
Intermediate Pressure Turbine Rotor All........................ 72-51-33-200-801
Shaft.
Low Pressure Turbine Stage 1 Rotor Disk. All........................ 72-52-31-200-801
Low Pressure Turbine Stage 2 Rotor Disk. All........................ 72-52-31-200-802
Low Pressure Turbine Stage 3 Rotor Disk. All........................ 72-52-31-200-803
Low Pressure Turbine Stage 4 Rotor Disk. All........................ 72-52-31-200-804
Low Pressure Turbine Stage 5 Rotor Disk. All........................ 72-52-31-200-805
Low Pressure Turbine Rotor Shaft........ All........................ 72-52-33-200-801''
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Alternative Methods of Compliance
(g) You must perform these mandatory inspections using the TLM
and the applicable Engine Manual unless you receive approval to use
an alternative method of compliance under paragraph (h) of this AD.
Section 43.16 of the Federal Aviation Regulations (14 CFR 43.16) may
not be used to approve alternative methods of compliance or
adjustments to the times in which these inspections must be
performed.
[[Page 12786]]
(h) 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.
Maintaining Records of the Mandatory Inspections
(i) You have met the requirements of this AD by using a TLM
changed as specified in paragraph (f) of this AD, and, for air
carriers operating under part 121 of the Federal Aviation
Regulations (14 CFR part 121), by modifying your continuous
airworthiness maintenance plan to reflect those changes. You must
maintain records of the mandatory inspections that result from those
changes to the TLM according to the regulations governing your
operation. You do not need to record each piece-part inspection as
compliance to this AD. For air carriers operating under part 121,
you may use either the system established to comply with section
121.369 or use an alternative system that your principal maintenance
inspector has accepted if that alternative system:
(1) Includes a method for preserving and retrieving the records
of the inspections resulting from this AD; and
(2) Meets the requirements of section 121.369(c); and
(3) Maintains the records either indefinitely or until the work
is repeated.
(j) These record keeping requirements apply only to the records
used to document the mandatory inspections required as a result of
revising the Time Limits Manual as specified in paragraph (f) of
this AD, and do not alter or amend the record keeping requirements
for any other AD or regulatory requirement.
Related Information
(k) CAA airworthiness directive G-2003-0005, dated September 18,
2003, also addresses the subject of this AD.
Issued in Burlington, Massachusetts, on March 5, 2004.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification
Service.
[FR Doc. 04-5620 Filed 3-17-04; 8:45 am]
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