[Federal Register: July 26, 2005 (Volume 70, Number 142)]
[Rules and Regulations]
[Page 43036-43039]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr26jy05-8]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2002-NE-40-AD; Amendment 39-14202; AD 2005-15-13]
RIN 2120-AA64
Airworthiness Directives; Rolls-Royce plc RB211-524 Series
Turbofan Engines
AGENCY: Federal Aviation Administration (FAA), Department of
Transportation (DOT).
ACTION: Final rule.
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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for
Rolls Royce plc (RR) RB211-524 series turbofan engines with certain
part number (P/N) intermediate pressure (IP) compressor stage 5 disks
installed. This AD requires new reduced IP compressor stage 5 disk
cyclic limits. This AD also requires removing from service affected
disks that already exceed the new reduced cyclic limit, and removing
other affected disks before exceeding their cyclic limits, using a
drawdown schedule. This AD results from the discovery of cracks in the
cooling air hole areas of the disk front spacer arm. We are issuing
this AD to prevent IP compressor stage 5 disk failure, which could
result in uncontained engine failure and possible damage to the
airplane.
DATES: This AD becomes effective August 30, 2005. The Director of the
Federal Register approved the incorporation by reference of certain
publications listed in the regulations as of August 30, 2005.
ADDRESSES: You can get the service information identified in this AD
from Rolls-Royce plc, P.O. Box 31 Derby, DE248BJ, United Kingdom;
telephone 011-44-1332-242424; fax 011-44-1332-249936.
You may examine the AD docket at the FAA, New England Region,
Office of the Regional Counsel, 12 New England Executive Park,
Burlington, MA. You may examine the service information, at the FAA,
New England Region, Office of the Regional Counsel, 12 New England
Executive Park, Burlington, MA; or at 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
.
FOR FURTHER INFORMATION CONTACT: Ian Dargin, Aerospace Engineer, Engine
Certification Office, FAA, Engine and Propeller Directorate, 12 New
England Executive Park, Burlington, MA 01803-
[[Page 43037]]
5299; telephone (781) 238-7178; fax (781) 238-7199.
SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39
with a proposed AD. The proposed AD applies to (RR) RB211-524 series
turbofan engines with certain P/N IP compressor stage 5 disks
installed. We published the proposed AD in the Federal Register on
February 2, 2005 (70 FR 5390). That action proposed to require:
Establishing new reduced IP compressor stage 5 disk cyclic
limits.
Removing from service affected disks that already exceed
the new reduced cyclic limit.
Removing other affected disks before exceeding their
cyclic limits, using a drawdown schedule.
Allowing optional inspections at each shop visit or an on-
wing eddy current inspection to extend the disk life beyond the
specified life.
Examining the AD Docket
You may examine the AD Docket (including any comments and service
information), by appointment, between 8:00 a.m. and 4:30 p.m., Monday
through Friday, except Federal holidays. See ADDRESSES for the
location.
Comments
We provided the public the opportunity to participate in the
development of this AD. We received no comments on the proposal or on
the determination of the cost to the public.
Conclusion
We have carefully reviewed the available data and determined that
air safety and the public interest require adopting the AD as proposed.
Costs of Compliance
There are about 939 RR RB211-524 series turbofan engines of the
affected design in the worldwide fleet. We estimate that this AD will
affect about 35 engines installed on airplanes of U.S. registry. We
also estimate that it will take about 8 work hours per engine to
perform an inspection, and 300 work hours per engine to replace an IP
compressor stage 5 disk. The average labor rate is $65 per work hour.
Required parts will cost about $49,000 per engine. Based on these
figures, we estimate the total cost of the AD to U.S. operators to be
$2,415,700.
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 this AD:
(1) Is not a ``significant regulatory action'' under Executive
Order 12866;
(2) Is not a ``significant rule'' under 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. 2002-NE-40-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 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:
2005-15-13 Rolls-Royce plc: Amendment 39-14202. Docket No. 2002-NE-
40-AD.
Effective Date
(a) This airworthiness directive (AD) becomes effective August
30, 2005.
Affected ADs
(b) None.
Applicability
(c) This AD applies to the Rolls-Royce plc (RR) RB211-524 series
turbofan engines listed in the following Table 1, with intermediate
pressure (IP) compressor stage 5 disk part numbers (P/Ns) listed in
Table 2 of this AD, installed.
Table 1.--Engine Models Affected
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-524B-02 -524B-B-02 -524B3-02 -524B4-02 -524B4-D-02
-524B2-19 -524B2-B-19 -524C2-19 -524C2-B-19 -524D4-19
-524D4-B-19 -524D4X-19 -524D4X-B-19 -524D4-39 -524D4-B-39
-524G2-19 -524G2-T-19 -524G3-19 -524G3-T-19 -524H2-19
-524H2-T-19 -524H-36 -524H-T-36
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These engines are installed on, but not limited to, Boeing 747,
767, and Lockheed L-1011 airplanes.
Table 2.--IP Compressor Stage 5 Disk P/Ns Affected
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LK60130 LK65932 LK69021 LK81269 LK83282
[[Page 43038]]
LK83283 UL12290 UL15743 UL15744 UL15745
UL19132 UL20785 UL20832 UL23291 UL25011
UL36821 UL36977 UL36978 UL36979 UL36980
UL36981 UL36982 UL36983 UL37078 UL37079
UL37080 UL37081 UL37082 UL37083 UL37084
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Unsafe Condition
(d) This AD results from discovery of cracks in the cooling air
hole areas of the disk front spacer arm. The actions specified in
this AD are intended to prevent IP compressor stage 5 disk failure,
which could result in uncontained engine failure and possible 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.
Cycle Limits
(f) Change the service cyclic limits contained in the Time
Limits Manual, 05-10-01, for the IP compressor stage 5 discs
installed in the engine models listed in the following Table 3,
within 30 days after the effective date of this AD.
Table 3.--Cyclic Life Limits Without Qualifying Magnetic Particle Inspection (MPI) or Eddy Current Inspection
(ECI)
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Engine models
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-524D4, D4-B, -524B-02, B-B-
Date of reduced life limit -524G2, G2-T, G3, G3-T, D4-B-39, D4X, -524B2, B2-B, 02, B3-02, B4-
H2, H2-T, H-36, H-T-36 D4X-B, D4-39 C2, C2-B CIS 02, B4-D-02
CIS CIS
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November 30, 2002..................... 13,500 cycles-in-service 16,150 16,000 16,200
(CIS).
April 1, 2003......................... 13,500 CIS.............. 13,500 13,500 14,000
December 1, 2003...................... 12,000 CIS.............. 13,500 13,500 14,000
December 1, 2004...................... 11,000 CIS.............. 13,500 12,000 12,000
December 1, 2005...................... 11,000 CIS.............. 12,000 12,000 12,000
December 1, 2008...................... 7,830 CIS............... 8,700 8,900 9,000
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Optional Inspections
(g) Before December 1, 2008, optional inspections are allowed at
each shop visit or on-wing to extend the disk life. Guidance for
these inspections is provided in paragraphs (h) or (i) of this AD.
Optional Inspections at Shop Visit
(h) Perform optional inspections at shop visit, as follows:
(1) Remove corrosion protection from IP stage 5 disk.
Information on corrosion protection removal can be found in the
Engine Manual.
(2) Visual-inspect and binocular-inspect the IP stage 5 disk for
corrosion pitting at the cooling air holes and defender holes in the
disk front spacer arm. Follow paragraph 3.C. of the Accomplishment
Instructions of RR MSB No. RB.211-72-D428, Revision 3, dated June
30, 2003. Information on disk corrosion pitting limits can be found
in the Engine Manual.
(i) If the disk has corrosion pitting in excess of limits,
remove the disk from service.
(ii) If the disk is free from corrosion pitting, MPI the entire
disk. Information on MPI can be found in the Engine Manual. If the
disk passes MPI and no cracks are found, complete all other
inspections, re-apply corrosion protection to disk, and return the
disk to service in accordance with the cyclic limits allowed by
paragraph (k) of this AD. Information on MPI limits can be found in
the Engine Manual. Information on re-applying corrosion protection
can be found in RR Repair FRS5900.
(iii) If the disk has corrosion pitting within limits, ECI all
disk cooling air holes, defender holes, and inner and outer faces.
Follow paragraph 3.D. of the Accomplishment Instructions of RR MSB
No. RB.211-72-D428, Revision 3, dated June 30, 2003. Information on
corrosion pitting limits can be found in the Engine Manual. If the
disk passes ECI and no cracks are found, MPI the entire disk.
Information on MPI can be found in the Engine Manual. If the disk
passes MPI and no cracks are found, re-apply corrosion protection to
disk, and return the disk to service in accordance with the cyclic
limits allowed by paragraph (k) of this AD.
Optional On-Wing EC Inspections
(i) For RB211-524B2/C2 and RB211-524B4/D4 engine models, an on-
wing ECI of the IP compressor stage 5 disk may be performed only
once between shop visit inspections. Follow paragraphs 3.A. through
3.F. of the Accomplishment Instructions of RR SB No. RB.211-72-E148,
dated March 13, 2003, and RR SB No. RB.211-72-E150, Revision 1,
dated June 4, 2003, respectively, to do the ECI. If the disk passes
the ECI and no cracks are found, an extension is allowed as
specified in paragraph (k) of this AD.
Definition of Shop Visit
(j) For the purposes of this AD, a shop visit is defined as the
separation of an engine major case flange. This definition excludes
shop visits when only field maintenance type activities are
performed in lieu of performing them on-wing. (i.e., for purposes
such as to perform an on-wing inspection of a tail engine
installation on a Lockheed L-1011 airplane).
Cyclic Life Extension
(k) Disks that pass an optional inspection may remain in service
after that inspection for the additional cycles listed in the
following Table 4, until the next inspection, or December 1, 2008,
or until the cyclic life limit published in the Time Limits Manual
is reached, whichever occurs first.
[[Page 43039]]
Table 4.--Cyclic Life Extension
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-524G2, G2-T,
G3, G3-T, H2, -524D4, D4-B, -524B2, B2-B, -524B-02, B-B-
Engine models H2-T, H-36, H- D4-B-39, D4X, C2, C2-B 02, B3-02, B4-
T-36 (cycles) D4X-B, D4-39 (cycles) 02, B4-D-02
(cycles) (cycles)
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Extension After Passing MPI 1,600 2,000 2,000 2,000
Extension After Passin In-Shop ECI 3,800 4,500 4,500 4,500
Extension After Passing On-Wing ECI 1,000 1,200 1,200 1,200
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Disks That Have Been Intermixed Between Engine Models
(l) Information on intermixing disks between engine models can
be found in the RR Time Limits Manual, 05-00-01.
Alternative Methods of Compliance
(m) 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.
Credit for Previous Inspections
(n) Inspections done using RR SB No. RB.211-72-E150, dated April
17, 2003 are acceptable in meeting the requirements of this AD.
Reporting Requirement
(o) Report findings of all inspections of the IP stage 5 disk
using paragraph 3.B.(2) of the Accomplishment Instructions of RR ASB
RB.211-72-D428, Revision 3, dated June 30, 2003. The Office of
Management and Budget (OMB) has approved the reporting requirements
specified in Paragraph 3.B. of the Accomplishment Instructions of RR
ASB RB.211-72-D428, Revision 3, dated June 30, 2003, and assigned
OMB control number 2120-0056.
Material Incorporated by Reference
(p) You must use Rolls-Royce plc Service Bulletins listed in
Table 5 of this AD to perform the actions required by this AD. The
Director of the Federal Register approved the incorporation by
reference of this service bulletin in accordance with 5 U.S.C.
552(a) and 1 CFR part 51. You can get a copy from Rolls-Royce plc,
P.O. Box 31 Derby, DE248BJ, United Kingdom; telephone 011-44-1332-
242424; fax 011-44-1332-249936. You can review copies by
appointment, at the FAA, New England Region, Office of the Regional
Counsel, 12 New England Executive Park, Burlington, MA; or at 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 5.--Incorporation by Reference
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Page number shown on the
Service bulletin page Revision Date shown on the page
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RB.211-72-D428, including All....................... 3......................... June 30, 2003.
Appendices 1 through 4, dated
June 30, 2003.
RB.211-72-E148 Total Pages--83. All....................... Original.................. March 13, 2003.
RB.211-72-E150 Total Pages--72. All....................... 1......................... June 4, 2003.
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Related Information
(q) CAA airworthiness directive 006-04-2002, dated April 2002,
also addresses the subject of this AD.
Issued in Burlington, Massachusetts, on July 18, 2005.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft
Certification Service.
[FR Doc. 05-14576 Filed 7-25-05; 8:45 am]
BILLING CODE 4910-13-P