[Federal Register: July 28, 2005 (Volume 70, Number 144)]
[Proposed Rules]
[Page 43659-43661]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr28jy05-10]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2003-NE-12-AD]
RIN 2120-AA64
Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan
Engines
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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SUMMARY: The FAA proposes to supersede an existing airworthiness
directive (AD) for Rolls-Royce plc (RR) RB211-22B series, RB211-524B, -
524C2, -524D4, -524G2, -524G3, and -524H series, and RB211-535C and -
535E series turbofan engines with high pressure compressor (HPC) stage
3 disc assemblies, part numbers (P/Ns) LK46210, LK58278, LK67634,
LK76036, UL11706, UL15358, UL22577, UL22578, and UL24738 installed.
That AD requires removing from service certain disc assemblies before
they reach their full life if not modified with anticorrosion
protection. This proposed AD would require the same actions as AD 2004-
01-20, but would shorten the compliance time for disks that entered
service before 1990. This proposed AD results from the manufacturer's
reassessment of the corrosion risk on HPC stage 3 disc assemblies not
modified with sufficient application of anticorrosion protection. We
are issuing this AD to prevent corrosion-induced uncontained disc
failure, resulting in damage to the airplane.
DATES: We must receive comments on this proposed AD by September 26,
2005.
ADDRESSES: Use one of the following addresses to comment on this
proposed AD:
By mail: Federal Aviation Administration (FAA), New
England Region, Office of the Regional Counsel, Attention: Rules Docket
No. 2003-NE-12-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 identified in this proposed AD
from Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; telephone:
011-44-1332-242424; fax: 011-44-1332-245-418.
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:
Comments Invited
We invite you to send any written relevant data, views, or
arguments regarding this proposal. Send your comments to an address
listed under ADDRESSES. Include ``AD Docket No. 2003-NE-12-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 proposed
AD. If a person contacts us verbally, and that contact relates to a
substantive part of this proposed 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 proposed 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.
Discussion
On January 8, 2004, we issued AD 2004-01-20, Amendment 39-13434 (69
FR 2661, January 20, 2004). That AD allows certain disc assemblies to
reach their full life only after modifying the disc assemblies with
anticorrosion protection. The Civil Aviation Authority (CAA), which is
the airworthiness authority for the United Kingdom, notified the FAA
that an unsafe condition may exist on RR RB211-22B series, RB211-524B,
-524C2, -524D4, -524G2, -524G3, and -524H series, and RB211-535C and -
535E series turbofan engines with HPC stage 3 disc assemblies, P/Ns
LK46210, LK58278, LK67634, LK76036, UL11706, UL15358, UL22577, UL22578,
and UL24738 installed. The CAA advises that inspections at overhaul
found many disc assemblies with corrosion-induced pitting. RR
reassessed the risk of corrosion-induced pitting of disc assemblies
that have not incorporated any revision of RR service bulletin (SB) No.
RB.211-72-9434, or any revision of RR SB No. RB.211-72-5420, which
rework the discs and apply anticorrosion protection, lowered the disc
lives from those published in the Time Limits Manuals. These SBs rework
the discs and apply anticorrosion protection, and lower the disc lives
accordingly in the Time Limits Manuals.
Actions Since AD 04-01-20 Was Issued
Since we issued that AD, we found that we made an oversight in the
rule regarding the compliance time for disks that entered into service
before 1990. We allowed operators to remove and rework these disks
within five years after the effective date of that AD, but we intended
to set a fixed calendar date based on inspection findings and
metallurgical results. This proposed AD corrects that oversight. Also,
we omitted paragraph (f)(5) from the original rule. We issued a
correction to AD 04-01-20 on July 29, 2004, to include paragraph
(f)(5). This proposed rule includes that paragraph.
Relevant Service Information
We have reviewed and approved the technical contents of Rolls-Royce
plc SB No. RB.211-72-9434, Revision 4, dated January 12, 2000, and SB
No. RB.211-72-5420, Revision 4, dated February 29, 1980, which describe
procedures for reworking of HPC stage 3 rotor disc assemblies by
machining, and application of anticorrosion protection. The CAA, which
is the airworthiness authority for the U.K., classified these SBs as
mandatory and issued airworthiness directive 004-01-94, dated January
4, 2002.
Bilateral Agreement Information
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. In keeping with 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
[[Page 43660]]
of this type design that are certificated for operation in the United
States.
FAA's Determination and Requirements of the Proposed AD
We have evaluated all pertinent information and identified an
unsafe condition that is likely to exist or develop on other products
of this same type design. We are proposing this AD, which would require
the following for affected HPC stage 3 rotor disc assemblies:
Removing affected disc assemblies from service.
Re-machining, inspecting, and applying anticorrosion
protection.
Re-marking, and returning disc assemblies into service.
The proposed AD would require that you do these actions using the
service information described previously.
Costs of Compliance
There are about 2,000 RR RB211-22B series, RB211-524B, -524C2, -
524D4, -524G2, -524G3, and -524H series, and RB211-535C and -535E
series turbofan engines of the affected design in the worldwide fleet.
We estimate that this proposed AD would affect 1,000 engines installed
on airplanes of U.S. registry. We also estimate that it would take
about 31 work hours per engine to perform the proposed actions, and
that the average labor rate is $65 per work hour. Required parts would
cost about $38,000 per engine. Based on these figures, we estimate the
total cost of the proposed AD to U.S. operators to be $40,015,000.
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 proposed AD would not have federalism
implications under Executive Order 13132. This proposed AD would 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 proposed
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. Would 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 proposal 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-12-AD'' in your request.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Safety.
The Proposed Amendment
Accordingly, under the authority delegated to me by the
Administrator, the Federal Aviation Administration proposes to amend 14
CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
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]
2. The FAA amends Sec. 39.13 by removing Amendment 39-13434 (69 FR
2661, January 20, 2004) and by adding a new airworthiness directive, to
read as follows:
Rolls-Royce plc: Docket No. 2003-NE-12-AD.
Comments Due Date
(a) The Federal Aviation Administration (FAA) must receive
comments on this airworthiness directive (AD) action by September
26, 2005.
Affected ADs
(b) This AD supersedes AD 2004-01-20, Amendment 39-13434.
Applicability
(c) This AD applies to Rolls-Royce plc (RR) RB211-22B series,
RB211-524B, -4C2, -524D4, -524G2, -524G3, and -524H series, and
RB211-535C and -535E series turbofan engines with high pressure
compressor (HPC) stage 3 disc assemblies, part numbers (P/Ns)
LK46210, LK58278, LK67634, LK76036, UL11706, UL15358, UL22577,
UL22578, and UL24738 installed. These engines are installed on, but
not limited to, Boeing 747, Boeing 757, Boeing 767, Lockheed L-1011,
and Tupolev Tu204 series airplanes.
Unsafe Condition
(d) This AD results from the manufacturer's reassessment of the
corrosion risk on HPC stage 3 disc assemblies that have not yet been
modified with sufficient application of anticorrosion protection.
The actions specified in this AD are intended to prevent corrosion-
induced uncontained disc failure, resulting in 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.
Removal of HPC Stage 3 Discs
(f) Remove from service affected HPC stage 3 disc assemblies
identified in the following Table 1, using one of the following
criteria:
[[Page 43661]]
Table 1.--Affected HPC Stage 3 Disc Assemblies
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Rework band for
Rework band for cyclic life
cyclic life Rework band for accumulated on P/
accumulated on cyclic life Ns LK76036,
disc assemblies P/ accumulated on UL11706, UL15358,
Engine model Ns LK46210 and disc assembly P/N UL22577, UL22578,
LK58278 (Pre RR LK67634 (Pre RR and UL24738 disc
service bulletin SB No. RB.211-72- assemblies (Pre RR
(SB) No. RB.211-72- 5420) SB No. RB.211-72-
5420) 9434)
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-22B series......................................... 4,000-6,200 7,000-10,000 11,500-14,000
-535E4 series....................................... N/A N/A 9,000-15,000
-524B-02, B-B-02, B3-02, and B4 series, Pre and SB 4,000-6,000 7,000-9,000 11,500-14,000
No. 72-7730........................................
-524B2 and C2 series, Pre SB No. 72-7730............ 4,000-6,000 7,000-9,000 11,500-14,000
-524B2-B-19 and C2-B-19, SB No. 72-7730............. 4,000-6,000 7,000-9,000 8,500-11,000
-524D4 series, Pre SB No. 72-7730................... 4,000-6,000 7,000-9,000 11,500-14,000
-524D4-B series, SB No. 72-7730..................... 4,000-6,000 7,000-9,000 8,500-11,000
-524G2, G3, H, and H2 series........................ 4,000-6,000 7,000-9,000 8,500-11,000
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(1) For discs that entered into service before 1990, remove disc
and rework as specified in paragraph (g)(2) of this AD, on or before
January 4, 2007, but not to exceed the upper cyclic limit in Table 1
of this AD before rework. Discs reworked may not exceed the
manufacturer's published cyclic limit in the time limits section of
the manual.
(2) For discs that entered into service in 1990 or later, remove
disc within the cyclic life rework bands in Table 1 of this AD, or
within 17 years after the date of the disc assembly entering into
service, whichever is sooner, but not to exceed the upper cyclic
limit of Table 1 of this AD before rework. Discs reworked may not
exceed the manufacturer's published cyclic limit in the time limits
section of the manual.
(3) For disc assemblies that when new, were modified with an
application of anticorrosion protection and re-marked to P/N LK76036
(not previously machined) as specified by Part 1 of the original
issue of RR service bulletin (SB) No. RB.211-72-5420, dated April
20, 1979, remove RB211-22B disc assemblies before accumulating
10,000 cycles-in-service (CIS), and remove RB211-524 disc assemblies
before accumulating 9,000 CIS.
(4) If the disc assembly date of entry into service cannot be
determined, the date of disc manufacture may be obtained from RR and
used instead.
(5) Discs in RB211-535C operation are unaffected by the interim
rework cyclic band limits in Table 1 of this AD, but must meet the
calendar life requirements of either paragraph (f)(1) or (f)(2) of
this AD, as applicable.
Optional Rework of HPC Stage 3 Discs
(g) Rework HPC stage 3 disc assemblies that were removed in
paragraph (f) of this AD as follows:
(1) For disc assemblies that when new, were modified with an
application of anticorrosion protection and re-marked to P/N LK76036
(not previously machined) as specified by Part 1 of the original
issue of RR SB RB.211-72-5420, dated April 20, 1979, rework disc
assemblies and re-mark to either LK76034 or LK78814 using paragraph
2.B. of the Accomplishment Instructions of RR SB No. RB.211-72-5420,
Revision 4, dated February 29, 1980. This rework constitutes
terminating action to the removal requirements in paragraph (f) of
this AD.
(2) For all other disc assemblies, rework using Paragraph 3.B.
of the Accomplishment Instructions of RR SB No. RB.211-72-9434,
Revision 4, dated January 12, 2000. This rework constitutes
terminating action to the removal requirements in paragraph (f) of
this AD.
Note 1: If rework is done on disc assemblies that are removed
before the disc assembly reaches the lower life of the cyclic life
rework band in Table 1 of this AD, artificial aging of the disc to
the lower life of the rework band, at time of rework, is required.
Alternative Methods of Compliance
(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.
Related Information
(i) Civil Aviation Authority airworthiness directive 004-01-94,
dated January 4, 2002, and RR Mandatory Service Bulletin No. RB.211-
72-9661, Revision 4, dated January 4, 2002, pertain to the subject
of this AD.
Issued in Burlington, Massachusetts, on July 21, 2005.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft
Certification Service.
[FR Doc. 05-14803 Filed 7-27-05; 8:45 am]
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