[Federal Register Volume 62, Number 83 (Wednesday, April 30, 1997)]
[Rules and Regulations]
[Pages 23339-23341]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 97-10469]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 97-ANE-09; Amendment 39-9970; AD 97-06-13]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB.211 Trent 800 Series 
Turbofan Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that 
is applicable to Rolls-Royce plc RB.211 Trent 800 series turbofan 
engines. This action requires initial and repetitive visual and 
fluorescent penetrant inspections (FPI) of the angled drive upper 
shroud tube for frettage and cracking, initial and repetitive visual 
inspections and FPI for cracking, a one-tine FPI for porosity of the 
intermediate gearbox housing (IGH), and initial and repetitive visual 
inspections for cracking of the external gearbox lower bevel box (LBB) 
housing. In addition, this action requires initial and repetitive 
master magnetic chip detector inspections. Finally, prior to initiation 
of Extended Range Twin-Engine Operations (ETOPS), or prior to September 
30, 1997, whichever occurs first, this action requires installation of 
a redesigned angled drive upper shroud tube and a lower splitter 
fairing with revised sealing. This amendment is prompted by reports of 
loss of oil from the angle drive upper shroud tube, the IGH, the LBB, 
and by reports of bearing failures. The actions specified by this AD 
are intended to prevent loss of oil, which could cause an engine fire. 
This AD is also intended to prevent inflight engine shutdowns and 
airplane diversions caused by oil loss and from bearing failures.

DATES: Effective May 15, 1997.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of May 15, 1997.
    Comments for inclusion in the Rules Docket must be received on or 
before June 30, 1997.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Assistant Chief 
Counsel, Attention: Rules Docket No. 97-ANE-09, 12 New England 
Executive Park, Burlington, MA 01803-5299. Comments may also be sent 
via the Internet using the following address: ``9__ad 
[email protected]''. Comments sent via the Internet must contain 
the docket number in the subject line.
    The service information referenced in this AD may be obtained from 
Rolls-Royce North America, Inc., 2001 South Tibbs Ave., Indianapolis, 
IN 46241; telephone (317) 230-3995, fax (317) 230-4743. This 
information may be examined at the FAA, New England Region, Office of 
the Assistant Chief Counsel, 12 New England Executive Park, Burlington, 
MA; or at the Office of the Federal Register, 800 North Capitol Street, 
NW., suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Chris Gavriel, Aerospace Engineer, 
Engine Certification Office, FAA, Engine and Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803-5299; telephone (617) 
238-7147, fax (617) 238-7199.

SUPPLEMENTARY INFORMATION: The Civil Aviation Authority, which is 
the airworthiness authority for the United Kingdom (UK), recently 
notified the FAA that an unsafe condition may exist on Rolls-Royce 
plc RB.211 Trent 800 series turbofan engines. The CAA advises that 
they have received ten reports of loss of oil and one report of 
intermediate pressure compressor (IPC) front bearing roller 
retainer tang failure.

    Loss of oil: The reports to the CAA indicate that oil can leak from 
the angled drive upper shroud tube, from the intermediate gearbox 
housing (IGH), or from the external gearbox lower bevel box (LBB) 
housing. The angled drive upper shroud tube may contact adjacent lower 
bifurcation structure initiating frettage on the tube. The nacelle 
structure may also transfer vibratory loads onto the tube to the point 
of fracture, causing oil leakage. The IGH, which is attached to the 
angled drive upper shroud tube assembly, or the LBB, which is attached 
to the external gearbox, can develop cracks, causing oil leakage.
    Bearing failure: The reports to the CAA indicate that the IPC front 
bearing, and bearings in the IGH and internal gearbox can fail and 
cause an inflight shutdown and aircraft diversion.
    These conditions, if not corrected, can result in loss of oil, that 
could cause an engine fire. These conditions may also result in 
inflight engine shutdowns and airplane diversions caused by oil loss 
and from bearing failures.
    Rolls-Royce plc has issued the following service documents: 
Mandatory Service Bulletin (SB) No. RB.211-72-C089, Revision 1, dated 
January 24, 1997, that describes procedures for inspection of angled 
drive upper shroud tubes for frettage and cracks; Mandatory SB No. 
RB.211-72-C129, Revision 2, dated March 21, 1997, that describes 
procedures for inspection of the IGH for cracks and porosity and the 
LBB housing for cracks; SB No. RB.211-72-C114, Original, dated February 
6, 1997, that describes procedures for installation of an improved 
angled drive upper shroud tube with a lower splitter fairing with 
revised sealing; and Mandatory SB No.

[[Page 23340]]

RB.211-79-C093, Revision 1, dated February 28, 1997, that describes 
procedures for inspection of the master magnetic chip detector. The CAA 
classified three of these service documents, identified above, as 
mandatory in order to assure the airworthiness of these engines.
    This engine model is manufactured in the UK and is type 
certificated for operation in the United States (US) under the 
provisions of section 21.29 of the Federal Aviation Regulations (14 CFR 
21.29) and the applicable bilateral airworthiness agreement. Pursuant 
to this bilateral airworthiness agreement, the CAA has kept the FAA 
informed of the situation described above. The FAA has 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 US.
    Since an unsafe condition has been identified that is likely to 
exist or develop on other engines of the same type design registered in 
the US, the proposed AD would require: initial and repetitive visual 
and FPI of the angled drive upper shroud tube for frettage and 
cracking, initial and repetitive visual inspections and FPI of the IGH 
for cracking, a one-time FPI of the IGH for porosity, and initial and 
repetitive visual inspections of the LBB housing for cracking. In 
addition, this action requires initial and repetitive master magnetic 
chip detector inspections. Finally, prior to initiation of Extended 
Range Twin-Engine Operations (ETOPS), or prior to September 30, 1997, 
whichever occurs first, this action requires installation of an 
improved angled drive upper shroud tube with a lower splitter fairing 
with revised sealing. The actions would be required to be accomplished 
in accordance with the service documents described previously. 
Following identification of additional corrective actions that would 
negate the need to continue frequent inspections, additional rulemaking 
may be forthcoming.
    Additionally, since this AD affects ETOPS service, the requirement 
to install the improved angled drive upper shroud tube with a lower 
splitter fairing with revised sealing prior to entering ETOPS service 
is in accordance with the airplane ETOPS requirements and has been 
coordinated with and concurred by the Transport Airplane Directorate of 
the FAA.
    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications should identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this notice must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 97-ANE-09.'' The postcard will be date stamped and 
returned to the commenter.
    The regulations adopted herein will not have substantial direct 
effects 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. Therefore, in 
accordance with Executive Order 12612, it is determined that this final 
rule does not have sufficient federalism implications to warrant the 
preparation of a Federalism Assessment.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and is not a ``significant regulatory action'' 
under Executive Order 12866. It has been determined further that this 
action involves an emergency regulation under DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979). If it is determined 
that this emergency regulation otherwise would be significant under DOT 
Regulatory Policies and Procedures, a final regulatory evaluation will 
be prepared and placed in the Rules Docket. A copy of it, if filed, may 
be obtained from the Rules Docket at the location provided under the 
caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to 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

    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. Section 39.13 is amended by adding the following new 
airworthiness directive:

97-06-13  Rolls-Royce plc: Amendment 39-9970. Docket 97-ANE-09.

    Applicability: Rolls-Royce plc (R-R) RB.211 Trent 800 series 
turbofan engines, installed on but not limited to Boeing 777 series 
aircraft.

    Note 1: This airworthiness directive (AD) applies to each engine 
identified in the preceding applicability provision, regardless of 
whether it has been modified, altered, or repaired in the area 
subject to the requirements of this AD. For engines that have been 
modified, altered, or repaired so that the performance of the 
requirements of this AD is affected, the owner/operator must request 
approval for an alternative method of compliance in accordance with 
paragraph (d) of this AD. The request should include an assessment 
of the effect of the modification, alteration, or repair on the 
unsafe condition addressed by this AD; and, if the unsafe condition 
has not been eliminated, the request should include specific 
proposed actions to address it.

    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent loss of oil, that could cause an engine fire, and 
inflight engine shutdowns and airplane diversions caused by oil loss 
and from bearing failures, accomplish the following:
    (a) Inspect angle drive upper shroud tubes as follows:
    (1) Within 50 CIS after the effective date of this AD, visually 
inspect and measure the frettage and fluorescent penetrant inspect

[[Page 23341]]

(FPI) for cracks the angle drive upper shroud tubes in accordance 
with R-R Service SB No. RB.211-72-C089, Revision 1, dated January 
24, 1997.
    (2) Thereafter, at intervals not to exceed 50 CIS since last 
inspection, visually inspect and measure the frettage and FPI for 
cracks the angled drive upper shroud tubes, in accordance with R-R 
SB No. RB.211-72-C089, Revision 1, dated January 24, 1997.
    (3) Prior to further flight, remove from service angled drive 
upper shroud tubes that exhibit frettage measured in excess of 0.020 
inches, or any cracks, and replace with serviceable parts.
    (4) Installation of an improved angled drive upper shroud tube 
with a lower splitter fairing with revised sealing in accordance 
with R-R SB No. RB.211-72-C114, dated February 6, 1997, constitutes 
terminating action to the inspection requirements of paragraphs 
(a)(1), (a)(2), and (a)(3) of this AD.
    (5) Prior to initiation of ETOPS, or prior to September 30, 
1997, whichever occurs first, install an improved angled drive upper 
shroud tube with a lower splitter fairing with revised sealing in 
accordance with R-R SB No. RB.211-72-C114, dated February 6, 1997.
    (b) Inspect the intermediate gearbox housing (IGH) and external 
gearbox lower bevel box (LBB) housing as follows:
    (1) Within 5 CIS after the effective date of this AD, perform an 
initial visual inspection of the IGH and LBB housing for cracks, in 
accordance with R-R Mandatory SB No. RB.211-72-C129, Revision 2, 
dated March 21, 1997.
    (2) Within 10 CIS after the effective date of this AD, perform 
an initial FPI of the IGH for cracks, in accordance with R-R 
Mandatory SB No. RB.211-72-C129, Revision 2, dated March 21, 1997.
    (3) Thereafter, at intervals not to exceed 5 CIS since last 
visual inspection, visually inspect the IGH and LBB housing for 
cracks, and at intervals not to exceed 10 CIS since last FPI, FPI 
the IGH, in accordance with R-R Mandatory SB No. RB.211-72-C129, 
Revision 2, dated March 21, 1997.
    (4) Within 10 CIS after the effective date of this AD, perform 
an FPI of the IGH for porosity in accordance with R-R Mandatory SB 
No. RB.211-72-C129, Revision 2, dated March 21, 1997.
    (5) Within the next 5 CIS, remove from service IGHs that exhibit 
porosity levels in excess of the acceptable criteria listed in the 
SB and replace with serviceable parts.
    (6) Prior to further flight, remove from service cracked IGHs 
and LLB housings and replace with serviceable parts.
    (c) Inspect the master magnetic chip detector as follows:
    (1) Within 100 hours time in service (TIS) after the effective 
date of this AD, perform an initial inspection of the master 
magnetic chip detector in accordance with Mandatory SB No. RB.211-
79-C093, Revision 1, February 28, 1997.
    (2) Thereafter, at intervals not less than 60 hours TIS and not 
greater than 130 hours TIS since last inspection, perform repetitive 
inspections of the master magnetic chip detector in accordance with 
Mandatory SB No. RB.211-79-C093, Revision 1, dated February 28, 
1997.
    (d) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Engine Certification Office. The 
request should be forwarded through an appropriate FAA Principal 
Maintenance Inspector, who may add comments and then send it to the 
Manager, Engine Certification Office.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the Engine Certification Office.

    (e) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the aircraft to a location where 
the inspection requirements of this AD can be accomplished.
    (f) The actions required by this AD shall be performed in 
accordance with the following R-R service documents:

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               Document No.                 Pages            Revision                         Date              
----------------------------------------------------------------------------------------------------------------
SB No. RB.211-72-C089....................      1-3  1........................  Jan. 24, 1997.                   
    Total pages: 3.                                                                                             
SB No. RB.211-72-C129....................      1-3  2........................  Mar. 21, 1997.                   
                                               4-6  1........................  Mar. 7, 1997.                    
                                                 7  2........................  Mar. 21, 1997.                   
    Total pages: 7.                                                                                             
SB No. RB.211-72-C114....................     1-48  Original.................  Feb. 6, 1997.                    
Supplement...............................      1-4  Original.................  Feb. 6, 1997.                    
    Total pages: 52.                                                                                            
SB No. RB.211-79-C093....................      1,2  1........................  Feb. 28, 1997.                   
    Total pages: 2.                                                                                             
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    This incorporation by reference was approved by the Director of 
the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR 
part 51. Copies may be obtained from Rolls-Royce North America, 
Inc., 2001 South Tibbs Ave., Indianapolis, IN 46241; telephone (317) 
230-3995, fax (317) 230-4743. Copies may be inspected at the FAA, 
New England Region, Office of the Assistant Chief Counsel, 12 New 
England Executive Park, Burlington, MA; or at the Office of the 
Federal Register, 800 North Capitol Street, NW., suite 700, 
Washington, DC.
    (g) This amendment becomes effective on May 15, 1997.

    Issued in Burlington, Massachusetts, on April 14, 1997.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 97-10469 Filed 4-29-97; 8:45 am]
BILLING CODE 4910-13-U