[Federal Register Volume 66, Number 144 (Thursday, July 26, 2001)]
[Proposed Rules]
[Pages 38961-38963]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 01-18554]


 ========================================================================
 Proposed Rules
                                                 Federal Register
 ________________________________________________________________________
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 This section of the FEDERAL REGISTER contains notices to the public of 
 the proposed issuance of rules and regulations. The purpose of these 
 notices is to give interested persons an opportunity to participate in 
 the rule making prior to the adoption of the final rules.
 
 ========================================================================
 

  Federal Register / Vol. 66, No. 144 / Thursday, July 26, 2001 / 
Proposed Rules  

[[Page 38961]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2000-NE-62-AD]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan 
Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The Federal Aviation Administration (FAA) proposes to adopt a 
new airworthiness directive (AD) that is applicable to Rolls-Royce plc 
RB211-535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75 and 
RB211-22B-02 series turbofan engines. This proposal would require 
inspection of certain high pressure (HP) turbine disks, manufactured 
between 1989 and 1999, for cracks in the rim cooling air holes, and, if 
necessary, replacement with serviceable parts. This proposal is 
prompted by reports of cracks in two high life Trent 800 disk rim 
cooling air holes produced at the same manufacturing facility using the 
same tooling as the RB211series turbofan engine HP turbine disks. The 
actions specified by the proposed AD are intended to prevent possible 
disk failure, which could result in an uncontained engine failure and 
damage to the aircraft.

DATES: Comments must be received by September 24, 2001.

ADDRESSES: Submit comments in triplicate to the 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. Comments may also be sent 
via the Internet using the following address: ``[email protected]''. Comments sent via the Internet must contain the 
docket number in the subject line. Comments may be inspected at this 
location between 8:00 a.m. and 4:30 p.m., Monday through Friday, except 
Federal holidays. The service information referenced in the proposed 
rule may be obtained from Rolls-Royce plc, PO Box 31, Derby, England; 
telephone: International Access Code 011, Country Code 44, 1332-249428, 
fax: International Access Code 011, Country Code 44, 1332-249223. This 
information may be examined at the FAA, New England Region, Office of 
the Regional Counsel, 12 New England Executive Park, Burlington, MA.

FOR FURTHER INFORMATION CONTACT: James Lawrence, Aerospace Engineer, 
Engine Certification Office, FAA, Engine and Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803-5299; telephone (781) 
238-7176, fax (781) 238-7199.

SUPPLEMENTARY INFORMATION:

Comments Invited

    Interested persons are invited to participate in the making of the 
proposed 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 above. All 
communications received on or before the closing date for comments, 
specified above, will be considered before taking action on the 
proposed rule. The proposals contained in this action may be changed in 
light of the comments received.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the proposed 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 summarizing each FAA-public contact concerned with 
the substance of this proposal will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this action must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2000-NE-62-AD.'' The postcard will be date stamped and 
returned to the commenter.

Availability of NPRM's

    Any person may obtain a copy of this NPRM by submitting a request 
to the 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.

Discussion

    The Civil Aviation Authority (CAA), which is the airworthiness 
authority for the United Kingdom (UK), recently notified the FAA that 
an unsafe condition may exist on certain Rolls-Royce plc (RR) RB211-
535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, and RB211-
22B-02 series turbofan engines. The CAA received reports of cracks in 
two Trent 800 high life HP turbine disks rim cooling air holes. 
Examination of the affected holes revealed smearing of the surface 
indicating machining damage during manufacture. Since the RB211-535E4-
37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, and RB211-22B-02 
HP turbine disks are similar in design to the Trent 800 disk and are 
produced at the same manufacturing facility utilizing the same tooling, 
it is likely that similar machining damage exists on RB211-535E4-37, 
RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, and RB211-22B-02 
disks. The existence of similar damage in these disks could result in 
disk failure if the component was operated to the currently declared 
lives without inspection of the disk rim cooling air holes. The RB211-
535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, and RB211-
22B-02 engines operate significantly higher, HPT disk lives than the 
Trent 800. As such, the Trent 800 is not subject to the same potential 
for disk failure identified in this proposed AD for the RB211-535E4-37, 
RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, and RB211-22B-02 
engines. Therefore, the Trent 800 engine is not included in this 
proposed AD.

Manufacturer's Service Information

    Rolls-Royce has issued Service Bulletin (SB) No. RB.211-72-C817, 
Revision 2, dated March 7, 2001, and SB No. RB.211-72-C877, Revision 1, 
dated March 7, 2001, that specify procedures for inspection of the HP 
turbine disk cooling air holes for cracks and provide

[[Page 38962]]

rejection criteria. The CAA classified these SB's as mandatory and 
issued airworthiness directives (AD) 003-12-99 and 004-01-2000 in order 
to ensure the airworthiness of these engines in the UK.

Bilateral Agreement Information

    This engine model is manufactured in the UK 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. 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 United States.

Proposed Requirements of This AD

    Since an unsafe condition has been identified that is likely to 
exist or develop on other Rolls-Royce plc RB211-535E4-37, RB211-535E4-
B-37, RB211-535C-37, RB211-535E4-B-75, and RB211-22B-02 series turbofan 
engines of the same type design that are used on airplanes registered 
in the United States, the proposed AD would require inspection of 
certain HPturbine disks, manufactured between 1989 and 1999, for cracks 
in the rim cooling air holes, and, if necessary, replacement with 
serviceable parts. The actions would be required to be accomplished in 
accordance with the mandatory service bulletins described previously.

Economic Impact

    There are approximately 549 engines of the affected design in the 
worldwide fleet. The FAA estimates that 300 engines installed on 
aircraft of U.S. registry would be affected by this proposed AD. The 
FAA also estimates that it would take approximately 4 work hours per 
engine to accomplish the proposed actions, and that the average labor 
rate is $60 per work hour. No parts are required. Based on these 
figures, the total cost impact of the proposed AD on U.S. operators is 
estimated to be $72,000.

Regulatory Impact

    This proposed rule does not have federalism implications, as 
defined in Executive Order 13132, because it 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. 
Accordingly, the FAA has not consulted with state authorities prior to 
publication of this proposed rule.
    For the reasons discussed above, I certify that this 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) if promulgated, 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. A copy of the draft 
regulatory evaluation prepared for this action is contained in the 
Rules Docket. A copy of it may be obtained by contacting the Rules 
Docket at the location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration proposes to amend 
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:

Rolls-Royce plc: Docket No. 2000-NE-62-AD.

    Applicability: Rolls-Royce plc (RR) RB211-535E4-37 and RB211-
535E4-B-37 series turbofan engines, with the following high pressure 
(HP) turbine disks installed: part number (P/N) UL10323, with serial 
numbers (S/N) CQDY6070 and higher; P/N UL27680, with any serial 
number; and P/N UL27681, with any serial number. RR RB211-535C-37 
series turbofan engines, with the following HP turbine disks 
installed: P/N LK80622, with S/N LQDY6316 and higher; P/N LK80623, 
with S/N CDQY5945 and higher; and P/N UL28267, with any serial 
number. RR RB211-535E4-B-75 series turbofan engines with the 
following HP turbine disks installed: P/N UL10323, with S/N CDQY6070 
and higher; and P/N UL27680, with any serial number. RR RB211-22B-02 
series turbofan engines with the following HP turbine disks 
installed: P/N LK80622, with S/N LQDY6316 and higher; P/N LK80623, 
with S/N CDQY5945 and higher; and P/N UL28267, having any serial 
number. These engines are installed on but not limited to Boeing 
757, Tupolev Tu204 and Lockheed L-1011 series airplanes.

    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 (c) 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: Compliance with this AD is required as indicated, 
unless already done.
    To prevent possible high pressure (HP) turbine disk failure, 
which could result in an uncontained engine failure and damage to 
the airplane, accomplish the following:

Inspection for All Except RB211-22B-02 Series

    (a) For RB211-535E4-37, RB211-535E4-B-37, RB211-535C-37, and 
RB211-535E4-B-75 series engines, conduct a one-time inspection of 
the HP turbine disks identified in Section A. (1) and (2), of RR SB 
No. RB.211-72-C817, Revision 2, dated March 7, 2001, for cracks on 
the rear face of the cooling air holes.
    (1) For disk life at or below 13,700 cycles on the effective 
date of this AD, inspect at the earlier of the following :
    (i) At the next shop visit when the HP turbine blades have been 
removed from the disk; or
    (ii) Prior to exceeding 14,500 cycles-in-service (CIS) since 
new.
    (2) For disk life above 13,700 cycles on the effective date of 
this AD, inspect at the earliest of the following:
    (i) Prior to reaching 15,300 CIS since new; or
    (ii) Within 800 cycles after the effective date of this AD; or
    (iii) At the next shop visit when the HP turbine blades have 
been removed from the disk.
    (3) Inspect the HP turbine disk for cracks on the rear face of 
the cooling air holes in accordance with the Accomplishment 
Instructions, Section 3 of RR SB No. RB.211-72-C817, dated December 
14, 1999; RR SB No. RB.211-72-C817, Revision 1, dated January 24, 
2000; or RR SB No. RB.211-72-C817, Revision 2, dated March 7, 2001.
    (4) Replace any cracked HP turbine disk with a serviceable part.

Inspections for RB211-22B-02 Series

    (b) For RB211-22B-02 series engines, conduct a one-time 
inspection of the HP turbine disks identified in Section A. of RR SB 
No.RB.211-72-C877, Revision 1, dated March 7, 2001, for cracks on 
the rear face of the cooling air holes.
    (1) For disk life at or below 11,000 CIS on the effective date 
of this AD, inspect at the earlier of the following:

[[Page 38963]]

    (i) At the next shop visit when the HP turbine blades have been 
removed from the disk; or
    (ii) Prior to exceeding 11,000 CIS since new.
    (2) HP turbine disks with more than 11,000 CIS on the effective 
date of this AD must be inspected within 300 CIS after the effective 
date of this AD.
    (3) Inspect the HP turbine disk for cracks on the rear face of 
the cooling air holes in accordance with the Accomplishment 
Instructions outlined in Section 3 of RR SB No. RB.211-72-C877, 
dated January 29, 2000, or RR SB No. RB.211-72-C877, Revision 1, 
dated March 7, 2001.
    (4) Replace any cracked HP turbine disk with a serviceable part.

Alternative Methods of Compliance

    (c) 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 (ECO). 
Operators shall submit their requests through an appropriate FAA 
Principal Maintenance Inspector, who may add comments and then send 
it to the Manager, ECO.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the ECO.

Ferry Flights

    (d) 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 airplane to a location where 
the requirements of this AD can be accomplished.

    Note 3: The subject of this AD is addressed in Civil Aviation 
Authority (CAA) Airworthiness Directives 003-12-99 and 004-01-2000.


    Issued in Burlington, Massachusetts, on July 16, 2001.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 01-18554 Filed 7-25-01; 8:45 am]
BILLING CODE 4910-13-P