[Federal Register Volume 66, Number 154 (Thursday, August 9, 2001)]
[Proposed Rules]
[Pages 41808-41810]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 01-19937]


 ========================================================================
 Proposed Rules
                                                 Federal Register
 ________________________________________________________________________
 
 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. 154 / Thursday, August 9, 2001 / 
Proposed Rules  

[[Page 41808]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2000-NE-13-AD]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce RB211 Series Turbofan 
Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: The Federal Aviation Administration proposes to adopt a new 
airworthiness directive (AD) that is applicable to Rolls-Royce (RR) plc 
RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 series turbofan 
engines. This proposal would require initial and repetitive ultrasonic 
inspections of low pressure compressor (LPC) fan blade roots for 
cracks. This proposal would also require relubrication of LPC fan 
blades before reinstallation. This proposal is prompted by the 
discovery of cracks on LPC fan blade roots during an engine overhaul. 
The actions specified by the proposed AD are intended to detect cracks 
in LPC fan blade roots, which if not detected, could lead to 
uncontained multiple fan blade failure, and damage to the airplane.

DATES: Comments must be received by October 9, 2001.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
Counsel, Attention: Rules Docket No. 2001-NE-13-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. Information regarding this proposed AD 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-13-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-13-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 Rolls-Royce plc (RR) RB211-535E4-37, 
RB211-535E4-B-37, and RB211-535E4-B-75 series turbofan engines. The CAA 
advises that during a recent overhaul inspection of a set of LPC fan 
blades having high cyclic lives, small cracks in the blade roots, on 
the concave root flanks, were discovered. Cracking of the blade roots, 
if not corrected, could lead to the propagation of blade cracks, 
resulting in uncontained multiple fan blade failure, and damage to the 
airplane.

Manufacturer's Service Information

    Rolls-Royce plc has issued service bulletin (SB) RB.211-72-C879, 
dated January 11, 2000, that specifies ultrasonic inspection of high 
cyclic life blades either on-wing or at shop visit. The CAA classified 
this service bulletin as mandatory and issued AD 002-01-2000 in order 
to assure the airworthiness of these Rolls-Royce plc engines in the UK.

Bilateral Airworthiness Agreement

    This engine series is manufactured in the UK, and is type 
certificated for operation in the United States under the provisions of 
Sec. 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.

FAA's Determination of an Unsafe Condition and Proposed Actions

    Since an unsafe condition has been identified that is likely to 
exist or develop on other RR RB211-535E4 series turbofan engines of the 
same type design, that are used on Boeing 757 airplanes registered in 
the United States, the proposed AD would require initial and repetitive 
ultrasonic inspections of fan blade roots on-wing and during overhaul, 
and relubrication, according to accumulated life cycles.

[[Page 41809]]

Economic Impact

    There are approximately 1,021 engines of the affected design in the 
worldwide fleet. The FAA estimates that 545 engines installed on 
aircraft of U.S. registry would be affected by this proposed AD. It 
will take approximately 7.0 work hours per engine to accomplish an on-
wing initial inspection, and 2 hours per engine to accomplish an 
overhaul initial inspection of the proposed actions. The average labor 
rate is $60 per work hour. Since the actions are inspections, there are 
no required parts costs. Based on these figures, the FAA estimates the 
total cost impact for on-wing initial inspections only, of the proposed 
AD on U.S. operators, to be $228,900, and for overhaul initial 
inspections only, to be $65,400.

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-13-AD.

    Applicability: This airworthiness directive (AD) is applicable to 
Rolls-Royce (RR) plc RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-
B-75 series turbofan engines with low pressure compressor (LPC) fan 
blades, part numbers (P/N) listed in the following Table 1 of this AD. 
These engines are installed on but not limited to Boeing 757 and 
Tupolev Tu204 series airplanes. Table 1 follows:

                Table 1.--Applicable LPC Fan Blade P/N's.
UL16135.....................    UL16171    UL16182    UL19643    UL20044
UL20132.....................    UL20616    UL21345    UL22286    UL23122
UL24525.....................    UL24528    UL24530    UL24532    UL24534
UL27992.....................    UL28601    UL28602    UL29511    UL29556
UL30817.....................    UL30819    UL30933    UL30935    UL33707
UL33709.....................    UL36992    UL37090    UL37272    UL37274
UL37276.....................    UL37278    UL38029    UL38032
 


    Note 1: This 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 detect cracks in LPC fan blade roots, which if not detected, 
could lead to uncontained multiple fan blade failure, and damage to the 
airplane, do the following using:

Initial Inspection and Relubrication

    (a) Ultrasonically inspect and relubricate all LPC fan blades using 
the cycles-since-new from one of the following appropriate Flight 
Profile tables, specified in paragraphs (a)(8), (a)(9), or (a)(10) this 
AD as follows:
    (1) If not already done, remove LPC fan blades.
    (2) Remove dry film lubricant from LPC fan blade roots.
    (3) Calibrate ultrasonic inspection probe and flaw detector in 
accordance with Appendix 1, paragraphs 2.A. through 2.I. of Rolls-Royce 
(RR) Service Bulletin (SB) RB.211-72-C879, dated January 11, 2000.
    (4) Ultrasonically inspect LPC fan blades in accordance with 
Appendix 1, paragraphs 3.A. through 3.D. of RR SB RB.211-72-C879, dated 
January 11, 2000.
    (5) Replace any LPC fan blades that do not meet the acceptance 
criteria in Appendix 1, paragraphs 4.A. through 4.B. of RR SB RB.211-
72-C879, dated January 11, 2000.
    (6) Replace any missing chocking pads.
    (7) Relubricate LPC fan blade roots with dry film lubricant before 
installing LPC fan blades.
    (8) For engines that have operated only to flight profile ``A,'' 
use the following Table 2:

  Table 2.--Engines Having Operated Only to Flight Profile ``A'' Before
       Inspection, as Defined in the Aircraft Maintenance Manual.
------------------------------------------------------------------------
Number of cycles-since-new (CSN) on the
       Effective Date of This AD:        Inspect and Relubricate Within:
------------------------------------------------------------------------
(i) 17,000 or fewer CSN................  350 cycles-in-service (CIS) of
                                          accumulating 17,000 CSN.

[[Page 41810]]

 
(ii) 17,001 to 18,000 CSN..............  350 CIS after the effective
                                          date of this AD.
(iii) 18,001 to 20,000 CSN.............  150 CIS after the effective
                                          date of this AD.
(iv) In excess of 20,000 CSN...........  50 CIS after the effective date
                                          of this AD.
------------------------------------------------------------------------

    (9) For engines that have operated only to flight profile ``B,'' 
use the following Table 3:

  Table 3.--Engines Having Operated Only to Flight Profile ``B'' Before
       Inspection, as Defined in the Aircraft Maintenance Manual.
------------------------------------------------------------------------
 Number of (CSN) on the Effective Date
              of This AD:                Inspect and Relubricate Within:
------------------------------------------------------------------------
(i) 12,000 or fewer CSN................  350 CIS of accumulating 13,000
                                          CSN.
(ii) 12,001 to 13,000 CSN..............  350 CIS after the effective
                                          date of this AD.
(iii) 13,001 to 15,000 CSN.............  150 CIS after the effective
                                          date of this AD.
(iv) In excess of 15,000 CSN...........  50 CIS after the effective date
                                          of this AD.
------------------------------------------------------------------------

    (10) For engines that have operated to flight profile ``A'' and 
``B,'' use the following Table 2:

   Table 4.--Engines Having Operated to Both Flight Profiles ``A'' and
 ``B'' Before Inspection, as Defined in the Aircraft Maintenance Manual.
------------------------------------------------------------------------
   Final Life (FL) Calculation on the
       Effective Date of This AD:        Inspect and Relubricate Within:
------------------------------------------------------------------------
(i) Less than 65% FL...................  350 CIS of accumulating 65% FL.
(ii) 65% FL to 65% FL plus 1,000 CIS...  350 CIS after the effective
                                          date of this AD.
(iii) 65% FL plus 1,000 CIS to 65% FL    150 CIS after the effective
 plus 3,000 CIS.                          date of this AD.
(iv) More than 65% FL plus 3,000 CIS...  50 CIS after the effective date
                                          of this AD.
------------------------------------------------------------------------

Repetitive Inspections and Relubrication

    (b) Thereafter, inspect for cracks and relubricate all LPC fan 
blades in accordance with paragraphs (a)(1) through (a)(7) of this AD, 
within 1,000 CIS of the last inspection and lubrication.

Alternative Method 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 request 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 airworthiness directive, 
if any, may be obtained from the ECO.

Special Flight Permits

    (d) Special flight permits may be issued in accordance with 
Secs. 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 
requirements of this AD can be accomplished.

    Issued in Burlington, Massachusetts, on July 12, 2001.
Mark C. Fulmer,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 01-19937 Filed 8-8-01; 8:45 am]
BILLING CODE 4910-13-P