[Federal Register Volume 68, Number 34 (Thursday, February 20, 2003)]
[Proposed Rules]
[Pages 8157-8161]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-4057]


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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: Supplemental notice of proposed rulemaking (NPRM); reopening of 
comment period.

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SUMMARY: This notice revises an earlier proposed airworthiness 
directive (AD), applicable to Rolls-Royce (RR) plc RB211-535E4-37, 
RB211-535E4-B-37, and RB211-535E4-B-75 series turbofan engines. That 
proposal would have required initial and repetitive ultrasonic 
inspections of low pressure compressor (LPC) fan blade roots for 
cracks, and relubrication of LPC fan blades before reinstallation. That 
proposal was prompted by the discovery of cracks on LPC fan blade roots 
during an engine overhaul. This action revises the proposed rule by 
introducing an alternative technique to ultrasonically inspect 
installed fan blades on-wing using a surface wave ultrasonic probe. 
This action also adds the application of

[[Page 8158]]

Metco 58 blade root coating as an optional terminating action. The 
actions specified by this 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 April 21, 2003.

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-13-AD, 12 New England 
Executive Park, Burlington, MA 01803-5299. Comments may be inspected at 
this location, by appointment, between 8:00 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. 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.
    The service information referenced in the proposed rule may be 
obtained from Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; 
telephone: 011-44-1332-242-424; fax: 011-44-1332-249-936. This 
information may be examined, by appointment, 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

    A proposal to amend part 39 of the Federal Aviation Regulations (14 
CFR part 39) to add an airworthiness directive (AD), applicable to RR 
plc RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 series 
turbofan engines, was published as an NPRM in the Federal Register on 
August 9, 2001 (66 FR 41808). That NPRM would have required initial and 
repetitive ultrasonic inspections of LPC fan blade roots for cracks, 
and relubrication of LPC fan blades before reinstallation. That NPRM 
was prompted by the discovery of cracks on LPC fan blade roots during 
an engine overhaul. That condition, if not corrected, could result in 
uncontained multiple fan blade failure, and damage to the airplane.
    The FAA received the following comments on the initial NPRM. The 
latest revision to RR Mandatory Service Bulletin (MSB) RB.211-72-C879, 
Revision 3, dated October 9, 2002, addresses those comments.
    Two commenters request the incorporation of Metco 58 blade root 
coating as a terminating action to the AD inspection requirements.
    The FAA agrees. The Civil Aviation Authority (CAA), which is the 
airworthiness authority for the United Kingdom (UK), has notified the 
FAA that incorporation of Metco 58 blade root coating using RR Service 
Bulletin (SB) RB.211-72-C946, dated August 6, 2002, is considered a 
terminating action to the inspections. The FAA has examined the 
information provided by RR and the CAA and agrees with the conclusions. 
Incorporation of Metco 58 blade root coating has been added to the 
proposed AD as a terminating action.
    One commenter requests a draw down inspection schedule for engines 
that have not previously had repetitive inspections. The commenter 
states that due to the age of its fleet, it would be difficult to do 
repetitive inspections in accordance with the AD.
    The FAA does not agree with the request due to the potential safety 
hazard associated with a possible multiple fan blade release. However, 
RR MSB RB211-72-C879, Revision 3, dated October 9, 2002, allows an 
alternative on-wing ultrasonic inspection method.
    Since the above comments expand the scope of the originally 
proposed rule, the FAA has determined that it is necessary to reopen 
the comment period to provide additional opportunity for public 
comment.

Manufacturer's Service Information

    RR has issued MSB RB.211-72-C879, Revision 3, dated October 9, 
2002, that specifies ultrasonic inspection of high cyclic life blades 
on-wing with either the LPC fan blades in place or removed from the 
LPC. The CAA classified this service bulletin as mandatory and issued 
AD 002-01-2000 in order to ensure the airworthiness of these RR engines 
in the UK.

Bilateral Agreement Information

    These engines are manufactured in the United Kingdom (UK), and are 
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.

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 LPC fan blade roots on-wing and during 
overhaul, and relubrication, according to accumulated life cycles.

Economic Analysis

    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.

[[Page 8159]]

registry would be affected by this proposed AD. It will take 
approximately 7.0 work hours per engine to conduct an on-wing initial 
inspection, and 2 hours per engine to do 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 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 Analysis

    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 with the 
part numbers (P/N's) 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
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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   ............
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    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 (g) 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:
    (a) If you have a full set of fan blades, modified using RR SB 
RB.211-72-C946, dated August 6, 2002, that can be identified by a blue 
triangle etched on the blade airfoil suction surface close to the 
leading edge tip of each blade, no further action is required.
    (b) On RB211-535E4 engines, operated to Flight Profile A, 
ultrasonically inspect, and if required, relubricate using the 
following Table 2:

                                     Table 2.--RB211-535E4 Flight Profile A
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                                  Initial                                                               Repeat
                                 inspection                                                           inspection
        Engine location            within         Type action              In accordance with           within
                                   (CSN)                                                                (CSN)
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(1) On-wing...................      17,350.  (i) Root Probe,        RB.211-72-C879 Revision 3,            1,400.
                                              inspect and            3.A.(1) through 3.A.(7), dated
                                              relubricate, OR.       October 9, 2002.
                                ...........  (ii) Wave Probe......  RB.211-72-C879 Revision 3,            1,150.
                                                                     3.B.(1) through 3.B.(7), dated
                                                                     October 9, 2002.
(2) In Shop...................      17,350.  Root Probe, inspect    RB.211-72-C879 Revision 3,            1,400.
                                              and relubricate.       3.C.(1) through 3.C.(4), dated
                                                                     October 9, 2002.
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[[Page 8160]]

    (c) On RB211-535E4 engines, operated to Flight Profile B, 
ultrasonically inspect, and if required, relubricate using the 
following Table 3:

                                     Table 3.--RB211-535E4 Flight Profile B
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                                                                                                        Repeat
                                  Initial                                                             inspection
        Engine location          inspection       Type action              In accordance with           within
                                ithin (CSN)                                                             (CSN)
----------------------------------------------------------------------------------------------------------------
(1) On-wing...................      12,350.  (i) Root Probe,        RB.211-72-C879 Revision 3,              850.
                                              inspect and            3.A.(1) through 3.A.(7), dated
                                              relubricate, OR.       October 9, 2002.
                                ...........  (ii) Wave Probe......  RB.211-72-C879 Revision 3,              700.
                                                                     3.B.(1) through 3.B.(7), dated
                                                                     October 9, 2002.
(2) In Shop...................      12,350.  Root Probe, inspect    RB.211-72-C879 Revision 3,              850.
                                              and relubricate.       3.C.(1) through 3.C.(4), dated
                                                                     October 9, 2002.
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    (d) On RB211-535E4 engines, operated to combined Flight Profile A 
and B, ultrasonically inspect, and if required, relubricate using the 
following Table 4:

                                  Table 4.--RB211-535E4 Flight Profile A and B
----------------------------------------------------------------------------------------------------------------
                               Initial inspection                                             Repeat inspection
       Engine location            within (CSN)         Type action       In accordance with      within (CSN)
----------------------------------------------------------------------------------------------------------------
(1) On-wing.................  65% hard life (To    (i) Root Probe,      RB.211-72-C879       As current flight
                               calculate,           inspect and          Revision 3,          profile.
                               Compliance Section   relubricate, OR.     3.A.(1) through
                               1.C.(4)).                                 see 3.A.(7), dated
                                                                         October 9, 2002.
                                                   (ii) Wave Probe....  RB.211-72-C879       As current flight
                                                                         Revision 3,          profile.
                                                                         3.B.(1) through
                                                                         3.B.(7), dated
                                                                         October 9, 2002.
(2) In Shop.................  65% hard life (To    Root Probe, inspect  RB.211-72-C879       As current flight
                               calculate,           and relubricate.     Revision 3,          profile.
                               Compliance Section                        3.C.(1) through
                               1.C.(4)).                                 see 3.C.(4), dated
                                                                         October 9, 2002.
----------------------------------------------------------------------------------------------------------------


    Note 2: Fan blades that have been operated within RB211-535E4 
Flight Profile A and B will have final life as defined in the Time 
Limits Manual. See References Section 1.G.(3), of MSB RB.211-72-
C879, Revision 3, dated October 9, 2002.

    (e) On RB211-535E4-B engines, ultrasonically inspect, and if 
required, relubricate using the following Table 5:

                                             Table 5.--RB211-535E4-B
----------------------------------------------------------------------------------------------------------------
                               Initial inspection                                            Repeat within (CSN)
       Engine location            within (CSN)         Type action       In accordance with       inspection
----------------------------------------------------------------------------------------------------------------
(1) On-wing.................  17,000.............  (i) Root Probe,      RB.211-72-C879       1,200.
                                                    inspect and          Revision 3,
                                                    relubricate OR.      3.A.(1) through
                                                                         3.A.(7), dated
                                                                         October 9, 2002.
                                                   (ii) Wave Probe....  RB.211-72-C879       1,000.
                                                                         Revision 3,
                                                                         3.B.(1) through
                                                                         3.B.(7), dated
                                                                         October 9, 2002.
(2) In Shop.................  17,000.............  Root Probe, inspect  RB.211-72-C879       1,200
                                                    and relubricate.     inspect and
                                                                         Revision 3,
                                                                         3.C.(1) through
                                                                         3.C.(4), dated
                                                                         October 9, 2002.
----------------------------------------------------------------------------------------------------------------

Optional Terminating Action

    (f) Application of Metco 58 blade root coating using RR SB RB.211-
72-C946, Revision 1, dated August 6, 2002, constitutes terminating 
action to the repetitive inspection requirements specified in 
paragraphs (b), (c), (d), and (e) of this AD.

Alternative Methods of Compliance

    (g) 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 must submit their request through an appropriate FAA 
Principal Maintenance Inspector, who may add comments and then send it 
to the Manager, ECO.

    Note 3: 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

    (h) Special flight permits may be issued in accordance with 
Sec. Sec.  21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the aircraft to a location

[[Page 8161]]

where the requirements of this AD can be done.


    Note 4: The subject of this AD is addressed in CAA airworthiness 
directive AD 002-01-2000, dated October 9, 2002.



    Issued in Burlington, Massachusetts, on February 10, 2003.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 03-4057 Filed 2-19-03; 8:45 am]
BILLING CODE 4910-13-U