[Federal Register Volume 68, Number 146 (Wednesday, July 30, 2003)]
[Proposed Rules]
[Pages 44672-44675]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-19310]


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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

AGENCY: Federal Aviation Administration (FAA), DOT.

[[Page 44673]]


ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new 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. This 
proposed AD would allow disc assemblies not modified by a certain RR 
service bulletin to reach their full life only after the disc 
assemblies are modified with anti-corrosion protection. This proposed 
AD is prompted by the manufacturer's reassessment of the corrosion risk 
on HPC stage 3 disc assemblies that have not yet been modified with 
sufficient application of anti-corrosion protection. The actions 
specified in this proposed AD are intended to prevent corrosion-induced 
uncontained disc failure, resulting in damage to the airplane.

DATES: We must receive any comments on this proposed AD by September 
29, 2003.

ADDRESSES: Use one of the following addresses to submit comments on 
this proposed AD:
    [sbull] 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.
    [sbull] By fax: (781) 238-7055.
    [sbull] By e-mail: [email protected]
    You may 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 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 submit 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 through a nonwritten communication, 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.
    We are reviewing the writing style we currently use in regulatory 
documents. We are interested in your comments on whether the style of 
this document is clear, and your suggestions to improve the clarity of 
our communications that affect you. You may get more information about 
plain language at http://www.plainlanguage.gov.

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

    The Civil Aviation Authority (CAA), which is the airworthiness 
authority for the U.K., recently 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 numerous disc assemblies have 
been found at overhaul inspection having corrosion-induced pitting. RR 
has 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 anti-corrosion protection, and RR has 
lowered the disc lives accordingly in the Time Limits Manuals.

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, dated February 29, 1980, which describe procedures 
for reworking of HP compressor stage 3 rotor disc assemblies by 
machining, and application of anti-corrosion 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.

FAA's Determination and Requirements of the Proposed AD

    These Rolls-Royce plc RR RB211-22B series, RB211-524B, -524C2, -
524D4, -524G2, -524G3, and -524H series, and RB211-535C and -535E 
series turbofan engines are manufactured in the U.K., 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 us informed of the 
situation described above. We have examined the CAA's findings, 
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. Therefore, we are proposing this AD, 
which would require the following for affected HP compressor disc 
assemblies:
    [sbull] Removing affected disc assemblies from service.
    [sbull] Re-machining, inspecting, and applying anti-corrosion 
protection.
    [sbull] Re-marking, and returning disc assemblies into service.
    The proposed AD would require that these actions be done per the 
service information described previously.

Changes to 14 CFR Part 39--Effect on the Proposed AD

    On July 10, 2002, we published a new version of 14 CFR part 39 (67 
FR 47997, July 22, 2002), which governs the FAA's AD system. This 
regulation now includes material that relates to altered products, 
special flight permits, and alternative methods of compliance. This 
material previously was included in each individual AD. Since this 
material is included in 14 CFR part 39, we will not include it in 
future AD actions.

Costs of Compliance

    There are approximately 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 1,000 engines installed

[[Page 44674]]

on airplanes of U.S. registry would be affected by this proposed AD. We 
also estimate that it would take approximately 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 approximately $38,000 per 
engine. Based on these figures, the total cost of the proposed AD to 
U.S. operators is estimated to be $40,015,000.

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 adding the following new 
airworthiness directive:

Rolls-Royce plc: Docket No. 2003-NE-12-AD.

Comments Due Date

    (a) The FAA must receive comments on this airworthiness 
directive (AD) action by September 29, 2003.

Affected ADs

    (b) None.

Applicability

    (c) This AD is applicable to 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. 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 was prompted by the manufacturer's reassessment of 
the corrosion risk on HPC stage 3 disc assemblies that have not been 
modified sufficiently with application of anti-corrosion 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:

                                 Table 1.--Affected HPC Stage 3 Disc Assemblies
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                                                                                               Rework band for
                                                     Rework band for                              cycle life
                                                        cycle life        Rework band for    accumulated on P/Ns
                                                   accumulated on disc       cycle life       LK76036, UL11706,
                                                     assemblies P/Ns    accumulated on disc   UL15358, UL22577,
                   Engine model                    LK46210 and LK58278      assembly P/N         UL22578, and
                                                     (pre RR service     LK67634 (pre RR SB      UL24738 disc
                                                    bulletin (SB) No.   No. RB.211-72-5420)   assemblies (pre RR
                                                     RB.211-72-5420)                          SB No. RB.211-72-
                                                                                                    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            4,000-6,000          7,000-9,000        11,500-14,000
 SB 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 1992, remove disc 
and rework as specified in paragraph (g)(2) of this AD, within five 
years from the effective date of this AD, but not to exceed the 
upper cyclic limit of Table 1 of this AD before rework. Discs 
reworked may not exceed the published cyclic limit in the 
manufacturer's Time Limits Manual.
    (2) For discs that entered into service in 1992 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 published cyclic life in the manufacturer's Time Limits 
Manual.
    (3) For disc assemblies that when new, were modified with an 
application of anti-corrosion 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.

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:

[[Page 44675]]

    (1) For disc assemblies that when new, were modified with an 
application of anti-corrosion 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 in 
accordance with 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 in accordance with 
Paragraph 3B. 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) Alternative methods of compliance must be requested in 
accordance with 14 CFR part 39.19, and must be approved by the 
Manager, Engine Certification Office, FAA.

Material Incorporated by Reference

    (i) The rework must be done in accordance with the following 
Rolls Royce service bulletins:

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             Document No.                              Pages                                Revision                                Date
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RB.211-72-5420.......................  1....................................  4...................................  February 29, 1980.
                                       2....................................  3...................................  January 12, 1980.
                                       3-8..................................  4...................................  February 29, 1980.
                                       9-10.................................  Original............................  April 20, 1979.
 Total pages: 8
 
RB.211-72-9434.......................  All..................................  4...................................  January 12, 2000.
 Total pages: 20
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    Approval of incorporation by reference from the Office of the 
Federal Register is pending.

Related Information

    (j) The subject of this AD is addressed in Civil Aviation 
Authority airworthiness directive 004-01-94.

    Issued in Burlington, Massachusetts, on July 24, 2003.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 03-19310 Filed 7-29-03; 8:45 am]
BILLING CODE 4910-13-P