[Federal Register Volume 68, Number 167 (Thursday, August 28, 2003)]
[Rules and Regulations]
[Pages 51682-51685]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-21740]


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

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NE-16-AD; Amendment 39-13290; AD 2003-17-15]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc. RB211-535 Turbofan 
Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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

SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD)

[[Page 51683]]

that applies to Rolls-Royce plc. (RR) models RB211-535E4-37, RB211-
535E4-B-37, and RB211-535E4-B-75 turbofan engines, with certain part 
number (P/N) low pressure (LP) turbine stage 2 discs installed. That AD 
currently requires establishing new reduced LP turbine stage 2 disc 
cyclic limits. That AD also requires removing from service affected 
discs that already exceed the new reduced cyclic limits, and removing 
other affected discs before exceeding their cyclic limits, using a 
drawdown schedule. This amendment requires changing certain cyclic 
limits, changing the effective date of certain disc cyclic lives, and 
would allow intermix of Flight Plan A and Flight Plan B intermix 
calculations. This amendment is prompted by a reassessment of the 
thermal and stress data from recent operational experience and comments 
received from operators on the current AD. We are issuing this AD to 
prevent LP turbine stage 2 disc failure, which could result in 
uncontained engine failure and possible loss of the airplane.

DATES: Effective October 2, 2003. The incorporation by reference of 
certain publications listed in the regulations is approved by the 
Director of the Federal Register as of October 2, 2003.

ADDRESSES: The service information referenced in this AD may be 
obtained from Rolls-Royce plc, P.O. Box 31 Derby, DE24 8BJ, United 
Kingdom; telephone 011-44-1332-242424; fax 011-44-1332-249936. This 
information may be examined, by appointment, at the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
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: 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: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) by superseding AD 2002-23-08, 
Amendment 39-12952 (67 FR 71094, November 29, 2002), which applies to 
RR models RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 
turbofan engines, with certain P/N low pressure LP turbine stage 2 
discs installed was published in the Federal Register on March 25, 2003 
(68 FR 14355). That action proposed to require establishing new reduced 
LP turbine stage 2 disc cyclic limits. That AD also requires removing 
from service affected discs that already exceed the new reduced cyclic 
limits, and removing other affected discs before exceeding their cyclic 
limits, using a drawdown schedule in accordance with mandatory service 
bulletin (MSB) RB.211-72-D181, Revision 3, dated August 16, 2002.

Comments

    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. No comments were received on the 
proposal or the FAA's determination of the cost to the public. The FAA 
has determined that air safety and the public interest require the 
adoption of the rule as proposed.

Regulatory Analysis

    This final 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 final rule.
    For the reasons discussed above, I certify that this action (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) 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 final evaluation has been prepared for this action 
and it 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, 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

0
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]

0
2. Section 39.13 is amended by removing Amendment 39-12952 (67 FR 
71094, November 29, 2002) and by adding a new airworthiness directive, 
Amendment 39-13290, to read as follows:

2003-17-15 Rolls-Royce plc: Amendment 39-13290. Docket No. 2002-NE-
16-AD. Supersedes AD 2002-23-08, Amendment 39-12952.

    Applicability: This airworthiness directive (AD) is applicable 
to Rolls-Royce plc. (RR) models RB211-535E4-37, RB211-535E4-B-37, 
and RB211-535E4-B-75 turbofan engines, with low pressure (LP) 
turbine stage 2 discs part numbers (P/Ns) UL11508, UL17141, UL18947, 
UL29029, and UL37352 installed. These engines are installed on, but 
not limited to, Boeing 757 and Tupolev Tu204 airplanes.

    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 (h) 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: You are responsible for having the actions required 
by this AD performed within the compliance times specified unless 
the actions have already been done.
    To prevent LP turbine stage 2 disc failure, which could result 
in an uncontained engine failure and possible loss of the airplane, 
do the following:

Cycle Limits

    (a) Change the RR Time Limits Manual cyclic limits for LP 
turbine stage 2 discs as specified in the following Table 1:

[[Page 51684]]



            Table 1.--Time Limits Manual (TLM) Cyclic Limits
------------------------------------------------------------------------
                                 Life limits for
                               RB211-535E4 engines     Life limits for
                               operating in flight   RB211-535E4 engines
 Date of reduced life limit    plan A, and  RB211-   operating in flight
                                 535E4-B engines           plan B
 
------------------------------------------------------------------------
(1) December 31, 2001.......  23,200 cycles-since-  19,700 CSN.
                               new (CSN).
(2) December 31, 2002.......  22,500 CSN..........  19,000 CSN.
(3) December 31, 2003.......  21,500 CSN..........  18,000 CSN.
(4) December 31, 2004.......  20,000 CSN..........  16,500 CSN.
(5) December 31, 2005.......  18,100 CSN..........  14,600 CSN.
------------------------------------------------------------------------

RB211-535E4 Engines Operating to Flight Plan A, and RB211-535E4-B 
Engines

    (b) For RB211-535E4 engines operating to flight plan A, and 
RB211-535E4-B engines, remove the LP turbine stage 2 disc from 
service using the CSN and Action times listed in the following Table 
2.

    Table 2.--Drawdown Schedule for RB211-535E4 Engines Operating to Flight Plan A, and RB211-535E4-B Engines
----------------------------------------------------------------------------------------------------------------
                                                                                  Replace disc
                                                               -------------------------------------------------
               Disc CSN                         Action            Without eddy current      With eddy current
                                                                       inspection               inspection
----------------------------------------------------------------------------------------------------------------
(1) 20,001 CSN or greater on December  Remove disc from         Within 21 days after     Within 3,000 cycles-in-
 31, 2000.                              service or perform       the effective date of    service (CIS) after
                                        optional on-wing eddy    this AD.                 the inspection, but do
                                        current disc                                      not exceed the new
                                        inspection within 21                              reduced life limit
                                        days after the                                    specified in Table 1
                                        effective date of this                            of this AD
                                        AD.
(2) 18,100 to 20,000 CSN on December   Remove disc from         Before accumulating      Within 3,000 CIS after
 31, 2000.                              service or perform       21,000 CSN or within     the inspection, but do
                                        optional on-wing eddy    21 days after the        not exceed the new
                                        current disc             effective date of this   reduced life limit
                                        inspection.              AD, whichever occurs     specified in Table 1
                                                                 first.                   of this AD.
(3) Fewer than 18,100 CSN on December  Remove disc from         Before accumulating      Within 3,000 CIS after
 31, 2000 and greater than 20,000 CSN   service or perform       20,500 CSN or by         the inspection, but do
 on December 31, 2004.                  optional on-wing eddy    December 31, 2004,       not exceed the new
                                        current disc             whichever occurs first.  reduced life limit
                                        inspection.                                       specified in Table 1
                                                                                          of this AD.
(4) Fewer than 18,100 CSN on December  Remove disc from         Before accumulating      Within 3,000 CIS after
 31, 2000 and greater than 18,100 CSN   service or perform on-   20,000 CSN or by         the inspection, but do
 on December 31, 2005.                  wing eddy current disc   December 31, 2005,       not exceed the new
                                        inspection.              whichever occurs first.  reduced life limit
                                                                                          specified in Table 1
                                                                                          of this AD.
(5) Fewer than 18,100 CSN on December  No action required.....  N/A....................  N/A.
 31, 2000 and fewer than 18,100 CSN
 on December 31, 2005.
----------------------------------------------------------------------------------------------------------------

    (c) Information regarding disc removal may be found in 3.A. of 
the Accomplishment Instructions of Mandatory Service Bulletin (MSB) 
RB.211-72-D181, Revision 3, dated August 16, 2002.
    (d) The optional on-wing eddy current disc inspection noted in 
Table 2 of this AD must be performed in accordance with 3.C.(1) 
through 3.C.(6) of the Accomplishment Instructions of MSB RB.211-72-
D181, Revision 3, dated August 16, 2002.

RB211-535E4 Engines Operating to Flight Plan B

    (e) For RB211-535E4 engines operating to flight plan B, remove 
the LP turbine stage 2 disc from service using the CSN and Action 
times listed in the following Table 3.

                 Table 3.--Drawdown Schedule for RB211-535E4 Engines Operating to Flight Plan B
----------------------------------------------------------------------------------------------------------------
                                                                                  Replace disc
                                                               -------------------------------------------------
               Disc CSN                         Action            Without eddy current      With eddy current
                                                                       inspection               inspection
----------------------------------------------------------------------------------------------------------------
(1) 16,501 CSN or greater on December  Remove disc from         Within 21 days after     Within 3,000 CIS after
 31, 2000.                              service or perform       the effective date of    the inspection, but do
                                        optional on-wing eddy    this AD.                 not exceed the new
                                        current disc                                      reduced life limit
                                        inspection within 21                              specified in Table 1
                                        days after the                                    of this AD.
                                        effective date of this
                                        AD.
(2) Greater than 14,600 CSN on         Remove disc from         Before accumulating      Within 3,000 CIS after
 December 31, 2000.                     service or perform       17,500 CSN or within     the inspection, but do
                                        optional on-wing eddy    21 days after the        not exceed the new
                                        current disc             effective date of this   reduced life limit
                                        inspection.              AD, whichever occurs     specified in Table 1
                                                                 first.                   of this AD.

[[Page 51685]]

 
(3) Fewer than 14,600 CSN on December  Remove disc from         Before accumulating      Within 3,000 CIS after
 31, 2000 and greater than 16,500 CSN   service or perform       17,000 CSN or by         the inspection, but do
 on December 31, 2004.                  optional on-wing eddy    December 31, 2004,       not exceed the new
                                        current disc             whichever occurs first.  reduced life limit
                                        inspection.                                       specified in Table 1
                                                                                          this AD.
(4) Fewer than 14,600 CSN on December  Remove disc from         Before accumulating      Within 3,000 CIS after
 31, 2000 and greater than 14,600 CSN   service or perform on-   16,500 CSN or by         the inspection, but do
 on December 31, 2005.                  wing eddy current disc   December 31, 2005,       not exceed the new
                                        inspection.              whichever occurs first.  reduced life limit
                                                                                          specified in this AD.
(5) Fewer than 14,600 CSN on December  No action required.....  N/A....................  N/A.
 31, 2000 and fewer than 14,600 CSN
 on December 31, 2005.
----------------------------------------------------------------------------------------------------------------

    (f) Information regarding disc removal may be found in 3.A. of 
the Accomplishment Instructions of MSB RB.211-72-D181, Revision 3, 
dated August 16, 2002.
    (g) The optional on-wing eddy current disc inspection must be 
performed in accordance with 3.C.(1) through 3.C.(6) of the 
Accomplishment Instructions of MSB RB.211-72-D181, Revision 3, dated 
August 16, 2002.

    Note 2: For engines moving from Flight Plans A to B or B to A, 
the intermix calculations found in MSB RB.211-72-D181, Revision 3, 
dated August 16, 2002, may be applied to the life limits.

Alternative Methods of Compliance

    (h) 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

    (i) 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 airplane to a location where 
the requirements of this AD can be done.

Documents That Have Been Incorporated By Reference

    (j) The actions must be done in accordance with Rolls-Royce plc 
mandatory service bulletin RB.211-72-D181, Revision 3, dated August 
16, 2002. 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 plc, P.O. 
Box 31 Derby, DE24 8BJ, United Kingdom; telephone 011-44-1332-
242424; fax 011-44-1332-249936. Copies may be inspected at the FAA, 
New England Region, Office of the Regional 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.

    Note 4: The subject of this AD is addressed in CAA airworthiness 
directive 006-05-2001, dated August 3, 2001.

Effective Date

    (k) This amendment becomes effective on October 2, 2003.

    Issued in Burlington, Massachusetts, on August 20, 2003.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 03-21740 Filed 8-27-03; 8:45 am]
BILLING CODE 4910-13-P