[Federal Register Volume 68, Number 207 (Monday, October 27, 2003)]
[Proposed Rules]
[Pages 61158-61161]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-26980]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NE-40-AD]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211-524 Series 
Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

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) RB211-524 series turbofan engines, with 
certain part number (P/N) intermediate pressure (IP) compressor stage 5 
discs installed. This proposed AD would establish new reduced IP 
compressor stage 5 disc cyclic limits. This action would also require 
removing from service, affected discs that already exceed the new 
reduced cyclic limit, and removing other affected discs before 
exceeding their cyclic limits, using a drawdown schedule. This action 
would also allow optional inspections at each shop visit or a one-time 
on-wing eddy current inspection (ECI) to extend the disc life beyond 
the lives specified. This proposed AD is prompted by the discovery of 
cracks in the cooling air hole areas of the disc front spacer arm. We 
are proposing this AD to prevent IP compressor stage 5 disc failure, 
which could result in uncontained engine failure and possible damage to 
the airplane.

DATES: We must receive any comments on this proposed AD by December 26, 
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. 
2002-NE-40-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.

    [sbull] By fax: (781) 238-7055.
    [sbull] By e-mail: [email protected].
    You can get the service information identified in this proposed AD 
from Rolls-Royce plc, P.O. Box 31 Derby, DE248BJ, United Kingdom; 
telephone 011-44-1332-242424; fax 011-44-1332-249936.
    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. 2002-NE-40-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 verbally, 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.faa.gov/language and 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 United Kingdom (U.K.), recently notified the FAA that 
an unsafe condition may exist on certain RR model RB211-524 series 
turbofan engines. The CAA reports that cracks were found, during 
overhaul, in the cooling air hole areas of the disc front spacer arm. 
The engine manufacturer has performed a reassessment of the safe cyclic 
limits of certain IP compressor stage 5 discs. The cyclic limits of 
these discs are reduced based on that reassessment. This condition, if 
not corrected, could result in uncontained engine failure and possible 
damage to the airplane.

Relevant Service Information

    We have reviewed and approved the technical contents of mandatory 
service bulletin (MSB) RB.211-72-D428, Revision 3, dated June 30, 2003, 
that specifies a drawdown schedule for removing from service affected 
IP compressor stage 5 discs, using new Time Limits Manual (TLM) cyclic 
limits. The MSB also describes procedures for optional inspections at 
each shop visit to extend the disc life beyond the lives specified. The 
CAA has classified this service bulletin as mandatory and issued AD 
006-04-2002 in order to ensure the airworthiness of these RR plc 
turbofan engines in the U.K. We have also reviewed and approved the 
technical contents of Service Bulletin (SB) RB.211-72-E148, dated March 
13, 2003 and SB RB.211-72-E150, dated April 17, 2003 that provide an 
optional on-wing ECI of the affected discs, to extend the disc life 
beyond the lives specified.

Differences Between This Proposed AD and the Manufacturer's Service 
Information

    The compliance time is added, to remove or inspect discs not later 
than 30 days after the effective date of this AD.

[[Page 61159]]

FAA's Determination and Requirements of the Proposed AD

    These engine models, 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. Under 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:

[sbull] Establishing new reduced IP compressor stage 5 disc cyclic 
limits.
[sbull] Removing from service affected discs that already exceed the 
new reduced cyclic limit.
[sbull] Removing other affected discs before exceeding their cyclic 
limits, using a drawdown schedule.
[sbull] Allowing optional inspections at each shop visit or a one-time 
on-wing ECI to extend the disc life beyond the specified life.

    The proposed AD would require you to use the service information 
described previously to perform these actions.

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 about 939 RR RB211-524 series turbofan engines of the 
affected design in the worldwide fleet. We estimate that 35 engines 
installed on airplanes of U.S. registry would be affected by this 
proposed AD. We also estimate that it would take about 8 work hours per 
engine to perform an inspection, and 300 work hours per engine to 
replace an IP compressor stage 5 disc. The average labor rate is $65 
per work hour. Required parts would cost about $49,000 per engine. 
Based on these figures, we estimate the total cost of the proposed AD 
to U.S. operators to be $2,397,500.

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. 2002-NE-40-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. 2002-NE-40-AD.

Comments Due Date

    (a) The FAA must receive comments on this airworthiness 
directive (AD) action by December 26, 2003.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to the Rolls-Royce plc RB211-524 series 
turbofan engines listed in the following Table 1, with intermediate 
pressure (IP) compressor stage 5 disc part numbers (P/Ns) listed in 
Table 2 of this AD, installed.

                                        Table 1.--Engine Models Affected
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-524B-02               -524B-B-02             -524B3-02              -524B4-02              -524B4-D-02
-524B2-19              -524B2-B-19            -524C2-19              -524C2-B-19            -524D4-19
-524D4-B-19            -524D4X-19             524D4X-B-19            -524D4-39              -524D4-B-39
-524G2-19              -524G2-T-19            -524G3-19              -524G3-T-19            -524H2-19
-524H2-T-19            -524H-36               -524H-T-36
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    These engines are installed on, but not limited to, Boeing 747, 
767, and Lockheed L-1011 airplanes.

                               Table 2.--IP Compressor Stage 5 Disc P/Ns Affected
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LK60130                LK65932                LK69021                LK81269                LK83282
LK83283                UL12290                UL15743                UL15744                UL15745
UL19132                UL20785                UL20832                UL23291                UL25011
UL36821                UL36977                UL36978                UL36979                UL36980
UL36981                UL36982                UL36983                UL37078                UL37079
UL37080                UL37081                UL37082                UL37083                UL37084
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[[Page 61160]]

Unsafe Condition

    (d) This AD is prompted by the discovery of cracks in the 
cooling air hole areas of the IP compressor stage 5 disc front 
spacer arm. We are issuing this AD to prevent IP compressor stage 5 
disc failure, which could result in uncontained engine failure and 
possible 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.

Cycle Limits

    (f) Change the service cyclic limits for the IP compressor stage 
5 discs installed in the engine models listed in the following Table 
3, within 30 days after the effective date of this AD.

  Table 3.--Cyclic Life Limits Without Qualifying Magnetic Particle Inspection (MPI) or Eddy Current Inspection
                                                      (ECI)
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                                                                       Engine models
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                                            -524G2, G2-T,
       Date of reduced life limit         G3, G3-T, H2, H2- -524D4, D4-B, D4-   -524B2, B2-B,    -524B-02, B-B-
                                           T, H-36,H-T-36    B-39, D4X, D4X-      C2, C2-B       02, B3-02, B4-
                                                                B, D4-39                           02, B4-D-02
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November 30, 2002.......................    \1\ 13,500 CIS        16,150 CIS        16,000 CIS        16,200 CIS
April 1, 2003...........................        13,500 CIS        13,500 CIS        13,500 CIS        14,000 CIS
December 1, 2003........................        12,000 CIS        13,500 CIS        13,500 CIS        14,000 CIS
December 1, 2004........................        11,000 CIS        13,500 CIS        12,000 CIS        12,000 CIS
December 1, 2005........................        11,000 CIS        12,000 CIS        12,000 CIS        12,000 CIS
December 1, 2008........................         7,830 CIS         8,700 CIS        12,000 CIS       12,000 CIS
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\1\ Cycles-in-service.

Optional Inspections

    (g) Before December 1, 2008, optional inspections are allowed at 
each shop visit or a one-time on-wing ECI is allowed to extend the 
disc life. Guidance for these inspections is provided in paragraphs 
(h) or (i) of this AD.

Optional Inspections at Shop Visit

    (h) Perform optional inspections at shop visit, as follows:
    (1) Remove corrosion protection from IP stage 5 disc. 
Information on corrosion protection removal can be found in the 
Engine Manual.
    (2) Visual-inspect and binocular-inspect the IP stage 5 disc for 
corrosion pitting at the cooling air holes and defender holes in the 
disc front spacer arm. Follow paragraph 3.C. of the Accomplishment 
Instructions of RR MSB No. RB.211-72-D428, Revision 3, dated June 
30, 2003.
    (3) Discs with corrosion pitting in excess of limits must be 
removed from service. Information on disc corrosion pitting limits 
can be found in the Engine Manual.
    (4) If the disc is free from corrosion pitting, MPI entire disc. 
Inspection on MPI can be found in the Engine Manual.
    (5) If the disc has corrosion pitting within limits, ECI all 
disc cooling air holes, defender holes, and inner and outer faces. 
Follow paragraph 3.D. of the Accomplishment Instructions of RR MSB 
No. RB.211-72-D428, Revision 3, dated June 30, 2003. Information on 
corrosion pitting limits can be found in the Engine Manual.
    (6) If the disc passes ECI and no cracks are found, MPI entire 
disc. Information on MPI can be found in the Engine Manual.
    (7) If the disc passes MPI and no cracks are found, re-apply 
corrosion protection to disc, and return the disc to service in 
accordance with the cyclic limits allowed by paragraph (l) of this 
AD. Information on MPI limits can be found in the Engine Manual. 
Information on re-applying corrosion protection can be found in RR 
Repair FRS5900.

Optional One-Time On-Wing EC Inspection

    (i) For RB211-524B2/C2 and RB211-524B4/D4 engine models, a one-
time on-wing ECI of the IP compressor stage 5 disc may be performed 
in lieu of a shop visit inspection. Follow RR paragraph 3.A. through 
3.F. of Accomplishment Instructions of SB No. RB.211-72-E148, and RR 
SB No. RB.211-72-E150, respectively, to do the ECI. If the disc 
passes the ECI and no cracks are found, an extension is allowed as 
specified in paragraph (l) of this AD.

Definition of Shop Visit

    (k) For the purposes of this AD, a shop visit is defined as the 
separation of an engine major case flange. This definition excludes 
shop visits when only field maintenance type activities are 
performed in lieu of performing them on-wing. (i.e., for purposes 
such as to perform an on-wing inspection of a tail engine 
installation on an L1011 airplane).

Cyclic Life Extension

    (l) Discs that pass an optional inspection may remain in service 
after that inspection for the additional cycles listed in the 
following Table 4, or until the next inspection, or until the 
December 1, 2008 life limit in Table 3 is reached, whichever occurs 
first.

    Note 1: Discs may remain in service for additional periods if 
repeat optional inspections are conducted and associated AD criteria 
are met.


                                                             Table 4.--Cyclic Life Extension
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                                                                                      Engine models
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                                  -524G2, G2-T, G3, G3-T, H2,    -524D4, D4-B, D4-B-39, D4X,                                -524B-02, B-B-02, B3-02, B4-
                                       H2-T, H-36, H-T-36               D4X-B, D4-39             -524B2, B2-B, C2, C2-B             0-2, B4-D-02
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Extension after passing MPI....  1,600 cycles.................  2,000 cycles................  2,000 cycles................  2,000 cycles.
Extension after passing In-Shop  3,800 cycles.................  4,500 cycles................  4,500 cycles................  4,500 cycles.
 ECI.
Extension after passing On-Wing  1,000 cycles.................  1,200 cycles................  1,200 cycles................  1,200 cycles.
 ECI.
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[[Page 61161]]

Discs That Have Been Intermixed Between Engine Models

    (m) Information on intermixing discs between engine models can 
be found in the RR Time Limits Manual, 05-00-01.

Alternative Methods of Compliance

    (n) The Manager, Engine Certification Office, has the authority 
to approve alternative methods of compliance for this AD if 
requested using the procedures found in 14 CFR 39.19.

Material Incorporated by Reference

    (o) You must use the service information specified in the 
following Table 5 to perform the inspections and drawdown required 
by this AD. Approval of incorporation by reference from the Office 
of the Federal Register is pending.

                                      Table 5.--Incorporation by Reference
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     Service bulletin No.                  Page                      Revision                     Date
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Mandatory Service Bulletin No.  All.......................  3........................  June 30, 2003.
 RB.211-72-D428.
 Total Pages: 27
Service Bulletin No. RB.211-72- All.......................  Original.................  March 13, 2003.
 E148.
 Total Pages: 83
Service Bulletin No. RB.211-72- All.......................  1........................  June 4, 2003.
 E150.
 Total pages: 72
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Related Information

    (p) CAA airworthiness directive 006-04-2002, dated April 2002, 
also addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on October 21, 2003.
Robert J. Ganley,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 03-26980 Filed 10-24-03; 8:45 am]
BILLING CODE 4910-13-P