[Federal Register Volume 69, Number 96 (Tuesday, May 18, 2004)]
[Proposed Rules]
[Pages 28094-28098]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-11200]


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

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2004-NE-19-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).

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

SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) for Rolls-Royce plc (RR) RB211-524 series turbofan 
engines. That AD currently requires initial and repetitive borescope 
inspections of the head section and meterpanel assembly of the 
combustion liner, and replacement, if necessary, with serviceable 
parts. In addition, that AD allows an optional installation of a front 
combustion liner with a strengthened head section as a terminating 
action to the inspection requirements. This proposed AD would require 
initial and repetitive borescope inspections of the head section and 
meterpanel assembly of the combustion liner, and replacement, if 
necessary, with serviceable parts, reduction of the inspection 
intervals of certain RB211-524 engine models that have not been 
repaired to RR Field Repair Scheme FRS5367/B, and a mandatory 
terminating action to be completed by a certain date. This proposed AD 
results from five events that are directly attributed to combustor head 
break-up and meterpanel failure which were found at overhaul 
inspection. At least one of these events resulted in a combustion case 
burn-through. We are proposing this AD to prevent engine combustion 
liner deterioration, which can result in combustion liner breakup, case 
burn-through, and engine fire.

DATES: We must receive any comments on this proposed AD by July 19, 
2004.

[[Page 28095]]


ADDRESSES: Use one of the following addresses to submit comments on 
this proposed AD:
     By mail: Federal Aviation Administration (FAA), New 
England Region, Office of the Regional Counsel, Attention: Rules Docket 
No. 2004-NE-19-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
     By fax: (781) 238-7055.
     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, DE24 8BJ, United Kingdom; 
telephone: 011-44-1332-242424; fax: 011-44-1332-249936.
    You may examine the AD docket, by appointment, 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. 2004-NE-19-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

    On March 26, 1997, the FAA issued AD 97-07-04, Amendment 39-9978 
(62 FR 16475, April 7, 1997). That AD requires initial and repetitive 
borescope inspections of the head section and meterpanel assembly of 
the combustion liner, and replacement, if necessary, with serviceable 
parts. In addition, that AD allows an optional installation of a front 
combustion liner with a strengthened head section as a terminating 
action to the inspection requirements.

Actions After AD 97-07-04 Was Issued

    After AD 97-07-04 was issued, the Civil Aviation Authority (CAA), 
which is the airworthiness authority for the United Kingdom (U.K.), 
notified the FAA that an unsafe condition may exist on RR RB211-524 
series turbofan engines. The CAA advises that in August 2002, an RB211-
524B engine suffered a combustion case burn-through as a result of 
combustor head break-up. The combustor head had been previously 
inspected within the inspection interval specified in RR Service 
Bulletin (SB) No. RB.211-72-B482, Revision 8, dated November 15, 2001, 
only 228 cycles before the event. Subsequent to the original AD, RR has 
issued several revisions to SB No. RB.211-72-B482 to expand the 
applicability and clarify or revise the inspection requirements. In 
2003, RR issued Alert Service Bulletin (ASB) No. RB.211-72-AB482, 
Revision 9, dated July 28, 2003, to reduce the inspection interval for 
RB211-524B-02, -524B2, -524B3, and -524B4 engines that have not been 
repaired to RR Field Repair Scheme FRS5367/B. This condition, if not 
corrected, could result in engine combustion liner deterioration, which 
can result in combustion liner breakup, case burn-through, and engine 
fire.

Relevant Service Information

    We have reviewed and approved the technical contents of the 
following RR SBs:
     RR ASB No. RB.211-72-AB482, Revision 9, dated July 28, 
2003, that describes the initial inspection procedures for the 
combustion liner head section and the meterpanel cracking. This ASB 
also describes the compliance intervals to do the initial and 
repetitive inspections.
     RR SB No. RB.211-72-9670, dated August 27, 1993, that 
describes the procedures to incorporate the improved combustion liner 
head with C263 material, and to incorporate local thickened diffuser 
walls around the struts for engine models -524B-02, -524B2, -524B3, -
524B4, -524C2 and -524D4.
     RR SB No. RB.211-72-9764, Revision 3, dated January 16, 
1998, that describes the procedures to incorporate the improved 
combustion liner with strengthened head and improved heat shields for 
engine models -524G and -524H.
    The CAA classified ASB No. RB.211-72-AB482, Revision 9, dated July 
28, 2003, as mandatory and issued AD G-2003-0011 (previously 005-07-
95), dated October 1, 2003, in order to ensure the airworthiness of 
these RR engines in the U.K.

Bilateral Agreement Information

    This engine model is manufactured in the U.K. 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. In keeping with this 
bilateral airworthiness agreement, the CAA has kept the FAA informed of 
the situation described above. We have 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 and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design. Therefore, we are proposing this AD, which 
would require the following:
     Initial and repetitive borescope inspections of the head 
section and meterpanel assembly of the combustion liner, and 
replacement, if necessary, with serviceable parts;
     Reduction of the inspection intervals of certain RB211-524 
engine models that have not been repaired to RR Field Repair Scheme 
FRS5367/B; and,
     A mandatory terminating action to the repetitive 
inspections to be completed within 10,000 CSN or no later than December 
31, 2012.
    The proposed AD would require that you do these actions using the 
service information described previously.

[[Page 28096]]

Costs of Compliance

    There are about 537 RB211-524 series turbofan engines of the 
affected design in the worldwide fleet. We estimate that 18 engines 
installed on airplanes of U.S. registry would be affected by this 
proposed AD. We also estimate that it would take approximately 2.0 work 
hours per engine to perform the proposed actions, and that the average 
labor rate is $65 per work hour. Required parts would cost about 
$228,389 per engine. Based on these figures, we estimate the total cost 
of the proposed AD to U.S. operators to be $4,113,351.

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. 2004-NE-19-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 removing Amendment 39-9978 (62 FR 
16475, April 7, 1997) and by adding a new airworthiness directive, to 
read as follows:

Rolls-Royce plc: Docket No. 2004-NE-19-AD. Supersedes AD 97-07-04, 
Amendment 39-9978.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by July 19, 
2004.

Affected ADs

    (b) This AD supersedes AD 97-07-04, Amendment 39-9978.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) engine models RB211-
524B-02, -524B2, -524B3, -524B4, -524C2, -524D4 series engines 
incorporating RR Service Bulletin (SB) No. RB.211-72-7221 or RR SB 
No. RB.211-72-7998 with front combustion liner assembly, part number 
(P/N) UL16885, UL26916, UL27107, UL28972 or UL28974 installed but 
not incorporating RR SB No. RB.211-72-9670 or RR SB No. RB.211-72-
9764, and engine models RB211-524G and -524H series engines with 
front combustion liner assembly P/N UL27659, UL23992, or UL22988 but 
not incorporating RR SB No. RB.211-72-9764. These engines are 
installed on, but not limited to, Boeing 747 and Lockheed L1011 
series airplanes.

Unsafe Condition

    (d) This AD results from five events that are directly 
attributed to combustor head break-up and meterpanel failure which 
were found at overhaul inspection. At least one of these events 
resulted in a combustion case burn-through. The actions specified in 
this AD are intended to prevent engine combustion liner 
deterioration, which can result in combustion liner breakup, case 
burn-through, and engine fire.

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. Engine inspections previously made 
to Rolls-Royce plc (RR) Service Bulletin RB.211-72-B482, Revision 8, 
can be credited for counting cycles since last inspection.

Inspections of Combustion Liner Head Sections--Not Previously Repaired

    (f) Borescope-inspect combustion liner head sections that have 
not been previously repaired. Use paragraphs 3.A.(1) through 3.A.(5) 
of the Accomplishment Instructions of RR Alert Service Bulletin 
(ASB) No. RB.211-72-AB482, Revision 9, dated July 28, 2003, and the 
compliance thresholds in Table 1 of this AD.

                            Table 1.--Combustor Head Section--Not Previously Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series                 (cycles-since-new       (cycles-since-last-       (cycles-in-service
                                                (CSN))             inspection (CSLI))             (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 1,400 to 1,600    Within 200 CSLI........  Within 100 CIS after
 524H.                                  CSN.                                              effective date of this
                                                                                          AD.
(2) RB211-524B-02, -524B2, -524B3,     Within 3,000 to 3,200    Within 200 CSLI........  Within 200 CIS after
 and -524B4.                            CSN.                                              the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Combustion Head Sections--Previously Repaired Using RR 
Field Repair Scheme FRS5367/B

    (g) Borescope-inspect combustion liner head sections previously 
repaired using RR Field Repair Scheme FRS5367/B. Use paragraphs 
3.A.(1) through 3.A.(5) of the Accomplishment Instructions of RR ASB 
No. RB.211-72-AB482, Revision 9, dated July 28, 2003, and the 
compliance thresholds in Table 2 of this AD.

          Table 2.--Combustor Head Section--Previously Repaired Using RR Field Repair Scheme FRS5367/B
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series                 (cycles-since-last      (cycles-since-last-       (cycles-in-service
                                            repair (CSLR))         inspection (CSLI))             (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 1,800 to 2,200    Within 400 CSLI........  Within 200 CIS after
 524H.                                  CSLR.                                             the effective date of
                                                                                          this AD.

[[Page 28097]]

 
(2) RB211-524B-02, -524B2, -524B3,     Within 3,000 to 3,200    Within 400 CSLI........  Within 200 CIS after
 and -524B4.                            CSLR.                                             the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Combustion Head Sections That Have Been Repaired But Did 
Not Use RR Field Repair Scheme FRS5367/B

    (h) Borescope-inspect combustion liner head sections that have 
been repaired using a method other than RR Field Repair Scheme 
FRS5367/B. Use paragraph 3.A.(1) through 3.A.(5) of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AB482, Revision 
9, dated July 28, 2003, and the compliance thresholds in Table 3 of 
this AD.

          Table 3.--Combustor Head Section--Repaired, But Did Not Use RR Field Repair Scheme FRS5367/B
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series               cycles (cycles-since-    cycles (cycles-since-      (cycles-in-service
                                         last repair (CSLR))    last-inspection (CSLI))           (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 500 to 700 CSLR.  Within 200 CSLI........  Within 100 CIS after
 524H.                                                                                    the efffective date of
                                                                                          this AD.
(2) RB211-524B-02, -524B2, -524B3,     Within 2,000 to 2,200    Within 200 CSLI........  Within 200 CIS after
 and -524B4.                            CSLR.                                             the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------


    Note 1: For an installed front combustion liner that is subject 
to RR ASB No. RB.211-72-AB482, Revision 9, dated July 28, 2003: If 
the operator can confirm with the relevant overhaul base or repair 
vendor that the nicrobraze repair RR Field Repair Scheme FRS5367 has 
been applied to all 18 struts, then this is equivalent to compliance 
with RR Field Repair Scheme FRS5367/B.


    Note 2: Head sections repaired by replacement of all 18 struts 
using RR Field Repair Scheme FRS6548 are considered as equivalent to 
fitting a new head section for inspection purposes.

Inspections of Meterpanel Assemblies--Not Repaired

    (i) Borescope-inspect meterpanel assemblies, incorporating 
Service Bulletin (SB) No. RB.211-72-7998, that have not been 
previously repaired. Use paragraph 3.B.(1) through 3.B.(7) of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AB482, Revision 
9, dated July 28, 2003, and the compliance thresholds in Table 4 of 
this AD.

                                   Table 4.--Meterpanel Assembly--Not Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series               cycles-since-new (CSN)   cycles (cycles-since-      (cycles-in-service
                                                                last-inspection (CSLI))           (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524D4, -524G, and -524H....  Within 1,000 to 1,200    Within 400 CSLI........  Within 50 CIS after the
                                        CSN.                                              effective date of this
                                                                                          AD.
(2) RB211-524D4, -524G, and -524H      Within 1,800 to 2,000    Within 400 CSLI........  Within 50 CIS after the
 that have not used RB211-524H          CSN.                                              effective date of this
 ratings at any time.                                                                     AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Meterpanel Assemblies--Repaired

    (j) Borescope-inspect meterpanel assemblies, incorporating 
Service Bulletin (SB) No. RB.211-72-7998, that have been previously 
repaired. Use paragraph 3.B.(1) through 3.B.(7) of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AB482, Revision 
9, dated July 28, 2003, and the compliance thresholds in Table 5 of 
this AD.

                                     Table 5.--Meterpanel Assembly--Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series               cycles (cycles-since-    cycles (cycles-since-      (cycles-in-service
                                         last repair (CSLR))    last-inspection (CSLI))           (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524D4, -524G, and -524H....  Within 500 to 700 CSLR.  Within 400 CSLI........  Within 50 CIS after the
                                                                                          effective date of this
                                                                                          AD.
----------------------------------------------------------------------------------------------------------------


    Note 3: There is no requirement to inspect meter panels for 
combustors to a pre-RR SB No. RB.211-72-7998 standard.

Reject Parts

    (k) Replace parts that exceed the acceptance criteria. 
Information about the acceptance criteria can be found in the 
Aircraft Maintenance Manual, 72-00-00, Inspection/Check.

Mandatory Terminating Action

    (l) Replace any front combustion liner assembly that has a P/N 
listed in paragraph (c) of this AD at the next shop visit or within 
10,000 CSN but no later than December 31, 2012.
    (m) Replacement of the front combustion liner assembly with a 
front combustion liner assembly that incorporates the modifications 
in RR SB No. RB.211-72-9670 or RR SB No. RB.211-72-9764 in the 
RB211-524B02, -524B2, -B3, -B4, -C2 and D4 engines

[[Page 28098]]

constitutes terminating action to the repetitive inspections in 
paragraphs (f), (g), (h), (i), and (j), of this AD.
    (n) Replacement of the front combustion liner assembly with a 
front combustion liner assembly that incorporates the modifications 
in RR SB No. RB.211-72-9764 in the RB211-524G and -524H engines 
constitutes terminating action to the repetitive inspections in 
paragraphs (f), (g), (h), (i), and (j) of this AD.

Definition of Shop Visit

    (o) For the purpose of this AD, a shop visit is defined as any 
time that the 04 module is removed for refurbishment or overhaul.

Alternative Methods of Compliance

    (p) 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

    (q) You must use Rolls-Royce plc (RR) Alert Service Bulletin No. 
RB.211-72-AB482, Revision 9, dated July 28, 2003; RR Service 
Bulletin (SB) No. RB.211-71-9670, dated August 27, 1993; and RR SB 
No. RB.211-72-9764, Revision 3, dated January 16, 1998 to do the 
inspections and replacements required by this AD. Approval of 
incorporation by reference from the Office of the Federal Register 
is pending.

Related Information

    (r) Civil Aviation Authority airworthiness directive AD G-2003-
0011 (previously 005-07-95), dated October 1, 2003, also addresses 
the subject of this AD. Aircraft Maintenance Manual 72-00-00 also 
addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on May 12, 2004.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-11200 Filed 5-17-04; 8:45 am]
BILLING CODE 4910-13-P