[Federal Register Volume 69, Number 215 (Monday, November 8, 2004)]
[Rules and Regulations]
[Pages 64653-64656]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-24817]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2004-19559; Directorate Identifier 2004-NE-03-AD; 
Amendment 39-13858; AD 2004-23-03]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 Trent 700 Series 
Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
Rolls-Royce plc (RR) RB211 Trent 700 series turbofan engines. This AD 
requires initial and repetitive borescope inspections of the high 
pressure-and-intermediate pressure (HP-IP) turbine internal and 
external oil vent tubes for coking and carbon buildup, and cleaning or 
replacing the vent tubes if necessary. This AD results from a report of 
a RB211 Trent 700 series engine experiencing a disk shaft separation, 
overspeed of the IP turbine rotor, and multiple blade release of IP 
turbine blades. Preliminary findings suggest these events resulted from 
an internal oil fire in the HP-IP turbine oil vent tubes due to coking 
and carbon buildup. This fire led to a second fire in the internal air 
cavity below the IP turbine disk drive shaft. We are issuing this AD to 
prevent internal oil fires due to coking and carbon buildup, that could 
cause uncontained engine failure and damage to the airplane.

DATES: Effective November 23, 2004. The Director of the Federal 
Register approved the incorporation by reference of certain 
publications listed in the regulations as of November 23, 2004.
    We must receive any comments on this AD by January 7, 2005.

ADDRESSES: Use one of the following addresses to comment on this AD.
     DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
     Government-wide rulemaking Web site: Go to http://www.regulations.gov

[[Page 64654]]

and follow the instructions for sending your comments electronically.
     Mail: Docket Management Facility; U.S. Department of 
Transportation, 400 Seventh Street, SW., Nassif Building, Room PL-401, 
Washington, DC 20590-001.
     Fax: (202) 493-2251.
     Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street, SW., Washington, DC, between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    Contact Rolls-Royce plc, PO Box 31, Derby, England; telephone: 011-
44-1332-249428; fax: 011-44-1332-249223 for the service information 
referenced in this AD. You may examine the comments on this AD in the 
AD docket on the Internet at http://dms.dot.gov.

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: As a member of the National Transportation 
Safety Board (NTSB) investigation team, we are investigating an 
incident event and possible unsafe condition on RR RB211 Trent 700 
series engines. The Civil Aviation Authority (CAA), which is the 
airworthiness authority for the United Kingdom (UK) is helping us 
investigate. A report was received of a RB211 Trent 700 series engine 
experiencing a disk shaft separation, overspeed of the IP turbine 
rotor, and multiple blade release of IP turbine blades. Preliminary 
findings suggest these events resulted from an internal oil fire in the 
HP-IP turbine oil vent tubes due to coking and carbon buildup. This 
fire led to a second fire in the internal air cavity below the IP 
turbine disk drive shaft. Because the oil vent tubes on the event 
engine were destroyed, the partner engine on the same airplane was 
inspected. That inspection revealed heavy coking and carbon buildup, 
with partial blockage of the HP-IP turbine oil vent tubes. Both engines 
had the same on-wing life of 15,169 hours with 2,344 cycles-since-new. 
Both engines contained Mobil Jet Oil 291, which also is suspect and 
will be removed from the list of approved oils for these engines. The 
NTSB investigation is ongoing and a finding of probable cause has not 
yet been made. The fire, disk overspeed, and blade release appear to be 
the result of the coking and carbon buildup, evident in the sister 
engine and linked by cycles and oil use to the event engine.

Relevant Service Information

    We have reviewed and approved the technical contents of RR Alert 
Service Bulletin (ASB) No. RB.211-72-AE302, Revision 1, dated May 25, 
2004, that describes procedures for:
     Initial and repetitive borescope inspections for coking 
and carbon buildup in the HP-IP turbine oil vent tubes; and
     Cleaning the tubes if necessary, and removing the engine 
from service to clean or replace the tubes.

This ASB requires that all operators submit inspection data to the 
manufacturer. The CAA classified this ASB as mandatory and issued AD G-
2004-0016, dated June 20, 2004, in order to ensure the airworthiness of 
these RB211 Trent 700 series engines in the UK.

Bilateral Airworthiness Agreement

    These engine models are manufactured in the 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. Under this bilateral 
airworthiness agreement, the CAA kept the FAA informed of the situation 
described above. As a member of the NTSB investigation team, we have 
examined the findings with 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 This AD

    Although no airplanes that are registered in the United States use 
these engines, the possibility exists that the engines could be used on 
airplanes that are registered in the United States in the future. The 
unsafe condition described previously is likely to exist or develop on 
other RB211 Trent 700 series turbofan engines of the same type design. 
We are issuing this AD to prevent internal oil fires due to coking and 
carbon buildup, that could cause uncontained engine failure and damage 
to the airplane. This AD requires:
     Initial and repetitive borescope inspections of the HP-IP 
turbine oil vent tubes for coking and carbon buildup; and
     Cleaning or replacing the oil vent tubes if they fail the 
inspection.

FAA's Determination of the Effective Date

    Since there are currently no domestic operators of this engine 
model, notice and opportunity for public comment before issuing this AD 
are unnecessary. A situation exists that allows the immediate adoption 
of this regulation.

Interim Action

    These actions are interim actions and we may take further 
rulemaking actions in the future.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment; however, we invite you to submit any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. FAA-2004-19559; 
Directorate Identifier 2004-NE-03-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify it.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this AD. Using the search function of the DMS Web 
site, anyone can find and read the comments in any of our dockets, 
including the name of the individual who sent the comment (or signed 
the comment on behalf of an association, business, labor union, etc.). 
You may review the DOT's complete Privacy Act Statement in the Federal 
Register published on April 11, 2000 (65 FR 19477-78) or you may visit 
http://dms.dot.gov.

Examining the AD Docket

    You may examine the docket that contains the AD, any comments 
received, and any final disposition in person at the DMS Docket Offices 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The Docket Office (telephone (800) 647-5227) is located on 
the plaza level of the Department of Transportation Nassif Building at 
the street address stated in ADDRESSES. Comments will be available in 
the AD docket shortly after the DMS receives them.

Regulatory Findings

    We have determined that this AD will not have federalism 
implications under Executive Order 13132. This AD will 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

[[Page 64655]]

responsibilities among the various levels of government.
    For the reasons discussed above, I certify that the 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. 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.
    We prepared a summary of the costs to comply with this AD 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.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

0
Under the authority delegated to me by the Administrator, the FAA 
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. The Federal Aviation Administration (FAA) amends Sec.  39.13 by 
adding the following new airworthiness directive (AD):

2004-23-03 Rolls-Royce plc: Amendment 39-13858. Docket No. FAA-2004-
19559; Directorate Identifier 2004-NE-03-AD.

Effective Date

    (a) This AD becomes effective November 23, 2004.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) RB211 Trent 768-60, 
RB211 Trent 772-60, and RB211 Trent 772B-60 series turbofan engines. 
These engines are installed on, but not limited to, Airbus A330-243, 
-341, -342 and -343 series airplanes.

Unsafe Condition

    (d) This AD results from a report of a RB211 Trent 700 series 
engine experiencing a disk shaft separation, overspeed of the IP 
turbine rotor, and multiple blade release of IP turbine blades. 
Preliminary findings suggest these events resulted from an internal 
oil fire in the HP-IP turbine oil vent tubes due to coking and 
carbon buildup. This fire led to a second fire in the internal air 
cavity below the IP turbine disk drive shaft. We are issuing this AD 
to prevent internal oil fires due to coking and carbon buildup, that 
could cause uncontained engine failure and 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.

Initial Visual Inspection

    (f) Using the inspection schedule in Table 1 of this AD, perform 
an initial borescope inspection of the high pressure-and-
intermediate pressure (HP-IP) turbine internal and external oil vent 
tubes for coking and carbon buildup as follows:
    (1) Insert an 8 mm diameter flex borescope to see if it will 
pass along the full length of the vent tube into the bearing 
chamber.
    (2) If the vent tube prevents an 8 mm diameter flex borescope 
from passing along the full length of the tube into the bearing 
chamber, repeat the action using a 6mm flex borescope.
    (3) If the 6 mm diameter flex borescope passes through to the 
bearing chamber, continue using the engine in service, and perform 
the repetitive inspections in this AD at the required intervals.
    (4) If the vent tube prevents the 6 mm diameter flex borescope 
from passing along the full length of the tube into the bearing 
chamber, clean or replace the vent tube. Information on oil vent 
tube cleaning or replacement can be found in Rolls-Royce plc Alert 
Service Bulletin No. RB.211-72-AE302, Revision 1, dated May 25, 
2004.

                  Table 1.--Initial Inspection Schedule
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  If the engine or the 05 module:          Then initially inspect:
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Has reached 10,000 hours time-since- Within 3 months after the effective
 new (TSN) or reached 2,500 cycles-   date of this AD.
 since-new (CSN) on the effective
 date of this AD.
Has fewer than 10,000 hours TSN or   Within 3 months after reaching
 fewer than 2,500 CSN on the          10,000 hours TSN or 2,500 CSN,
 effective date of this AD.           whichever occurs first.
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Repetitive Visual Inspections

    (g) Using the inspection schedule in Table 2 of this AD and 
paragraphs (f)(1) through (f)(4) of this AD, perform repetitive 
borescope inspections of the HP-IP turbine internal and external oil 
vent tubes for coking and carbon buildup.

                Table 2.--Repetitive Inspection Schedule
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   If at the previous inspection,
 before any cleaning was performed:                 Then:
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(1) There was no coking and carbon   Reinspect within 6,400 hours time-
 buildup of a visible thickness; or   since-last-inspection (TSLI) or
 an 8 mm diameter flex borescope      within 1,600 cycles-since-last-
 could pass along the full length     inspection (CSLI), whichever
 of the internal vent tube into the   occurs first.
 bearing chamber.
(2) The coking or carbon buildup     Reinspect within 1,600 hours TSLI
 prevented an 8 mm diameter flex      or within 400 CSLI, whichever
 borescope from passing through the   occurs first.
 internal vent tube, but a 6 mm
 diameter flex borescope could pass
 along the full length of the
 internal vent tube into the
 bearing chamber.
(3) The coking or carbon buildup     Clean or replace the vent tubes
 prevented the 6 mm diameter flex     within 10 CSLI. Information on oil
 borescope from passing through the   vent tube cleaning or replacement
 full length of the internal vent     can be found in Rolls-Royce plc
 tube and into the bearing chamber.   Alert Service Bulletin No. RB.211-
                                      72-AE302, Revision 1, dated May
                                      25, 2004.
------------------------------------------------------------------------

Alternative Methods of Compliance

    (h) 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

    (i) None.

[[Page 64656]]

Related Information

    (j) CAA airworthiness directive No. G-2004-0016, dated June 20, 
2004, also addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on November 1, 2004.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-24817 Filed 11-5-04; 8:45 am]
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