[Federal Register Volume 69, Number 249 (Wednesday, December 29, 2004)]
[Rules and Regulations]
[Pages 77881-77885]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-28144]



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  Federal Register / Vol. 69, No. 249 / Wednesday, December 29, 2004 / 
Rules and Regulations  

[[Page 77881]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2000-NE-62-AD; Amendment 39-13915; AD 2004-26-03]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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

SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for Rolls-Royce plc (RR) models RB211-535E4-37, RB211-535E4-B-37, 
RB211-535C-37, RB211-535E4-B-75, and RB211-22B-02 turbofan engines. 
That AD currently requires inspecting certain high pressure (HP) 
turbine discs, manufactured between 1989 and 1999, for cracks in the 
rim cooling air holes, and, if necessary, replacing the disc's 
serviceable parts. This AD requires the same actions but at reduced 
compliance schedules and adds the RR model RB211-535E4-C turbofan 
engine to the applicability. This AD results from a report of cracks in 
a model RB211-524 HP turbine disc that had propagated further than 
expected. We are issuing this AD to prevent possible disc failure, 
which could result in an uncontained engine failure and damage to the 
airplane.

DATES: Effective January 13, 2005. The incorporation by reference of 
certain publications listed in the AD is approved by the Director of 
the Federal Register as of January 13, 2005.
    We must receive any comments on this AD by February 28, 2005. On 
December 24, 2001 (66 FR 57859, November 19, 2001), the Director of the 
Federal Register approved the incorporation by reference of certain 
other publications, as listed in the regulations.

ADDRESSES: Use one of the following addresses to comment on this AD:
     By mail: Federal Aviation Administration (FAA), New 
England Region, Office of the Regional Counsel, Attention: Rules Docket 
No. 2000-NE-62-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 referenced in this AD from 
Rolls-Royce plc, PO Box 31, Derby, England; telephone: 011 44 1332-
249428, fax: 011 44 1332-249223.
    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: On November 5, 2001, the FAA issued AD 2001-
23-02, Amendment 39-12499 (66 FR 57859, November 19, 2001), for RR 
models RB211-535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-
75, and RB211-22B-02 turbofan engines. That AD requires inspecting 
certain HP turbine discs, manufactured between 1989 and 1999, for 
cracks in the rim cooling air holes, and, if necessary, replacing the 
discs with serviceable parts. That AD resulted from reports of cracks 
in rim cooling air holes in two high-life RR Trent 800 discs. That 
condition, if not corrected, could result in possible disc failure, 
which could result in an uncontained engine failure and damage to the 
airplane.

Actions Since AD 2001-23-02 Was Issued

    Since that AD was issued, the Civil Aviation Authority (CAA), which 
is the airworthiness authority for the United Kingdom, recently 
notified the FAA that an unsafe condition may exist on Rolls-Royce plc 
models RB211-535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-
75, and RB211-535E4-C series turbofan engines. The CAA advises that 
cracks in a model RB211-524 HP turbine disc had propagated further than 
expected based on recent inspection findings and a re-assessment of the 
disc lifing model used to define the inspection thresholds in AD 2001-
23-02. This AD requires inspection of certain HP turbine discs, 
manufactured between 1989 and 1999, for cracks in the rim cooling air 
holes, and, if necessary, replacement with serviceable parts. We are 
reducing the inspection schedules required by AD 2001-23-02, for the 
high risk discs which includes all models except for model RB211-22B-02 
engines and adds the RB211-535E4-C due to manufacture at the same 
facility as the Trent 800 discs using the same tooling. Discs used in 
the model RB211-535 engines have a significantly higher HP turbine life 
than those used in the RB211-524 and operate in a harsher environment. 
Therefore, although the cracking of the rim cooling air holes will not 
affect the safe operation of the RB211-524 discs, the 535 discs are at 
higher risk of failure and the inspection intervals must be reduced. 
This AD retains the same inspection schedules, currently required for 
the model RB211-22B-02 engine, that were in AD 2001-23-02. The actions 
specified in this AD are intended to prevent possible disc failure, 
which could result in an uncontained engine failure and damage to the 
airplane.

Bilateral Airworthiness Agreement

    This engine model is manufactured in the United Kingdom and is 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 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 This AD

    The unsafe condition described previously is likely to exist or 
develop on other RR models RB211-535E4-37,

[[Page 77882]]

RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4-C, and 
RB211-22B-02 turbofan engines of the same type design. We are issuing 
this AD to prevent possible disc failure, which could result in an 
uncontained engine failure and damage to the airplane. This AD requires 
inspection of certain HP turbine discs, manufactured between 1989 and 
1999, for cracks in the rim cooling air holes, and, if necessary, 
replacement with serviceable parts.

FAA's Determination of the Effective Date

    Since an unsafe condition exists that requires the immediate 
adoption of this AD, we have found that notice and opportunity for 
public comment before issuing this AD are impracticable, and that good 
cause exists for making this amendment effective in less than 30 days.

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 make any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2000-NE-62-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 rule 
that might suggest a need to modify it. If a person contacts us 
verbally, and that contact relates to a substantive part of this 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 AD 
in light of those comments.

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.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, Section 106, describes the 
authority of the FAA Administrator. Subtitle VII, Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    We are issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701, ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
rulemaking action.

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 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. Include 
``AD Docket No. 2000-NE-62-AD'' in your request.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

0
Accordingly, under 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. The FAA amends Sec.  39.13 by removing Amendment 39-12499 (66 FR 
57859, November 19, 2001), and by adding a new airworthiness directive, 
Amendment 39-13915, to read as follows:

2004-26-03 Rolls-Royce plc: Amendment 39-13915. Docket No. 2000-NE-
62-AD. Supersedes AD 2001-23-02, Amendment 39-12499.

Effective Date

    (a) This airworthiness directive (AD) becomes effective January 
13, 2005.

Affected ADs

    (b) This AD supersedes AD 2001-23-02, Amendment 39-12499.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) models RB211-535E4-
37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4-
C, and RB211-22B-02 turbofan engines with turbine discs having part 
numbers and serial numbers listed in the following Tables 1, 3, and 
5 of this AD. These turbofan engines are installed on, but not 
limited to, Boeing 757, Tupolev Tu204, and Lockheed L-1011 series 
airplanes.

Unsafe Condition

    (d) This AD results from a report of cracks, in an RB211 HP 
turbine disc, that had propagated further than expected. We are 
issuing this AD to prevent possible disc failure, which could result 
in an 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.

Eddy Current Inspection for All Except Model RB211-22B-02

    (f) For all except model RB211-22B-02 engines, do the following:
    (1) Perform an eddy current inspection of the high pressure (HP) 
turbine discs listed in Table 1 of this AD, for cracks in the rim 
cooling air holes. Use paragraph 3. of the Accomplishment 
Instructions of RR Alert SB No. RB.211-72-AE651, dated November 22, 
2004, to perform the eddy current inspection.

[[Page 77883]]



                     Table 1--Affected HP Turbine Discs Using Compliance Schedule in Table 2
----------------------------------------------------------------------------------------------------------------
             Part No.                       Serial No.                 Part No.                Serial No.
----------------------------------------------------------------------------------------------------------------
LK80623...........................  CQDY6397                    UL27681..............  LDRCZ12893
LK80623...........................  CQDY6504                    UL27681..............  LDRCZ12985
UL27680...........................  CQDY6451                    UL27681..............  LDRCZ13044
UL27680...........................  CQDY6452                    UL27681..............  LDRCZ13047
UL27680...........................  CQDY6466                    UL27681..............  LQDY6803
UL27680...........................  CQDY6468                    UL27681..............  LQDY6814
UL27680...........................  CQDY6471                    UL27681..............  LQDY6847
UL27680...........................  CQDY6496                    UL27681..............  LQDY6868
UL27680...........................  CQDY6505                    UL27681..............  LQDY6875
UL27680...........................  CQDY6653                    UL27681..............  LQDY6892
UL27680...........................  CQDY6656                    UL27681..............  LQDY6898
UL27680...........................  CQDY6657                    UL27681..............  LQDY6904
UL27680...........................  CQDY6684                    UL27681..............  LQDY6909
UL27680...........................  CQDY6883                    UL27681..............  LQDY6910
UL27681...........................  CQDY6465                    UL27681..............  LQDY9133
UL27681...........................  LAQDY6002                   UL27681..............  LQDY9574
UL27681...........................  LAQDY6083                   UL27681..............  LQDY9579
UL27681...........................  LAQDY6087                   UL27681..............  LQDY9672
UL27681...........................  LDRCZ10247                  UL27681..............  LQDY9770
UL27681...........................  LDRCZ10277                  UL27681..............  LQDY9783
UL27681...........................  LDRCZ10318                  UL27681..............  LQDY9786
UL27681...........................  LDRCZ10335                  UL27681..............  LQDY9900
UL27681...........................  LDRCZ10430                  UL27681..............  LQDY9902
UL27681...........................  LDRCZ10531                  UL27681..............  LQDY9929
UL27681...........................  LDRCZ10750                  UL27681..............  LQDY9957
UL27681...........................  LDRCZ10899                  UL27681..............  LQDY9982
UL27681...........................  LDRCZ11616                  UL27681..............  LQDY9992
UL27681...........................  LDRCZ11720                  UL27681..............  WGQDY90005
UL27681...........................  LDRCZ11893                  .....................
----------------------------------------------------------------------------------------------------------------

    (2) Use the compliance schedule in Table 2 of this AD.

  Table 2.--Compliance Schedule for HP Turbine Discs Listed in Table 1
------------------------------------------------------------------------
   If disc cycles-since-new (CSN) on
          October 8, 2004 are:              Then eddy current inspect:
------------------------------------------------------------------------
(1) 12,750 CSN or more.................  Within 250 cycles-in-service
                                          (CIS) from October 8, 2004 or
                                          within 14,500 CSN, whichever
                                          occurs first.
(2) Fewer than 12,750 CSN but 10,500     Within 500 CIS from October 8,
 CSN or more.                             2004.
(3) Fewer than 10,500 CSN..............  Before 11,000 CSN or at next
                                          shop visit after the effective
                                          date of this AD, whichever
                                          occurs first.
------------------------------------------------------------------------

    (3) On discs that pass inspection, use paragraph 3. of the 
Accomplishment Instructions of RR Alert SB No. RB.211-72-AE651, 
dated November 22, 2004, to permanently etch NMSB 72-AE651 onto the 
disc, adjacent to the part number.
    (4) Perform an eddy current inspection of the HP turbine discs 
listed in Table 3 of this AD, for cracks in the rim cooling air 
holes. Use paragraph 3. of the Accomplishment Instructions of RR 
Alert SB No. RB.211-72-AE651, dated November 22, 2004, to perform 
the eddy current inspection.

Table 3.--Affected HP Turbine Discs Using Compliance Schedule in Table 4
------------------------------------------------------------------------
              Part No.                            Serial No.
------------------------------------------------------------------------
UL10323............................  CQDY6070 and higher.
UL27680............................  All.
UL27681............................  All.
LK80622............................  LQDY6316 and higher.
LK80623............................  CQDY5945 and higher.
UL28267............................  All.
------------------------------------------------------------------------

    (5) Use the compliance schedule in Table 4 of this AD.

  Table 4.--Compliance Schedule for HP Turbine Discs Listed in Table 3
------------------------------------------------------------------------
   If disc cycles-since-new (CSN) on
         January 29, 2001 are:              Then eddy current inspect:
------------------------------------------------------------------------
(1) Fewer than 13,700 CSN..............  Before reaching 14,500 CSN, or
                                          at the next shop visit after
                                          the effective date of this AD,
                                          whichever occurs first.
(2) 13,700 CSN or more.................  Before reaching one of the
                                          following, whichever occurs
                                          first after the effective date
                                          of this AD:
                                         (i) 15,300 CSN.
                                         (ii) Within 800 CIS since
                                          January 29, 2001.
                                         (iii) At next shop visit.
------------------------------------------------------------------------


[[Page 77884]]

    (6) For discs that pass inspection, use paragraph 3. of the 
Accomplishment Instructions of RR Alert SB No. RB.211-72-AE651, 
dated November 22, 2004, to permanently etch NMSB 72-AE651 onto the 
disc, adjacent to the part number.

Eddy Current Inspection for Model RB211-22B-02

    (g) For model RB211-22B-02 engines, do the following:
    (1) Perform an eddy current inspection of the HP turbine discs 
listed in Table 5 of this AD, for cracks in the rim cooling air 
holes. Use paragraph 3. of the Accomplishment Instructions of RR SB 
No. RB.211-72-C877, Revision 1, dated March 7, 2001, to perform the 
eddy current inspection.

Table 5.--Affected HP Turbine Discs in RR Model RB211-02 Series Turbofan
                                 Engines
------------------------------------------------------------------------
              Part No.                            Serial No.
------------------------------------------------------------------------
LK80622............................  LQDY6316 and higher.
LK80623............................  CQDY5945 and higher.
UL28267............................  All.
------------------------------------------------------------------------

    (2) Use the compliance schedule in Table 6 of this AD.

  Table 6.--Compliance Schedule for HP Turbine Discs Listed in Table 5
------------------------------------------------------------------------
   If disc cycles-since-new (CSN) on
         December 24, 2001 are:             Then eddy current inspect:
------------------------------------------------------------------------
(1) 11,000 CSN or fewer................  Before exceeding 11,000 CSN, or
                                          at the next shop visit after
                                          the effective date of this AD,
                                          whichever occurs first.
(2) More than 11,000 CSN...............  Within 300 CIS after December
                                          24, 2001.
------------------------------------------------------------------------

    (3) For discs that pass inspection, use paragraph 3. of the 
Accomplishment Instructions of RR SB No. RB.211-72-C877, Revision 1, 
dated March 7, 2001, to permanently etch NMSB 72-C877 onto the disc, 
adjacent to the part number.

Other Conditions for All Engines

    (h) Do not perform the actions of this AD to a disc until that 
disc has reached at least 1,500 CSN.
    (i) Engines with an affected HP turbine disc at shop visit on 
the effective date of this AD and with the HPT rotor still removed 
from the combustor outer case, must have the disc eddy current 
inspected before assembling the engine.
    (j) Engines with an affected HP turbine disc at shop visit on 
the effective date of this AD with the HPT rotor reinstalled in the 
combustor case need not have the disc eddy current inspected at this 
time.
    (k) HP turbine discs previously eddy current inspected at fewer 
than 1,500 CSN must be inspected again using this AD.
    (l) Replace cracked HP turbine discs with a serviceable disc.

Definition

    (m) For the purpose of this AD, next shop visit is defined as 
the first shop visit opportunity when the HPT rotor is removed from 
the combustion case.
    (n) For the purpose of this AD, a serviceable part is one with 
cyclic life remaining and either not listed in any of the preceding 
tables or one listed in a preceding table, but previously eddy 
current inspected and permanently etch marked with the Service 
Bulletin (SB) number NMSB 72-AE651 or NMSB 72-C877 on the disc.

Previous Credit

    (o) Previous credit is allowed for the actions in this AD for HP 
turbine discs with 1,500 CSN or more that were eddy current 
inspected using applicable RR SB No. RB.211-72-C817, Revision 2, 
dated March 7, 2001, RR TSD 594-J, Overhaul Processes Manual, Task 
70-00-00-200-223, or RR SB No. RB.211-72-C877, Revision 1, dated 
March 7, 2001.

Reporting Requirements

    (p) For all except model RB211-22B-02 engines, report findings 
of the inspection using paragraph 3.E. of the Accomplishment 
Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004. The 
Office of Management and Budget (OMB) has approved the reporting 
requirements specified in paragraph 3.E. of the Accomplishment 
Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004, and 
assigned OMB control number 2120-0056.
    (q) For model RB211-22B-02 engines, report findings of the 
inspection using paragraph 3.E. of the Accomplishment Instructions 
of RR SB RB.211-72-C877, Revision 1, dated March 7, 2001. The Office 
of Management and Budget (OMB) has approved the reporting 
requirements specified in paragraph 3.E. of the Accomplishment 
Instructions of RR SB RB.211-72-C877, Revision 1, dated March 7, 
2001, and assigned OMB control number 2120-0056.

Alternative Methods of Compliance

    (r) 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

    (s) You must use the service information specified in Table 7 of 
this AD to perform the inspections required by this AD. The Director 
of the Federal Register approved the incorporation by reference of 
RR Alert SB No. RB.211-72-AE651, dated November 22, 2004, listed in 
Table 7 of this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part 
51. The incorporation by reference of RR MSB No. RB.211-72-C877, 
Revision 1, dated March 7, 2001, was approved previously by the 
Director of the Federal Register as of December 24, 2001 (66 FR 
57859, November 19, 2001). You can get a copy from Rolls-Royce plc, 
PO Box 31, Derby, England; telephone: 011 44 1332-249428, fax: 011 
44 1332-249223, for a copy of this service information. You may 
review copies at the FAA, New England Region, Office of the Regional 
Counsel, 12 New England Executive Park, Burlington, MA; or the 
National Archives and Records Administration (NARA). For information 
on the availability of this material at NARA, call 202-741-6030, or 
go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. Table 7 follows:

                                      Table 7.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
        Service bulletin              Page numbers           Revision                       Date
----------------------------------------------------------------------------------------------------------------
RB.211-72-AE651.................  All................  Original...........  November 22, 2004.
Total Pages--7
RB.211-72-C877..................  All................  1..................  March 7, 2001.
Total Pages--5
----------------------------------------------------------------------------------------------------------------


[[Page 77885]]

Related Information

    (t) CAA airworthiness directive G-2004-0027, dated November 19, 
2004, also addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on December 15, 2004.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-28144 Filed 12-28-04; 8:45 am]
BILLING CODE 4910-13-P