[Federal Register Volume 70, Number 9 (Thursday, January 13, 2005)]
[Rules and Regulations]
[Pages 2336-2339]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-485]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2001-NE-17-AD; Amendment 39-13940; AD 2005-01-15]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 Trent 875, 877, 
884, 884B, 892, 892B, and 895 Series Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for Rolls-Royce plc (RR) RB211 Trent 875, 877, 884, 892, 892B, and 
895 series turbofan engines with certain part number (P/N) low pressure 
compressor (LPC) fan blades installed. That AD currently requires 
initial and repetitive ultrasonic inspections of the fan blade dovetail 
roots. This AD requires the same actions except at reduced compliance 
times for certain blades, defines a specific terminating action to the 
repetitive blade inspection requirements, and adds the 884B series to 
the applicability. This AD results from a report of a cracked fan blade 
found before the blade reached the initial inspection threshold of AD 
2002-11-08. This AD also results from the need to reduce a repetitive 
inspection compliance time due to potential breakdown of blade coating 
and lubrication on certain blades. We are issuing this AD to prevent 
multiple LPC fan blade failures due to cracks, which could result in 
uncontained engine failure and possible damage to the airplane.

DATES: Effective January 28, 2005. The Director of the Federal Register 
approved the incorporation by reference of certain publications listed 
in the regulations as of January 28, 2005.
    We must receive any comments on this AD by March 14, 2005.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD:
     By mail: Federal Aviation Administration (FAA), New 
England Region, Office of the Regional Counsel, Attention: Rules Docket 
No. 2001-NE-17-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, P.O. Box 31, Derby DE24 6BJ, UK; telephone 44 (0) 1332 
242424; fax 44 (0) 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: Christopher Spinney, Aerospace 
Engineer, Engine Certification Office, FAA, Engine and Propeller 
Directorate, 12 New England Executive Park, Burlington, MA 01803-5299; 
telephone (781) 238-7175; fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: On May 27, 2002, the FAA issued AD 2002-11-
08, Amendment 39-12769 (67 FR 38852, June 6, 2002). That AD requires 
initial and repetitive ultrasonic inspections of the fan blade dovetail 
roots. That AD was the result of the loss of an LPC fan blade during 
takeoff. That condition, if not corrected, could result in multiple LPC 
fan blade failures due to cracks, which could result in uncontained 
engine failure and possible damage to the airplane.

Actions Since AD 2002-11-08 Was Issued

    Since that AD was issued, the Civil Aviation Authority (CAA), which 
is the airworthiness authority for the United Kingdom (UK), notified us 
that an unsafe condition may exist on RR RB211 Trent 875, 877, 884, 
884B, 892, 892B, and 895 series turbofan engines. The CAA advises that 
a cracked fan blade was found before the blade reached the initial 
inspection threshold specified in AD 2002-11-08. The CAA also advises 
that potential breakdown of blade coating and lubrication on certain 
blades might occur, leading to blade cracking.

Relevant Service Information

    We have reviewed and approved the technical contents of Rolls-Royce 
(RR) Alert Service Bulletin (ASB) No. RB.211-72-AD344, Revision 7, 
dated March 12, 2004, that provides procedures to ultrasonic-inspect 
the blade root on LPC fan blades. We have also reviewed and approved 
the technical contents of RR Service Bulletin (SB) No. RB.211-72-D672, 
dated February 1, 2002, that provides procedures to rework, 
relubricate, and remark the fan blades at fan blade overhaul, and lists 
part numbers for new fan blades that feature additional blade root 
processing requirements. The CAA classified these service bulletins as 
mandatory and issued AD G-2004-0008, dated April 29, 2004, in order to 
ensure the airworthiness of these RR 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 
Sec.  21.29 of the Federal Aviation Regulations (14 CFR 21.29) and the 
applicable bilateral airworthiness agreement. Pursuant to this 
bilateral airworthiness agreement, the CAA has kept the FAA informed of 
the situation described above. The FAA has 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 RB211 Trent 875, 877, 884, 884B, 892, 892B, and 895 
series turbofan engines of the same type design. We are issuing this AD 
to prevent multiple LPC fan blade failures due to cracks, which could 
result in uncontained engine failure and possible damage to the 
airplane. This AD:
     Requires initial and repetitive ultrasonic-inspections of 
the dovetail

[[Page 2337]]

roots of LPC fan blades P/Ns FK30838, FK30840, FK30842, FW12960, 
FW12961, FW12962, and FW13175.
     Reduces the initial inspection threshold for fan blades, 
P/Ns FK30838, FK30840, and FK30842 in Table 1 for Airplane Maximum 
Gross Weight of 632,500 pounds and 648,000 pounds, from 2,400 cycles-
since-new (CSN) to 1,200 CSN.
     Reduces the repetitive inspection threshold for fan 
blades, P/Ns FW12960, FW12961, FW12962, and FW13175 in Table 4 for 
Airplane Maximum Gross Weight of 545,000 pounds from 1,200 CSN to 600 
CSN.
     Defines a terminating action to the repetitive blade 
inspection requirements in the AD, to be done at the next shop visit 
when fan blades are removed, but no later than December 31, 2009. The 
terminating action consists of replacing LPC fan blades with a complete 
set of reworked, relubricated, and remarked LPC fan blades, using 
Rolls-Royce SB No. RB.211-72-D672, dated February 1, 2002, or with a 
complete set of new LPC fan blades that feature additional blade root 
processing requirements.
     Adds the 884B series engine to the applicability.

You must use the service information described previously to perform 
the actions required by this AD.

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 submit any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2001-NE-17-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.
    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 with 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.

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. 2001-NE-17-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 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 
removing Amendment 39-12769 (67 FR 38852; June 6, 2002), and by adding 
a new airworthiness directive (AD), Amendment 39-13940, to read as 
follows:

2005-01-15 Rolls-Royce plc: Amendment 39-13940. Docket No. 2001-NE-
17-AD. Supersedes AD 2002-11-08, Amendment 39-12769.

Effective Date

    (a) This AD becomes effective January 28, 2005.

Affected ADs

    (b) This AD supersedes AD 2002-11-08, Amendment 39-12769.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) RB211 Trent 875, 
877, 884, 884B, 892, 892B, and 895 series turbofan engines with low 
pressure compressor (LPC) fan blades, part numbers (P/Ns) FK30838, 
FK30840, FK30842, FW12960, FW12961, FW12962, and FW13175, installed. 
These engines are installed on, but not limited to, Boeing Company 
777 series airplanes.

Unsafe Condition

    (d) This AD results from a report of a cracked fan blade found 
before the blade reached the initial inspection threshold of AD 
2002-11-08. This AD also results from the need to reduce a 
repetitive inspection compliance time due to potential breakdown of 
blade coating and lubrication on certain blades. We are issuing this 
AD to prevent multiple LPC fan blade failures due to cracks,

[[Page 2338]]

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.
    (f) Ultrasonic-inspect and disposition the dovetail roots of LPC 
fan blades, P/Ns FK30838, FK30840, FK30842, FW12960, FW12961, 
FW12962, and FW13175, that are removed from the engine, using 
3.A.(1) through 3.A.(5) or, for blades that are not removed from the 
engine, using 3.B.(1) through 3.B.(5) of the Accomplishment 
Instructions of RR Alert Service Bulletin (ASB) No. RB.211-72-AD344, 
Revision 7, dated March 12, 2004, as follows:
    (1) For blades P/Ns FK30838, FK30840, and FK30842, that have not 
been relubricated during any interval exceeding 600 cycles-since-new 
(CSN) or cycles-since-rework (CSR) using either RR ASB No. RB.211-
72-AD344 or No. RB.211-72-D347, inspect as specified in paragraph 
(f) of this AD and within the compliance times specified in the 
following Table 1:

                    Table 1.--Compliance Times for Blades P/Ns FK30838, FK30840, and FK30842
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                                                                                                     Repetitive
                                                                                                     inspection
                                            Boeing 777      Airplane maximum gross       Initial      (cycles-
              Engine series                   series     weight (times 1,000 pounds)   inspection    since-last-
                                                                                           CSN       inspection)
                                                                                                       (CSLI)
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(i) -884B,-892...........................          -300  (A) 660 and 632.5..........           600            80
                                                         (B) 580....................         2,000           600
(ii) -884, -892, -892B, and -895.........          -200  (A) 632.5 and 648..........         1,200           100
                                                         (B) 656....................           600            80
                                                         (C) 555....................         2,000           600
(iii) -875...............................          -200  535........................         2,000           600
(iv) -877................................          -200  545........................         2,000           600
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    (2) For blades P/Ns FK30838, FK30840, and FK30842, that have 
been relubricated at intervals not exceeding 600 CSN or CSR using 
either RR ASB No. RB.211-72-AD344 or SB RB.211-72-D347, inspect as 
specified in paragraph (f) of this AD and within the compliance 
times specified in the following Table 2:

                    Table 2.--Compliance Times for Blades P/Ns FK30838, FK30840, and FK30842
----------------------------------------------------------------------------------------------------------------
                                                                                         Initial     Repetitive
              Engine series                 Boeing 777      Airplane maximum gross     inspection    inspection
                                              series     weight (times 1,000 pounds)       CSN          CSLI
----------------------------------------------------------------------------------------------------------------
(i) -884B, 892...........................          -300  (A) 660 and 632.5..........           600            80
                                                         (B) 580....................         2,400           600
(ii) 884, -892, -892B, and -895..........          -200  (A) 632.5 and 648..........         1,200           100
                                                         (B) 656....................           600            80
                                                         (C) 555....................         2,400           600
(iii) -875;..............................          -200  535........................         2,400           600
(iv) -877................................          -200   545.......................         2,400           600
----------------------------------------------------------------------------------------------------------------

    (3) For blades P/Ns FW12960, FW12961, FW12962, and FW13175, 
either new or reworked to that configuration at greater than 600 CSN 
or since previous rework, or that have not been relubricated during 
any interval exceeding 600 CSN or CSR using either RR ASB No. 
RB.211-72-AD344 or RB.211-72-D347 requirements, inspect as specified 
in paragraph (f) of this AD and within the compliance times 
specified in the following Table 3:

                Table 3.--Compliance Times for Blades P/Ns FW12960, FW12961, FW12962, and FW13175
----------------------------------------------------------------------------------------------------------------
                                                                                         Initial     Repetitive
              Engine series                 Boeing 777      Airplane maximum gross     inspection    inspection
                                              series     weight (times 1,000 pounds)       CSN          CSLI
----------------------------------------------------------------------------------------------------------------
(i) -884B, -892..........................          -300   (A) 660 and 632.5.........           600           100
                                                         (B) 580....................         2,000           600
(ii) -884, -892, -892B, and -895.........          -200  (A) 632.5 and 648..........         1,200           125
                                                         (B) 656....................           600           100
                                                         (C) 555....................         2,000           600
(iii) -875...............................          -200  535........................         2,000           600
(iv) -877................................          -200  545........................         2,000           600
----------------------------------------------------------------------------------------------------------------

    (4) For blades P/Ns FW12960, FW12961, FW12962, and FW13175, 
either new or reworked to that configuration at fewer than 600 CSN 
or since previous rework, and that have been relubricated at 
intervals not exceeding 600 CSN using either RR ASB No. RB.211-72-
AD344 or SB No. RB.211-72-D347, inspect as specified in paragraph 
(f) of this AD and within the compliance times specified in the 
following Table 4:

[[Page 2339]]



                Table 4.--Compliance Times for Blades P/Ns FW12960, FW12961, FW12962, and FW13175
----------------------------------------------------------------------------------------------------------------
                                                                                         Initial     Repetitive
              Engine series                 Boeing 777      Airplane maximum gross     inspection    inspection
                                              series     weight (times 1,000 pounds)       CSN          CSLI
----------------------------------------------------------------------------------------------------------------
(i) -884B, -892..........................          -300  (A) 660 and 632.5..........           600           100
                                                         (B) 580....................         2,400         1,200
(ii) -884, -892, -892B, and -895.........          -200  (A) 632.5 and 648..........         2,400           125
                                                         (B) 656....................           600           100
                                                         (C) 535....................         2,400         1,200
(iii) -875...............................          -200  535........................         2,400         1,200
(iv) -877................................          -200  545........................         2,400           600
----------------------------------------------------------------------------------------------------------------

    (g) When engines containing blades P/Ns FK30838, FK30840, 
FK30842, FW12960, FW12961, FW12962, and FW13175 are moved from one 
gross weight category to another, the inspection schedule that is 
applicable to the higher gross weight category must be used.

Terminating Action

    (h) As terminating action to the repetitive inspection 
requirements of this AD, at the next shop visit when the fan blades 
are removed for repair or overhaul, but no later than December 31, 
2009:
    (1) Replace LPC fan blades P/Ns FK30838, FK30840, FK30842, 
FW12960, FW12961, FW12962, or FW13175 with a complete set of LPC fan 
blades that have been reworked, relubricated, and remarked using RR 
SB No. RB.211-72-D672, dated February 1, 2002; or;
    (2) Replace LPC fan blades P/Ns FK30838, FK30840, FK30842, 
FW12960, FW12961, FW12962, or FW13175 with a complete set of new LPC 
fan blades that feature additional blade root processing 
requirements found in RR SB No. RB.211-72-D672, dated February 1, 
2002.

Previous Credit

    (i) Previous credit is allowed for initial inspections of fan 
blades that were done using RR ASB No. RB.211-72-AD344, Revision 4, 
dated March 15, 2002, Revision 5, dated June 20, 2003, Revision 6, 
dated February 27, 2004, or Revision 7, dated March 12, 2004, before 
the effective date of this AD.

Alternative Methods of Compliance

    (j) 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

    (k) You must use the Rolls-Royce plc service information 
specified in Table 5 of this AD to perform the blade inspections and 
replacements required by this AD. The Director of the Federal 
Register approved the incorporation by reference of the documents 
listed in Table 5 of this AD in accordance with 5 U.S.C. 552(a) and 
1 CFR part 51. You can get a copy from Rolls-Royce plc, P.O. Box 31, 
Derby DE24 6BJ, UK; telephone 44 (0) 1332 242424; fax 44 (0) 1332 
249936. You may review copies at the FAA, New England Region, Office 
of the Regional Counsel, Attention: Rules Docket No. 2001-NE-17-AD, 
12 New England Executive Park, Burlington, MA; or at 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 5 follows:

                                      Table 5.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
       Service Bulletin No.                  Page                 Revision                     Date
----------------------------------------------------------------------------------------------------------------
RB.211-72-AD344...................  ALL..................  7....................  March 12, 2004.
    Total Pages: 11
RB.211-72-AD344, Appendices 1       ALL..................  7....................  March 12, 2004.
 through 5.
    Total Pages: 18
RB.211-72-D672....................  ALL..................  Original.............  February 1, 2002.
    Total Pages: 24
----------------------------------------------------------------------------------------------------------------

Related Information

    (l) Civil Aviation Authority (CAA) airworthiness directive G-
2004-0008, dated April 29, 2004, also addresses the subject of this 
AD.

    Issued in Burlington, Massachusetts, on January 3, 2005.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-485 Filed 1-12-05; 8:45 am]
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