[Federal Register Volume 70, Number 45 (Wednesday, March 9, 2005)]
[Proposed Rules]
[Pages 11585-11588]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-4561]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2001-NE-17-AD]
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: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to revise an existing airworthiness directive 
(AD) for Rolls-Royce plc (RR) RB211 Trent 875, 877, 884, 884B, 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 and defines a specific terminating action to the 
repetitive blade inspection requirements. This proposed AD would 
require the same actions but would clarify the terminating action. This 
proposed AD results from a request by an operator to clarify the 
terminating action in the existing AD. We are proposing 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: We must receive any comments on this proposed AD by May 9, 2005.

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. 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 identified in this proposed 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,

[[Page 11586]]

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:

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. 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 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.

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 January 3, 2005, we issued AD 2005-01-15, Amendment 39-13940 (70 
FR 2336, January 13, 2005). That AD requires initial and repetitive 
ultrasonic inspections of the fan blade dovetail roots and defines a 
specific terminating action to the repetitive blade inspection 
requirements. That AD results from a report of a cracked fan blade 
found before the blade reached the initial inspection threshold of AD 
2002-11-08. That AD also resulted from the need to reduce a repetitive 
inspection compliance time due to potential breakdown of blade coating 
and lubrication on certain blades.

Actions Since AD 2005-01-15 Was Issued

    Since we issued AD 2005-01-15, we received a comment from an 
operator requesting that we clarify the terminating action in that AD. 
As the AD is currently written, LPC fan blades must be installed in 
complete sets to comply with the terminating action. We agree that the 
terminating action needs clarification. All blades must be replaced 
with blades that meet the replacement criteria to qualify as 
terminating action, but not necessarily replaced as a complete set. We 
have rewritten paragraph (h) in this proposed AD to address the 
commenter's request.

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 Civil Aviation Authority (CAA), which is 
the airworthiness authority for the United Kingdom (UK), 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 Agreement Information

    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 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:
     Require initial and repetitive ultrasonic-inspections of 
the dovetail roots of LPC fan blades P/Ns FK30838, FK30840, FK30842, 
FW12960, FW12961, FW12962, and FW13175.
     Define 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 would consist of replacing LPC fan blades with 
reworked, relubricated, and remarked LPC fan blades, using Rolls-Royce 
SB No. RB.211-72-D672, dated February 1, 2002, or with LPC fan blades 
that feature additional blade root processing requirements.
    The proposed AD would require that you do these actions using the 
service information described previously.

Costs of Compliance

    There are about 350 RR RB211 Trent 875, 877, 884, 884B, 892, 892B, 
and 895 series turbofan engines of the affected design in the worldwide 
fleet. We estimate that 90 engines installed on airplanes of U.S. 
registry would be affected by this proposed AD. We also estimate that 
it would take about 8 work hours per engine to perform the proposed 
inspections, and about 260 work hours per engine to perform the 
proposed terminating action. The average labor rate is $65 per work 
hour. Based on these figures, we estimate the total cost of the 
proposed AD to U.S. operators to be $1,567,800.

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 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

[[Page 11587]]

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. 2001-NE-17-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 39-13940 (70 FR 
2336, January 13, 2005) and by adding a new airworthiness directive, to 
read as follows:

Rolls-Royce plc: Docket No. 2001-NE-17-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by May 9, 2005.

Affected ADs

    (b) This AD revises AD 2005-01-15, Amendment 39-13940.

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 request by an operator to clarify the 
terminating action in AD 2005-01-15. 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.

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 600 cycles-since-rework (CSR) using either RR ASB No. 
RB.211-72-AD344 or Service Bulletin (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 1:

                    Table 1.--Compliance Times for Blades P/Ns FK30838, FK30840, and FK30842
----------------------------------------------------------------------------------------------------------------
                                                                                                   Repetitive
                                                        Airplane maximum gross      Initial        inspection
             Engine series                Boeing 777      weight (times 1,000      inspection    (cycles-since-
                                            series              pounds)               CSN       last-inspection)
                                                                                                     (CSLI)
----------------------------------------------------------------------------------------------------------------
(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 600 CSR 
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 2:

                    Table 2.--Compliance Times for Blades P/Ns FK30838, FK30840, and FK30842
----------------------------------------------------------------------------------------------------------------
                                                        Airplane maximum gross      Initial
             Engine series                Boeing 777      weight (times 1,000      inspection      Repetitive
                                            series              pounds)               CSN       inspection  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
----------------------------------------------------------------------------------------------------------------


[[Page 11588]]

    (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 600 CSR using either RR ASB No. 
RB.211-72-AD344 or SB No. 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
----------------------------------------------------------------------------------------------------------------
                                                        Airplane maximum gross      Initial
             Engine series                Boeing 777      weight (times 1,000      inspection      Repetitive
                                            series              pounds)               CSN       inspection 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:

                Table 4.--Compliance Times for Blades P/Ns FW12960, FW12961, FW12962, and FW13175
----------------------------------------------------------------------------------------------------------------
                                                        Airplane maximum gross      Initial
             Engine series                Boeing 777      weight (times 1,000      inspection      Repetitive
                                            series              pounds)               CSN       inspection 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) 555...................        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 LPC 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 serviceable LPC fan 
blades.
    (2) For the purposes of this AD, serviceable LPC fan blades are 
blades that feature additional blade root processing requirements 
found in RR SB No. RB.211-72-D672, dated February 1, 2002; or are 
LPC fan blades that feature a full form root profile. Information on 
full form root profile blades can be found in RR SB No. RB.211-72-
D390, RR SB No. RB.211-72-E044, and RR SB No. RB.211-72-E382.

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.

Related Information

    (k) 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 March 2, 2005.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 05-4561 Filed 3-8-05; 8:45 am]
BILLING CODE 4910-13-P