[Federal Register Volume 70, Number 175 (Monday, September 12, 2005)]
[Rules and Regulations]
[Pages 53725-53728]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-17976]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2001-NE-17-AD; Amendment 39-14265; AD 2005-01-15R1]
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.

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SUMMARY: The FAA is revising 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 AD requires the same 
actions but clarifies the terminating action. 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: This AD becomes effective October 17, 2005. The Director of the 
Federal Register previously approved the incorporation by reference of 
certain publications listed in the regulations as of January 28, 2005 
(70 FR 2336, January 13, 2005).

ADDRESSES: Contact Rolls-Royce plc, P.O. Box 31, Derby DE24 6BJ, UK; 
telephone 44 (0) 1332 242424; fax 44 (0) 1332 249936, for the service 
information identified in this AD.
    You may examine the AD docket at the FAA, New England Region, 
Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA. You may examine the service information, 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 January 3, 2005, we issued AD 2005-01-15, 
Amendment 39-13940 (70 FR 2336, January 13, 2005). That AD superseded 
AD 2002-11-08, Amendment 39-12769 (67 FR 38852 June 6, 2002). AD 2005-
01-15 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 was the result of a 
report of a cracked fan blade found before the blade reached the 
initial inspection threshold of AD 2002-11-08. That AD also reduced the 
repetitive inspection compliance time due to potential breakdown of 
blade coating and lubrication on certain blades. Those conditions, if 
not corrected, could result in uncontained engine failure and possible 
damage to the airplane.

Actions Since We Issued AD 2005-01-15

    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 that AD is currently written, you must install LPC fan blades in 
complete sets to comply with the terminating action. Our intent is that 
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. In response to the comment, we published a proposed 
AD in the Federal Register on March 9, 2005 (70 FR 11585). That action 
proposed to require initial and repetitive ultrasonic inspections of 
the fan blade dovetail roots, and to clarify a specific terminating 
action to the repetitive blade inspection requirements.

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.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We received no comments on the proposal or on 
the determination of the cost to the public.

[[Page 53726]]

Conclusion

    We have carefully reviewed the available data and determined that 
air safety and the public interest require adopting the AD as proposed.

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 will be affected by this AD. We also estimate that it would 
take about 8 work hours per engine to perform the inspections, and 
about 260 work hours per engine to perform the terminating action. The 
average labor rate is $65 per work hour. Based on these figures, we 
estimate the total cost of the AD to U.S. operators to be $1,567,800.

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 this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866;
    (2) Is not a ``significant rule'' under 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 Federal Aviation Administration amends 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 39-13940 (70 FR 
2336, January 13, 2005), and by adding the following new airworthiness 
directive, Amendment 39-14265:

2005-01-15R1 Rolls-Royce plc: Amendment 39-14265. Docket No. 2001-
NE-17-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective October 
17, 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 revision 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
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                                                                                                    Repetitive
                                                                                                    inspection
                                          Boeing 777     Airplane maximum gross       Initial     (cycles-since-
             Engine series                  series        weight  (times 1,000      inspection         last-
                                                                 pounds)                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, 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
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                                                         Airplane maximum gross       Initial       Repetitive
             Engine series                Boeing 777      weight  (times 1,000      inspection      inspection
                                            series               pounds)                CSN            CSLI
----------------------------------------------------------------------------------------------------------------
(i) -884B, 892........................            -300  (A) 660 and 632.5.......             600              80

[[Page 53727]]

 
                                        ..............  (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
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    (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.--Compliance Times for Blades P/Ns FW12960, FW12961, FW12962, and FW13175
----------------------------------------------------------------------------------------------------------------
                                                         Airplane maximum gross       Initial       Repetitive
             Engine series                Boeing 777      weight  (times 1,000      inspection      inspection
                                            series               pounds)                CSN            CSLI
----------------------------------------------------------------------------------------------------------------
(i) -884B, -892.......................            -300  (A) 660 and 632.5.......             600             100
                                                        (B) 580.................           2,000             600
(ii) -884B, -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
(iii) -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       Repetitive
             Engine series                Boeing 777      weight  (times 1,000      inspection      inspection
                                            series               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) 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.

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 as of January 28, 2005 (70 FR 2336, 
January 13, 2005). 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

[[Page 53728]]

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 September 6, 2005.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-17976 Filed 9-9-05; 8:45 am]
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