[Federal Register Volume 71, Number 19 (Monday, January 30, 2006)]
[Proposed Rules]
[Pages 4832-4836]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E6-1092]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2000-NE-62-AD]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Notice of proposed rulemaking (NPRM).

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

SUMMARY: The FAA proposes to supersede 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, RB211-535E4-C, 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 discs with serviceable parts. This proposed AD would require the 
same inspections, and would reduce the compliance times for eddy 
current inspection (ECI) for the RR RB211-22B-02 engines. This proposed 
AD results from the manufacturer reducing their recommended compliance 
times for inspections on RB211-22B-02 engines. We are proposing this AD 
to prevent possible disc failure, which could result in an uncontained 
engine failure and damage to the airplane.

DATES: We must receive any comments on this proposed AD by March 31, 
2006.

ADDRESSES: Use one of the following addresses to comment on this 
proposed 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 identified in this proposed 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:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments regarding this proposal. 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 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

[[Page 4833]]

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 December 15, 2004, the FAA issued AD 2004-26-03, Amendment 39-
13915 (69 FR 77881, December 29, 2004) 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.

Actions Since AD 2004-26-03 Was Issued

    Since we issued AD 2004-26-03, the Civil Aviation Authority (CAA), 
which is the airworthiness authority for the United Kingdom, notified 
us that an unsafe condition might exist on RR model RB211-22B-02 
turbofan engines manufactured between 1989 and 1999. The CAA advises 
that cracks were found in a Trent 800 HP turbine disc attributable to 
machining anomalies during new manufacture. The RB211-22B-02 HP turbine 
is similar in design to the Trent 800, manufactured at the same 
facility and with the same tooling. This proposed AD would require 
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 2004-26-03, for the high risk discs installed 
on model RB211-22B-02 engines. This AD retains the same inspection 
schedules, currently required for RR models RB211-535E4-37, RB211-
535E4-B-37, RB211-535C-37, RB211-535E4-B-75 turbofan engines that were 
in AD 2004-26-03. The actions specified in this proposed 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.

Relevant Service Information

    We have reviewed and approved the technical contents of RR ASB 
RB.211-72-AE717, dated January 21, 2005, that describes procedures for 
inspecting the RB211-22B disk for cracks. The CAA classified this 
service bulletin as mandatory and issued AD G-2005-0003, dated January 
24, 2005, in order to ensure the airworthiness of these RR RB211-22 
turbofan engines in the U.K.

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 same inspections specified in AD 2004-26-03, but 
would reduce the compliance times for the model RB211-22B engine to:
     Within 500 cycles-in-service (CIS) after January 1, 2005 
or before accumulating 11,000 cycles-since-new (CSN), whichever occurs 
first, on engines with more than 9,000 CSN on January 1, 2005, and
     Before accumulating 9,500 CSN or at the next shop visit 
after the effective date of this proposed AD, whichever occurs first, 
on engines with more than 1,500 CSN but fewer than 9,001 CSN on January 
1, 2005.
    The proposed AD would require that you do these actions using the 
service information described previously.

Costs of Compliance

    We estimate that this proposed AD would affect six RR RB211-22B 
engines installed on airplanes of U.S. registry. We also estimate that 
it would take about 4.0 work hours per engine to perform the proposed 
actions, and that the average labor rate is $65 per work hour. There 
are no required parts. Based on these figures, we estimate the total 
cost of the proposed AD to U.S. operators to be $1,560.

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 ExecutiveOrder 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 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. 2000-NE-62-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.

[[Page 4834]]

Sec.  39.13  [Amended]

    2. The FAA amends Sec.  39.13 by removing Amendment 39-13915 (69 FR 
77881, December 29, 2004) and by adding a new airworthiness directive, 
to read as follows:

Rolls-Royce plc: Docket No. 2000-NE-62-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by March 31, 
2006.

Affected ADs

    (b) This AD supersedes AD 2004-26-03, Amendment 39-13915.

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 the manufacturer reducing the 
inspection compliance times for the RB211-22B-02 turbofan engines. 
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 Engines

    (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 Service Bulletin (ASB) No. RB.211-72-AE651, 
dated November 22, 2004, to perform the eddy current inspection.

                    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       Within 500 CIS from October 8, 2004.
 10,500 CSN or more.
(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 ASB 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 ASB 
No. RB.211-72-AE651, dated November 22, 2004, to perform the eddy 
current inspection.

[[Page 4835]]



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 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.
------------------------------------------------------------------------

    (6) For discs that pass inspection, use paragraph 3. of the 
Accomplishment Instructions of RR ASB 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 Engines

    (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 ASB 
No. RB.211-72-AE717, dated January 21, 2005, to perform the eddy 
current inspection.

    Table 5.--Affected HP Turbine Discs in RR Model RB211-02 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 CSN on January 1, 2005
               are:                      Then Eddy Current Inspect:
------------------------------------------------------------------------
(1) More than 9,000 CSN...........  Within 500 CIS after January 1,
                                     2005, but before 11,000 CSN,
                                     whichever is sooner.
(2) More than 1,500, but fewer      Before exceeding 9,500 CSN, or at
 than 9,001 CSN.                     the next shop visit after the
                                     effective date of this AD,
                                     whichever occurs first.
------------------------------------------------------------------------

    (3) For discs that pass inspection, use paragraph 3. of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AE717, dated 
January 21, 2005, to permanently etch NMSB 72-AE717 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 without the HP turbine rotor 
installed in 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 installed 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 ASB RB.211-72-AE717, dated January 21, 2005. The OMB has 
approved the reporting requirements specified in paragraph 3.E. of 
the Accomplishment Instructions of RR ASB RB.211-72-AE717, dated 
January 21, 2005, and assigned OMB control number 2120-0056.

[[Page 4836]]

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.

Related Information

    (s) CAA Airworthiness Directive G-2004-0027, dated November 19, 
2004, and CAA Airworthiness Directive G-2005-0003, dated January 24, 
2005, also address the subject of this AD.

    Issued in Burlington, Massachusetts, on January 19, 2006.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
 [FR Doc. E6-1092 Filed 1-27-06; 8:45 am]
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