[Federal Register Volume 71, Number 132 (Tuesday, July 11, 2006)]
[Proposed Rules]
[Pages 39025-39028]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E6-10771]


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

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NE-40-AD]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211-524 Series 
Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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

SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) for Rolls Royce plc (RR) RB211-524 series turbofan 
engines with certain part number (P/N) intermediate pressure compressor 
(IPC) stage 5 disks installed. That AD currently requires new reduced 
IPC stage 5 disk cyclic limits. This proposed AD would require the same 
reduced IPC stage 5 disk cyclic limits, the requirement to remove from 
service affected disks that already exceed the new reduced cyclic 
limit, and to remove from service other affected disks before exceeding 
their cyclic limits using a drawdown schedule. This proposed AD also 
would exempt disks reworked to RR Service Bulletin (SB) RB.211-72-E182, 
Revision 1, dated July 30, 2004, and would allow an on-wing eddy 
current inspection (ECI) on RB211-524G and RB211-524H series engines. 
This proposed AD results from the manufacturer issuing a revised Alert 
Service Bulletin (ASB) to remove certain disks from applicability, and 
to allow an on-wing ECI on RB211-524G and RB211-524H series engines. We 
are proposing this AD to prevent failure of the IPC stage 5 disk, which 
could result in uncontained engine failure and possible damage to the 
airplane.

DATES: We must receive any comments on this proposed AD by September 
11, 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. 2002-NE-40-AD, 12 New England Executive Park, Burlington, MA 01803.
     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, DE248BJ, United Kingdom; 
telephone 011-44-1332-242424; fax 011-44-1332-249936.
    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: Ian Dargin, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; 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. 2002-NE-40-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 July 18, 2005, the FAA issued AD 2005-15-13, Amendment 39-14202 
(70 FR 43036, July 26, 2005). That AD requires:
     Establishing new reduced IPC stage 5 disk cyclic limits.
     Removing from service affected disks that already exceed 
the new reduced cyclic limit.
     Removing from service other affected disks before 
exceeding their cyclic limits, using a drawdown schedule.
     Allowing optional inspections at each shop visit or an on-
wing ECI to extend the disk life beyond the specified life.

Actions Since We Issued AD 2005-15-13

    Since we issued that AD, the manufacturer issued a new revision to 
ASB RB.211-72-AD428 to reference AD G-2005-0008.

Relevant Service Information

    We have reviewed and approved the technical contents of RR ASB No. 
RB.211-72-AD428, Revision 5, dated March 18, 2005, that specifies a 
drawdown schedule for removing from service affected IPC stage 5 disks, 
using new RR Time Limits Manual (TLM), 05-10-01 cyclic limits. The ASB 
also describes procedures for optional inspections at each shop visit 
to extend the disk life beyond the lives specified. The Civil Aviation 
Authority (CAA), the airworthiness authority of the United Kingdom 
(U.K.), has classified this service bulletin as mandatory and issued AD 
G-2005-0008 to ensure the airworthiness of these RR turbofan engines in 
the U.K. We have also reviewed and approved the technical contents of 
the following SBs:
     SB No. RB.211-72-E148, dated March 13, 2003,
     SB No. RB.211-72E150, Revision 1, dated June 4, 2003, and
     SB No. RB.211-72-E171, Revision 1, dated February 8, 2005.
    These SBs provide an optional on-wing ECI of the affected disks, to 
extend the disk life beyond the lives specified.

Differences Between the Proposed AD and the Service Information

    This proposed AD adds a requirement to comply with the reduced 
cyclic life limits not later than 30 days after the effective date of 
this AD.

Bilateral Agreement Information

    This engine model is manufactured in the U.K., 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 us informed of the situation 
described above.

[[Page 39026]]

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. We are proposing this AD, which would 
require:
     Establishing new reduced IPC stage 5 disk cyclic limits.
     Removing from service affected disks that already exceed 
the new reduced cyclic limit.
     Removing from service other affected disks before 
exceeding their cyclic limits, using a drawdown schedule.
     Allowing optional inspections at each shop visit or an on-
wing ECI to extend the disk life beyond the specified life.
    The proposed AD would require you to use the service information 
described previously to perform these actions.

Changes to 14 CFR Part 39--Effect on the Proposed AD

    On July 10, 2002, we issued a new version of 14 CFR part 39 (67 FR 
47998, July 22, 2002), which governs the FAA's AD system. This 
regulation now includes material that relates to altered products, 
special flight permits, and alternative methods of compliance. This 
material previously was included in each individual AD. Since this 
material is included in 14 CFR part 39, we will not include it in 
future AD actions.

Costs of Compliance

    We estimate this proposed AD would not affect any engines installed 
on airplanes of U.S. registry. Based on this, we estimate this proposed 
AD will not have any cost to U.S. operators.

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 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. 2002-NE-40-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 39-14202 (70 FR 
43036, July 26, 2005) and by adding a new airworthiness directive, to 
read as follows:

Rolls-Royce plc: Docket No. 2002-NE-40-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by September 
11, 2006.

Affected ADs

    (b) This AD supersedes AD 2005-15-13, Amendment 39-14202.

Applicability

    (c) This AD applies to the Rolls-Royce plc (RR) RB211-524 series 
turbofan engines listed in the following Table 1, with intermediate 
pressure compressor (IPC) stage 5 disk part numbers (P/Ns) listed in 
Table 2 of this AD, installed.

                                        Table 1.--Engine Models Affected
----------------------------------------------------------------------------------------------------------------
 
----------------------------------------------------------------------------------------------------------------
-524B-02               -524B-B-02             -524B3-02              -524B4-02              -524B4-D-02
-524B2-19              -524B2-B-19            -524C2-19              -524C2-B-19            -524D4-19
-524D4-B-19            -524D4X-19             -524D4X-B-19           -524D4-39              -524D4-B-39
-524G2-19              -524G2-T-19            -524G3-19              -524G3-T-19            -524H2-19
-524H2-T-19            -524H-36               -524H-T-36
----------------------------------------------------------------------------------------------------------------

    These engines are installed on, but not limited to, Boeing 747, 
767, and Lockheed L-1011 airplanes.

                                    Table 2.--IPC Stage 5 Disk P/Ns Affected
----------------------------------------------------------------------------------------------------------------
 
----------------------------------------------------------------------------------------------------------------
LK60130                LK65932                LK69021                LK81269                LK83282
LK83283                UL12290                UL15743                UL15744                UL15745
UL19132                UL20785                UL20832                UL23291                UL25011
UL36821                UL36977                UL36978                UL36979                UL36980
UL36981                UL36982                UL36983                UL37078                UL37079

[[Page 39027]]

 
UL37080                UL37081                UL37082                UL37083                UL37084
----------------------------------------------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from the manufacturer issuing a revised 
Alert Service Bulletin (ASB) to remove certain disks from 
applicability and to allow an on-wing eddy current inspection (ECI) 
on RB211-524G and RB211-524H series engines. The actions specified 
in this AD are intended to prevent failure of the IPC stage 5 disk, 
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.

Exempted Disks

    (f) For engines with an IPC stage 5 disk P/N listed in Table 2 
of this AD, reworked to RR SB No. RB.211-72-E182, Revision 1, dated 
July 30, 2004, no further action is necessary.

Cycle Limits

    (g) Comply with the reduced cyclic life limits in Table 3 of 
this AD or conduct qualifying nondestructive test (NDT) inspections 
to extend the IPC stage 5 disk life within 30 days after the 
effective date of this AD, but before December 1, 2008.

                         Table 3.--Cyclic Life Limits Without Qualifying NDT Inspection
----------------------------------------------------------------------------------------------------------------
                                                  Engine models
-----------------------------------------------------------------------------------------------------------------
                                                   -524G2, G2-T,
                                                   G3, G3-T, H2,   -524D4, D4-B,   -524B2, B2-B,  -524B-02, B-B-
           Date of reduced life limit             H2-T, H-36, H-   D4-B-39, D4X,     C2, C2-B     02, B3-02, B4-
                                                       T-36        D4X-B, D4-39                     02, B4-D-02
----------------------------------------------------------------------------------------------------------------
November 30, 2002...............................  13,500 cycles-      16,150 CIS      16,000 CIS      16,200 CIS
                                                      in-service
                                                           (CIS)
April 1, 2003...................................      13,500 CIS      13,500 CIS      13,500 CIS      14,000 CIS
December 1, 2003................................      12,000 CIS      13,500 CIS      13,500 CIS      14,000 CIS
December 1, 2004................................      11,000 CIS      13,500 CIS      12,000 CIS      12,000 CIS
December 1, 2005................................      11,000 CIS      12,000 CIS      12,000 CIS      12,000 CIS
----------------------------------------------------------------------------------------------------------------

    (h) On December 1, 2008, the revised cyclic life limits 
specified in Table 4 of this AD become effective. Incorporate the 
revised cyclic life limits specified in Table 4 of this AD into the 
RR Time Limits Manual, 05-10-01.

                                Table 4.--Cyclic Life Limits on December 1, 2008
----------------------------------------------------------------------------------------------------------------
                                                  Engine models
-----------------------------------------------------------------------------------------------------------------
                                                   -524G2, G2-T,
                                                   G3, G3-T, H2,   -524D4, D4-B,   -524B2, B2-B,  -524B-02, B-B-
           Date of reduced life limit             H2-T, H-36, H-   D4-B-39, D4X,     C2, C2-B     02, B3-02, B4-
                                                       T-36        D4X-B, D4-39                     02, B4-D-02
----------------------------------------------------------------------------------------------------------------
December 1, 2008................................       7,830 CIS       8,700 CIS       8,900 CIS       9,000 CIS
----------------------------------------------------------------------------------------------------------------

Optional Inspections

    (i) Before December 1, 2008, you may perform an optional NDT 
inspection on-wing or at each shop visit to extend the disk life. 
Guidance for these inspections is provided in paragraphs (j) or (k) 
of this AD.

Optional Inspections at Shop Visit

    (j) Perform optional inspections at shop visit, as follows:
    (1) Remove corrosion protection from IPC stage 5 disk. 
Information on corrosion protection removal can be found in the 
Engine Maintenance Manual.
    (2) Perform a visual inspection and a binocular inspection of 
the IPC stage 5 disk for corrosion pitting at the cooling air holes 
and defender holes in the disk front spacer arm. Follow paragraph 
3.C. of the Accomplishment Instructions of RR ASB No. RB.211-72-
AD428, Revision 5, dated March 18, 2005. The RR Engine Maintenance 
Manual, Inspection Check-00 (ATA 72-32-31-200-000), contains limits 
for corrosion pitting of the IPC stage 5 disk.
    (3) If the disk has corrosion pitting in excess of limits, 
remove the disk from service.
    (4) If the disk is free from corrosion pitting, perform a 
magnetic penetrant inspection (MPI) of the entire disk as follows:
    (i) For RB211-524G2-T, RB211-524G3-T, and RB211-524H-T series 
engines, the RR Engine Maintenance Manual, Inspection Check 08 (ATA 
72-32-31-200-008), contains limits for corrosion pitting of the IPC 
stage 5 disk.
    (ii) For RB211-524G2, RB211-524G3, and RB211-524H series 
engines, the RR Engine Maintenance Manual, Inspection Check 09 (ATA 
72-32-31-200-009), contains limits for corrosion pitting of the IPC 
stage 5 disk.
    (iii) If the disk passes the MPI and you find no cracks, 
complete all other inspections, re-apply corrosion protection to the 
disk, and return the disk to service using the cyclic limits allowed 
by paragraph (m) of this AD. RR Repair FRS5900 contains information 
on re-applying corrosion protection.
    (5) If the disk has corrosion pitting that is within limits, do 
the following:
    (i) Perform an ECI on all disk cooling air holes, defender 
holes, and inner and outer faces. Use paragraph 3.D. of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AD428, Revision 
5, dated March 18, 2005. The RR Engine Maintenance Manual, 
Inspection Check-00 (ATA 72-32-31-200-000), contains limits for 
corrosion pitting of the IPC stage 5 disk.
    (ii) If the disk passes the ECI and you find no cracks, perform 
an MPI on the entire disk.
    (iii) If the disk passes the MPI and you find no cracks, re-
apply corrosion protection to the disk, and return the disk to 
service using the cyclic limits allowed by paragraph (m) of this AD.

Optional On-Wing Eddy Current Inspections

    (k) You may perform an optional on-wing ECI of the IPC stage 5 
disk only once between shop visit inspections as follows:
    (1) For RB211-524B2/C2 and RB211-524B4/D4 series engines, use 
paragraphs 3.A.

[[Page 39028]]

through 3.F. of the Accomplishment Instructions of RR SB No. RB.211-
72-E148, dated March 13, 2003, and RR SB No. RB.211-72-E150, 
Revision 1, dated June 4, 2003.
    (2) For RB211-524G2, RB211-524G2-T, RB211-524G3, RB211-524G3-T, 
RB211-524H, and RB211-524H-T series engines, use paragraphs 3.A. 
through 3.M. of the Accomplishment Instructions of RR SB No. RB.211-
72-E171, Revision 1, dated February 8, 2005.
    (3) If the disk passes the ECI and you find no cracks, you may 
extend the cycle life as specified in paragraph (m) of this AD.

Definition of Shop Visit

    (l) The manufacturer defines a shop visit as the separation of 
an engine major case flange. This definition excludes shop visits 
when only field maintenance type activities are performed in lieu of 
performing them on-wing (such as to perform an on-wing inspection of 
a tail engine installation on a Lockheed L-1011 airplane).

Cyclic Life Extension

    (m) Disks that pass an optional inspection may remain in service 
after that inspection for the additional cycles listed in the 
following Table 5, until the next inspection, until the cyclic life 
limit published in the RR Time Limits Manual, 05-10-01, is reached, 
or December 1, 2008, whichever occurs first.

                                         Table 5.--Cyclic Life Extension
----------------------------------------------------------------------------------------------------------------
                                                  Engine models
-----------------------------------------------------------------------------------------------------------------
                                                   -524G2, G2-T,
                                                   G3, G3-T, H2,   -524D4, D4-B,   -524B2, B2-B,  -524B-02, B-B-
                Type of extension                 H2-T, H-36, H-   D4-B-39, D4X,     C2, C2-B     02, B3-02, B4-
                                                       T-36        D4X-B, D4-39                     02, B4-D-02
----------------------------------------------------------------------------------------------------------------
Extension After Passing MPI.....................    1,600 cycles    2,000 cycles    2,000 cycles    2,000 cycles
Extension After Passing In-Shop ECI.............    3,800 cycles    4,500 cycles    4,500 cycles    4,500 cycles
Extension After Passing On-Wing ECI.............    1,000 cycles    1,200 cycles    1,200 cycles    1,200 cycles
----------------------------------------------------------------------------------------------------------------

Disks That Have Been Intermixed Between Engine Models

    (n) The RR Time Limits Manual, 05-00-01, contains information on 
intermixing disks between engine models.

Alternative Methods of Compliance

    (o) 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.

Credit for Previous Inspections

    (p) Inspections done using RR SB No. RB.211-72-E150, dated April 
17, 2003, SB No. RB.211-72-E171, dated December 14, 2004, SB No. 
RB.211-72-D428, Revision 3, dated June 30, 2003, and ASB No. RB.211-
72-AD428, Revision 4, dated March 7, 2005, meet the requirements of 
this AD.

Reporting Requirement

    (q) Report findings of all inspections of the IPC stage 5 disk 
using paragraph 3.B.(2) of the Accomplishment Instructions of RR No. 
ASB RB.211-72-AD428, Revision 5, dated March 18, 2005. The Office of 
Management and Budget (OMB) has approved the reporting requirements 
specified in Paragraph 3.B. of the Accomplishment Instructions of RR 
No. ASB RB.211-72-AD428, Revision 5, dated March 18, 2005, and 
assigned OMB control number 2120-0056.

Related Information

    (r) CAA airworthiness directive G-2005-0008, dated March 8, 
2005, also addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on June 30, 2006.
Thomas A. Boudreau,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
 [FR Doc. E6-10771 Filed 7-10-06; 8:45 am]
BILLING CODE 4910-13-P