[Federal Register Volume 72, Number 129 (Friday, July 6, 2007)]
[Proposed Rules]
[Pages 36916-36920]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E7-13090]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2007-27811; Directorate Identifier 2004-NE-11-AD]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce Deutschland Tay 611-8, Tay 
611-8C, Tay 620-15, Tay 650-15, and Tay 651-54 Turbofan Engines

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

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) for Rolls-Royce Deutschland (RRD) Tay 611-8, Tay 620-15, 
Tay 650-15, and Tay 651-54 turbofan engines. That AD currently requires 
initial and repetitive visual

[[Page 36917]]

inspections of all ice-impact panels and fillers in the low pressure 
(LP) compressor case for certain conditions and replacing as necessary, 
any or all panels. This proposed AD would require the same initial and 
repetitive inspections, provide terminating action to those repetitive 
actions, and add the Tay 611-8C turbofan engine to the applicability. 
This proposed AD results from RRD introducing new LP compressor case 
ice-impact panels with additional retention features, to these Tay 
turbofan engines. We are proposing this AD to prevent release of ice-
impact panels due to improper bonding that can result in loss of thrust 
in both engines.

DATES: We must receive any comments on this proposed AD by September 4, 
2007.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
     Government-wide rulemaking Web site: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue, SE., Washington, DC 20590.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
     Fax: (202) 493-2251.
    Contact Rolls-Royce Deutschland Ltd & Co KG, Eschenweg 11, D-15827 
Dahlewitz, Germany; telephone 49 (0) 33-7086-1768; fax 49 (0) 33-7086-
3356, for the service information referenced in this proposed AD.

FOR FURTHER INFORMATION CONTACT: Jason Yang, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803-5299; e-mail: 
[email protected]; telephone (781) 238-7747; 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 ``Docket No. FAA-2007-27811; 
Directorate Identifier 2004-NE-11-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the proposed AD. We will 
consider all comments received by the closing date and may amend the 
proposed AD in light of those comments.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this proposed AD. Using the search function of the 
DMS Web site, anyone can find and read the comments in any of our 
dockets, including the name of the individual who sent the comment (or 
signed the comment on behalf of an association, business, labor union, 
etc.). You may review the DOT's complete Privacy Act Statement in the 
Federal Register published on April 11, 2000 (65 FR 19477-78) or you 
may visit http://dms.dot.gov.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://dms.dot.gov; or in person at the Docket Operations office between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD 
docket contains this proposed AD, the regulatory evaluation, any 
comments received, and other information. The street address for the 
Docket Operations office (telephone (800) 647-5527) is the same as the 
Mail address provided in the ADDRESSES section. Comments will be 
available in the AD docket shortly after receipt.

Discussion

    On December 22, 2004, the FAA issued AD 2004-26-10, Amendment 39-
13922 (70 FR 1172, January 6, 2005). That AD requires initial and 
repetitive visual inspections of all ice-impact panels and fillers in 
the LP compressor case for certain conditions and replacing as 
necessary, any or all panels. That AD also introduced a new compliance 
date of no later than March 1, 2005, to have all but one engine on each 
airplane in compliance with the polysulfide bonding of panels.

Actions Since AD 2004-26-10 Was Issued

    Since AD 2004-26-10 was issued, the Luftfahrt-Bundesamt, (LBA), 
which is the airworthiness authority for Germany, notified us that RRD 
has introduced new LP compressor case ice-impact panels with additional 
retention features. The LP compressor case must be reworked to accept 
the new ice-impact panels, by December 31, 2011.

Relevant Service Information

    We have reviewed and approved the technical contents of RRD Alert 
Service Bulletin (ASB) No. TAY-72-A1643, Revision 1, dated November 2, 
2005, and ASB No. TAY-72-A1650, dated November 2, 2005. These ASBs 
describe procedures for reworking the LP compressor case and installing 
new ice-impact panels with additional retention features. The LBA 
classified these ASBs as mandatory and issued AD D-2004-313R5 in order 
to ensure the airworthiness of these Tay turbofan engines in Germany.

Bilateral Agreement Information

    These engine models are manufactured in Germany and are 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 LBA kept us informed of the situation 
described above. We have examined the findings of the LBA, 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. We are proposing this AD, which would 
require:
     Adding the Tay 611-8C turbofan engine, serial numbers 
below 85078, to the applicability.
     Initial visual inspection of all ice-impact panels and 
fillers in the LP compressor case for certain conditions and replacing 
as necessary, any or all panels, before further flight, if not 
previously done.
     Repetitive visual inspections of all ice-impact panels and 
fillers in the LP compressor case for certain conditions and replacing 
as necessary, any or all panels.
     Having all but one engine on each airplane in compliance 
with the polysulfide bonding of panels.
     Rework of LP compressor cases and installation of new LP 
compressor case ice-impact panels with additional retention features by 
December 31, 2011, as mandatory terminating action to the repetitive 
visual inspections, repairs, and replacements.
    The proposed AD would require that you do these actions using the 
service information described previously.

[[Page 36918]]

Costs of Compliance

    We estimate that this proposed AD would affect about 1,085 engines 
installed on airplanes of U.S. registry. We also estimate that it would 
take about 2.5 work-hours per engine to perform an inspection, and 
about 12 work-hours to perform a repair as proposed. The average labor 
rate is $80 per work-hour. Required terminating action parts would cost 
about $7,500 per engine. Based on these figures, for the proposed AD, 
we estimate:
     The cost of one inspection to the U.S. fleet to be 
$217,000.
     The cost of a repair to the U.S fleet to be $1,041,600.
     The cost of parts to the U.S. fleet for terminating 
action, to be $8,137,500.

Docket Number Change

    We are transferring the docket for this AD to the Docket Management 
System as part of our ongoing docket management consolidation efforts. 
The new Docket No. is FAA-2007-27811. The old Docket No. became the 
Directorate Identifier, which is 2004-NE-11-AD. This AD might get 
logged into the DMS docket, ahead of the previously collected documents 
from the old docket file, as we are in the process of sending those 
items to the DMS.

Engine Models Added and Removed From Applicability

    Since we issued AD 2004-26-10, turbofan engine model Tay 611-8C 
received a U.S. DOT FAA type certificate. We added that engine model to 
the applicability, as certain serial numbers of those engines are 
affected by this AD.
    Although AD 2004-26-10 inadvertently lists turbofan engine models 
Tay 620-15/20 and Tay 650-15/10 in the applicability, this proposed AD 
does not list them. Those engines do not have a U.S. DOT FAA type 
certificate.

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 AD:
    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 regulatory evaluation of the estimated costs to 
comply with this proposed AD. See the ADDRESSES section for a location 
to examine the regulatory evaluation.

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 39-13922 (70 FR 
1172, January 6, 2005) and by adding the following new AD:

Rolls-Royce Deutschland (Formerly Rolls-Royce plc): Docket No. FAA-
2007-27811; Directorate Identifier 2004-NE-11-AD.

Comments Due Date

    (a) We must receive comments on this airworthiness directive 
(AD) action by September 4, 2007.

Affected ADs

    (b) This AD supersedes AD 2004-26-10, Amendment 39-13922.

Applicability

    (c) This AD applies to:
    (1) RRD Tay 611-8, Tay 620-15, Tay 650-15, and Tay 651-54 
turbofan engines that have one or more ice-impact panels installed 
in the low pressure (LP) compressor case that conform to the Rolls-
Royce Deutschland (RRD) Service Bulletin (SB) No. TAY-72-1326 
standard.
    (2) RRD Tay 611-8C turbofan engines with serial numbers (SN) 
below SN 85078.
    (3) The turbofan engines listed in paragraph (c) of this AD are 
installed on, but not limited to, Fokker F.28 Mk.0070 and Mk.0100 
series airplanes, Gulfstream Aerospace G-IV and G-IV-X series 
airplanes, and Boeing Company 727-100 series airplanes modified in 
accordance with Supplemental Type Certificate SA8472SW (727-QF).

Unsafe Condition

    (d) This AD results from RRD introducing new LP compressor case 
ice-impact panels with additional retention features, to these Tay 
turbofan engines. We are issuing this AD to prevent release of ice-
impact panels due to improper bonding that can result in loss of 
thrust in both engines.

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.

Inspecting Ice-Impact Panels in Tay 620-15, Tay 650-15, and Tay 651-54 
Engines

    (f) For airplanes that have any Tay 620-15, Tay 650-15, or Tay 
651-54 engines with ice-impact panels incorporated by the RR SB No. 
TAY-72-1326 standard, and not all panels were repaired using 
polysulfide bonding material by RR repair scheme TV5451R, HRS3491, 
HRS3615, HRS3648, or HRS3649, do the following:
    (1) Before further flight, rework all six ice-impact panels 
using repair scheme HRS3648 or HRS3649 on at least one of the 
affected engines.
    (2) Before further flight, inspect the ice-impact panels and the 
surrounding fillers on the engine not reworked. Use paragraph 3.E. 
of the Accomplishment Instructions of RRD SB No. TAY-72-1638, 
Revision 2, dated September 21, 2004, and the inspection disposition 
criteria in Table 1 of this AD.

[[Page 36919]]



                Table 1.--Inspection Disposition Criteria
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                  If:                                 Then:
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(i) Any movement or rocking motion of    Before further flight, replace
 LP compressor ice-impact panel, or any   all panels using repair scheme
 movement of the front edge of ice-       HRS3648 or HRS3649.
 impact panel.
(ii) Reappearing signs of moisture on    Before further flight, replace
 the ice-impact panel or the              all panels using repair scheme
 surrounding filler.                      HRS3648 or HRS3649.
(iii) Any dents or impact damage on the  Before further flight, replace
 ice-impact panel that is greater than    the damaged panel using repair
 3.1 square inch in total.                scheme HRS3648 or HRS3649.
(iv) Any dents or impact damage on the   Within 5 flight cycles or 5
 ice-impact panel that is between 1.55    flight hours, whichever occurs
 square inch and 3.1 square inch in       first, replace the damaged
 total.                                   panel using repair scheme
                                          HRS3648 or HRS3649.
(v) Any dents or impact damage on the    Within 50 flight cycles or 50
 ice-impact panel that is less than       flight hours, whichever occurs
 1.55 square inch in total.               first, replace the damaged
                                          panel using repair scheme
                                          HRS3648 or HRS3649.
(vi) Any crack appears on the ice-       Within 50 flight cycles or 50
 impact panel and there is visible        flight hours, whichever occurs
 distortion of the airwashed surface.     first, replace the damaged
                                          panel using repair scheme
                                          HRS3648 or HRS3649.
(vii) Any crack appears on the ice-      Within 150 flight cycles or 150
 impact panel and there is no visible     flight hours, whichever occurs
 distortion of the airwashed surface.     first, replace the damaged
                                          panel using repair scheme
                                          HRS3648 or HRS3649.
(viii) Delamination or peeling of the    Before further flight, replace
 compound layers of the airwashed         the damaged panel using repair
 surface and the penetrated area is       scheme HRS3648 or HRS3649.
 greater than 3.1 square inch in total.
(iv) Delamination or peeling of the      Within 5 flight cycles or 5
 compound layers of the airwashed         flight hours, whichever occurs
 surface and the penetrated area is       first, replace the damaged
 between 1.55 square inch and 3.1         panel using repair scheme
 square inch in total.                    HRS3648 or HRS3649.
(x) Delamination or peeling of the       Within 50 flight cycles or 50
 compound layers of the airwashed         flight hours, whichever occurs
 surface and the penetrated area is       first, replace the damaged
 less than 1.55 square inch in total.     panel using repair scheme
                                          HRS3648 or HRS3649.
(xi) Delamination or peeling of the      Within 150 flight cycles or 150
 compound layers but the airwashed        flight hours, whichever occurs
 surface is not penetrated.               first, repair the damaged
                                          panel using repair scheme
                                          HRS3630.
(xii) Missing filler surrounding the LP  Before further flight, repair
 compressor case.                         the damaged filler using
                                          repair scheme HRS3630.
(xiii) Damage to the filler surrounding  Within 25 flight cycles or 25
 the LP compressor case such as           flight hours, whichever occurs
 chipped, cracked, or missing material.   first, repair damaged filler
                                          using repair scheme HRS 3630.
------------------------------------------------------------------------

    (3) Re-inspect all ice-impact panels within every 500 cycles-
since-last-inspection (CSLI) or two months since-last-inspection, 
whichever occurs first. Use paragraph 3.E. of the Accomplishment 
Instructions of RRD SB No. TAY-72-1638, Revision 2, dated September 
21, 2004, and the inspection disposition criteria in Table 1 of this 
AD.

Repetitive Inspections for Tay 620-15, Tay 650-15, and Tay 651-54 
Engines With All Ice-Impact Panels Repaired by Polysulfide Bonding 
Material

    (g) For Tay 620-15, Tay 650-15, and Tay 651-54 engines with ice-
impact panels incorporated by the RRD SB No. TAY-72-1326 standard, 
and all panels were repaired using polysulfide bonding material by 
RR repair scheme TV5451R, HRS3491, HRS3615, HRS3648 or HRS3649, do 
the following:
    (1) Re-inspect within every 1,500 CSLI, for the condition of the 
ice-impact panels and the surrounding fillers.
    (2) Use paragraph 3.E. of the Accomplishment Instructions of RRD 
SB No. TAY-72-1638, Revision 2, dated September 21, 2004, and the 
inspection disposition criteria in Table 1 of this AD.

Inspecting Ice-Impact Panels in Tay 611-8 Engines

    (h) For airplanes that have any Tay 611-8 engines with ice-
impact panels incorporated by the RR SB No. TAY-72-1326 standard, 
and RR repair scheme HRS3491 or HRS3615 was done with two pack epoxy 
(Omat 8/52) on one or more of the six ice-impact panels, do the 
following:
    (1) Before further flight, rework all six ice-impact panels 
using repair scheme HRS3648 or HRS3649 on at least one of the 
affected engines.
    (2) Before further flight, inspect the ice-impact panels and the 
surrounding fillers on the engine not reworked. Use paragraph 3.E. 
of the Accomplishment Instructions of RRD SB No. TAY-72-1638, 
Revision 2, dated September 21, 2004, and the inspection disposition 
criteria in Table 1 of this AD.
    (3) Re-inspect the ice-impact panels within every 1,000 CSLI or 
six months since-last-inspection, whichever occurs first. Use 
paragraph 3.E. of the Accomplishment Instructions of RRD SB No. TAY-
72-1639, Revision 2, dated September 21, 2004, and the inspection 
disposition criteria in Table 1 of this AD.

Repetitive Inspections for Tay 611-8 Engines With All Ice-Impact Panels 
Repaired by Polysulfide Bonding Material or Introduced Since New 
Production

    (i) For Tay 611-8 engines with ice-impact panels incorporated by 
the RRD SB No. TAY-72-1326 standard and all panels were repaired 
using polysulfide bonding material by RR repair scheme TV5451R, 
HRS3491, HRS3615, HRS3648 or HRS3649, or panels were introduced 
since new production, do the following:
    (1) Re-inspect within every 3,000 CSLI, for the condition of the 
ice-impact panels and the surrounding fillers.
    (2) Use paragraph 3.E. of the Accomplishment Instructions of RRD 
SB No. TAY-72-1638, Revision 2, dated September 21, 2004, and the 
inspection disposition criteria in Table 1 of this AD.

Installing Tay 620-15, Tay 650-15, or Tay 651-54 Engines That Are Not 
Inspected

    (j) After the effective date of this AD, do not install any Tay 
620-15, Tay 650-15, or Tay 651-54 engines with ice-impact panels if:
    (1) Those ice-impact panels incorporate the RR SB No. TAY-72-
1326 standard; and
    (2) Ice-impact panels were repaired using RR repair scheme 
TV5451R, HRS3491, or HRS3615 and bonding material other than 
polysulfide; unless
    (3) The panels and the surrounding fillers are inspected for 
condition using 3.B. through 3.D.(3) (in-service) or 3.K.(1) through 
3.(M)(3) (at overhaul or shop visit) of the Accomplishment 
Instructions of RRD SB No. TAY-72-1638, Revision 2, dated September 
21, 2004.
    (k) Perform repetitive inspections as specified in paragraph (g) 
of this AD.

Installing Tay 611-8 Engines That Are Not Inspected

    (l) After the effective date of this AD, do not install any Tay 
611-8 engine with ice-impact panels if:
    (1) Those ice-impact panels incorporate the RR SB No. TAY-72-
1326 standard; and
    (2) Ice-impact panels were repaired using RR repair scheme 
TV5451R, HRS3491, or HRS3615 and bonding material other than 
polysulfide, unless
    (3) The panels and the surrounding fillers are inspected for 
condition using 3.B. through 3.D.(2) (in-service) or 3.K.(1) through 
3.M.(3) (at overhaul or shop visit) of the Accomplishment 
Instructions of RRD SB No. TAY-72-1639, Revision 2, dated September 
21, 2004.

[[Page 36920]]

    (m) Perform repetitive inspections as specified in paragraph (i) 
of this AD.

Mandatory Terminating Action

    (n) No later than December 31, 2011, as mandatory terminating 
action to the repetitive visual inspections or rework required by 
paragraphs (f), (g), (h), (i), (j), (k), (l), and (m) of this AD, do 
the following:
    (1) Rework the LP compressor case and install new LP compressor 
case ice-impact panels with additional retention features, at the 
next shop visit requiring the removal of any module, except when the 
work scope requires only the removal of the high speed gearbox 
module.
    (2) For Tay 620-15, Tay 650-15, and Tay 651-54 turbofan engines, 
do the rework and installation using the Accomplishment Instructions 
of RRD Alert SB No. TAY-72-A1643, Revision 1, dated November 2, 
2005.
    (3) For Tay 611-8 turbofan engines, do the rework and 
installation using the Accomplishment Instructions of RRD Alert SB 
No. TAY-72-A1650, dated November 2, 2005.

Tay 611-8C Turbofan Engines

    (o) For Tay 611-8C turbofan engines, no later than December 31, 
2011, do the following:
    (1) Rework the LP compressor case and install new LP compressor 
case ice-impact panels with additional retention features, at the 
next shop visit after the effective date of this AD, requiring the 
removal of any module, except when the work scope requires only the 
removal of the high speed gearbox module.
    (2) Do the rework and installation using the Accomplishment 
Instructions of RRD Alert SB No. TAY-72-A1650, dated November 2, 
2005.

Alternative Methods of Compliance

    (p) 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

    (q) German AD D2004-313R5, dated November 15, 2005, also 
addresses the subject of this AD.
    (r) Contact Jason Yang, Aerospace Engineer, Engine Certification 
Office, FAA, Engine and Propeller Directorate, 12 New England 
Executive Park, Burlington, MA 01803-5299; e-mail: 
[email protected]; telephone (781) 238-7747; fax (781) 238-7199, 
for more information about this AD.

    Issued in Burlington, Massachusetts, on June 29, 2007.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E7-13090 Filed 7-5-07; 8:45 am]
BILLING CODE 4910-13-P