Airworthiness Directives; Rolls-Royce plc. RB211-535 Turbofan Engines

[Federal Register Volume 67, Number 230 (Friday, November 29, 2002)]
[Rules and Regulations]
[Pages 71094-71097]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 02-29001]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NE-16-AD; Amendment 39-12952; AD 2002-23-08]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc. RB211-535 Turbofan 
Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that 
is applicable to Rolls-Royce plc. (RR) models RB211-535E4-37, RB211-
535E4-B-37, and RB211-535E4-B-75 turbofan engines, with certain part 
number (P/N) low pressure (LP) turbine stage 2 discs installed. This 
action requires establishing new reduced LP turbine stage 2 disc cyclic 
limits. This action also requires removing from service affected discs 
that already exceed the new reduced cyclic limit, and removing other 
affected discs before exceeding their cyclic limits, using a drawdown 
schedule. The actions specified in this AD are intended to prevent LP 
turbine stage 2 disc failure, which could result in uncontained engine 
failure and possible loss of the airplane.

DATES: Effective December 30, 2002. The incorporation by reference of 
certain publications listed in the rule is approved by the Director of 
the Federal Register as of December 30, 2002.
    Comments for inclusion in the Rules Docket must be received on or 
before January 28, 2003.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
Counsel, Attention: Rules Docket No. 2002-NE-16-AD, 12 New England 
Executive Park, Burlington, MA 01803-5299. Comments may be inspected at 
this location, by appointment, between 8 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. Comments may also be sent via 
the Internet using the following address: [email protected]. 
Comments sent via the Internet must contain the docket number in the 
subject line.
    The service information referenced in this AD may be obtained from 
Rolls-Royce plc, P.O. Box 31 Derby, DE24 8BJ, United Kingdom; telephone 
011-44-1332-242424; fax 011-44-1332-249936. This information may be 
examined, by appointment, at the FAA, New England Region, Office of the 
Regional Counsel, 12 New England Executive Park, Burlington, MA; or at 
the Office of the Federal Register, 800 North Capitol Street, NW., 
Suite 700, Washington, DC.

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: The Civil Aviation Authority (CAA), which is 
the airworthiness authority for the United Kingdom (U.K.), recently 
notified the FAA that an unsafe condition may exist on RR models RB211-
535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 turbofan engines. The 
CAA advises that a reassessment of the safe cyclic limits of LP turbine 
stage 2 discs, P/N's UL11508, UL17141, UL18947, UL29029, and UL37352 
has been performed by the manufacturer. The cyclic limits of these 
discs are reduced based on more recent thermal and stress data obtained 
from operational experience. This condition, if not corrected, could 
result in uncontained engine failure and possible loss of the airplane.

Manufacturer's Service Information

    Rolls-Royce plc. has issued mandatory service bulletin (MSB) 
RB.211-72-D181, Revision 3, dated August 16, 2002, that specifies a 
drawdown schedule for removing from service affected LP turbine stage 2 
discs, using new Time Limits Manual (TLM) cyclic limits. This MSB 
provides a scheduled reduction, by engine and flight plan, of LP 
turbine stage 2 disc lives until the full life-cycle reduction on 
December 31, 2005. This MSB also provides instructions for performing a 
one-time on-wing eddy current inspection for cracks of affected LP 
turbine stage 2 discs to allow a disc to remain in service for an 
additional 3,000 cycles, if it does not exceed the new, lower TLM 
cyclic limit. The CAA has classified this service bulletin as mandatory 
and issued AD 006-05-2001 in order to assure the airworthiness of these 
Rolls-Royce plc. turbofan engines in the U.K.

[[Page 71095]]

Bilateral Airworthiness Agreement

    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. Pursuant to this 
bilateral airworthiness agreement, the CAA has kept the FAA informed of 
the situation described above. The FAA has examined the findings of the 
CAA, reviewed all available information, and determined that AD action 
is necessary for products of this type design that are certificated for 
operation in the United States.

FAA's Determination of an Unsafe Condition and Required Actions

    Since an unsafe condition has been identified that is likely to 
exist or develop on other RR models RB211-535E4-37, RB211-535E4-B-37, 
and RB211-535E4-B-75 turbofan engines of the same type design, this AD 
is being issued to prevent LP stage 2 turbine disc failure, which could 
result in uncontained engine failure and possible loss of the airplane. 
This AD requires:
    [sbull] Reducing the LP turbine stage 2 disc life-cyclic limits; 
and
    [sbull] Removing from service affected discs that already exceed 
the new reduced cyclic limits; and
    [sbull] Removing other affected discs before exceeding their cyclic 
limits, using a drawdown schedule.
The actions must be done in accordance with the MSB described 
previously.

Immediate Adoption of This AD

    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications should identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this action must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2002-NE-16-AD.'' The postcard will be date stamped and 
returned to the commenter.

Regulatory Analysis

    This final rule does not have federalism implications, as defined 
in Executive Order 13132, because it 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. Accordingly, 
the FAA has not consulted with state authorities prior to publication 
of this final rule.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and is not a ``significant regulatory action'' 
under Executive Order 12866. It has been determined further that this 
action involves an emergency regulation under DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979). If it is determined 
that this emergency regulation otherwise would be significant under DOT 
Regulatory Policies and Procedures, a final regulatory evaluation will 
be prepared and placed in the Rules Docket. A copy of it, if filed, may 
be obtained from the Rules Docket at the location provided under the 
caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (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. Section 39.13 is amended by adding the following new 
airworthiness directive:

2002-23-08 Rolls-Royce plc.: Amendment 39-12952.


     Docket No. 2002-NE-16-AD.Applicability: This airworthiness 
directive (AD) is applicable to Rolls-Royce plc. (RR) models RB211-
535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 turbofan engines, 
with low pressure (LP) turbine stage 2 discs part numbers (P/N's) 
UL11508, UL17141, UL18947, UL29029, and UL37352 installed. These 
engines are installed on, but not limited to, Boeing 757 and Tupolev 
Tu204 airplanes.

    Note 1: This AD applies to each engine identified in the 
preceding applicability provision, regardless of whether it has been 
modified, altered, or repaired in the area subject to the 
requirements of this AD. For engines that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (d) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.

    Compliance: Compliance with this AD is required as indicated, 
unless already done.
    To prevent LP turbine stage 2 disc failure, which could result 
in an uncontained engine failure and possible loss of the airplane, 
do the following:

Cyclic Limits

    (a) Change the RR Time Limits Manual cyclic limits for LP 
turbine stage 2 discs as specified in the following Table 1:

[[Page 71096]]



            Table 1.--Time Limits Manual (TLM) Cyclic Limits
------------------------------------------------------------------------
                                    Life limits for
                                      RB211-535E4       Life limits for
                                   engines operating      RB211-535E4
   Date of reduced life limit      in flight plan A,   engines operating
                                   and RB211-535E4-B   in flight plan B
                                        engines
------------------------------------------------------------------------
(1) December 31, 2001...........  22,500 cycles-      19,700 CSN.
                                   since-new (CSN).
(2) December 31, 2002...........  22,500 cycles-      19,000 CSN.
                                   since-new (CSN).
(3) December 31, 2003...........  21,500 CSN........  18,000 CSN.
(4) December 31, 2004...........  20,000 CSN........  16,500 CSN.
(5) December 31, 2005...........  18,100 CSN........  14,600 CSN.
------------------------------------------------------------------------

RB211-535E4 Engines Operating to Flight Plan A, and RB211-535E4-B 
Engines

    (b)(1) For RB211-535E4 engines operating to flight plan A, and 
RB211-535E4-B engines, remove the LP turbine stage 2 disc from 
service using the CSN and Action times listed in the following Table 
2.

    Table 2.--Drawdown Schedule for RB211-535E4 Engines Operating to Flight Plan A, and RB211-535E4-B Engines
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                                                                                  Replace Disc
  Disc CSN on the effective date of                            -------------------------------------------------
               this AD                          Action           Without Eddy  current      With Eddy  current
                                                                       inspection               inspection
----------------------------------------------------------------------------------------------------------------
(i) 20,001 CSN or greater............  Remove disc from         Within 21 days after     Within 3,000 cycles-in-
                                        service or perform       the effective date of    service (CIS) after
                                        optional on-wing eddy    this AD.                 the inspection, but do
                                        current disc                                      not exceed the new
                                        inspection within 21                              reduced life limit
                                        days after the                                    specified in Table 1
                                        effective date of this                            of this AD.
                                        AD.
(ii) 18,100 to 20,000 CSN............  Remove disc from         Before accumulating      Within 3,000 cycles-in-
                                        service or perform       21,000 CSN or by         service (CIS) after
                                        optional on-wing eddy    December 31, 2002,       the inspection, but do
                                        current disc             whichever occurs first.  not exceed the new
                                        inspection.                                       reduced life limit
                                                                                          specified in Table 1
                                                                                          of this AD.
(iii) Fewer than 18,100 CSN..........  Remove disc from         Before accumulating      Within 3,000 cycles-in-
                                        service or perform       20,500 CSN or by         service (CIS) after
                                        optional on-wing eddy    December 31, 2004,       the inspection, but do
                                        current disc             whichever occurs first.  not exceed the new
                                        inspection.                                       reduced life limit
                                                                                          specified in Table 1
                                                                                          of this AD.
----------------------------------------------------------------------------------------------------------------

    (2) Information regarding disc removal may be found in 3.A. of 
the Accomplishment Instructions of Mandatory Service Bulletin (MSB) 
RB.211-72-D181, Revision 3, dated August 16, 2002.
    (3) The optional on-wing eddy current disc inspection noted in 
Table 2 of this AD must be performed in accordance with 3.C.(1) 
through 3.C.(6) of the Accomplishment Instructions of MSB RB.211-72-
D181, Revision 3, dated August 16, 2002.

RB211-535E4 Engines Operating to Flight Plan B

    (c)(1) For RB211-535E4 engines operating to flight plan B, 
remove the LP turbine stage 2 disc from service using the CSN and 
Action times listed in the following Table 3.

                 Table 3.--Drawdown Schedule for RB211-535E4 Engines Operating to Flight Plan B
----------------------------------------------------------------------------------------------------------------
                                                                                  Replace Disc
  Disc CSN on the effective date of                            -------------------------------------------------
               this AD                          Action           Without Eddy  current      With Eddy  current
                                                                       inspection               inspection
----------------------------------------------------------------------------------------------------------------
(i) 16,501 CSN or greater............  Remove disc from         Within 21 days after     Within 3,000 cycles-in-
                                        service or perform       the effective date of    service (CIS) after
                                        optional on-wing eddy    this AD.                 the inspection, but do
                                        current disc                                      not exceed the new
                                        inspection within 21                              reduced life limit
                                        days after the                                    specified in Table 1
                                        effective date of this                            of this AD.
                                        AD.
(ii) 14,600 to 16,500 CSN............  Remove disc from         Before accumulating      Within 3,000 cycles-in-
                                        service or perform       17,500 CSN or by         service (CIS) after
                                        optional on-wing eddy    December 31, 2002,       the inspection, but do
                                        current disc             whichever occurs first.  not exceed the new
                                        inspection.                                       reduced life limit
                                                                                          specified in Table 1
                                                                                          of this AD.
(iii) Fewer than 14,600 CSN..........  Remove disc from         Before accumulating      Within 3,000 cycles-in-
                                        service or perform       17,000 CSN or by         service (CIS) after
                                        optional on-wing eddy    December 31, 2004,       the inspection, but do
                                        current disc             whichever occurs first.  not exceed the new
                                        inspection.                                       reduced life limit
                                                                                          specified in Table 1
                                                                                          of this AD.
----------------------------------------------------------------------------------------------------------------


[[Page 71097]]

    (2) Information regarding disc removal may be found in 3.A. of 
the Accomplishment Instructions of MSB RB.211-72-D181, Revision 3, 
dated August 16, 2002.
    (3) The optional on-wing eddy current disc inspection must be 
performed in accordance with 3.C.(1) through 3.C.(6) of the 
Accomplishment Instructions of MSB RB.211-72-D181, Revision 3, dated 
August 16, 2002.

Alternative Methods of Compliance

    (d) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Engine Certification Office (ECO). 
Operators must submit their requests through an appropriate FAA 
Principal Maintenance Inspector, who may add comments and then send 
it to the Manager, ECO.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the ECO.

Special Flight Permits

    (e) Special flight permits may be issued in accordance with 
Sec. Sec.  21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the airplane to a location where 
the requirements of this AD can be done.

Documents That Have Been Incorporated By Reference

    (f) The disc removals and inspections must be done in accordance 
with Roll-Royce MSB RB.211-72-D181, Revision 3, dated August 16, 
2002. This incorporation by reference was approved by the Director 
of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR 
part 51. Copies may be obtained from Rolls-Royce plc, PO Box 31, 
Derby, England; telephone: 011-44-1332-249428; fax 011-44-1332-
249223. Copies may be inspected at the FAA, New England Region, 
Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA; or at the Office of the Federal Register, 800 North 
Capitol Street, NW, Suite 700, Washington, DC.

    Note 3: The subject of this AD is addressed in CAA airworthiness 
directive 006-05-2001.

Effective Date

    (g) This amendment becomes effective on December 16, 2002.

    Issued in Burlington, Massachusetts, on November 8, 2002.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 02-29001 Filed 11-27-02; 8:45 am]
BILLING CODE 4910-13-P

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