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

[Federal Register Volume 67, Number 31 (Thursday, February 14, 2002)]
[Rules and Regulations]
[Pages 6859-6861]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 02-3162]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2000-NE-02-AD; Amendment 39-12460; AD 2002-02-12]
RIN 2120-AA64


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

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD) that is applicable to Rolls-Royce plc (RR) RB211-524G and -524H 
series turbofan engines. That AD currently requires initial and 
repetitive ultrasonic inspections for cracks in fan blade dovetail 
roots, and, if necessary, replacement with serviceable parts. That 
action also provides the options of installing improved design fan 
blades or reworking current fan blades to the improved configuration as 
terminating action for the inspections. This amendment requires initial 
inspection at lower thresholds, using either the blade root probe 
method or the surface wave probe method. This amendment also removes 
the option of reworking blades as terminating action for the 
inspections. Lastly, this amendment adds the model RB211-524H-T-36 
engine to the applicability of this AD. This amendment is prompted by 
two additional reports of fan blade cracks found during inspections 
performed in accordance with the current AD. The actions specified in 
this AD are intended to detect cracked fan blades, which could result 
in an uncontained engine failure and damage to the airplane.

DATES: Effective March 1, 2002. The incorporation by reference of 
certain publications listed in the rule is approved by the Director of 
the Federal Register as of March 1, 2002.
    Comments for inclusion in the Rules Docket must be received on or 
before April 15, 2002.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
Counsel, Attention: Rules Docket No. 2000-NE-02-AD, 12 New England 
Executive Park, Burlington, MA 01803-5299. Comments may be inspected at 
this location, by appointment, between 8:00 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, PO Box 31, Derby, England; telephone: 011 44 1332-
249428; fax: 011 44 1332-249223. This information may be examined 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: Keith Mead, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803-5299; telephone (781) 238-
7744 fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: The Civil Aviation Authority (CAA), which is 
the airworthiness authority for the United Kingdom (UK), had notified 
the Federal Aviation Administration (FAA) in March of 2000, that an 
unsafe condition may exist on certain Rolls-Royce plc (RR) RB211-524 
series turbofan engines. The CAA had received reports of three fan 
blade failures up to that time. Subsequent inspections of the dovetail 
root area on other fan blades revealed the existence of dovetail root 
cracks in the same region as the failed blades.
    The FAA issued AD 2000-05-12 to require initial and repetitive 
ultrasonic inspections for cracks in fan blade dovetail roots, and, if 
necessary, replacement with serviceable parts. That action also 
provided the options of installing improved design fan blades or 
reworking current fan blades to the improved configuration as 
terminating action for the inspections. Since that AD was published, 
two additional reports of fan blades found cracked have been received. 
The FAA has determined through information provided by RR

[[Page 6860]]

that the fan blade inspection requirements and rejection criteria need 
to be changed. This condition, if not corrected, could result in 
possible multiple fan blade failures, which could result in an 
uncontained engine failure and damage to the aircraft.

Manufacturer's Service Information

    Rolls-Royce plc has issued mandatory service bulletin (MSB) No. 
RB.211-72-C818, Revision 5, dated March 30, 2001, that specifies lower 
initial inspection thresholds, and repetitive ultrasonic inspections 
for cracks in fan blade dovetail roots, using either the blade root 
probe method, or the surface wave probe method. However, fan blades 
part numbers (P/N's) UL38052 and UL38628, are restricted to the root 
probe method only. Investigation by the manufacturer has shown that the 
surface wave probe method on these fan blades does not routinely detect 
cracking of this blade root design configuration. Also, this MSB 
Revision 5 adds the model RB211-524H-T-36 engine to the applicability.

Bilateral Airworthiness Agreement

    These engine models are manufactured in the United Kingdom (UK) 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. Pursuant 
to this bilateral airworthiness agreement, the UK has kept the FAA 
informed of the situation described above. The FAA has examined the 
findings of the UK, 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

    Although none of these affected engine models are used on any 
airplanes that are registered in the United States, the possibility 
exists that the engine models could be used on airplanes that are 
registered in the United States in the future. Since an unsafe 
condition has been identified that is likely to exist or develop on 
other Rolls-Royce plc RB211-524G series and RB211-524H series turbofan 
engines of the same type design, this AD is being issued to detect 
cracked fan blades, which could result in an uncontained engine failure 
and damage to the airplane. This AD requires initial ultrasonic 
inspection at lower thresholds, and repetitive ultrasonic inspections, 
for cracks in fan blade dovetail roots, using either the blade root 
probe method or the surface wave probe method. This AD also adds the 
model RB211-524H-T-36 engine to the applicability. The actions are 
required to be done in accordance with the mandatory service bulletin 
described previously.

Immediate Adoption of This AD

    Since there are currently no domestic operators of these engine 
models, notice and opportunity for prior public comment are 
unnecessary. Therefore, a situation exists that allows the immediate 
adoption of this regulation.

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 2000-NE-02-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 removing Amendment 39-11622 (65 FR 
14207, March 16, 2000) and adding a new airworthiness directive, 
Amendment 39-12460, to read as follows:

2002-02-12  Rolls-Royce plc: Amendment 39-12460. Docket No. 2000-NE-
02-AD. Supersedes AD 2000-05-12, Amendment 39-11622.

    Applicability: This airworthiness directive (AD) is applicable 
to Rolls-Royce plc (RR) models RB211-524G2-19, RB211-524G2-T-19, 
RB211-524G3-19, RB211-524G3-T-19, RB211-524H2-19, RB211-524H2-T-19, 
RB211-524H-36, and RB211-524H-T-36 turbofan engines, with fan blades 
part numbers (P/N's) UL23061, UL25772, UL27253, UL29561, UL29573, 
UL30533, UL36245, UL38009, UL38052, or UL38628, installed. These 
engines are installed on, but not limited to Boeing 747-400 series 
and 767 series airplanes.



[[Page 6861]]


    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 (f) 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 detect cracked fan blades, which could result in an 
uncontained engine failure and damage to the airplane, do the 
following:

Initial Inspection

    (a) Ultrasonically inspect for cracks in the dovetail slots of 
the fan blades using the Initial Inspection cycles-since-new (CSN) 
for Root Probe Method or Wave Probe Method, in accordance with 
EITHER paragraph 3.E. (Root Probe Method) OR 3.F. (Wave Probe 
Method) of the Accomplishment Instructions of RR service bulletin 
(SB) RB.211-72-C818, Revision 5, dated March 30, 2001 and using 
Table 1 of this AD:

                          Table 1.--Initial and Repetitive Inspection Compliance Times
----------------------------------------------------------------------------------------------------------------
                                       For root probe method                    For wave probe method
                               ---------------------------------------------------------------------------------
        Fan blade P/N's              Initial          Repetitive          Initial
                                    inspection        inspection        inspection       Repetitive inspection
----------------------------------------------------------------------------------------------------------------
(1) UL23061, UL25772, UL27253,  Within 6,500 CSN.  Within 330        Within 6,500 CSN  Within 270 CSLI.
 UL29561, UL29573, UL30533.                         cycles-since-
                                                    last-inspection
                                                    (CSLI).
(2) UL36245, UL38009..........  Within 1,150 CSN.  Within 290 CSLI.  Within 1,150 CSN  Within 250 CSLI.
(3) UL38052, UL38628..........  Within 1,150 CSN.  Within 290 CSLI.  Not Allowed.....  Not Allowed.
----------------------------------------------------------------------------------------------------------------

    (b) For fan blades P/N's UL38052 or UL38628 initially inspected 
using paragraph 3.F. of the Accomplishment Instructions of RR SB 
RB.211-72-C818, Revision 4, dated June 23, 2000, inspect the blades 
for cracks in accordance with paragraph 3.E. of the Accomplishment 
Instructions of RR SB RB.211-72-C818, Revision 5, dated March 30, 
2001 using the cycles-since-last-inspection (CSLI) times specified 
in Table 2 of this AD:

Table 2.--Inspection CSLI for Fan Blades Inspected Using RR SB RB.211-72-
                  C818, Revision 4, Dated June 23, 2000
------------------------------------------------------------------------
                                              Inspection interval after
              Number of CSLI                 the effective date of this
                                                         AD
------------------------------------------------------------------------
(1) 290 to 500 CSLI.......................  Within 100 cycles-in-service
                                             (CIS).
(2) 501 to 750 CSLI.......................  Within 50 CIS.
(3) More than 750 CSLI....................  Within 25 CIS.
------------------------------------------------------------------------

Additional Requirement When Both Engines of the Same Boeing 767 
Airplane Have One or More Fan Blades P/N's UL38052 or UL38628 Installed

    (c) For fan blades, P/N's UL38052 and UL38628 that are installed 
in both engines of the same Boeing 767 airplane, and that have 
accumulated more than 290 CSLI, ultrasonic-inspect blades of one 
engine for cracks within 25 CIS after the effective date of this AD 
in accordance with paragraph 3.E. of the Accomplishment Instructions 
of RR SB RB.211-72-C818, Revision 5, dated March 30, 2001.

Repetitive Inspections

    (d) Thereafter, ultrasonically inspect for cracks in the 
dovetail slots of the fan blades using the Repetitive Inspection 
CSLI for Root Probe Method or Wave Probe Method, in accordance with 
EITHER paragraph 3.E. OR 3.F. of the Accomplishment Instructions of 
RR SB RB.211-72-C818, Revision 5, dated March 30, 2001 and using 
Table 1 of this AD.

Dispositioning of Cracked Fan Blades

    (e) Before further flight, replace any fan blade that does not 
meet the acceptance criteria specified in paragraph 3.E or 3.F. of 
the Accomplishment Instructions of SB RR SB RB.211-72-C818, Revision 
5, dated March 30, 2001.

Terminating Action

    (f) Removal from service of fan blades P/N's UL23061, UL25772, 
UL27253, UL29561, UL29573, UL30533, UL36245, UL38009, UL38052, and 
UL38628, and replacement with serviceable fan blades with P/N's 
other than these P/N's constitutes terminating action for the 
inspection requirements of this AD.

Alternative Methods of Compliance

    (g) 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

    (h) Special flight permits may be issued in accordance with 
Secs. 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

    (i) The inspections must be done in accordance with Rolls-Royce 
plc Mandatory Service Bulletin No. RB.211-72-C818, Revision 5, dated 
March 30, 2001. 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, 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.

Effective Date

    (j) This amendment becomes effective on March 1, 2002.

    Issued in Burlington, Massachusetts, on February 1, 2002.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 02-3162 Filed 2-13-02; 8:45 am]
BILLING CODE 4910-13-U

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