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

[Federal Register Volume 68, Number 206 (Friday, October 24, 2003)]
[Rules and Regulations]
[Pages 60843-60845]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-26470]



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Federal Register / Vol. 68, No. 206 / Friday, October 24, 2003 / 
Rules and Regulations

[[Page 60843]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2003-NE-36-AD; Amendment 39-13346; AD 2003-21-11]
RIN 2120-AA64


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

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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

SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Rolls-Royce plc (RR) RB211-524 series turbofan engines. This AD 
requires replacing the dedicated generator rotor assembly, the adaptor 
casing on the high speed gearbox (HSGB), and bearings with new design 
parts on certain engines. This AD is prompted by several reports of 
dedicated generator rotor assembly bearing failures. We are issuing 
this AD to prevent possible uncommanded engine acceleration with no 
reaction to throttle movement, which could result in uncontrollable 
asymmetric engine thrust levels during takeoff or climb.

DATES: Effective November 10, 2003. The Director of the Federal 
Register approved the incorporation by reference of certain 
publications listed in the regulations as of November 10, 2003.
    We must receive any comments on this AD by December 23, 2003.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD:
    [sbull] By mail: The Federal Aviation Administration (FAA), New 
England Region, Office of the Regional Counsel, Attention: Rules Docket 
No. 2003-NE-36-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
    [sbull] By fax: (781) 238-7055.
    [sbull] By e-mail: [email protected].
    You can get the service information referenced in this AD from 
Rolls-Royce plc, P.O. Box 31, Derby, England, DE248BJ; telephone: 011-
44-1332-242424; fax: 011-44-1332-245418.
    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. You may examine the service 
information, 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: James Lawrence, Aerospace Engineer, 
Engine Certification Office, FAA, Engine And Propeller Directorate, 12 
New England Executive Park; Burlington, MA 01803-5299; telephone (781) 
238-7176; 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 certain RR 
RB211-524 series turbofan engines. The CAA advises that a number of 
dedicated generator rotor assembly bearing failures have occurred due 
to low fatigue life of the bearing material and inadequate bearing 
lubrication. Bearing failure can lead to an erratic high pressure (HP) 
shaft speed signal sent to the Full Authority Fuel Controller (FAFC). 
This erratic signal can cause possible uncommanded engine acceleration 
with no reaction to throttle movement, which could result in 
uncontrollable asymmetric engine thrust levels during takeoff or climb.

Relevant Service Information

    We have reviewed and approved the technical contents of RR 
Mandatory Service Bulletin (MSB) No. RB.211-72-E037, dated March 26, 
2003, that describes procedures for replacing the dedicated generator 
adaptor casing, and the rotor assembly bearings with new design parts. 
The CAA classified RR MSB No. RB.211-72-E037 as mandatory and issued AD 
004-03-2003, dated March 26, 2003, in order to ensure the airworthiness 
of these RR engines in the U.K.

FAA's Determination and Requirements of this AD

    Although no airplanes that are registered in the United States use 
these engines, the possibility exists that the engines could be used on 
airplanes that are registered in the United States in the future. The 
unsafe condition described previously is likely to exist or develop on 
other RB211-524 series turbofan engines. We are issuing this AD to 
prevent possible uncommanded engine acceleration with no reaction to 
throttle movement, which could result in uncontrollable asymmetric 
engine thrust levels during takeoff or climb.
    This AD requires replacing the dedicated generator rotor assembly, 
part number (P/N) UL39102, the adaptor casing P/N UL26756 or UL26729, 
on the high speed gearbox (HSGB), and bearings P/N UL21029 with new 
design parts on the following:
    [sbull] RB211-524G2-19, RB211-524G3-19, and RB211-H2-19 turbofan 
engines with SNs before SN 13793.
    [sbull] RB211-524H-36 turbofan engines with SNs before SN 13472.
    [sbull] All SN RB211-524G2-T-19 turbofan engines.
    [sbull] All SN RB211-524G3-T-19 turbofan engines.
    [sbull] All SN RB211-524H2-T-19 turbofan engines.
    [sbull] All SN RB211-524H-T-36 turbofan engines.
    The actions must be done within 62 months after the effective date 
of the AD for RB211-524G2-19, RB211-524G2-T-19, RB211-524G3-19, RB211-
524G3-T-19, RB211-524H2-19, RB211-524H2-T-19 engines, and within 16 
months after the effective date of the AD for SN RB211-524H-36, RB211-
524H-T-36 engines. You must use the service information described 
previously to perform the actions required by this AD.

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. 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,

[[Page 60844]]

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 the Effective Date

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

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

    On July 10, 2002, we issued a new version of 14 CFR part 39 (67 FR 
47998, July 22, 2002), which governs our AD system. This regulation now 
includes material that relates to special flight permits, alternative 
methods of compliance, and altered products. 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.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment; however, we invite you to submit any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2003-NE-36-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 rule 
that might suggest a need to modify it. If a person contacts us 
verbally, and that contact relates to a substantive part of this 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 AD 
in light of those comments.
    We are reviewing the writing style we currently use in regulatory 
documents. We are interested in your comments on whether the style of 
this document is clear, and your suggestions to improve the clarity of 
our communications with you. You may get more information about plain 
language at http://www.faa.gov/language and http://www.plainlanguage.gov.

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.

Regulatory Findings

    We have determined that this AD will not have federalism 
implications under Executive Order 13132. This AD will 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 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. Will 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 AD 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. 2003-NE-36-AD'' in your request.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

0
Accordingly, under 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

0
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]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

2003-21-11 Rolls-Royce plc: Amendment 39-13346. Docket No. 2003-NE-
36-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective November 
10, 2003.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to the Rolls-Royce plc (RR) engines in the 
following Table 1, with the dedicated generator rotor assembly, part 
number (P/N) UL39102, adaptor casing P/N UL26756 or UL26729, on the 
high speed gearbox (HSGB), and bearings P/N UL21029 installed.

                                 Table 1.--Affected Engines and Compliance Times
----------------------------------------------------------------------------------------------------------------
                                                                         Comply after the effective date of this
             Engine model                    Engine serial numbers                         AD
----------------------------------------------------------------------------------------------------------------
RB211-524G2-19........................  Before SN 13793...............  Within 62 months.
RB211-524G2-T-19......................  All SNs.......................  Within 62 months.
RB211-524G3-19........................  Before SN 13793...............  Within 62 months.
RB211-524G3-T-19......................  All SNs.......................  Within 62 months.
RB211-524H2-19........................  Before SN 13793...............  Within 62 months.
RB211-524H2-T-19......................  All SNs.......................  Within 62 months.
RB211-524H-36.........................  Before SN 13472...............  Within 16 months.
RB211-524H-T-36.......................  All SNs.......................  Within 16 months.
----------------------------------------------------------------------------------------------------------------

    These engines are installed on, but not limited to, Boeing 747 
and 767 series airplanes.

Unsafe Condition

    (d) This AD is prompted by several reports of dedicated 
generator rotor assembly bearing failures. We are issuing this AD to 
prevent possible uncommanded engine acceleration with no reaction to 
throttle movement, which could result in uncontrollable asymmetric 
engine thrust levels during takeoff or climb.

[[Page 60845]]

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified in Table 1 of 
this AD, unless the actions have already been done.

Removal and Installation of Adaptor Gearbox and Dedicated Generator On 
Engines In-Service

    (f) For engines in-service, do the following:
    (1) Remove the adaptor gearbox and the dedicated generator. 
Follow paragraph 3.C. of the Accomplishment Instructions of RR 
Mandatory Service Bulletin (MSB) No. RB.211-72-E037, dated March 26, 
2003.
    (2) Install the adaptor gearbox and the dedicated generator onto 
the engine. Follow paragraph 3.I. of the Accomplishment Instructions 
of RR MSB No. RB.211-72-E037, dated March 26, 2003.

Removal, Disassembly, Rework, Assembly, and Installation of Adaptor 
Gearbox and Dedicated Generator On Engines At Overhaul

    (g) For engines at overhaul, do the following:
    (1) Remove the adaptor gearbox and the dedicated generator. 
Follow paragraph 3.D. of the Accomplishment Instructions of RR MSB 
No. RB.211-72-E037, dated March 26, 2003.
    (2) Disassemble the adaptor gearbox. Follow paragraph 3.E. of 
the Accomplishment Instructions of RR MSB No. RB.211-72-E037, dated 
March 26, 2003.
    (3) Rework the existing gearbox adaptor casing assemblies (P/N 
UL26756 or P/N UL26729). Follow paragraph 3.F. of the Accomplishment 
Instructions of RR MSB No. RB.211-72-E037, dated March 26, 2003.
    (4) Assemble the adaptor gearbox. Follow paragraph 3.H. of the 
Accomplishment Instructions of RR MSB No. RB.211-72-E037, dated 
March 26, 2003.
    (5) Install the adaptor gearbox and the dedicated generator onto 
the engine. Follow paragraph 3.J. of the Accomplishment Instructions 
of RR MSB No. RB.211-72-E037, dated March 26, 2003.

Alternative Methods of Compliance

    (h) 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.

Material Incorporated by Reference

    (i) You must use Rolls-Royce plc Mandatory Service Bulletin No. 
RB.211-72-E037, dated March 26, 2003, to perform the inspections 
required by this AD. The Director of the Federal Register approved 
the incorporation by reference of this service bulletin in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51. You can get a 
copy from Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; 
telephone: 011-44-1332-242424; fax: 011-44-1332-245-418. You may 
review copies 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.

Related Information

    (j) CAA airworthiness directive 004-03-2003, dated March 26, 
2003, also addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on October 15, 2003.
Robert G. Mann,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 03-26470 Filed 10-23-03; 8:45 am]
BILLING CODE 4910-13-P

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