Airworthiness Directives; Rolls-Royce plc RB211 Trent 800 Series Turbofan Engines

[Federal Register Volume 69, Number 144 (Wednesday, July 28, 2004)]
[Rules and Regulations]
[Pages 44925-44927]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-16548]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2003-NE-38-AD; Amendment 39-13736; AD 2004-15-02]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 Trent 800 Series 
Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

[[Page 44926]]


ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
Rolls-Royce plc (RR) models RB211 Trent 875-17, Trent 877-17, Trent 
884-17, Trent 884B-17, Trent 892-17, Trent 892B-17, and Trent 895-17 
turbofan engines with low pressure (LP) compressor fan blades part 
number (P/N) FW18548, installed. This AD requires LP compressor fan 
blade replacement with new or previously reworked blades, or rework of 
the existing LP compressor fan blades. This AD results from a number of 
new production LP compressor fan blades found with surfaces formed 
outside of design intent. Findings included sharp edges, burrs, and 
damage present in the area at the top of the shear key slots. We are 
issuing this AD to prevent possible multiple uncontained LP compressor 
fan blade failure, due to cracking in the blade root caused by 
increased stresses in the shear key slots.

DATES: This AD becomes effective September 1, 2004. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of September 1, 2004.

ADDRESSES: You can get the service information identified in this AD 
from Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; telephone: 
011-44-1332-242424; fax: 011-44-1332-245418.
    You may examine the AD docket at the FAA, New England Region, 
Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA. You may examine the service information at the FAA, New 
England Region, Office of the Regional Counsel, 12 New England 
Executive Park, Burlington, MA; or at the National Archives and Records 
Administration (NARA). For information on the availability of this 
material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.

FOR FURTHER INFORMATION CONTACT: Christopher Spinney, Aerospace 
Engineer, Engine Certification Office, FAA, Engine And Propeller 
Directorate, 12 New England Executive Park; Burlington, MA 01803-5299; 
telephone (781) 238-7175; fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR Part 39 
with a proposed AD. The proposed AD applies to Rolls-Royce plc models 
RB211 Trent 875-17, Trent 877-17, Trent 884-17, Trent 892-17, Trent 
892B-17, and Trent 895-17 turbofan engines with LP compressor fan 
blades P/N FW18548 installed. We published the proposed AD in the 
Federal Register on October 23, 2003 (68 FR 60627). That action 
proposed to require LP compressor fan blade replacement with new or 
previously reworked blades, or rework of the existing LP compressor fan 
blades.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comments received.

Include Trent 884B-17 Model

    One commenter requests that we add the Trent 884B-17 model to the 
AD applicability, as it is missing from the proposal.
    We agree, and we have added the Trent 884B-17 model to 
applicability paragraph (c) and to Table 1. There are currently no U.S. 
operators of this engine model.

Include a Service Bulletin Reference

    Two commenters request that we include a reference to RR Service 
Bulletin (SB) No. RB.211-72-E055, Revision 1, dated June 20, 2003, 
which contains source life information on the cycle limits specified in 
the proposal compliance section.
    We agree, and we have added a reference to RR Alert Service 
Bulletin (ASB) No. RB.211-72-AE055, Revision 3, dated May 28, 2004, in 
paragraph (i) of the AD for informational purposes only.

Changes to SB No. RB.211-72-E055

    RR revised SB No. RB.211-72-E055, Revision 2, to an Alert SB No. 
RB.211-72-AE055, Revision 3, issued on May 28, 2004. The bulletin 
changes the reference to Boeing 777-200IGW to Boeing 777-200ER as the 
IGW designation is old terminology. The revision also changes the 
limits from using the lowest limit on mixed model configurations to 
using a combination of the lives for mixed model configurations. We 
concur in part with the changes to the SB and have incorporated into 
the AD the changes that are pertinent. We also discovered that the 
Boeing 777-200IGW and 777-200ER models are not official, type-certified 
designations, so we removed reference to these models from the AD. The 
incorporated changes do not represent a substantive change in the AD 
compliance requirements and therefore do not require new notice of 
proposed rulemaking.

Conclusion

    We have carefully reviewed the available data, including the 
comments received, and determined that air safety and the public 
interest require adopting the AD with the changes described previously. 
We have determined that these changes will neither increase the 
economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

    There are about 350 RR models RB211 Trent 875-17, Trent 877-17, 
Trent 884-17, Trent 884B-17, Trent 892-17, Trent 892B-17, and Trent 
895-17 turbofan engines of the affected design in the worldwide fleet. 
We estimate that 106 engines installed on airplanes of U.S. registry 
would be affected by this AD. We also estimate that it would take about 
100 work hours per engine to perform blade rework, and that the average 
labor rate is $65 per work hour. Based on these figures, we estimate 
the total cost of the AD to U.S. operators to be $689,000.

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 this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866;
    (2) Is not a ``significant rule'' under 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-38-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 14 CFR part 39 as follows:

[[Page 44927]]

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 (AD):

2004-15-02 Rolls-Royce plc: Amendment 39-13736. Docket No. 2003-NE-
38-AD.

Effective Date

    (a) This AD becomes effective September 1, 2004.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) models RB211 Trent 
875-17, Trent 877-17, Trent 884-17, Trent 884B-17, Trent 892-17, 
Trent 892B-17, and Trent 895-17 turbofan engines, with low pressure 
(LP) compressor fan blades, part number (P/N) FW18548, installed. 
These engines are installed on, but not limited to, Boeing 777 
series airplanes.

Unsafe Condition

    (d) This AD was prompted by a number of new production LP 
compressor blades found with surfaces formed outside of design 
intent. Findings included sharp edges, burrs, and damage present in 
the area at the top of the shear key slots. We are issuing this AD 
to prevent possible multiple uncontained LP compressor fan blade 
failure, due to cracking in the blade root caused by increased 
stresses in the shear key slots.

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.

Actions Required for LP Compressor Fan Blades

    (f) Replace LP compressor fan blades with new or previously 
reworked LP compressor blades at or before accumulating the 
specified cycles-since-new (CSN) in the following Table 1, or rework 
the existing blades as specified in paragraph (g) of this AD.
    (g) Rework LP compressor fan blades at or before accumulating 
the specified CSN in the following Table 1. Follow paragraphs 
3.B.(1) through 3.B.(22) of Accomplishment Instructions of RR 
service bulletin (SB) No. RB.211-72-E044, Revision 1, dated May 2, 
2003, to do the blade rework.

                        Table 1.--LP Compressor Fan Blade Replacement or Rework Schedule
----------------------------------------------------------------------------------------------------------------
                                                                            Replace or rework LP compressor fan
        For engines installed on:                  Engine model:              blades at or before accumulating
----------------------------------------------------------------------------------------------------------------
Boeing 777-300 Series...................  Trent 884-17...................  2,400 CSN.
Boeing 777-300 Series...................  Trent 884B-17..................  2,400 CSN.
Boeing 777-300 Series...................  Trent 892-17...................  2,400 CSN.
Boeing 777-200 Series...................  Trent 895-17...................  3,200 CSN.
Boeing 777-200 Series...................  Trent 892-17...................  4,100 CSN.
Boeing 777-200 Series...................  Trent 892B-17..................  4,100 CSN.
Boeing 777-200 Series...................  Trent 884-17...................  4,100 CSN.
Boeing 777-200 Series...................  Trent 875-17...................  4,100 CSN.
Boeing 777-200 Series...................  Trent 877-17...................  4,100 CSN.
----------------------------------------------------------------------------------------------------------------

    (h) For engines moved between configurations, the cycles 
remaining may be calculated using either of the following:
    (1) Subtract the total CSN from the most limiting 
configuration's limit from Table 1; or
    (2) Calculate the cycles remaining using the following equation:
    Where:
    Xr = Cycles remaining in current configuration.
    Lc = Cyclic limit of current configuration from Table 1 of this 
AD.
    Xn = Cycles accumulated in configuration n.
    Ln = Cyclic limit in configuration n from Table 1.

    (i) Information on the source life of the cycle limits in Table 
1 of this AD can be found in RR Alert SB No. RB.211-72-AE055, 
Revision 3, dated May 28, 2003.

Alternative Methods of Compliance

    (j) 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

    (k) You must use RR SB No. RB.211-72-E044, Revision 1, dated May 
2, 2003, to perform the blade rework 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: 011-44-1332-245418. You can review copies at FAA, New England 
Region, Office of the Regional Counsel, 12 New England Executive 
Park, Burlington, MA; or at the National Archives and Records 
Administration (NARA). For information on the availability of this 
material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.

Related Information

    (l) CAA airworthiness directive 001-05-2003, dated June 20, 
2003, and RR Alert SB No. RB.211-72-AE055, Revision 3, dated May 28, 
2004, pertain to the subject of this AD.

    Issued in Burlington, Massachusetts, on July 14, 2004.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-16548 Filed 7-27-04; 8:45 am]
BILLING CODE 4910-13-P

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