Airworthiness Directives; Rolls-Royce plc RB211-22B, RB211-524, and RB211-535 Series Turbofan Engines

[Federal Register Volume 69, Number 183 (Wednesday, September 22, 2004)]
[Rules and Regulations]
[Pages 56683-56687]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-21173]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2003-NE-57-AD; Amendment 39-13798; AD 2004-19-04]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211-22B, RB211-524, 
and RB211-535 Series Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
Rolls-Royce plc (RR) RB211-22B, RB211-524, and RB211-535 series 
turbofan engines. This AD requires revising the Time Limits Manual for 
RR RB211-22B, RB211-524, and RB211-535 series turbofan engines. These 
revisions include required enhanced inspection of selected critical 
life-limited parts at each piece-part exposure. This AD results from 
the need to require enhanced inspection of selected critical life-
limited parts of RB211-22B, RB211-524, and RB211-535 series turbofan 
engines. We are issuing this AD to prevent failure of critical life-
limited rotating engine parts, which could result in an uncontained 
engine failure and damage to the airplane.

DATES: This AD becomes effective October 27, 2004.

ADDRESSES: You can get the service information identified in this AD 
from Rolls-Royce plc, P.O. Box 31, Derby, DE24 8BJ, United Kingdom; 
telephone: 011-44-1332-242424; fax: 011-44-1332-249936.
    You may examine the AD docket at the FAA, New England Region, 
Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA.

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 airworthiness directive (AD). The proposed AD applies 
to Rolls-Royce plc RB211-22B, RB211-524, and RB211-535 series turbofan 
engines. We published the proposed AD in the Federal Register on March 
12, 2004 (69 FR 11821). That action proposed to require revisions to 
the Time Limits Manual for RR RB211-22B, RB211-524, and RB211-535 
series turbofan engines to include required enhanced inspection of 
selected critical parts at each piece-part exposure.

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.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We received no

[[Page 56684]]

comments on the proposal or on the determination of the cost to the 
public.

Conclusion

    We have carefully reviewed the available data and determined that 
air safety and the public interest require adopting the AD as proposed.

Costs of Compliance

    There are about 882 RB211-22B and RB211-524 series engines and 
about 1,160 RB211-535 series engines of the affected design in the 
worldwide fleet. We estimate that 30 RB211-22B and RB211-524 series 
engines and 620 RB211-535 series engines installed on airplanes of U.S. 
registry will be affected by this AD. We also estimate that it will 
take about 75 work hours per engine to perform the inspections, and 
that the average labor rate is $65 per work hour. Since this is an 
added inspection requirement, included as part of the normal 
maintenance cycle, no additional part costs are involved. Based on 
these figures, the total cost impact of this AD on U.S. operators is 
estimated to be $3,169,000.

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-57-AD'' in your request.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the FAA amends 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 Federal Aviation Administration (FAA) amends Sec.  39.13 by 
adding the following new airworthiness directive (AD):

2004-19-04 Rolls-Royce plc: Docket No. 2003-NE-57-AD.

Effective Date

    (a) This AD becomes effective October 27, 2004.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) RB211-22B, RB211-
524, and RB211-535 series turbofan engines. These engines are 
installed on, but not limited to, Boeing 747, 757, 767, Lockheed L-
1011, and Tupolev Tu204 airplanes.

Unsafe Condition

    (d) This AD results from the need to require enhanced inspection 
of selected critical life-limited parts of RB211-22B, RB211-524, and 
RB211-535 series turbofan engines. The actions specified in this AD 
are intended to prevent failure of critical life-limited rotating 
engine parts, which could result in an uncontained engine failure 
and damage to the airplane.

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.
    (f) Within the next 40 days after the effective date of this AD, 
revise the Time Limits Manual (TLM), and for air carrier operations 
revise the approved continuous airworthiness maintenance program, by 
adding the following text and the applicable table determined by 
engine model number:

``GROUP A PARTS MANDATORY INSPECTION

    (1) Inspections referred to as `Focus Inspect' in the applicable 
Engine Manual inspection Task are mandatory inspections for the 
components given below, when the conditions that follow are 
satisfied:
    (i) When the component has been completely disassembled to 
piece-part level as given in the applicable disassembly procedures 
contained in the Engine Manual; and
    (ii) The part has more than 100 recorded flight cycles in 
operation since the last piece-part inspection; or
    (iii) The component removal was for damage or a cause directly 
related to its removal; or
    (iv) Where serviceable used components, for which the inspection 
history is not fully known, are to be used again.
    (2) The list of Group A Parts for RB211-22B engines is specified 
below:

----------------------------------------------------------------------------------------------------------------
                                                                                         Inspected per overhaul
 Part nomenclature (RB211-22B series engines)                Part number                      manual task
----------------------------------------------------------------------------------------------------------------
Low Pressure Compressor Rotor Disc............  All..................................           72-31-12-200-006
Low Pressure Compressor Rotor Shaft...........  All..................................           72-31-20-200-000
Intermediate Pressure Compressor Rotor Shaft    All..................................           72-32-31-200-000
 Stages 1 to 5.
Intermediate Pressure Compressor Rotor Shaft    All..................................           72-32-31-200-001
 Stages 6 to 7.
Intermediate Pressure Compressor Rotor Rear     All..................................           72-33-31-200-000
 Stubshaft.
High Pressure Compressor Rotor Stage 1 to 2     All..................................           72-41-31-200-000
 Disc Shaft.
High Pressure Compressor Rotor Stage 3 Disc...  All..................................           72-41-31-200-001
High Pressure Compressor Rear Rotor Shaft       All..................................           72-41-31-200-002
 Assembly.
Compressor/Turbine Joint Flange Support Disc..  All..................................           72-41-31-200-003
High Pressure Turbine Disc....................  All..................................           72-41-51-200-000
Intermediate Pressure Turbine Disc............  All..................................           72-51-31-200-000
Intermediate Pressure Turbine Shaft...........  All..................................           72-51-33-200-000
Low Pressure Turbine Stage 1 Disc.............  All..................................           72-51-61-200-000
Low Pressure Turbine Stage 2 Disc.............  All..................................           72-51-61-200-001
Low Pressure Turbine Stage 3 Disc.............  All..................................           72-51-61-200-002
Low Pressure Turbine Shaft....................  All..................................           72-51-63-200-000
----------------------------------------------------------------------------------------------------------------


[[Page 56685]]

    (3) The list of Group A Parts for RB211-535 series engines is 
specified below:

----------------------------------------------------------------------------------------------------------------
                                                                                         Inspected per overhaul
 Part nomenclature (RB211-535 series engines)                Part number                      manual task
----------------------------------------------------------------------------------------------------------------
Low Pressure Compressor Rotor Disc............  All..................................           72-31-12-200-000
Low Pressure Compressor Rotor Shaft...........  All..................................           72-31-20-200-000
Intermediate Pressure Compressor Rotor Shaft..  All..................................           72-32-31-200-001
Intermediate Pressure Compressor Rotor Rear     All..................................           72-33-21-200-000
 Stubshaft.
High Pressure Compressor Rotor Stage 1 & 2      All..................................           72-41-31-200-000
 Disc.
High Pressure Compressor Rotor Stage 3 Disc...  All..................................           72-41-31-200-001
High Pressure Compressor Rear Rotor Shaft       All..................................           72-41-31-200-002
 Assembly.
Compressor/Turbine Joint Flange Support Disc    All..................................           72-41-31-200-003
 (applicable to -535C only).
High Pressure Turbine Disc....................  All..................................           72-41-51-200-000
Intermediate Pressure Turbine Rotor Disc......  All..................................           72-51-31-200-000
Intermediate Pressure Turbine Shaft...........  All..................................           72-51-33-200-000
Low Pressure Turbine Stage 1 Disc.............  All..................................           72-51-61-200-000
Low Pressure Turbine Stage 2 Disc.............  All..................................           72-51-61-200-001
Low Pressure Turbine Stage 3 Disc.............  All..................................           72-51-61-200-002
Low Pressure Turbine Shaft....................  All..................................           72-51-63-200-000
----------------------------------------------------------------------------------------------------------------

    (4) The list of Group A Parts for RB211-524B, -524B3, and -524B4 
series engines is specified below:

----------------------------------------------------------------------------------------------------------------
 Part nomenclature (RB211-524B, -524B3, and -                                            Inspected per overhaul
             524B4 series engines)                           Part number                      manual task
----------------------------------------------------------------------------------------------------------------
Low Pressure Compressor Rotor Disc............  All..................................        \1\ 72-31-12-200-05
                                                                                            \2\ 72-31-12-200-013
Low Pressure Compressor Rotor Shaft...........  All..................................           72-31-20-200-000
Intermediate Pressure Compressor Stage 1 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 2 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 3 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 4 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 5 Disc.  All..................................           72-32-31-200-001
Intermediate Pressure Compressor Rotor Shaft    All..................................           72-32-31-200-001
 Stages 6 to 7.
Intermediate Pressure Compressor Front          All..................................           72-32-31-200-008
 Stubshaft Drive Cone.
Intermediate Pressure Compressor Rotor Rear     All..................................           72-33-21-200-010
 Stubshaft.
High Pressure Compressor Rotor Stage 1 to 2     All..................................           72-41-31-200-000
 Disc.
High Pressure Compressor Rotor Stage 3 Disc...  All..................................           72-41-31-200-001
High Pressure Compressor Rear Rotor Shaft       All..................................           72-41-31-200-002
 Assembly.
High Pressure Compressor/Turbine Joint Flange   All..................................           72-41-31-200-006
 Support Disc.
High Pressure Turbine Bearing Inner Race        All..................................           72-41-51-200-005
 Support Panel.
High Pressure Turbine Disc....................  All..................................           72-41-51-200-019
High Pressure Turbine Conical Shaft...........  All..................................           72-41-51-200-021
Intermediate Pressure Turbine Disc............  All..................................           72-51-31-200-003
Intermediate Pressure Turbine Shaft...........  All..................................           72-51-33-200-005
Low Pressure Turbine Stage 1 Disc.............  All..................................       \1\ 72-51-61-200-000
                                                                                            \2\ 72-51-61-200-007
Low Pressure Turbine Stage 2 Disc.............  All..................................       \1\ 72-51-61-200-001
                                                                                            \2\ 72-51-61-200-008
Low Pressure Turbine Stage 3 Disc.............  All..................................       \1\ 72-51-61-200-002
                                                                                            \2\ 72-51-61-200-009
Low Pressure Turbine Shaft....................  All..................................       \1\ 72-51-63-200-000
                                                                                           \2\ 72-51-63-200-003
----------------------------------------------------------------------------------------------------------------
\1\ (Configuration 1).
\2\ (Configuration 2).

    (5) The list of Group A Parts for RB211-524B2, -524C2, and -
524D4 series engines is specified below:

----------------------------------------------------------------------------------------------------------------
 Part nomenclature (RB211-524B2, -524C2, and -                                           Inspected per overhaul
             524D4 series engines)                           Part number                      manual task
----------------------------------------------------------------------------------------------------------------
Low Pressure Compressor Rotor Disc............  All..................................           72-31-12-200-013
Low Pressure Compressor Rotor Shaft...........  All..................................           72-31-20-200-000
Intermediate Pressure Compressor Stage 1 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 2 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 3 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 4 Disc.  All..................................           72-32-31-200-000

[[Page 56686]]

 
Intermediate Pressure Compressor Stage 5 Disc.  All..................................           72-32-31-200-001
Intermediate Pressure Compressor Rotor Shaft    All..................................           72-32-31-200-001
 Stages 6 to 7.
Intermediate Pressure Compressor Front          All..................................           72-32-31-200-008
 Stubshaft Drive Cone.
Intermediate Pressure Compressor Rotor Rear     All..................................           72-33-21-200-010
 Stubshaft.
High Pressure Compressor Rotor Stage 1 to 2     All..................................           72-41-31-200-000
 Disc.
High Pressure Compressor Rotor Stage 3 Disc...  All..................................           72-41-31-200-001
High Pressure Compressor Rear Rotor Shaft       All..................................           72-41-31-200-002
 Assembly.
High Pressure Compressor/Turbine Joint Flange   All..................................           72-41-31-200-006
 Support Disc.
High Pressure Turbine Bearing Inner Race        All..................................           72-41-51-200-005
 Support Panel.
High Pressure Turbine Disc....................  All..................................           72-41-51-200-019
High Pressure Turbine Conical Shaft...........  All..................................           72-41-51-200-021
Intermediate Pressure Turbine Rotor Disc......  All..................................           72-51-31-200-003
Intermediate Pressure Turbine Shaft...........  All..................................           72-51-33-200-005
Low Pressure Turbine Stage 1 Disc.............  All..................................           72-51-61-200-007
Low Pressure Turbine Stage 2 Disc.............  All..................................           72-51-61-200-008
Low Pressure Turbine Stage 3 Disc.............  All..................................           72-51-61-200-009
Low Pressure Turbine Shaft....................  All..................................           72-51-63-200-003
----------------------------------------------------------------------------------------------------------------

    (6) The list of Group A Parts for RB211-524G and -524H series 
engines is specified below:

----------------------------------------------------------------------------------------------------------------
Part nomenclature (RB211-524G and -524H series                                           Inspected per overhaul
                   engines)                                  Part number                      manual task
----------------------------------------------------------------------------------------------------------------
Low Pressure Compressor Rotor Disc............  All..................................           72-31-12-200-000
Low Pressure Compressor Rotor Shaft...........  All..................................           72-31-20-200-000
Intermediate Pressure Compressor Stage 1 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 2 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 3 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 4 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Stage 5 Disc.  All..................................           72-32-31-200-000
Intermediate Pressure Compressor Rotor Shaft    All..................................           72-32-31-200-001
 Stages 6 to 7.
Intermediate Pressure Compressor Front          All..................................           72-32-31-200-008
 Stubshaft Drive Cone.
Intermediate Pressure Compressor Rotor Rear     All..................................           72-33-21-200-010
 Stubshaft.
High Pressure Compressor Rotor Stage 1 to 2     All..................................       \1\ 72-41-31-200-000
 Disc.
High Pressure Compressor Rotor Stage 3 Disc...  All..................................       \1\ 72-41-31-200-001
High Pressure Compressor Rear Rotor Shaft       All..................................       \1\ 72-41-31-200-002
 Assembly.
Compressor/Turbine Joint Flange Support Disc..  All..................................       \1\ 72-41-31-200-003
High Pressure Compressor Rotor Shaft Assembly.  All..................................       \2\ 72-41-31-200-014
High Pressure Turbine Disc....................  All..................................       \1\ 72-41-51-200-010
                                                                                            \2\ 72-41-51-200-024
Intermediate Pressure Turbine Disc............  All..................................           72-51-31-200-003
Intermediate Pressure Turbine Shaft...........  All..................................           72-51-33-200-005
Low Pressure Turbine Stage 1 Disc.............  All..................................           72-51-61-200-007
Low Pressure Turbine Stage 2 Disc.............  All..................................           72-51-61-200-008
Low Pressure Turbine Stage 3 Disc.............  All..................................           72-51-61-200-009
Low Pressure Turbine Shaft....................  All..................................        72-51-63-200-003''
----------------------------------------------------------------------------------------------------------------
\1\ (Configuration 1).
\2\ (Configuration 2).

Alternative Methods of Compliance

    (g) You must perform these mandatory inspections using the TLM 
and the applicable Engine Manual unless you receive approval to use 
an alternative method of compliance under paragraph (h) of this AD. 
Section 43.16 of the Federal Aviation Regulations (14 CFR 43.16) may 
not be used to approve alternative methods of compliance or 
adjustments to the times in which these inspections must be 
performed.
    (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.

Maintaining Records of the Mandatory Inspections

    (i) You have met the requirements of this AD by using a TLM 
changed as specified in paragraph (f) of this AD, and, for air 
carriers operating under part 121 of the Federal Aviation 
Regulations (14 CFR part 121), by modifying your continuous 
airworthiness maintenance plan to reflect those changes. You must 
maintain records of the mandatory inspections that result from those 
changes to the TLM according to the regulations governing your 
operation. You do not need to record each piece-part inspection as 
compliance to this AD. For air carriers operating under part 121, 
you may use either the system established to comply with section 
121.369 or use an alternative system that your principal inspector 
has accepted if that alternative system:
    (1) Includes a method for preserving and retrieving the records 
of the inspections resulting from this AD; and
    (2) Meets the requirements of Sec.  121.369(c); and
    (3) Maintains the records either indefinitely or until the work 
is repeated.
    (j) These record keeping requirements apply only to the records 
used to document the mandatory inspections required as a result of 
revising the Time Limits Manual as specified in paragraph (f) of 
this AD, and do not alter or amend the record keeping requirements 
for any other AD or regulatory requirement.

[[Page 56687]]

Material Incorporated by Reference

    (k) None.

Related Information

    (l) Civil Aviation Authority (CAA) airworthiness directives No. 
G-2003-0006, dated September 18, 2003, No. G-2003-0009, dated 
September 19, 2003, and No. G-2003-0007, dated September 18, 2003 
also address the subject of this AD.

    Issued in Burlington, Massachusetts, on September 10, 2004.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-21173 Filed 9-21-04; 8:45 am]
BILLING CODE 4910-13-P

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