Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan Engines

[Federal Register Volume 69, Number 12 (Tuesday, January 20, 2004)]
[Rules and Regulations]
[Pages 2661-2663]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-759]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2003-NE-12-AD; Amendment 39-13434; AD 2004-01-20]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 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 series, RB211-524B, -524C2, -524D4, -
524G2, -524G3, and -524H series, and RB211-535C and -535E series 
turbofan engines with high pressure compressor (HPC) stage 3 disc 
assemblies, part numbers (P/Ns) LK46210, LK58278, LK67634, LK76036, 
UL11706, UL15358, UL22577, UL22578, and UL24738 installed. This AD 
allows disc assemblies not modified by a certain RR service bulletin to 
reach their full life only after the disc assemblies are modified with 
anti-corrosion protection. This AD results from the manufacturer's 
reassessment of the corrosion risk on HPC stage 3 disc assemblies that 
have not yet been modified with sufficient application of anti-
corrosion protection. We are issuing this AD to prevent corrosion-
induced uncontained disc failure, resulting in damage to the airplane.

DATES: This AD becomes effective February 24, 2004.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of February 24, 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: 011-44-1332-245-418.
    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, 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 FAA proposed to amend 14 CFR Part 39 
with a proposed airworthiness directive (AD). The proposed AD applies 
to RR RB211-22B series, RB211-524B, -524C2, -524D4, -524G2, -524G3, and 
-524H series, and RB211-535C and -535E series turbofan engines with HPC 
stage 3 disc assemblies, P/Ns LK46210, LK58278, LK67634, LK76036, 
UL11706, UL15358, UL22577, UL22578, and UL24738 installed. We published 
the proposed AD in the Federal Register on July 30, 2003 (68 FR 44672). 
That action proposed to allow disc assemblies not modified by a certain 
RR service bulletin to reach their full life only after the disc 
assemblies are modified with anti-corrosion protection.

[[Page 2662]]

Comments

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

Request To Add a Service Bulletin Reference

    Three commenters request that the FAA include a reference to RR 
Mandatory Service Bulletin (MSB) No. RB.211-72-9661, since the AD 
action is based on compliance with the procedures in this service 
bulletin.
    We agree that the AD action is based on performing the procedures 
in (MSB) No. RB.211-72-9661, however, we included all pertinent 
compliance requirements in the AD and chose to not incorporate by 
reference that MSB. However, because that MSB is the basis for the AD 
action, we have added a reference to it in the Related Information 
paragraph.

Request To Change Compliance Date

    One commenter requests that the AD be changed to have the same 
compliance dates as Service Bulletin (SB) No. RB.211-72-9434, Revision 
4, dated January 12, 2002. The commenter points out that the SB 
compliance time for discs in service more than 12 years is from the 
date of introduction of the original SB. The commenter also points out 
that the compliance time is based on the date of the SB revision date 
of January 4, 2002, and would, therefore, require rework to be 
completed before January 4, 2007.
    We partially agree. While the commenter is correct regarding the 
compliance date differences between the AD and the SB, the intent of 
the SB is met because the AD is consistent with the SB by mandating 
rework before exceeding the upper cyclic limit of the discs. Further, 
we agree that removal of discs in service more than 12 years from the 
date of the SB revision date, would require the AD to reference 1990 
instead of 1992. Therefore, we have changed this date in the AD 
accordingly.

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.

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

    On July 10, 2002, the FAA published a new version of 14 CFR part 39 
(67 FR 47997, July 22, 2002), which governs the FAA's AD system. That 
regulation now includes material that relates to altered products, 
special flight permits, and alternative methods of compliance. The 
material previously was included in each individual AD. Since the 
material is included in 14 CFR part 39, we will not include it in 
future AD actions.

Cost of Compliance

    There are about 2,000 RR RB211-22B series, RB211-524B, -524C2, -
524D4, -524G2, -524G3, and -524H series, and RB211-535C and -535E 
series turbofan engines of the affected design in the worldwide fleet. 
We estimate that 1,000 engines installed on airplanes of U.S. registry 
would be affected by this AD. We also estimate that it would take about 
31 work hours per engine to perform the actions, and that the average 
labor rate is $65 per work hour. Required parts would cost about 
$38,000 per engine. Based on these figures, the total cost of the AD to 
U.S. operators is estimated to be $40,015,000.

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-12-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:

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):

2004-01-20 Rolls-Royce plc: Amendment 39-13434. Docket No. 2003-NE-
12-AD.

Effective Date

    (a) This AD becomes effective February 24, 2004.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) RB211-22B series, 
RB211-524B, -524C2, -524D4, -524G2, -524G3, and -524H series, and 
RB211-535C and--535E series turbofan engines with high pressure 
compressor (HPC) stage 3 disc assemblies, part numbers (P/Ns) 
LK46210, LK58278, LK67634, LK76036, UL11706, UL15358, UL22577, 
UL22578, and UL24738 installed. These engines are installed on, but 
not limited to, Boeing 747, Boeing 757, Boeing 767, Lockheed L-1011, 
and Tupolev Tu204 series airplanes.

Unsafe Condition

    (d) This AD results from the manufacturer's reassessment of the 
corrosion risk on HPC stage 3 disc assemblies that have not yet been 
modified with sufficient application of anti-corrosion protection. 
The actions specified in this AD are intended to prevent corrosion-
induced uncontained disc failure, resulting in damage to the 
airplane.

Compliance

    (e) Compliance with this AD is required as indicated, unless 
already done.

Removal of HPC Stage 3 Discs

    (f) Remove from service affected HPC stage 3 disc assemblies 
identified in the following Table 1, using one of the following 
criteria:

[[Page 2663]]



                                 Table 1.--Affected HPC Stage 3 Disc Assemblies
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                                                                                                Rework band for
                                                         Rework band for                          cyclic life
                                                           cyclic life       Rework band for   accumulated on P/
                                                          accumulated on       cyclic life        Ns LK76036,
                                                        disc assemblies P/   accumulated on    UL11706, UL15358,
                     Engine model                         Ns LK46210 and    disc assembly P/N  UL22577, UL22578,
                                                         LK58278 (pre RR   LK67634 (pre RR SB   and UL24738 disc
                                                         service bulletin  No.RB.211-72-5420)   assemblies (pre
                                                         (SB) No. RB.211-                      RR SB No. RB.211-
                                                             72-5420)                               72-9434)
----------------------------------------------------------------------------------------------------------------
-22B series...........................................        4,000-6,200        7,000-10,000      11,500-14,000
-535E4 series.........................................                N/A                 N/A       9,000-15,000
-524B-02, B-B-02, B3-02, and B4 series, Pre and SB No.        4,000-6,000         7,000-9,000      11,500-14,000
 72-7730..............................................
-524B2 and C2 series, Pre SB No. 72-7730..............        4,000-6,000         7,000-9,000      11,500-14,000
-524B2-B-19 and C2-B-19, SB No. 72-7730...............        4,000-6,000         7,000-9,000       8,500-11,000
-524D4 series, Pre SB No. 72-7730.....................        4,000-6,000         7,000-9,000      11,500-14,000
-524D4-B series, SB No. 72-7730.......................        4,000-6,000         7,000-9,000       8,500-11,000
-524G2, G3, H, and H2 series..........................        4,000-6,000         7,000-9,000       8,500-11,000
----------------------------------------------------------------------------------------------------------------

    (1) For discs that entered into service before 1990, remove disc 
and rework as specified in paragraph (g)(2) of this AD, within five 
years from the effective date of this AD, but not to exceed the 
upper cyclic limit of Table 1 of this AD before rework. Discs 
reworked may not exceed the manufacturer's published cyclic limit in 
the time limits section of the manual.
    (2) For discs that entered into service in 1990 or later, remove 
disc within the cyclic life rework bands in Table 1 of this AD, or 
within 17 years after the date of the disc assembly entering into 
service, whichever is sooner, but not to exceed the upper cyclic 
limit of Table 1 of this AD before rework. Discs reworked may not 
exceed the manufacturer's published cyclic limit in the time limits 
section of the manual.
    (3) For disc assemblies that when new, were modified with an 
application of anti-corrosion protection and re-marked to P/N 
LK76036 (not previously machined) as specified by Part 1 of the 
original issue of RR service bulletin (SB) No. RB.211-72-5420, dated 
April 20, 1979, remove RB211-22B disc assemblies before accumulating 
10,000 cycles-in-service (CIS), and remove RB211-524 disc assemblies 
before accumulating 9,000 CIS.
    (4) If the disc assembly date of entry into service cannot be 
determined, the date of disc manufacture may be obtained from RR and 
used instead.

Optional Rework of HPC Stage 3 Discs

    (g) Rework HPC stage 3 disc assemblies that were removed in 
paragraph (f) of this AD as follows:
    (1) For disc assemblies that when new, were modified with an 
application of anti-corrosion protection and re-marked to P/N 
LK76036 (not previously machined) as specified by Part 1 of the 
original issue of RR SB RB.211-72-5420, dated April 20, 1979, rework 
disc assemblies and re-mark to either LK76034 or LK78814 using 
paragraph 2.B. of the Accomplishment Instructions of RR SB No. 
RB.211-72-5420, Revision 4, dated February 29, 1980. This rework 
constitutes terminating action to the removal requirements in 
paragraph (f) of this AD.
    (2) For all other disc assemblies, rework using Paragraph 3B. of 
the Accomplishment Instructions of RR SB No. RB.211-72-9434, 
Revision 4, dated January 12, 2000. This rework constitutes 
terminating action to the removal requirements in paragraph (f) of 
this AD.

    Note 1: If rework is done on disc assemblies that are removed 
before the disc assembly reaches the lower life of the cyclic life 
rework band in Table 1 of this AD, artificial aging of the disc to 
the lower life of the rework band, at time of rework, is required.

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 Service Bulletin No. RB.211-72-
5420, Revision 4, dated February 29, 1980, and Rolls-Royce Service 
Bulletin No. RB.211-72-9434, Revision 4, dated January 12, 2000, to 
perform the rework required by this AD. The Director of the Federal 
Register approved the incorporation by reference of these service 
bulletins in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. You 
can get copies from Rolls-Royce plc, PO Box 31, Derby, England, 
DE248BJ; telephone: 011-44-1332-242424; fax: 011-44-1332-245-418. 
You can 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) Civil Aviation Authority airworthiness directive 004-01-94, 
dated January 4, 2002, and RR Mandatory Service Bulletin No. RB.211-
72-9661, Revision 3, dated December 20, 1999, pertain to the subject 
of this AD.

    Issued in Burlington, Massachusetts, on January 8, 2004.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 04-759 Filed 1-16-04; 8:45 am]
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