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

[Federal Register Volume 70, Number 142 (Tuesday, July 26, 2005)]
[Rules and Regulations]
[Pages 43036-43039]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-14576]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NE-40-AD; Amendment 39-14202; AD 2005-15-13]
RIN 2120-AA64


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

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

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

SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
Rolls Royce plc (RR) RB211-524 series turbofan engines with certain 
part number (P/N) intermediate pressure (IP) compressor stage 5 disks 
installed. This AD requires new reduced IP compressor stage 5 disk 
cyclic limits. This AD also requires removing from service affected 
disks that already exceed the new reduced cyclic limit, and removing 
other affected disks before exceeding their cyclic limits, using a 
drawdown schedule. This AD results from the discovery of cracks in the 
cooling air hole areas of the disk front spacer arm. We are issuing 
this AD to prevent IP compressor stage 5 disk failure, which could 
result in uncontained engine failure and possible damage to the 
airplane.

DATES: This AD becomes effective August 30, 2005. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of August 30, 2005.

ADDRESSES: You can get the service information identified in this AD 
from Rolls-Royce plc, P.O. Box 31 Derby, DE248BJ, 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. 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: Ian Dargin, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803-

[[Page 43037]]

5299; telephone (781) 238-7178; fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39 
with a proposed AD. The proposed AD applies to (RR) RB211-524 series 
turbofan engines with certain P/N IP compressor stage 5 disks 
installed. We published the proposed AD in the Federal Register on 
February 2, 2005 (70 FR 5390). That action proposed to require:
    <bullet> Establishing new reduced IP compressor stage 5 disk cyclic 
limits.
    <bullet> Removing from service affected disks that already exceed 
the new reduced cyclic limit.
    <bullet> Removing other affected disks before exceeding their 
cyclic limits, using a drawdown schedule.
    <bullet> Allowing optional inspections at each shop visit or an on-
wing eddy current inspection to extend the disk life beyond the 
specified life.

Examining the AD Docket

    You may examine the AD Docket (including any comments and service 
information), by appointment, between 8:00 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 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 939 RR RB211-524 series turbofan engines of the 
affected design in the worldwide fleet. We estimate that this AD will 
affect about 35 engines installed on airplanes of U.S. registry. We 
also estimate that it will take about 8 work hours per engine to 
perform an inspection, and 300 work hours per engine to replace an IP 
compressor stage 5 disk. The average labor rate is $65 per work hour. 
Required parts will cost about $49,000 per engine. Based on these 
figures, we estimate the total cost of the AD to U.S. operators to be 
$2,415,700.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, Section 106, describes the 
authority of the FAA Administrator. Subtitle VII, Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    We are issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701, ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
rulemaking action.

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. 2002-NE-40-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:

2005-15-13 Rolls-Royce plc: Amendment 39-14202. Docket No. 2002-NE-
40-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective August 
30, 2005.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to the Rolls-Royce plc (RR) RB211-524 series 
turbofan engines listed in the following Table 1, with intermediate 
pressure (IP) compressor stage 5 disk part numbers (P/Ns) listed in 
Table 2 of this AD, installed.

                                        Table 1.--Engine Models Affected
----------------------------------------------------------------------------------------------------------------
 
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-524B-02               -524B-B-02             -524B3-02              -524B4-02              -524B4-D-02
-524B2-19              -524B2-B-19            -524C2-19              -524C2-B-19            -524D4-19
-524D4-B-19            -524D4X-19             -524D4X-B-19           -524D4-39              -524D4-B-39
-524G2-19              -524G2-T-19            -524G3-19              -524G3-T-19            -524H2-19
-524H2-T-19            -524H-36               -524H-T-36
----------------------------------------------------------------------------------------------------------------

    These engines are installed on, but not limited to, Boeing 747, 
767, and Lockheed L-1011 airplanes.

                               Table 2.--IP Compressor Stage 5 Disk P/Ns Affected
----------------------------------------------------------------------------------------------------------------
 
----------------------------------------------------------------------------------------------------------------
LK60130                LK65932                LK69021                LK81269                LK83282

[[Page 43038]]

 
LK83283                UL12290                UL15743                UL15744                UL15745
UL19132                UL20785                UL20832                UL23291                UL25011
UL36821                UL36977                UL36978                UL36979                UL36980
UL36981                UL36982                UL36983                UL37078                UL37079
UL37080                UL37081                UL37082                UL37083                UL37084
----------------------------------------------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from discovery of cracks in the cooling air 
hole areas of the disk front spacer arm. The actions specified in 
this AD are intended to prevent IP compressor stage 5 disk failure, 
which could result in uncontained engine failure and possible 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.

Cycle Limits

    (f) Change the service cyclic limits contained in the Time 
Limits Manual, 05-10-01, for the IP compressor stage 5 discs 
installed in the engine models listed in the following Table 3, 
within 30 days after the effective date of this AD.

  Table 3.--Cyclic Life Limits Without Qualifying Magnetic Particle Inspection (MPI) or Eddy Current Inspection
                                                      (ECI)
----------------------------------------------------------------------------------------------------------------
                                                                      Engine models
                                       -------------------------------------------------------------------------
                                                                   -524D4, D4-B,                  -524B-02, B-B-
      Date of reduced life limit         -524G2, G2-T, G3, G3-T,   D4-B-39, D4X,   -524B2, B2-B,  02, B3-02, B4-
                                         H2, H2-T, H-36, H-T-36    D4X-B, D4-39    C2, C2-B  CIS    02, B4-D-02
                                                                        CIS                             CIS
----------------------------------------------------------------------------------------------------------------
November 30, 2002.....................  13,500 cycles-in-service          16,150          16,000          16,200
                                         (CIS).
April 1, 2003.........................  13,500 CIS..............          13,500          13,500          14,000
December 1, 2003......................  12,000 CIS..............          13,500          13,500          14,000
December 1, 2004......................  11,000 CIS..............          13,500          12,000          12,000
December 1, 2005......................  11,000 CIS..............          12,000          12,000          12,000
December 1, 2008......................  7,830 CIS...............           8,700           8,900           9,000
----------------------------------------------------------------------------------------------------------------

Optional Inspections

    (g) Before December 1, 2008, optional inspections are allowed at 
each shop visit or on-wing to extend the disk life. Guidance for 
these inspections is provided in paragraphs (h) or (i) of this AD.

Optional Inspections at Shop Visit

    (h) Perform optional inspections at shop visit, as follows:
    (1) Remove corrosion protection from IP stage 5 disk. 
Information on corrosion protection removal can be found in the 
Engine Manual.
    (2) Visual-inspect and binocular-inspect the IP stage 5 disk for 
corrosion pitting at the cooling air holes and defender holes in the 
disk front spacer arm. Follow paragraph 3.C. of the Accomplishment 
Instructions of RR MSB No. RB.211-72-D428, Revision 3, dated June 
30, 2003. Information on disk corrosion pitting limits can be found 
in the Engine Manual.
    (i) If the disk has corrosion pitting in excess of limits, 
remove the disk from service.
    (ii) If the disk is free from corrosion pitting, MPI the entire 
disk. Information on MPI can be found in the Engine Manual. If the 
disk passes MPI and no cracks are found, complete all other 
inspections, re-apply corrosion protection to disk, and return the 
disk to service in accordance with the cyclic limits allowed by 
paragraph (k) of this AD. Information on MPI limits can be found in 
the Engine Manual. Information on re-applying corrosion protection 
can be found in RR Repair FRS5900.
    (iii) If the disk has corrosion pitting within limits, ECI all 
disk cooling air holes, defender holes, and inner and outer faces. 
Follow paragraph 3.D. of the Accomplishment Instructions of RR MSB 
No. RB.211-72-D428, Revision 3, dated June 30, 2003. Information on 
corrosion pitting limits can be found in the Engine Manual. If the 
disk passes ECI and no cracks are found, MPI the entire disk. 
Information on MPI can be found in the Engine Manual. If the disk 
passes MPI and no cracks are found, re-apply corrosion protection to 
disk, and return the disk to service in accordance with the cyclic 
limits allowed by paragraph (k) of this AD.

Optional On-Wing EC Inspections

    (i) For RB211-524B2/C2 and RB211-524B4/D4 engine models, an on-
wing ECI of the IP compressor stage 5 disk may be performed only 
once between shop visit inspections. Follow paragraphs 3.A. through 
3.F. of the Accomplishment Instructions of RR SB No. RB.211-72-E148, 
dated March 13, 2003, and RR SB No. RB.211-72-E150, Revision 1, 
dated June 4, 2003, respectively, to do the ECI. If the disk passes 
the ECI and no cracks are found, an extension is allowed as 
specified in paragraph (k) of this AD.

Definition of Shop Visit

    (j) For the purposes of this AD, a shop visit is defined as the 
separation of an engine major case flange. This definition excludes 
shop visits when only field maintenance type activities are 
performed in lieu of performing them on-wing. (i.e., for purposes 
such as to perform an on-wing inspection of a tail engine 
installation on a Lockheed L-1011 airplane).

Cyclic Life Extension

    (k) Disks that pass an optional inspection may remain in service 
after that inspection for the additional cycles listed in the 
following Table 4, until the next inspection, or December 1, 2008, 
or until the cyclic life limit published in the Time Limits Manual 
is reached, whichever occurs first.

[[Page 43039]]



                                         Table 4.--Cyclic Life Extension
----------------------------------------------------------------------------------------------------------------
                                                   -524G2, G2-T,
                                                   G3, G3-T, H2,   -524D4, D4-B,   -524B2, B2-B,  -524B-02, B-B-
                  Engine models                   H2-T, H-36, H-   D4-B-39, D4X,     C2, C2-B     02, B3-02, B4-
                                                  T-36  (cycles)   D4X-B, D4-39      (cycles)       02, B4-D-02
                                                                     (cycles)                        (cycles)
----------------------------------------------------------------------------------------------------------------
Extension After Passing MPI                                1,600           2,000           2,000           2,000
Extension After Passin In-Shop ECI                         3,800           4,500           4,500           4,500
Extension After Passing On-Wing ECI                        1,000           1,200           1,200           1,200
----------------------------------------------------------------------------------------------------------------

Disks That Have Been Intermixed Between Engine Models

    (l) Information on intermixing disks between engine models can 
be found in the RR Time Limits Manual, 05-00-01.

Alternative Methods of Compliance

    (m) 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.

Credit for Previous Inspections

    (n) Inspections done using RR SB No. RB.211-72-E150, dated April 
17, 2003 are acceptable in meeting the requirements of this AD.

Reporting Requirement

    (o) Report findings of all inspections of the IP stage 5 disk 
using paragraph 3.B.(2) of the Accomplishment Instructions of RR ASB 
RB.211-72-D428, Revision 3, dated June 30, 2003. The Office of 
Management and Budget (OMB) has approved the reporting requirements 
specified in Paragraph 3.B. of the Accomplishment Instructions of RR 
ASB RB.211-72-D428, Revision 3, dated June 30, 2003, and assigned 
OMB control number 2120-0056.

Material Incorporated by Reference

    (p) You must use Rolls-Royce plc Service Bulletins listed in 
Table 5 of this AD to perform the actions 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, 
P.O. Box 31 Derby, DE248BJ, United Kingdom; telephone 011-44-1332-
242424; fax 011-44-1332-249936. You can review copies by 
appointment, 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.

                                      Table 5.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
                                  Page number shown on the
        Service bulletin                    page                      Revision            Date shown on the page
----------------------------------------------------------------------------------------------------------------
RB.211-72-D428, including        All.......................  3.........................  June 30, 2003.
 Appendices 1 through 4, dated
 June 30, 2003.
RB.211-72-E148 Total Pages--83.  All.......................  Original..................  March 13, 2003.
RB.211-72-E150 Total Pages--72.  All.......................  1.........................  June 4, 2003.
----------------------------------------------------------------------------------------------------------------

Related Information

    (q) CAA airworthiness directive 006-04-2002, dated April 2002, 
also addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on July 18, 2005.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-14576 Filed 7-25-05; 8:45 am]
BILLING CODE 4910-13-P

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