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

[Federal Register Volume 70, Number 3 (Wednesday, January 5, 2005)]
[Rules and Regulations]
[Pages 680-684]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-85]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2004-NE-19-AD; Amendment 39-13917; AD 2004-26-05]
RIN 2120-AA64


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

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for certain Rolls-Royce plc (RR) RB211-524 series turbofan 
engines. That AD currently requires initial and repetitive borescope 
insepctions of the head section and meterpanel assembly of the 
combustion liner, and replacement, if necessary, with serviceable 
parts. In addition, that AD allows an optional installation of a front 
combustion liner with a strengthened head section as a terminating 
action to the inspection requirements. This AD requires initial and 
repetitive borescope inspections of the head section and meterpanel 
assembly of the combustion liner, and replacement if necessary with 
serviceable parts. This AD also requires reduction of the inspection 
intervals of certain RB211-524 engine models that have not been 
repaired to RR Field Repair Scheme FRS5367/B, and a mandatory 
terminating action to be completed by a certain date. This AD results 
from five events that are directly attributed to combustor head breakup 
and meterpanel failure which were found at overhaul inspection. At 
least one of these events resulted in a combustion case burn-through. 
We are issuing this AD to prevent engine combustion liner 
deterioration, which

[[Page 681]]

can result in combustion liner breakup, case burn-through, and engine 
fire.

DATES: This AD becomes effective February 9, 2005. The incorporation by 
reference of RR ASB RB.211-72-AB482, Revision 9, dated July 28, 2003; 
Rolls-Royce Service Bulletins (SB's) RB.211-72-9764, Revision 3, dated 
January 16, 1998, RB.211-72-9670, Original Issue, dated August 27, 
1993; and RB.211-72-9764 Supplement 1, dated January 16, 1998; are 
approved by the Director of the Federal Register as of February 9, 
2005.

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. 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 to 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 01803-5299; 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. We published the proposed AD in the Federal Register 
on May 18, 2004 (69 FR 28094). That action proposed to require initial 
and repetitive borescope inspections of the head section and meterpanel 
assembly of the combustion liner and replacement if necessary, with 
serviceable parts. That action also proposed a reduction of the 
inspection intervals of certain RB211-524 engine models that have not 
been repaired to RR Field Repair Scheme FRS53667/B, and a mandatory 
terminating action to be completed by a certain date.

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 comments on the proposal or on 
the determination of the cost to the public. However, we corrected RR 
Service Bulletin (SB) No. RB.211-71-9670 in Compliance paragraph (q) of 
this AD to RR SB No. RB.211.-72-9670.

Conclusion

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

Costs of Compliance

    There are about 537 RB211-524 series turbofan engines of the 
affected design in the worldwide fleet. We estimate that 18 engines 
installed on airplanes of U.S. registry will be affected by this AD. We 
also estimate that it will take approximately 2.0 work hours per engine 
to perform the actions, and that the average labor rate is $65 per work 
hour. Required parts will cost about $228,389 per engine. Based on 
these figures, we estimate that total cost of the AD to U.S. operators 
to be $4,113,342.

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. 2004-NE-19-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 removing Amendment 39-9978 (62 FR 
16475, April 7, 1997) and by adding a new airworthiness directive, 
Amendment 39-13917, to read as follows:

2004-26-05 Rolls-Royce plc: Amendment 39-13917. Docket No. 2004-NE-
19-AD. Supersedes AD 97-07-04, Amendment 39-9978.

Effective Date

    (a) This AD becomes effective February 9, 2005.

Affected ADs

    (b) This AD supersedes AD 97-07-04, Amendment 39-9978.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) engine models RB211-
524B-02, -524B2, -524B3, -524B4, -524C2, and -524D4 series engines 
incorporating RR Service Bulletin (SB) No. RB.211-72-7221 or RR SB 
No. RB.211-72-7998 with front combustion liner

[[Page 682]]

assembly, part number (P/N) UL16885, UL29916, UL27107, UL28972, or 
UL28974 installed but not incorporating RR SB No. RB.211-72-9670 or 
RR SB No. RB.211-72-9764, and engine models RB211-524G and -524H 
series engines with front combustion liner assembly P/N UL27659, 
UL23992, or UL22988 but not incorporating RR SB No. RB.211-72-9764. 
These engines are installed on, but not limited to, Boeing 747 and 
Lockheed L1011 series airplanes.

Unsafe Condition

    (d) This AD results from five events that are directly 
attributed to combustor head breakup and meterpanel failure which 
were found at overhaul inspection. At least one of these events 
resulted in a combustion case burn-through. The actions specified in 
this AD are intended to prevent engine combustion liner 
deterioration, which can result in combustion liner breakup, case 
burn-through, and engine fire.

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. Engine inspections previously made 
to RR Service Bulletin No. RB.211-72-B482, Revision 8, can be 
credited for counting cycles since last inspection.

Inspections of Combustion Liner Head Sections--Not Previously Repaired

    (f) Borescope-inspect combustion liner head sections that have 
not been previously repaired. Use paragraphs 3.A.(1) through 3.A.(5) 
of the Accomplishment Instructions of RR Alert Service Bulletin 
(ASB) No. RB.211-72-AB482, Revision 9, dated July 28, 2003, and the 
compliance thresholds in Table 1 of this AD.

                            Table 1.--Combustor Head Section--Not Previously Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series                 (cycles since-new       (cycles-since-last-       (cycles-in-service
                                                (CSN))             inspection (CSLI))             (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 1,400 to 1,600    Within 200 CSLI........  Within 100 CIS after
 524H.                                  CSN.                                              the effective date of
                                                                                          this AD.
(2) RB211-524B-02, -524B, -524B3, and  Within 3,000 to 3,200    Within 200 CSLI........  Within 200 CIS after
 -524B4.                                CSN.                                              the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Combustion Head Sections--Previously Repaired Using RR 
Field Repair Scheme FRS5367/B

    (g) Borescope-inspect combustion liner head sections previously 
repaired using RR Field Repair Scheme FRS5367/B. Use paragraphs 
3.A.(1) through 3.A.(5) of the Accomplishment Instructions of RR ASB 
No. RB.211-72-AB482, Revision 9, dated July 28, 2003, and the 
compliance thresholds in Table 2 of this AD.

          Table 2.--Combustor Head Section--Previously Repaired Using RR Field Repair Scheme FRS5367/B
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series                (cycles-since-last-      (cycles-since-last-       (cycles-in-service
                                            repair (CSLR))         inspection (CSLI))             (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 1,800 to 2,200    Within 400 CSLI........  Within 200 CIS after
 524H.                                  CSLR.                                             the effective date of
                                                                                          this AD.
(2) RB211-524B-02, -524B2, -524B3,     Within 3,000 to 3,200    Within 400 CSLI........  Within 200 CIS after
 and -524B4.                            CSLR.                                             the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Combustion Head Sections That Have Been Repaired But Did 
Not Use RR Field Repair Scheme FRS5367/B

    (h) Borescope-inspect combustion liner sections that have been 
repaired using a method other than RR Field Repair Scheme FRS5367/B. 
Use paragraphs 3.A.(1) through 3.A.(5) of the Accomplishment 
Instructions of RR ASB No. RB.211-72-AB482, Revision 9, dated July 
28, 2003, and the compliance thresholds in Table 3 of this AD.

          Table 3.--Combustor Head Section--Repaired, But Did Not Use RR Field Repair Scheme FRS5367/B
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series               cycles (cycles-since-    cycles (cycles-since-      (cycles-in-service
                                         last-repair (CSLR))    last-inspection (CSLI))           (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 500 to 700 CSLR.  Within 200 CSLI........  Within 100 CIS after
 524H.                                                                                    the effective date of
                                                                                          this AD.
(2) RB211-524B-02, -524B2, -524B3,     Within 2,000 to 2,200    Within 200 CSLI........  Within 200 CIS after
 and -524B4.                            CSLR.                                             the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------


    Note 1: For an installed front combustion liner that is subject 
to RR ASB No. RB.211-72-AB482, Revision 9, dated July 28, 2003: If 
the operator can confirm with the relevant overhaul base or repair 
vendor that the nicrobraze repair RR Field Repair Scheme FRS5367 has 
been applied to all 18 struts, then this is equivalent to compliance 
with RR Field Repair Scheme FRS5367/B.


    Note 2: Head sections repaired by replacement of all 18 struts 
using RR Field Repair Scheme FRS6548 are considered as equivalent to 
fitting a new head section for inspection purposes.

Inspections of Meterpanel Assemblies--Not Repaired

    (i) Borescope-inspect meterpanel assemblies, incorporating 
Service Bulletin (SB) No. RB.211-72-7998, that have not been 
previously repaired. Using Paragraphs 3.B.(1) through 3.B.(7) of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AB482, Revisions 
9, dated July 28, 2003, and the compliance thresholds in Table 4 of 
this AD.

[[Page 683]]



                                   Table 4.--Meterpanel Assembly--Not Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series               cycles-since-new (CSN)   cycles (cycles-since-      (cycles-in-service
                                                                last-inspection (CSLI))           (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524D4, -524G, and -524H....  Within 1,000 to 1,200    Within 400 CSLI........  Within 50 CIS after the
                                        CSN.                                              effective date of this
                                                                                          AD.
(2) RB211-524D4, -524G, and -524H      Within 1,800 to 2,000    Within 400 CSLI........  Within 50 CIS after the
 that have not used RB211-524H          CSN.                                              effective date of this
 ratings at any time.                                                                     AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Meterpanel Assemblies--Repaired

    (J) Borescope-inspect meterpanel assemblies, incorporating 
Service Bulletin (SB) No. RB.211-72-7998, that have been previously 
repaired. Use paragraphs 3.B.(1) through 3.B.(7) of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AB482, Revision 
9, dated July 28, 2003, and the compliance thresholds in Table 5 of 
this AD.

                                     Table 5.--Meterpanel Assembly--Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
                                          Initial inspection     Repetitive inspection      inspection cycles
            Engine series               cycles (cycles-since-    cycles (cycles-since-      (cycles-in-service
                                         last-repair (CSLR))    last-inspection (CSLI))           (CIS))
----------------------------------------------------------------------------------------------------------------
(1) RB211-524D4, -524G, and -524H....  Within 500 to 700 CSLR.  Within 400 CSLI........  Within 50 CIS after the
                                                                                          effective date of this
                                                                                          AD.
----------------------------------------------------------------------------------------------------------------


    Note 3: There is no requirement to inspect meter panels for 
combustors to a pre-RR SB No. RB.211-72-7998 standard.

Reject Parts

    (k) Replace parts that exceed the acceptance criteria. 
Information about the acceptance criteria can be found in the 
Aircraft Maintenance Manual, 72-00-00, Inspection/Check.

Mandatory Terminating Action

    (l) Replace any front combustion liner assembly that has a P/N 
listed in paragraph (c) of this AD at the next shop visit or within 
10,000 CSN but no later than December 31, 2012.
    (m) Replacement of the front combustion liner assembly with a 
front combustion liner assembly that incorporates the modifications 
in RR SB No. RB.211-72-9670 or RR SB No. RB.211-72-9764 in the 
RB211-524B02, -524B2, -524B3, -524B4, -524C2 and -524D4 engines 
constitutes terminating action to the repetitive inspections in 
paragraphs (f), (g), (h), (i), and (j), of this AD.
    (n) Replacement of the front combustion liner assembly with a 
front combustion liner assembly that incorporates the modifications 
in RR SB No. RB.211-72-9764 in the RB211-524G and -524H engines 
constitutes terminating action to the repetitive inspections in 
paragraphs (f), (g), (h), (i), and (j) of this AD.

Definition of Shop Visit

    (o) For the purpose of this AD, a shop visit is defined as any 
time that the 04 module is removed for refurbishment or overhaul.

Alternative Methods of Compliance

    (p) 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

    (q) You must use the Rolls-Royce plc (RR) Alert Service Bulletin 
(ASB) and Service Bulletins (SB's) listed in Table 6 of this AD to 
do the inspections and replacements required by this AD. The 
Director of the Federal Register approved the incorporation by 
reference of RR ASB No. RB.211-72-AB482, Revision 9, dated July 28, 
2003; SB's No. RB.211-72-9764, Revision 3, dated January 16, 1998, 
No. RB.211-72-9670, Original Issue, dated August 27, 1993; and SB 
No. RB.211-72-9764 Supplement, Revision 1, dated January 16, 1998; 
in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. You can get 
copies 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 6 follows:

                                      Table 6.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
                                      Page number(s) shown    Revision level shown
          Service bulletin                 on the page             on the page          Date shown on the page
----------------------------------------------------------------------------------------------------------------
RB.211-72-AB482,...................  All...................  9.....................  July 28, 2003.
    Total Pages: 12
RB.211-72-9670,....................  All...................  Original..............  Aug. 27, 1993.
    Total Pages: 49
RB.211-72-9764.....................  1.....................  3.....................  Jan. 16, 1998.
                                     2.....................  Original..............  Aug. 20, 1993.
                                     3, 4..................  3.....................  Jan. 16, 1998.
                                     5.....................  1.....................  Aug. 25, 1995.
                                     6.....................  3.....................  Jan. 16, 1998.
                                     7-10..................  Original..............  Aug. 20, 1993.
                                     11....................  3.....................  Jan. 16, 1998.
                                     12-30.................  Original..............  Aug. 20, 1993.
    Total Pages: 30
RB.211-72-9764 Supplement..........  1.....................  1.....................  Jan. 16, 1998.
    Total Pages: 1
----------------------------------------------------------------------------------------------------------------


[[Page 684]]

Related Information

    (r) Civil Aviation Authority airworthiness directive AD G-2003-
0011, dated October 1, 2003, (previously 005-07-95, dated November 
15, 2001), also addresses the subject of this AD. Aircraft 
Maintenance Manual 72-00-00 also addresses the subject of this AD.


    Issued in Burlington, Massachusetts, on December 20, 2004.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-85 Filed 1-4-05; 8:45 am]
BILLING CODE 4910-13-P

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