Airworthiness Directives; Rolls-Royce plc Turbofan Engines

[Federal Register Volume 77, Number 127 (Monday, July 2, 2012)]
[Rules and Regulations]
[Pages 39157-39159]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2012-15985]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2010-0748; Directorate Identifier 2010-NE-13-AD; 
Amendment 39-17082; AD 2012-12-03]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: We are superseding an existing airworthiness directive (AD) 
for all Rolls-Royce plc (RR) models RB211-Trent 970-84, 970B-84, 972-
84, 972B-84, 977-84, 977B-84, and 980-84 turbofan engines. That AD 
currently requires inspecting the intermediate-pressure (IP) shaft 
rigid coupling splines for wear resulting in rearward movement of the 
IP turbine. This AD requires the same inspections, and new inspections 
based on possible changes in wear rate. This AD was prompted by RR 
identifying wear beyond engine manual limits on the abutment faces of 
the splines. RR also determined that an additional IP shaft rigid 
coupling configuration requires inspection. We are issuing this AD to 
detect wear on the abutment faces of the splines, which could result in 
loss of disc integrity, an uncontained failure of the engine, and 
damage to the airplane.

DATES: This AD is effective July 17, 2012.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in the AD as of July 17, 2012.
    We must receive any comments on this AD by August 16, 2012.

ADDRESSES: You may send comments by any of the following methods:
    <bullet> Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
    <bullet> Fax: 202-493-2251.
    <bullet> Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
    <bullet> Hand Delivery: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590, between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays.
    For service information identified in this AD, contact Rolls-Royce 
plc, P.O. Box 31, Derby, DE24 8BJ, United Kingdom; phone: 011 44 1332 
242424; fax: 011 44 1332 249936; email: http://www.rolls-royce.com/contact/civil_team.jsp; or Web: https://www.aeromanager.com. You may 
review copies of the referenced service information at the FAA, Engine 
& Propeller Directorate, 12 New England Executive Park, Burlington, MA. 
For information on the availability of this material at the FAA, call 
781-238-7125.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Management Facility 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this AD, the regulatory evaluation, 
any comments received, and other information. The street address for 
the Docket Office (phone: 800-647-5527) is in the ADDRESSES section. 
Comments will be available in the AD docket shortly after receipt.

FOR FURTHER INFORMATION CONTACT: Alan Strom, Aerospace Engineer, Engine 
Certification Office, FAA, Engine & Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; email: 
[email protected]; phone: 781-238-7143; fax: 781-238-7199.

SUPPLEMENTARY INFORMATION:

Discussion

    On July 26, 2010, we issued AD 2010-16-07, Amendment 39-16384 (75 
FR 49368, August 13, 2010), for RR model RB211-Trent 970-84, 970B-84, 
972-84, 972B-84, 977-84, 977B-84, and 980-84 turbofan engines. That AD 
requires inspecting the IP shaft rigid coupling splines for wear 
resulting in rearward movement of the IP turbine. That AD resulted from 
RR identifying wear beyond engine manual limits on the abutment faces 
of the splines on the Trent 900 IP shaft rigid coupling on several 
engines during engine disassembly. We issued that AD to detect wear on 
the abutment faces of the splines, which could result in loss of disc 
integrity, an uncontained failure of the engine, and damage to the 
airplane.

Actions Since AD Was Issued

    Since we issued AD 2010-16-07 (75 FR 49368, August 13, 2010), RR 
determined that engines that are moved from one position to another on 
the same airplane or to a different airplane, may exhibit a change in 
the rate of IP shaft rigid coupling spline wear. RR also determined 
that an additional IP shaft rigid coupling configuration requires 
inspection, because it also exhibits wear.

Relevant Service Information

    We reviewed RR RB211 Trent 900 Series Propulsion Systems Alert Non-
Modification Service Bulletin (NMSB) No. RB.211-72-AG329, Revision 4, 
dated March 23, 2012. That Alert NMSB describes procedures for 
inspecting and replacing the IP shaft rigid coupling.
    We also reviewed RR RB211 Trent 900 Series Propulsion Systems Alert 
NMSB No. RB.211-72-AG871, dated March 23, 2012. That Alert NMSB 
describes procedures for inspecting the IP shaft rigid coupling on 
engines that have incorporated RR RB211 Trent 900 Series Propulsion 
Systems Service Bulletin (SB) No. RB.211-72-G585, Original Issue, or 
any revision. Service Bulletin No. RB.211-72-G585 is the SB that 
introduces the additional configuration that this AD adds.

FAA's Determination

    We are issuing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design.

AD Requirements

    This AD requires accomplishing the actions specified in the service 
information described previously.

FAA's Justification and Determination of the Effective Date

    No domestic operators use this product. Therefore, we find that 
notice and opportunity for prior public comment are unnecessary and 
that good cause exists for making this amendment effective in less than 
30 days.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety, and

[[Page 39158]]

we did not provide you with notice and an opportunity to provide your 
comments before it becomes effective. However, we invite you to send 
any written data, views, or arguments about this AD. Send your comments 
to an address listed under the ADDRESSES section. Include the docket 
number FAA-2010-0748 and directorate identifier 2010-NE-13-AD at the 
beginning of your comments. We specifically invite comments on the 
overall regulatory, economic, environmental, and energy aspects of this 
AD. We will consider all comments received by the closing date and may 
amend this AD because of those comments.
    We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact we 
receive about this AD.

Costs of Compliance

    We estimate that this AD will affect no engines installed on 
airplanes of U.S. registry. We also estimate that it would take about 4 
work-hours per engine to perform one borescope inspection required by 
the AD. The average labor rate is $85 per work-hour. Based on these 
figures, we estimate the cost of the AD on U.S. operators to be $0.

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

    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),
    (3) Will not affect intrastate aviation in Alaska, and
    (4) 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.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends part 39 of the Federal Aviation 
Regulations (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 airworthiness directive (AD) 
2010-16-07, Amendment 39-16384 and adding the following new AD:

2012-12-03 Rolls-Royce plc: Amendment 39-17082; Docket No. FAA-2010-
0748; Directorate Identifier 2010-NE-13-AD.

(a) Effective Date

    This AD is effective July 17, 2012.

(b) Affected ADs

    This AD supersedes AD 2010-16-07, Amendment 39-16384 (75 FR 
49368, August 13, 2010).

(c) Applicability

    This AD applies to Rolls-Royce plc (RR) models RB211-Trent 970-
84, 970B-84, 972-84, 972B-84, 977-84, 977B-84, and 980-84 turbofan 
engines.

(d) Unsafe Condition

    This AD was prompted by RR identifying wear beyond engine manual 
limits on the abutment faces of the splines on the Trent 900 
intermediate pressure (IP) shaft rigid coupling on several engines 
during engine disassembly. RR also determined that engines that are 
moved from one position to another on the same airplane or to a 
different airplane, may exhibit a change in the rate of IP shaft 
rigid coupling spline wear. RR also determined that an additional IP 
shaft rigid coupling configuration requires inspection. We are 
issuing this AD to detect wear on the abutment faces of the splines, 
which could result in loss of disc integrity, an uncontained failure 
of the engine, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(f) Engines That Have Not Incorporated RR RB211 Trent 900 Series 
Propulsion Systems Service Bulletin (SB) No. RB.211-72-G585, Original 
Issue, or Any Revision

(1) On-Wing Borescope Inspections

    (i) Initially borescope-inspect the IP shaft rigid coupling 
splines. Use paragraphs 3.A.(2)(a) through 3.A.(2)(k) of RR RB211 
Trent 900 Series Propulsion Systems Alert Non-Modification Service 
Bulletin (NMSB) No. RB.211-72-AG329, Revision 4, dated March 23, 
2012, to do the inspection. Inspect per the following:
    (A) If the IP shaft rigid coupling has 250 or fewer flight 
cycles-since-new (FCSN) on the effective date of this AD, inspect 
before accumulating 400 FCSN; or
    (B) If the IP shaft rigid coupling has more than 250 FCSN on the 
effective date of this AD, inspect within 150 additional flight 
cycles.
    (ii) Repetitively borescope-inspect the IP shaft rigid coupling 
splines. Use paragraphs 3.A.(2)(a) through 3.A.(2)(l) of RR RB211 
Trent 900 Series Propulsion Systems Alert NMSB No. RB.211-72-AG329, 
Revision 4, dated March 23, 2012, to determine the re-inspection 
interval and to do the inspections.
    (iii) If during the initial or any repetitive inspection, the 
average spline crest length measured dimension is less than 0.5 
millimeters (mm), remove the engine from service before further 
flight.

(2) In-Shop Inspections

    (i) At every shop visit after the effective date of this AD, 
where the IP shaft rigid coupling is exposed, visually inspect and 
magnetic particle inspect (MPI) the IP shaft rigid coupling splines.
    (ii) At every shop visit after the effective date of this AD, 
where the IP shaft rigid coupling is not exposed:
    (A) Inspect the IP shaft as specified in paragraph (f)(1) of 
this AD and determine the next inspection interval using Figure 10 
of RR RB211 Trent 900 Series Propulsion Systems Alert NMSB No. 
RB.211-72-AG329, Revision 4, dated March 23, 2012; and
    (B) Reject any IP shaft with an average spline crest length 
measured dimension less than 1.0 mm.

(3) After Any Shop Inspection

    After any shop inspection, where the IP shaft rigid coupling is 
exposed, perform a borescope inspection per paragraph (f)(1) of this 
AD within 400 cycles after the in-shop visual inspection and MPI.

(4) Engine Installation

    (i) Before installing an engine in a new position on the same 
airplane, or before installing an engine on a different airplane in 
any position:

[[Page 39159]]

    (A) Inspect the IP shaft rigid coupling splines as specified in 
paragraphs (f)(1) or (f)(2) of this AD as applicable and determine 
the next inspection interval using Figure 10 of RR RB211 Trent 900 
Series Propulsion Systems Alert NMSB No. RB.211-72-AG329, Revision 
4, dated March 23, 2012; and
    (B) Do not install an engine that has an IP shaft with an 
average spline crest length measured dimension of less than 0.5 mm.
    (ii) Before installing an engine in the same position on the 
airplane it was removed from:
    (A) Inspect the IP shaft rigid coupling splines using paragraph 
(f)(1) or (f)(2) of this AD as applicable and determine the next 
inspection interval; and
    (B) Do not install an engine that has an IP shaft with an 
average spline crest length measured dimension of less than 0.5 mm.

(g) Engines That Have Incorporated RR RB211 Trent 900 Series Propulsion 
Systems SB No. RB.211-72-G585, Original Issue, or Any Revision

(1) On-Wing Borescope Inspections

    (i) Initially borescope-inspect the IP shaft rigid coupling 
splines before accumulating 400 FCSN or 400 cycles since the last 
inspection per paragraph (g)(2)(i) of this AD. Use paragraph 3.A.(2) 
of RR RB211 Trent 900 Series Propulsion Systems Alert NMSB No. 
RB.211-72-AG871, dated March 23, 2012, to do the inspection.
    (ii) Repetitively borescope-inspect the IP shaft rigid coupling 
splines. Use paragraphs 3.A.(2)(e), 3.A.(2)(f), and 3.A.(3) of RR 
RB211 Trent 900 Series Propulsion Systems Alert NMSB No. RB.211-72-
AG871, dated March 23, 2012, to determine the re-inspection interval 
and to do the inspections.

(2) In-Shop Inspections

    (i) At every shop visit after the effective date of this AD, 
where the IP shaft rigid coupling is exposed, visually inspect and 
MPI the IP shaft rigid coupling splines.
    (ii) At every shop visit after the effective date of this AD, 
where the IP shaft rigid coupling is not exposed, borescope-inspect 
using paragraphs 3.A.(2)(a) through 3.A.(2)(f) of RR RB211 Trent 900 
Series Propulsion Systems Alert NMSB No. RB.211-72-AG871, dated 
March 23, 2012.
    (A) If at the time of initial inspection, the average value of 
length ``B'' is equal to, or less than, 6.00 mm, repeat the 
borescope inspection using paragraph (g)(1) or (g)(2) of this AD 
within 400 flight cycles.
    (B) If at the time of initial inspection the average value of 
length ``B'' is greater than 6.00 mm, MPI the IP turbine shaft, and 
visually inspect and MPI the intermediate turbine shaft and IP rigid 
coupling.

(3) After Any Shop Inspection

    After any shop inspection, where the rigid shaft coupling is 
exposed, perform a borescope inspection per paragraph (g)(1) of this 
AD within 400 cycles after the in-shop visual inspection and MPI.

(h) Definition

    For the purpose of this AD, a shop visit is the induction of an 
engine into the shop for maintenance involving the separation of 
pairs of major mating engine flanges, except that the separation of 
engine flanges solely for the purposes of transportation without 
subsequent engine maintenance does not constitute an engine shop 
visit.

(i) Credit for Previous Actions for Engines That Have Not Incorporated 
RR RB211 Trent 900 Series Propulsion Systems SB No. RB.211-72-G585

    If you performed inspections and corrective actions that are 
required by paragraph (f) of this AD using RR RB211 Trent 900 Series 
Propulsion Systems Alert NMSB No. RB.211-72-AG329, Original Issue, 
dated November 26, 2009; Revision 1, dated January 13, 2010; 
Revision 2, dated July 7, 2010; or Revision 3, dated November 25, 
2010, before the effective date of this AD, you have met the 
requirements of paragraph (f) of this AD.

(j) Alternative Methods of Compliance (AMOCs)

    The Manager, Engine Certification Office, may approve AMOCs for 
this AD. Use the procedures found in 14 CFR 39.19 to make your 
request.

(k) Related Information

    (1) For more information about this AD, contact Alan Strom, 
Aerospace Engineer, Engine Certification Office, FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, MA 
01803; phone: 781-238-7143; fax: 781-238-7199; email: 
[email protected].
    (2) Refer to European Aviation Safety Agency AD 2012-0057, dated 
April 3, 2012, and AD 2012-0057 (corrected), dated April 20, 2012, 
for related information.
    (3) RB211-Trent 900 Engine Manual, tasks 72-33-21-200-804 and 
72-00-00-200-808, pertain to the visual inspections and MPIs 
required by this AD.

(l) Material Incorporated by Reference

    (1) You must use the following service information to do the 
actions required by this AD, unless the AD specifies otherwise. The 
Director of the Federal Register approved the incorporation by 
reference (IBR) under 5 U.S.C. 552(a) and 1 CFR part 51 of the 
following service information:
    (i) Rolls-Royce plc RB211 Trent 900 Series Propulsion Systems 
Alert Non-Modification Service Bulletin No. RB.211-72-AG329, 
Revision 4, dated March 23, 2012.
    (ii) Rolls-Royce plc RB211 Trent 900 Series Propulsion Systems 
Alert Non-Modification Service Bulletin No. RB.211-72-AG871, dated 
March 23, 2012.
    (2) For service information identified in this AD, contact 
Rolls-Royce plc, Corporate Communications, P.O. Box 31, Derby, 
England, DE248BJ, phone: 011-44-1332-242424; fax: 011-44-1332-
245418, or email: http://www.rolls-royce.com/contact/civil_team.jsp.
    (3) You may review copies at the FAA, New England Region, 12 New 
England Executive Park, Burlington, MA. For information on the 
availability of this material at the FAA, call 781-238-7125.
    (4) You may also review copies of the service information that 
is incorporated by reference 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/cfr/ibr-locations.html.

    Issued in Burlington, Massachusetts, on June 5, 2012.
Peter A. White,
Manager, Engine & Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 2012-15985 Filed 6-29-12; 8:45 am]
BILLING CODE 4910-13-P

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