Airworthiness Directives; Rolls-Royce plc Turbofan Engines

[Federal Register Volume 78, Number 170 (Tuesday, September 3, 2013)]
[Rules and Regulations]
[Pages 54152-54156]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2013-21109]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2013-0143; Directorate Identifier 2013-NE-06-AD; 
Amendment 39-17561; AD 2013-16-23]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are adopting a new airworthiness directive (AD) for certain 
Rolls-Royce plc (RR) RB211-524B-02; -524B2-19; -524B3-02; -524B4-02; -
524C2-19; -524D4-19; -524D4-B-19; -524D4-39; -535C-37; -535E4-37; -
535E4-B-37, and -535E4-B-75 turbofan engines, and all RB211-524G2-19; -
524G3-19; -524H2-19; and -524H-36 turbofan engines. This AD requires a 
one-time inspection of the front combustion liner (FCL) metering panel 
to determine if it is made from N75 material and, if so, replacing it 
with an FCL made from C263 material. This AD was prompted by the 
discovery of a cracked and distorted FCL metering panel, which was made 
from N75 material. We are issuing this AD to prevent hot gases from 
burning through the engine casing, which could result in an under-cowl 
fire and damage to the airplane.

DATES: This AD becomes effective October 8, 2013.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in this AD as of October 8, 
2013.

ADDRESSES: The Docket Operations office is located at Docket Management 
Facility, U.S. Department of Transportation, 1200 New Jersey Avenue 
SE., West Building Ground Floor, Room W12-140, Washington, DC 20590-
0001.

[[Page 54153]]

Examining the AD Docket

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

FOR FURTHER INFORMATION CONTACT: Robert Green, Aerospace Engineer, 
Engine Certification Office, FAA, Engine & Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803; phone: 781-238-7754; 
fax: 781-238-7199; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 to include an AD that would apply to the specified products. 
The NPRM was published in the Federal Register on April 5, 2013 (78 FR 
20505). The NPRM proposed to correct an unsafe condition for the 
specified products. The MCAI states:

    During investigation of a starting problem with an RB211-535E4-
B-37 engine, the Fuel Spray Nozzles (FSNs) appeared misaligned and 
the engine was removed. Further investigation found that the FSNs 
were correctly positioned but that the Front Combustion Liner (FCL) 
metering panel (reference Engine Illustrated Parts Catalogue (EIPC) 
section 72-41-13, Figure/Item 02-324) was cracked and distorted. 
Laboratory investigation revealed that the FCL metering panel was 
made of N75 material rather than the specified C263 material.
    Rolls-Royce (RR) issued SB RB.211-72-7221 in 1984, to address 
the issue of cracking of FCL metering panels manufactured in N75 
material. SB RB.211-72-7221 replaces the FCL metering panel 
manufactured in N75 material with one manufactured in C263 material. 
The FCL metering panel in so-called Phase 2 combustors of the RB211-
524G/H and RB211-535C/E4/E4-B series engines was specified in C263 
material from engine type at entry into service.
    Based on these findings, it was determined that installation of 
N75 material FCL metering panels on an engine where C263 was the 
intended material may result in metering panel cracking and 
distortion.

Comments

    We gave the public the opportunity to participate in developing 
this AD. We considered the comments received.

Request To Correct an Applicability Date

    American Airlines (AAL) requested that we correct a date cited in 
paragraph (c)(4)(i) of the NPRM (78 FR 20505, April 5, 2013) used to 
determine the affected engines. The NPRM states that combustion liners 
supplied by RR after April 23, 2011 are not affected by this AD, 
whereas RR Alert Non-Modification Service Bulletin (NMSB) No. RB.211-
72-AG046, Revision 3, dated December 6, 2012, and RR Alert NMSB No. 
RB.211-72-AF572, Revision 2, dated April 2, 2009, cite the correct date 
as April 23, 2007.
    We agree. We changed the date. Paragraph (c)(4) of this AD now 
states that combustion liners supplied by RR after April 23, 2007, are 
not affected by this AD.

Request To Allow Alternative Inspection Method During Engine Shop 
Visits

    AAL and Texas Aero Engine Services, LLC (TAESL) requested that we 
allow using RR Alert NMSB No. RB.211-72-AF572, Revision 2, dated April 
2, 2009, as a means to comply with the FCL inspections. AAL indicated 
that the Alert NMSB defines an inspection equivalent to that in the AD, 
which therefore should allow using the NMSB at the shop level. In 
addition, TAESL requested that we allow using Revision 1, Revision 2, 
or later revisions of RR Alert NMSB No.RB.211-72-AF572 to comply with 
the AD.
    We partially agree. We agree that RR Alert NMSB No. RB.211-72-
AF572, Revision 2, dated April 2, 2009, or Revision 1, dated October 
10, 2008, provide an acceptable inspection. We changed the AD to add RR 
Alert NMSB No. RB.211-72-AF572, Revision 2, dated April 2, 2009, and 
Revision 1, dated October 10, 2008, to the compliance paragraph, by 
adding paragraphs (e)(2)(ii) and (e)(3)(ii).
    New paragraph (e)(2)(ii) states: ``You may use paragraph 3.B. of 
the Accomplishment Instructions in RR Alert NMSB No. RB.211-72-AF572, 
Revision 2, dated April 2, 2009, or Revision 1, dated October 10, 2008, 
or paragraph 3. of RR Alert NMSB No. RB.211-72-AG183, Revision 3, dated 
December 6, 2012, for engine shop visit inspections.''
    New paragraph (e)(3)(ii) states: ``You may use paragraph 3.B. of 
the Accomplishment Instructions in RR Alert NMSB No. RB.211-72-AF572, 
Revision 2, dated April 2, 2009, or Revision 1, dated October 10, 2008, 
or paragraph 3. of RR Alert NMSB No. RB.211-72-AG046, Revision 3, dated 
December 6, 2012, for engine shop visit inspections.''
    We disagree with including possible future versions of the Alert 
NMSB because what future versions may contain is speculation. We did 
not change the AD.

Request To Use Spectroscopic Analysis To Determine if the FCL Metering 
Panel Is Made From N75 Material

    AAL requested that we allow an alternate procedure to obtain and 
analyze the FCL material. RR Alert NMSB No. RB.211-72-AG046, Revision 
3, dated December 6, 2012, requires the use of an alloy sorter to 
identify the FCL material as either C263 or N75. If the sorter 
identifies the material as N75, the Alert NMSB requires that a sample 
be provided to RR for confirmation by spectroscopic analysis. AAL 
proposed an alternate procedure be accepted to obtain and analyze a 
sample of material from the FCL in accordance with RB.211-72-AG046, 
paragraph 3.(B).5.(p)(i) for all inspections instead of using the alloy 
sorter as a preliminary step. The alternative procedure includes the 
use of a local laboratory for the spectroscopic analysis.
    We agree. Paragraph 3.(B).5.(p)(i) identifies, among other things, 
how to obtain the sample. AAL's alternate process uses paragraph 
3.(B).5.(p)(i) to obtain the sample. AAL's proposed follow-on analysis 
is simpler as it avoids use of the alloy sorter. However, spectroscopic 
analysis then becomes required. The analysis need not be limited to RR 
facilities, but can be conducted locally in the context of an FAA-
accepted maintenance or quality plan.
    We changed the AD by adding paragraphs (e)(2)(iii) and (e)(2)(iv), 
and also (e)(3)(iii) and (e)(3)(iv).
    New paragraph (e)(2)(iii) states: ``You may use paragraph 
3.B.(5)(p)(i) of RR Alert NMSB No. RB.211-72-AG183, Revision 3, dated 
December 6, 2012, and a spectroscopic analysis, instead of paragraphs 
3.B.(3) through 3.B.(5)(p) and paragraphs 3.C.(5)(q) and (r).''
    New paragraph (e)(3)(iii) states: ``You may use paragraph 
3.C.(5)(p)(i) of RR Alert NMSB No. RB.211-72-AG046, Revision 3, dated 
December 6, 2012, and a spectroscopic analysis, instead of paragraphs 
3.C.(3) through 3.C.(5)(p), and paragraph 3.C.(5)(q).''
    New paragraphs (e)(2)(iv) and (e)(3)(iv) state: ``You may use a 
local facility in the context of an FAA-accepted maintenance or quality 
plan to perform the spectroscopic analysis.''

[[Page 54154]]

Request To Substitute Locally Sourced Tools To Conduct Pressure Test

    AAL requested that we allow the use of a locally sourced pressure 
test adaptor and pressure gauge in place of tools specified by part 
number in RR Alert NMSB No. RB.211-72-AG046, Revision 3, dated December 
6, 2012.
    We agree. Locally sourced tooling approved under an FAA-accepted 
maintenance or quality plan is acceptable for use. We changed the AD by 
adding paragraph (e)(3)(v) which states: ``The accomplishment 
instructions in paragraphs 3.B.(6)(g)(iii) and 3.B.(6)(j)(i) of RR 
Alert NMSB No. RB.211-72-AG046, Revision 3, dated December 6, 2012, 
specify use of RR tooling for the post-inspection fuel manifold 
pressure test. However, you may use locally sourced tooling in the 
context of an FAA-accepted maintenance or quality plan.''

Request To Be Less Precise in References to NMSB Revision Numbers

    TAESL requested that we not specify use of RR Alert NMSB No. 
RB.211-72-AG046, Revision 3, dated December 6, 2012, for the 
inspection, and that we either remove the revision number or add the 
words ``or later revision'' because service bulletins can be revised 
frequently. Similarly, TAESL requested that in paragraph (c)(ii), 
Applicability, we change the reference to RR Alert NMSB No. RB.211-72-
AF572 to say ``Revision 1 or 2, or later revision.''
    We partially agree.
    We agree that RR Alert NMSB No. RB.211-72-AF572, Revision 2, dated 
April 2, 2009, and Revision 1, dated October 10, 2008, and Initial 
Issue, dated October 15, 2007 are acceptable inspections for prior 
compliance. We changed the AD by adding paragraph (f), Credit for 
Previous Actions.
    New paragraph (f) states: ``(1) You have satisfied the inspection 
requirement of paragraph (e) of this AD if, before the effective date 
of this AD, you performed the actions prescribed in this AD using: (i) 
RR Alert NMSB No. RB.211-72-AG183, Revision 3, dated December 6, 2012, 
or Revision 2, dated June 8, 2012, or Revision 1, dated November 16, 
2010, or Initial Issue, dated December 17, 2009; or (ii) RR Alert NMSB 
No. RB.211-72-AG046, Revision 3, dated December 6, 2012, or Revision 2, 
dated June 7, 2012, or Revision 1, dated January 17, 2011, or Initial 
Issue, dated December 17, 2009; or (iii) RR Alert NMSB No. RB.211-72-
AF572, Revision 2, dated April 2, 2009, or Revision 1, dated October 
10, 2008, or Initial Issue, dated October 15, 2007; or (iv) RR Repeater 
Technical Variance No. 75295, Issue 1, dated April 20, 2007.''
    We disagree with including possible future versions of the Alert 
NMSB because what future versions may contain is speculation. We did 
not change the AD.

Request To Replace Flight Cycle Requirement With Compliance at Next 
Shop Visit

    UPS requested that we remove from compliance the flight cycle 
requirement and instead require compliance at the next shop visit. UPS 
has completed inspection of 67 of 89 affected engines, with no 
findings. The remaining engines are locked in specific geographic areas 
that do not afford favorable opportunities to accomplish material 
verification. UPS believes the risk of finding a combustion liner 
metering panel fabricated of N75 material is low.
    We disagree. The RR risk assessment that we reviewed estimates 25 
field findings. There have been seven findings to date, leaving 18 
potential additional findings. The cyclic compliance requirement, 
average fleet utilization, and alternative inspection methods provide 
adequate ability to manage remaining inspections in a timely manner 
during scheduled maintenance opportunities. We did not change the AD.

Request To Lower the Estimated Costs of Compliance

    AAL requested that we lower, based on the inspection results to 
date, our estimate of costs of compliance. The NPRM (78 FR 20505, April 
5, 2013) estimates that 315 engines of U.S. registry are affected, and 
that 12 engines will test positive for N75. AAL believes that this 
estimate is too high.
    AAL stated that, to date, 770 engines of the worldwide fleet have 
been inspected using RR NMSB No. RB.211-72-AF572 and RB.211-72-AG046. 
Two engines were confirmed to have an N75 material FCL metering panel 
in the shop using RB.211-72-AF572 and one was the original event 
engine. No engines with confirmed FCL metering panel with N75 material 
have been found in the worldwide fleet using RR NMSB No. RB.211-72-
AG046.
    We disagree. As of March 15, 2013, we are aware of seven findings--
the known failure of one engine, two findings for new productions 
engines, and four findings for engines inspected in the field. We did 
not change the AD.

Conclusion

    We reviewed the available data, including the comments received, 
and determined that air safety and the public interest require adopting 
this AD with the changes described previously. We determined that these 
changes will not increase the economic burden on any operator or 
increase the scope of this AD.

Costs of Compliance

    We estimate that this AD will affect about 315 RR RB211-524 and 
RB211-535 turbofan engines installed on airplanes of U.S. registry. We 
also estimate that it will take about 11 hours per engine to comply 
with this AD. The average labor rate is $85 per hour. Required parts 
will cost about $108,887 per engine. We anticipate that 12 FCL metering 
panels will fail inspection. Based on these figures, we estimate the 
cost of the AD on U.S. operators to be $1,601,169.

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 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 this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866,
    (2) Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979),
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction, and

[[Page 54155]]

    (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.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this AD and placed it in the AD docket.

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 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 AD:

2013-16-23 Rolls-Royce plc: Amendment 39-17561; Docket No. FAA-2013-
0143; Directorate Identifier 2013-NE-06-AD.

(a) Effective Date

    This airworthiness directive (AD) becomes effective October 8, 
2013.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to:
    (1) All Rolls-Royce plc (RR) RB211-524G2-19; -524G3-19; -524H2-
19; and -524H-36 turbofan engines;
    (2) RR RB211-524B-02; -524B2-19; -524B3-02; -524B4-02; -524C2-
19; -524D4-19; -524D4-B-19; and -524D4-39 turbofan engines that have 
incorporated RR Service Bulletin (SB) No. RB.211-72-7221, dated 
December 7, 1984;
    (3) All RR RB211-535C-37; -535E4-37; -535E4-B-37, and -535E4-B-
75 turbofan engines, except those engines that have incorporated RR 
SB No. RB.211-72-C230, Revision 1, dated November 22, 2012, or 
Initial Issue, dated November 16, 1999.
    (4) This AD does not apply to engines listed in paragraphs 
(c)(1) through (c)(3) of this AD that have installed a front 
combustion liner (FCL) metering panel delivered from RR after April 
23, 2007.

(d) Reason

    This AD was prompted by the discovery of a cracked and distorted 
FCL metering panel, made from N75 material. We are issuing this AD 
to prevent hot gases from burning through the engine casing, which 
could result in an under-cowl fire and damage to the airplane.

(e) Actions and Compliance

    Unless already done, do the following actions.
    (1) At the next engine shop visit or within 625 flight cycles, 
whichever occurs first after the effective date of this AD, perform 
a one-time inspection of the FCL metering panel to determine if it 
is made from N75 material, and if made from N75 material, replace it 
with one made from C263 material.
    (2) To inspect RR RB211-524 series turbofan engines:
    (i) Use paragraph 3. of the Accomplishment Instructions of RR 
Alert Non-Modification Service Bulletin (NMSB) No. RB.211-72-AG183, 
Revision 3, dated December 6, 2012; or
    (ii) You may use paragraph 3.B. of the Accomplishment 
Instructions in RR Alert NMSB No. RB.211-72-AF572, Revision 2, dated 
April 2, 2009, or Revision 1, dated October 10, 2008, or paragraph 
3. of RR Alert NMSB No. RB.211-72-AG183, Revision 3, dated December 
6, 2012, for engine shop visit inspections.
    (iii) You may use paragraph 3.B.(5)(p)(i) of RR Alert NMSB No. 
RB.211-72-AG183, Revision 3, dated December 6, 2012, and a 
spectroscopic analysis, instead of paragraphs 3.B.(3) through 
3.B.(5)(p), and paragraphs 3.C.(5)(q) and (r).
    (iv) You may use a local facility in the context of an FAA-
accepted maintenance or quality plan to perform the spectroscopic 
analysis.
    (3) To inspect RR RB211-535 series turbofan engines:
    (i) Use paragraph 3. of the Accomplishment Instructions of RR 
Alert NMSB No. RB.211-72-AG046, Revision 3, dated December 6, 2012; 
or
    (ii) You may use paragraph 3.B. of the Accomplishment 
Instructions in RR Alert NMSB No. RB.211-72-AF572, Revision 2, dated 
April 2, 2009, or Revision 1, dated October 10, 2008, or paragraph 
3. of RR Alert NMSB No. RB.211-72-AG046, Revision 3, dated December 
6, 2012, for engine shop visit inspections.
    (iii) You may use paragraph 3.C.(5)(p)(i) of RR Alert NMSB No. 
RB.211-72-AG046, Revision 3, dated December 6, 2012, and a 
spectroscopic analysis, instead of paragraphs 3.C.(3) through 
3.C.(5)(p), and paragraph 3.C.(5)(q).
    (iv) You may use a local facility to perform the spectroscopic 
analysis in the context of an FAA-accepted maintenance or quality 
plan.
    (v) The accomplishment instructions in paragraphs 
3.B.(6)(g)(iii) and 3.B.(6)(j)(i) of RR Alert NMSB No. RB.211-72-
AG046, Revision 3, dated December 6, 2012, specify use of RR tooling 
for the post-inspection fuel manifold pressure test. However, you 
may use locally sourced tooling in the context of an FAA-accepted 
maintenance or quality plan.

(f) Credit for Previous Actions

    (1) You have satisfied the inspection requirement of paragraph 
(e) of this AD if, before the effective date of this AD, you 
performed the actions prescribed in this AD using:
    (i) RR Alert NMSB No. RB.211-72-AG183, Revision 3, dated 
December 6, 2012, or Revision 2, dated June 8, 2012, or Revision 1, 
dated November 16, 2010, or Initial Issue, dated December 17, 2009; 
or
    (ii) RR Alert NMSB No. RB.211-72-AG046, Revision 3, dated 
December 6, 2012, or Revision 2, dated June 7, 2012, or Revision 1, 
dated January 17, 2011, or Initial Issue, dated December 17, 2009; 
or
    (iii) RR Alert NMSB No. RB.211-72-AF572, Revision 2, dated April 
2, 2009, or Revision 1, dated October 10, 2008, or Initial Issue, 
dated October 15, 2007; or
    (iv) RR Repeater Technical Variance No. 75295, Issue 1, dated 
April 20, 2007.

(g) Definition

    For the purpose of this AD, a shop visit is the induction of an 
engine into the shop for maintenance or overhaul. The separation of 
engine flanges solely for the purposes of transporting the engine 
without subsequent engine maintenance does not constitute an engine 
shop visit.

(h) 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.

(i) Related Information

    For more information about this AD, contact Robert Green, 
Aerospace Engineer, Engine Certification Office, FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington, MA 
01803; phone: 781-238-7754; fax: 781-238 7199; email: 
[email protected].
    Refer to European Aviation Safety Agency AD 2012-0215R1, dated 
January 4, 2013, for more information. You may examine the AD on the 
Internet at http://www.regulations.gov/#!documentDetail;D=FAA-2013-
0143-0009.

(j) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Rolls-Royce plc (RR) Alert Non-Modification Service Bulletin 
(NMSB) No. RB.211-72-AF572, Revision 2, dated April 2, 2009.
    (ii) RR Alert NMSB No. RB.211-72-AF572, Revision 1, dated 
October 10, 2008.
    (iii) RR Alert NMSB No. RB.211-72-AG183, Revision 3, dated 
December 6, 2012.
    (iv) RR Alert NMSB No. RB.211-72-AG046, Revision 3, dated 
December 6, 2012.
    (3) For Rolls-Royce plc 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-
1332-249936; email: http://www.rolls-royce.com/contact/civil_team.jsp; Internet: https://www.aeromanager.com.
    (4) You may view this service information at FAA, Engine & 
Propeller Directorate, 12 New England Executive Park, Burlington,

[[Page 54156]]

MA. For information on the availability of this material at the FAA, 
call 781-238-7125.
    (5) You may view this service information 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 August 7, 2013.
Colleen M. D'Alessandro,
Assistant Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2013-21109 Filed 8-30-13; 8:45 am]
BILLING CODE 4910-13-P

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