Airworthiness Directives; Rolls-Royce, Deutschland Ltd. & Co. KG (Formerly Rolls-Royce plc) Turbofan Engines

[Federal Register Volume 85, Number 62 (Tuesday, March 31, 2020)]
[Rules and Regulations]
[Pages 17738-17742]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2020-06640]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2018-0538; Product Identifier 2012-NE-47-AD; Amendment 
39-19885; AD 2020-06-16]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce, Deutschland Ltd. & Co. KG 
(Formerly Rolls-Royce plc) Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is superseding Airworthiness Directive (AD) AD 2017-
03-02 for certain Rolls-Royce, Deutschland Ltd. & Co. KG RB211 Trent 
768-60, 772-60, and 772B-60 model turbofan engines. AD 2017-03-02 
required initial and repetitive ultrasonic inspections (UIs) of the 
affected low-pressure (LP) compressor blades. This

[[Page 17739]]

AD requires initial and repetitive UIs of the affected LP compressor 
blades and, depending on the results of the UIs, their replacement with 
a part eligible for installation. This AD was prompted by LP compressor 
blade partial airfoil release events. The FAA is issuing this AD to 
address the unsafe condition on these products.

DATES: This AD is effective May 5, 2020.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of May 5, 2020.

ADDRESSES: For service information identified in this final rule, 
contact Rolls-Royce, Deutschland Ltd. & Co. KG, Eschenweg 11, 15827 
Blankenfelde-Mahlow, Germany; phone: +49 (0) 33 708 6 0; email: https://www.rolls-royce.com/contact-us.aspx. You may view this service 
information at the FAA, Engine and Propeller Standards Branch, 1200 
District Avenue, Burlington, MA 01803. For information on the 
availability of this material at the FAA, call 781-238-7759. It is also 
available on the internet at https://www.regulations.gov by searching 
for and locating Docket No. FAA-2018-0538.

Examining the AD Docket

    You may examine the AD docket on the internet at https://www.regulations.gov by searching for and locating Docket No. FAA-2018-
0538; or in person at Docket Operations 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), 
regulatory evaluation, any comments received, and other information. 
The address for Docket Operations is U.S. Department of Transportation, 
Docket Operations, M-30, West Building Ground Floor, Room W12-140, 1200 
New Jersey Avenue SE, Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Stephen Elwin, Aerospace Engineer, ECO 
Branch, FAA, 1200 District Avenue, Burlington, MA 01803; phone: 781-
238-7236; fax: 781-238-7199; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    The FAA issued a supplemental notice of proposed rulemaking (SNPRM) 
to amend 14 CFR part 39 to supersede AD 2017-03-02, Amendment 39-18793 
(82 FR 10701, February 15, 2017), (``AD 2017-03-02''). AD 2017-03-02 
applied to Rolls-Royce, Deutschland Ltd. & Co. KG (formerly Rolls-Royce 
plc) RB211 Trent 768-60, 772-60, and 772B-60 turbofan engines, with LP 
compressor blade, part number (P/N) FK23411, FK25441, FK25968, FW11901, 
FW15393, FW23643, FW23741, FW23744, KH23403, or KH23404, installed. The 
SNPRM published in the Federal Register on November 15, 2019 (84 FR 
62482). The FAA preceded the SNPRM with an NPRM that published in the 
Federal Register on August 14, 2018 (83 FR 40161). The NPRM proposed to 
continue to require initial and repetitive UIs of the affected LP 
compressor blades at a reduced interval. The SNPRM proposed to require 
initial and repetitive UIs of the affected LP compressor blade and 
replacement of the LP compressor blade with a part eligible for 
installation if the LP compressor blade fails a UI. The FAA is issuing 
this AD to address the unsafe condition on these products.
    The European Union Aviation Safety Agency (EASA), which is the 
Technical Agent for the Member States of the European Community, has 
issued EASA AD 2018-0188R1, dated September 5, 2018 (referred to after 
this as ``the MCAI''), to address the unsafe condition on these 
products. The MCAI states:

    Occurrences have been reported of LP compressor partial aerofoil 
blade release events on RR Trent 700 engines. While primary 
containment of the released sections was achieved in each case, some 
of the releases did exhibit secondary effects that are considered to 
present a potential hazard.
    This condition, if not detected and corrected, could lead to LP 
compressor blade release with possible consequent loss of the engine 
nose cowl, under cowl fires and forward projection of secondary 
debris, possibly resulting in damage to the aeroplane and/or injury 
to persons on the ground.
    To address this potential unsafe condition, RR published NMSB 
RB.211-72-G872, providing inspection instructions and, consequently, 
EASA issued AD 2012-0247 to require a one-time inspection of the 
higher life LP compressor blades. After identification of a 
population of these LP compressor blades that were incorrectly 
inspected, RR issued NMSB RB.211-72-H311 and, consequently, EASA 
issued AD 2013-0060, retaining the requirements of EASA AD 2012-
0247, which was superseded, to require a one-time re-inspection of 
the affected blades.
    After that AD was issued, to mitigate the risk of further 
partial LP compressor blade release events, RR issued NMSB RB.211-
72-AH465, providing instructions for ultrasonic inspection of the 
affected parts to detect sub-surface anomalies in the aerofoil. 
Consequently, EASA issued AD 2014-0031, superseding [EASA] AD 2013-
0060, to require repetitive inspections of all affected LP 
compressor blades and, depending on findings, replacement.
    Thereafter, EASA issued AD 2016-0141, retaining the requirements 
of [EASA] AD 2014-0031, which was superseded, to reduce inspection 
threshold (RR Alert NMSB RB.211-72-AH465 Revision 2). Prompted by 
further analysis, EASA issued AD 2017-0241, retaining the 
requirements of EASA AD 2016-0141, which was superseded, further 
reducing the inspection threshold and interval (RR Alert NMSB 
RB.211-72-AH465 Revision 4).
    Since EASA AD 2017-0241 was issued, RR issued the NMSB to 
distinguish between standard operations and NSO and to determine the 
applicable inspection threshold and interval. The flight cycles (FC) 
accumulated by operators conducting NSO have to be calculated using 
the beta factor shown in Table of the NMSB. The NMSB also 
introduces, for engines that have accumulated more than 600 FC or 
standard duty cycles (SDC, for engines used in NSO), a closing date 
by which these have to be inspected at least once.
    For the reason described above, this [EASA] AD retains the 
requirements of EASA AD 2017-0241, which is superseded, and requires 
implementation of the changes introduced.

    You may obtain further information by examining the MCAI in the AD 
docket on the internet at https://www.regulations.gov by searching for 
and locating Docket No. FAA-2018-0538.

Comments

    The FAA gave the public the opportunity to participate in 
developing this AD. The following presents the comments received on the 
SNPRM and the FAA's response to each comment.

Request To Update Service Information

    Rolls-Royce plc (RR), American Airlines (American), and Delta Air 
Lines (Delta) requested that RR Alert Non-Modification Service Bulletin 
(NMSB) RB.211-72-AH465, Revision 6, dated November 29, 2019 (``the 
NMSB''), be referenced in this AD instead of Revision 5 of the NMSB. 
Delta and American commented Revision 6 offers an optional water-
coupled phased array inspection that provides a more reliable and 
repeatable technique and increases detection sensitivity to identify 
smaller defects. RR further commented that Revision 6 has been approved 
by the European Aviation Safety Agency.
    The FAA agrees. RR published Revision 6 of the NMSB to allow an 
alternative water-coupled phased array inspection. Operators may still 
use the C-scan and gel-coupled phased array inspection techniques as 
specified in Revision 6, or earlier versions, of the NMSB.

Request To Allow Use of Later Versions of Service Information

    Delta requested that this AD allow the use of later approved 
revisions of RR Alert NMSB RB.211-72-AH465. Delta

[[Page 17740]]

indicated that this is something that has been achieved before in other 
FAA ADs when an FAA AD incorporates by reference the EASA AD.
    The FAA disagrees. As set forth in Title 1 of the Code of Federal 
Regulations, Section 51.1(f), incorporation by reference of a 
publication is limited to the edition of the publication that is 
approved. Future amendments or revisions of the publication are not 
included. Further, this AD does not incorporate by reference the EASA 
AD.

Support for the AD

    The Air Line Pilots Association commented that it supports the AD 
as proposed.

Conclusion

    The FAA reviewed the relevant data, considered the comments 
received, and determined that air safety and the public interest 
require adopting this AD with the change described previously.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed RR Alert NMSB RB.211-72-AH465, Revision 6, dated 
November 29, 2019. The NMSB describes procedures for performing a UI of 
the LP compressor blades. This service information is reasonably 
available because the interested parties have access to it through 
their normal course of business or by the means identified in the 
ADDRESSES section.

Costs of Compliance

    The FAA estimates that this AD affects 56 engines installed on 
airplanes of U.S. registry.
    The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
Inspect LP compressor blade...........  44 work-hours x $85 per               $0          $3,740        $209,440
                                         hour = $3,740.
----------------------------------------------------------------------------------------------------------------

    The FAA estimates the following costs to do any necessary 
replacements that would be required based on the results of the 
inspection. The FAA has no way of determining the number of engines 
that might need this replacement.

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                    Action                                 Labor cost               Parts cost        product
----------------------------------------------------------------------------------------------------------------
Replace LP compressor blade (one blade per 77   6 work-hours x $85 per hour =           $103,000        $103,510
 engine sets).                                   $510.
----------------------------------------------------------------------------------------------------------------

    According to the manufacturer, some of the costs of this AD may be 
covered under warranty, thereby reducing the cost impact on affected 
individuals. The FAA does not control warranty coverage for affected 
individuals. As a result, the FAA has included all costs in our cost 
estimate.

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.
    The FAA is 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) Will not affect intrastate aviation in Alaska, 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.

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) 
2017-03-02, Amendment 39-18793 (82 FR 10701, February 15, 2017), and 
adding the following new AD:

2020-06-16 Rolls-Royce, Deutschland Ltd. & Co. KG (formerly Rolls-
Royce plc): Amendment 39-19885; Docket No. FAA-2018-0538; Product 
Identifier 2012-NE-47-AD.

(a) Effective Date

    This AD is effective May 5, 2020.

[[Page 17741]]

(b) Affected ADs

    This AD replaces AD 2017-03-02, Amendment 39-18793 (82 FR 10701, 
February 15, 2017).

(c) Applicability

    This AD applies to Rolls-Royce Deutschland Ltd. & Co. KG 
(formerly Rolls-Royce plc) RB211 Trent 768-60, 772-60, and 772B-60 
turbofan engines, with low-pressure (LP) compressor blade, part 
number (P/N) FK23411, FK25441, FK25968, FW11901, FW15393, FW23643, 
FW23741, FW23744, KH23403, or KH23404, installed.

(d) Subject

    Joint Aircraft System Component (JASC) Code 7230, Turbine Engine 
Compressor Section.

(e) Unsafe Condition

    This AD was prompted by LP compressor blade partial airfoil 
release events. While released sections were contained in each case, 
projection of secondary debris and effects could present a potential 
hazard. The FAA is issuing this AD to prevent LP compressor blade 
airfoil separation. The unsafe condition, if not addressed, could 
result in damage to the engine and damage to the airplane.

(f) Compliance

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

(g) Required Actions

    (1) Within the compliance time specified in Figure 1 to 
paragraph (g)(1) of this AD and thereafter, at intervals not to 
exceed 1,200 flight cycles (FCs) or Standard Duty Cycles (SDCs) for 
Non-Standard Operations (NSO), as applicable, since the last 
ultrasonic inspection (UI), perform a UI of each affected LP 
compressor blade in accordance with the Accomplishment Instructions, 
paragraph 3, of Rolls-Royce plc (RR) Alert Non-Modification Service 
Bulletin (NMSB) RB.211-72-AH465, Revision 6, dated November 29, 
2019.

    Note 1 to paragraph (g)(1):  Paragraph 1.D of RR Alert NMSB 
RB.211-72-AH465, Revision 6, dated November 29, 2019, describes how 
to determine the applicable SDCs. The Time Limits Manual (TLM), 05-
00-01, defines NSO.

[GRAPHIC] [TIFF OMITTED] TR31MR20.002

    (2) If, during any inspection required by paragraph (g)(1) of 
this AD, a LP compressor blade is rejected by the UI, as defined in 
Accomplishment Instructions, paragraph 3, of RR Alert NMSB RB.211-
72-AH465, Revision 6, dated November 29, 2019, before further 
flight, or before returning the LP compressor blade to service, 
whichever occurs first, remove the affected LP compressor blade from 
service and replace with a part eligible for installation.

(h) Installation Prohibition

    After the effective date of this AD, do not install an affected 
LP compressor blade on an engine unless the LP compressor blade 
meets the conditions specified in paragraphs (h)(1) or (2) of this 
AD, as applicable.
    (1) The affected part has not exceeded 1,200 FC or SDCs (for 
NSO) since new, or since an inspection performed in accordance with 
either RR Alert NMSB RB.211-72-AH465, Revision 6, dated, November 
29, 2019, or with any of the service information referenced in 
paragraph (j)(1) and (2) of this AD.
    (2) Prior to installation, the affected part has passed an 
ultrasonic inspection in accordance with paragraph (g)(1) of this 
AD.

(i) No Reporting Requirement

    The reporting requirements in the Accomplishment Instructions, 
paragraph 3 of RR Alert NMSB RB.211-72-AH465, Revision 6, dated 
November 29, 2019, are not required by this AD.

(j) Credit for Previous Actions

    You may take credit for LP compressor blade UIs required by 
paragraph (g)(1) of this AD, if you performed the UI before the 
effective date of this AD using:
    (1) For initial inspections: RR NMSB RB.211-72-G702, dated May 
23, 2011; RR NMSB RB.211-72-G872, Revision 2, dated March 8, 2013, 
or earlier versions; RR NMSB RB.211-72-H311, dated March 8, 2013; RR 
NMSB RB.211-72-AH465, Revision 5, dated July 26, 2018, or earlier 
versions; RR Engine Manual E-Trent-1RR, Task 72-31-11-200-806; or 
Airbus A330 Aircraft Maintenance Manual (AMM) Task 72-31-41-270-801, 
or AMM Task 72-31-41-270-802.
    (2) For repetitive inspections: The instructions referenced in 
the mandatory inspection paragraph of the applicable engine TLM, 
provided the compliance times of this AD are not exceeded.

(k) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, ECO Branch, FAA, has the authority to approve 
AMOCs for this AD, if requested using the procedures found in 14 CFR 
39.19. In accordance with 14 CFR 39.19, send your request to your 
principal inspector or local Flight Standards District Office, as 
appropriate. If sending information directly to the manager of the 
ECO Branch, send it to the attention of the person identified in 
paragraph (l)(1) of this AD. You may email your request to: [email protected].
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.

(l) Related Information

    (1) For more information about this AD, contact Stephen Elwin, 
Aerospace Engineer, ECO Branch, FAA, 1200 District Avenue, 
Burlington, MA, 01803; phone: 781-238-7236; fax: 781-238-7199; 
email: [email protected].
    (2) Refer to European Union Aviation Safety Agency (EASA) AD 
2018-0188R1, dated September 5, 2018, for more information. You may 
examine the EASA AD in the AD docket on the internet at https://www.regulations.gov by searching for and locating it in Docket No. 
FAA-2018-0538.

(m) 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.

[[Page 17742]]

    (i) Rolls-Royce plc (RR) Alert Non-Modification Service Bulletin 
RB.211-72-AH465, Revision 6, dated November 29, 2019.
    (ii) [Reserved]
    (3) For RR service information identified in this AD, contact 
Rolls-Royce Deutschland Ltd & Co KG, Eschenweg 11, 15827 
Blankenfelde-Mahlow, Germany; phone: +49 (0) 33 708 6 0; email: 
https://www.rolls-royce.com/contact-us.aspx.
    (4) You may view this service information at FAA, Engine and 
Propeller Standards Branch, 1200 District Avenue, Burlington, MA, 
01803. For information on the availability of this material at the 
FAA, call 781-238-7759.
    (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, email: [email protected], 
or go to: https://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued on March 26, 2020.
Gaetano A. Sciortino,
Deputy Director for Strategic Initiatives, Compliance & Airworthiness 
Division, Aircraft Certification Service.
[FR Doc. 2020-06640 Filed 3-30-20; 8:45 am]
 BILLING CODE 4910-13-P

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