Airworthiness Directives; Rolls-Royce Deutschland Ltd & Co KG (Type Certificate Previously Held by Rolls-Royce plc) Turbofan Engines

[Federal Register Volume 85, Number 110 (Monday, June 8, 2020)]
[Rules and Regulations]
[Pages 34959-34962]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2020-12346]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2019-1109; Project Identifier MCAI-2019-00115-E; 
Amendment 39-21135; AD 2020-12-01]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce Deutschland Ltd & Co KG 
(Type Certificate Previously Held by Rolls-Royce plc) Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Rolls-Royce Deutschland Ltd. & Co KG (RRD) Trent XWB-75, XWB-
79, XWB-79B, and XWB-84 model turbofan engines. This AD was prompted by 
analysis by the manufacturer of the low-pressure compressor (LPC) 
outlet guide vane (OGV) assembly and LPC OGV outer mount ring assembly. 
The analysis predicted that when the front engine mount is in the fail-
safe condition, the most highly stressed LPC OGV outer mount ring 
assembly has a life that could be substantially less than one shop 
visit interval. This AD requires initial and repetitive inspections of 
the LPC OGV outer mount ring assembly and, depending on the results of 
the inspections, possible replacement of the LPC OGV outer mount ring 
assembly. The FAA is issuing this AD to address the unsafe condition on 
these products.

DATES: This AD is effective July 13, 2020.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of July 13, 
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, Airworthiness Products Section, Operational 
Safety 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-2019-
1109.

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-2019-
1109; 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 final rule, the mandatory continuing airworthiness information 
(MCAI), 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 notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to certain RRD Trent XWB-
75, XWB-79, XWB-79B, and XWB-84 turbofan engines. The NPRM published in 
the Federal Register on February 12, 2020 (85 FR 7899). The NPRM was 
prompted by analysis by the manufacturer of the LPC OGV assembly and 
LPC OGV outer mount ring assembly. The analysis predicted that when the 
front engine mount is in the fail-safe condition, the most highly 
stressed LPC OGV outer mount ring assembly has a life that could be 
substantially less than one shop visit interval. The NPRM proposed to 
require initial and repetitive inspections of the LPC OGV outer mount 
ring assembly and, depending on the results of the inspections, 
possible replacement of the LPC OGV outer mount ring assembly. 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 2019-0234, dated September 19, 2019 (referred to after 
this as ``the MCAI''), to address the unsafe condition on these 
products. The MCAI states:

    The purpose of the engine mount is to position the engine 
relative to the pylon and to transfer all loads and rotational 
moments between the engine and pylon. The front engine mount support 
structure (EMSS) consists of the low pressure compressor (LPC) 
outlet guide vane (OGV) assembly and OGV outer mount ring assembly. 
Revised analysis of these parts, when the front engine mount (FEM) 
is engaged in the fail-safe condition, has now been undertaken using 
more advanced modelling techniques. This analysis predicts that, 
once the FEM is in the fail-safe condition, the most highly stressed 
LPC OGV has a life that could be substantially less than one shop 
visit interval.
    This condition, if not detected and corrected, could lead to 
failure of the EMSS, possibly resulting in engine separation and 
reduced control of the aeroplane.
    To address this potential unsafe condition, Rolls-Royce 
introduced inspections to protect against the FEM entering the 
failsafe condition following a failure of the OGV outer mount ring 
assembly lugs, and published the NMSB to provide instructions.
    For the reason described above, this [EASA] AD requires 
repetitive inspections of the OGV outer mount ring assembly lug 
fillet area and, depending on findings, accomplishment of applicable 
corrective action(s).

    You may obtain further information by examining the MCAI in the AD

[[Page 34960]]

docket on the internet at https://www.regulations.gov by searching for 
and locating Docket No. FAA-2019-1109.

Comments

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

Request To Allow Replacement of the Engine

    Delta Air Lines, Inc. (DAL) requested that the FAA revise paragraph 
(g)(4)(i), Required Actions, of this AD to ``Before further flight or 
before release to service of the engine, as applicable, replace the 
engine or the OGV outer mount ring assembly with a part eligible for 
installation.'' DAL reasoned that neither the aircraft maintenance 
manual (AMM) nor Rolls-Royce plc (RR) Alert Non-Modification Service 
Bulletin (NMSB) Trent XWB 72-AK188, Revision 2, dated December 17, 
2019, provide instructions on replacing the LPC OGV outer mount ring 
assembly. Therefore, if the LPC OGV outer mount ring assembly requires 
replacement, the engine will be removed per the AMM, and the LPC OGV 
outer mount ring assembly replaced per the engine manual.
    The FAA agrees that the installation of another engine with an LPC 
OGV outer mount ring assembly that meets the initial and repetitive 
inspection requirements of paragraphs (g)(1) through (3) of this AD 
would be acceptable. However, the FAA disagrees with adding the 
language suggested by DAL because the operator is only responsible for 
correcting the unsafe condition. The FAA identified the unsafe 
condition in the LPC OGV outer mount ring assembly and this AD, 
therefore, requires that this part be replaced.

Request To Define Parts Eligible for Installation

    DAL commented that the proposed AD does not define what would be 
considered a part eligible for installation. On the other hand, the 
MCAI requires that the LPC OGV outer mount ring assembly be replaced 
with a new part. DAL suggested that a part eligible for installation 
include an engine that satisfies the requirements of paragraphs (g)(1) 
through (3) of this AD or a new LPC OGV outer mount ring assembly.
    The FAA agrees to add a definition of ``a part eligible for 
installation'' in this AD. The FAA disagrees with adding the language 
suggested by DAL because the FAA agrees with the MCAI requirement of 
replacing the LPC OGV outer mount ring assembly with a new part. As 
noted in the previous response, the operator may elect to install 
another engine that meets the initial and repetitive inspection 
requirements of paragraphs (g)(1) through (3) of this AD.

Support for the AD

    The Air Line Pilots Association, International expressed support 
for the AD as written.

Conclusion

    The FAA reviewed the relevant data, considered the comments 
received, and determined that air safety and the public interest 
require adopting this final rule with the changes described previously 
and minor editorial changes. The FAA has determined that these minor 
changes:
    <bullet> Are consistent with the intent that was proposed in the 
NPRM for addressing the unsafe condition; and
    <bullet> Do not add any additional burden upon the public than was 
already proposed in the NPRM.
    The FAA has also determined that these changes will not increase 
the economic burden on any operator or increase the scope of this final 
rule.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed RR Alert NMSB Trent XWB 72-AK188, Revision 2, 
dated December 17, 2019. The NMSB describes procedures for performing 
fluorescent penetrant inspections (FPIs) of the LPC OGV outer mount 
ring assembly. 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 26 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
----------------------------------------------------------------------------------------------------------------
FPI the LPC OGV outer mount ring      3 work-hours x $85 per               $0             $255           $6,630
 assembly.                             hour = $255.
----------------------------------------------------------------------------------------------------------------

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

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                    Action                                Labor cost               Parts cost        product
----------------------------------------------------------------------------------------------------------------
Replace the LPC OGV outer mount ring assembly  8 work-hours x $85 per hour =        $2,418,121       $2,418,801
 (KH10678).                                     $680.
----------------------------------------------------------------------------------------------------------------

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

[[Page 34961]]

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 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 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 (AD):

2020-12-01 Rolls-Royce Deutschland Ltd & Co KG (Type Certificate 
previously held by Rolls-Royce plc): Amendment 39-21135; Docket No. 
FAA-2019-1109; Project Identifier MCAI-2019-00115-E.

(a) Effective Date

    This AD is effective July 13, 2020.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to Rolls-Royce Deutschland Ltd. & Co KG (RRD) 
(Type Certificate previously held by Rolls-Royce plc) Trent XWB-75, 
XWB-79, XWB-79B, and XWB-84 model turbofan engines.

(d) Subject

    Joint Aircraft System Component (JASC) Code 7120, Engine Mount 
Section.

(e) Unsafe Condition

    This AD was prompted by analysis by the manufacturer of the low-
pressure compressor (LPC) outlet guide vane (OGV) assembly and LPC 
OGV outer mount ring assembly. The analysis predicted that when the 
front engine mount is in the fail-safe condition, the most highly 
stressed LPC OGV outer mount ring assembly has a life that could be 
substantially less than one shop visit interval. The FAA is issuing 
this AD to prevent failure of the front engine mount support 
structure. The unsafe condition, if not addressed, could result in 
engine separation, reduced control of the airplane, and loss of the 
airplane.

(f) Compliance

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

(g) Required Actions

    (1) For affected RRD Trent XWB turbofan engines with 1,700 
flight cycles since new (FCSN) or greater as of the effective date 
of this AD:
    (i) Within 300 flight cycles (FCs) after the effective date of 
this AD, perform a fluorescent penetrant inspection (FPI) of the LPC 
OGV outer mount ring assembly.
    (ii) Use Accomplishment Instructions, paragraph 3.A. or 3.B., as 
applicable, of Rolls-Royce plc (RR) Alert Non-Modification Service 
Bulletin (NMSB) Trent XWB 72-AK188, Revision 2, dated December 17, 
2019, to perform the FPI of the LPC OGV outer mount ring assembly.
    (iii) Thereafter, perform repetitive FPIs of the LPC OGV outer 
mount ring assembly within 1,000 FCs after the previous inspection.
    (2) For affected RRD Trent XWB turbofan engines with fewer than 
1,700 FCSN as of the effective date of this AD:
    (i) Before exceeding 2,000 FCSN after the effective date of this 
AD, perform an FPI of the LPC OGV outer mount ring assembly.
    (ii) Use Accomplishment Instructions, paragraph 3.A. or 3.B., as 
applicable, of RR Alert NMSB Trent XWB 72-AK188, Revision 2, dated 
December 17, 2019, to perform the FPI of LPC OGV outer mount ring 
assembly.
    (iii) Thereafter, perform repetitive FPIs of the LPC OGV outer 
mount ring assembly within 1,000 FCs after the previous inspection.
    (3) If, during any FPI required by paragraph (g)(1) or (2) of 
this AD, an LPC OGV outer mount ring assembly discrepancy is 
detected, as defined in the Accomplishment Instructions, paragraph 
3.A. or 3.B., of RR Alert NMSB Trent XWB 72-AK188, Revision 2, dated 
December 17, 2019, repeat the FPI within the interval specified in 
Accomplishment Instructions, paragraph 3.A. or 3.B., of RR Alert 
NMSB Trent XWB 72-AK188, Revision 2, dated December 17, 2019.
    (4) If, during any FPI required by paragraphs (g)(1) through (3) 
of this AD, an LPC OGV outer mount ring assembly is rejected as a 
result of the FPI, as defined in the Accomplishment Instructions, 
paragraph 3.A. or 3.B., of RR Alert NMSB Trent XWB 72-AK188, 
Revision 2, dated December 17, 2019:
    (i) Before further flight, replace the LPC OGV outer mount ring 
assembly with a part eligible for installation.
    (ii) [Reserved]

(h) Definition

    For the purpose of this AD, ``a part eligible for installation'' 
is a new LPC OGV outer mount ring assembly that has not been 
previously installed on an engine.

(i) No Reporting Requirement

    The reporting requirements in the Accomplishment Instructions, 
paragraph 3, of RR Alert NMSB Trent XWB 72-AK188, Revision 2, dated 
December 17, 2019, are not required by this AD.

(j) Credit for Previous Actions

    You may take credit for the initial and repetitive FPIs that are 
required by paragraphs (g)(1) through (3) of this AD if you 
performed the FPIs before the effective date of this AD using RR 
Alert NMSB Trent XWB 72-AK188, Revision 1, dated September 20, 2019, 
or Initial Issue, dated August 13, 2019.

(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 
2019-0234, dated September 19, 2019, 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 Docket No. FAA-
2019-1109.

(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.
    (i) Rolls-Royce plc (RR) Alert Non-Modification Service Bulletin 
Trent XWB 72-AK188, Revision 2, dated December 17, 2019.

[[Page 34962]]

    (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, Airworthiness 
Products Section, Operational Safety 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 that is incorporated 
by reference 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 May 27, 2020.
Gaetano A. Sciortino,
Deputy Director for Strategic Initiatives, Compliance & Airworthiness 
Division, Aircraft Certification Service.
[FR Doc. 2020-12346 Filed 6-5-20; 8:45 am]
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