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

[Federal Register Volume 85, Number 159 (Monday, August 17, 2020)]
[Rules and Regulations]
[Pages 49959-49961]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2020-17822]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2020-0265; Project Identifier MCAI-2019-00131-E; 
Amendment 39-21201; AD 2020-16-17]
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 all 
Rolls-Royce Deutschland Ltd. & Co KG (RRD) Trent XWB-75, Trent XWB-79, 
Trent XWB-79B, and Trent XWB-84 model turbofan engines. This AD was 
prompted by reports of a lack of weld fusion on the resistance welding 
during manufacturing, which could result in air leakage through the 
low-pressure turbine (LPT) rear support seal panel assembly (``LPT seal 
panel''). This AD requires replacement of the LPT seal panel. The FAA 
is issuing this AD to address the unsafe condition on these products.

DATES: This AD is effective September 21, 2020.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of September 
21, 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-2020-
0265.

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-2020-
0265; 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,

[[Page 49960]]

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 all RRD Trent XWB-75, 
Trent XWB-79, Trent XWB-79B, and Trent XWB-84 model turbofan engines. 
The NPRM published in the Federal Register on March 30, 2020 (85 FR 
17513). The NPRM was prompted by reports of a lack of weld fusion on 
the resistance welding during manufacturing, which could result in air 
leakage through the LPT seal panel. The NPRM proposed to require 
replacement of the LPT seal panel. 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 2019-0071, dated March 28, 2019 (referred to after this 
as ``the MCAI''), to address the unsafe condition on these products. 
The MCAI states:

    The affected parts, as defined in this [EASA] AD, are static 
parts, located behind the intermediate pressure (IP) turbine 2 disc, 
forming a seal between the IP and LP cavities through an interface 
with the rotating IP flying seal. It was recently determined that, 
on certain affected parts, insufficient fusion was achieved on the 
resistance welding during manufacturing.
    This condition, if not corrected, could lead to air leakage 
through the LP seal panel, affecting the service lives of the IP 
turbine 2 and LP turbine 1 discs, possibly resulting in premature 
disc failure and high energy uncontained debris release from the 
engine, with consequent damage to, and reduced control of, the 
aeroplane.
    To address this potential unsafe condition, Rolls-Royce 
identified the affected parts and published the NMSB, providing 
instructions to replace these affected parts.
    For the reason described above, this [EASA] AD requires 
replacement of affected parts during a qualified shop visit.

    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-2020-0265.

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 Revise Definition of Module 51

    Delta Air Lines, Inc. (DAL) requested that the definition of 
``module 51'' in paragraph (h) of this AD be revised to ``intermediate 
pressure turbine module.'' DAL reasoned that the RRD Trent XWB Engine 
Manual and Rolls-Royce plc (RR) Alert Non-Modification Service Bulletin 
(NMSB) Trent XWB 72-AJ994, Revision 2, dated August 29, 2019, both 
refer to module 51 as the intermediate-pressure turbine (IPT) module 
and refer to module 52 as the LPT module. Therefore, revising this 
definition would alleviate confusion.
    The FAA agrees and revised the definition of module 51 to read, 
``For the purpose of this AD, `module 51' is the IPT module.''

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 change 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.

Service Information Incorporated by Reference Under 1 CFR Part 51

    The FAA reviewed RR Alert NMSB Trent XWB 72-AJ994, Revision 2, 
dated August 29, 2019. The Alert NMSB describes procedures for removing 
and replacing the LPT seal panel. 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
----------------------------------------------------------------------------------------------------------------
Replace the LPT seal panel............  1 work-hour x $85 per           $282,890        $282,975      $7,357,350
                                         hour = $85.
----------------------------------------------------------------------------------------------------------------

    According to the manufacturer, all 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

[[Page 49961]]

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) Would not affect intrastate aviation in Alaska, and
    (3) Would 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):

2020-16-17 Rolls-Royce Deutschland Ltd & Co KG (Type Certificate 
previously held by Rolls-Royce plc): Amendment 39-21201; Docket No. 
FAA-2020-0265; Project Identifier MCAI-2019-00131-E.

(a) Effective Date

    This AD is effective September 21, 2020.

(b) Affected ADs

    None.

(c) Applicability

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

(d) Subject

    Joint Aircraft System Component (JASC) Code 7250, Turbine 
Section.

(e) Unsafe Condition

    This AD was prompted by reports of a lack of weld fusion on the 
resistance welding during manufacturing, which could result in air 
leakage through the low-pressure turbine (LPT) rear support seal 
panel assembly (``LPT seal panel'') causing a life reduction to the 
intermediate-pressure turbine (IPT) 2 and LPT 1 disks. The FAA is 
issuing this AD to prevent failure of the IPT 2 and LPT 1 disks. The 
unsafe condition, if not addressed, could result in uncontained 
debris release, 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

    During the next qualified shop visit after the effective date of 
this AD, or during the current shop visit, if, on the effective date 
of this AD, the engine or module 51 is in a qualified shop visit, 
remove the affected LPT seal panel from service and replace it with 
a part eligible for installation in accordance with the 
Accomplishment Instructions, paragraph 3.A., of Rolls-Royce plc 
Alert Non-Modification Service Bulletin (NMSB) Trent XWB 72-AJ994, 
Revision 2, dated August 29, 2019.

(h) Definitions

    (1) For the purpose of this AD, a ``qualified shop visit'' is a 
Level 4 (Overhaul) or Level 3 (Refurbishment) shop visit of an 
affected engine with an affected LPT seal panel installed, or Level 
2 shop visit (Check and Repair) of module 51 with an affected LPT 
seal panel installed.
    (2) For the purpose of this AD, ``module 51'' is the IPT module.
    (3) For the purpose of this AD, an ``affected LPT seal panel'' 
is LPT rear support seal panel assembly, identified as catalogue 
serial number (CSN) 72512301890, with a serial number (S/N) listed 
in Appendix 1 of RR Alert NMSB Trent XWB 72-AJ994, Revision 2, dated 
August 29, 2019. This appendix additionally lists the module 51 S/N 
and engine S/N in which these panels were originally installed.
    (4) For the purpose of this AD, a ``part eligible for 
installation'' is a LPT seal panel, CSN 72512301890, with a S/N not 
listed in Appendix 1 of RR Alert NMSB Trent XWB 72-AJ994, Revision 
2, dated August 29, 2019.

(i) Credit for Previous Actions

    You may take credit for replacement of the LPT seal panel 
requirements of paragraph (g) of this AD if you performed the 
replacement before the effective date of this AD using RR Alert NMSB 
Trent XWB 72-AJ994, Revision 1, dated November 15, 2018, or Initial 
Issue, dated September 5, 2018.

(j) 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 (k)(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.

(k) 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 AD 2019-0071, 
dated March 28, 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-2020-0265.

(l) 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-AJ994, Revision 2, dated August 29, 2019.
    (ii) [Reserved]
    (3) For RR service information identified in this AD, contact 
Rolls-Royce Deutschland Ltd & Co KG, Eschenweg 11, Blankenfelde-
Mahlow, Germany; phone: 9 011 49 03370860.
    (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: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued on July 29, 2020.
Gaetano A. Sciortino,
Deputy Director for Strategic Initiatives, Compliance & Airworthiness 
Division, Aircraft Certification Service.
[FR Doc. 2020-17822 Filed 8-14-20; 8:45 am]
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