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

[Federal Register Volume 86, Number 133 (Thursday, July 15, 2021)]
[Rules and Regulations]
[Pages 37226-37229]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2021-15055]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2020-1025; Project Identifier MCAI-2020-00757-E; 
Amendment 39-21630; AD 2021-14-03]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce Deutschland Ltd & Co KG 
(Type Certificate Previously Held by BMW Rolls-Royce GmbH and BMW 
Rolls-Royce Aero Engines) 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) BR700-715A1-30, 
BR700-715B1-30, and BR700-715C1-30 model turbofan engines. This AD was 
prompted by reports of HPT stage 1 blades failing in service due to 
sulphidation and subsequent crack initiation. This AD requires removal 
and replacement of the HPT stage 1 blade and HPT stage 1 blade damper. 
The FAA is issuing this AD to address the unsafe condition on these 
products.

DATES: This AD is effective August 19, 2021.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of August 19, 
2021.

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: 
rrd.techhelp@rolls-royce; website: 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 at https://www.regulations.gov by searching for and 
locating Docket No. FAA-2020-1025.

Examining the AD Docket

    You may examine the AD docket at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2020-1025; 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, 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: Barbara Caufield, Aviation Safety 
Engineer, ECO Branch, FAA, 1200 District Avenue, Burlington, MA 01803; 
phone: (781) 238-7146; fax: (781) 238-7199; email: 
[email protected].

SUPPLEMENTARY INFORMATION:

Background

    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 BR700-
715A1-30, BR700-715B1-30, and BR700-715C1-30 model turbofan engines. 
The NPRM published in the Federal Register on November 13, 2020 (85 FR 
72608). The NPRM was prompted by reports of HPT stage 1 blades failing 
in service due to sulphidation and subsequent crack initiation, due to 
contamination of the blade shank passing by the blade damper. In the 
NPRM, the FAA proposed to require removal and replacement of the HPT 
stage 1 blade and HPT stage 1 blade damper. The

[[Page 37227]]

FAA is issuing this AD to address the unsafe condition on these 
products.
    The European Aviation Safety Agency (EASA), which is the Technical 
Agent for the Member States of the European Community, has issued EASA 
AD 2018-0194, dated September 4, 2018 (referred to after this as ``the 
MCAI''), to address the unsafe condition on these products. The MCAI 
states:

    Occurrences have been reported on RRD BR700-715 engines where 
certain HP turbine stage 1 blades failed in service. Investigation 
of these events showed that these were caused by sulphidation and 
subsequent crack initiation, due to contamination of the blade shank 
passing by the blade damper.
    This condition, if not corrected, could lead to further HP 
turbine stage 1 blade failures, possibly resulting in engine in-
flight shut-down and consequent reduced control of the aeroplane. To 
address this potential unsafe condition, RRD published the NMSB to 
provide instructions to replace the affected assembly.
    For the reasons described above, this [EASA] AD requires 
determination of the engine configuration and, depending on 
findings, removal of the engine from service to replace the affected 
assembly.

    You may obtain further information by examining the MCAI in the AD 
docket at https://www.regulations.gov by searching for and locating 
Docket No. FAA-2020-1025.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from one commenter. The commenter was 
Delta Airlines (Delta). The following presents the comments received on 
the NPRM and the FAA's response to each comment.

Request To Revise Definition of ``Parts Eligible for Installation''

    Delta requested that the FAA revise the definition of ``parts 
eligible for installation'' to avoid the necessity of an alternate 
method of compliance (AMOC) request each time Rolls-Royce introduces a 
new part number for the HPT stage 1 blade or HPT stage 1 damper.
    The FAA agrees and revised the definition of ``parts eligible for 
installation'' to allow installation of HPT stage 1 blades and HPT 
stage 1 dampers approved as eligible for installation in accordance 
with certain RRD service information.

Request To Clarify Compliance Time Language

    Delta requested that the FAA revise paragraph (g)(1)(i) in the 
Required Actions section of this AD to refer to ``flight cycles since 
new'' instead of ``flight cycles since first installation,'' as 
proposed in the NPRM. Delta noted that the proposed language could be 
misinterpreted as referring to any affected HPT stage 1 blade, 
regardless of whether the affected HPT stage 1 blade is currently 
installed on an engine.
    The FAA partially agrees. The FAA agrees to update this reference 
to avoid possible misinterpretation, but disagrees with the specific 
language proposed by the commenter. The FAA has updated paragraph 
(g)(1)(i) of this AD to read: ``Before an affected HPT stage 1 blade 
exceeds 10,000 flight cycles (FCs) since first installation . . .''

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting this AD as 
proposed. Accordingly, the FAA is issuing this AD to address the unsafe 
condition on these products. Except for minor editorial changes and any 
other changes described previously, this AD is adopted as proposed in 
the NPRM. None of the changes will increase the economic burden on any 
operator.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed RRD BR700 Series Alert Non-Modification Service 
Bulletin (NMSB) SB-BR700-72-A900640, Revision 1, dated August 31, 2018. 
The Alert NMSB describes procedures for removing and replacing the HPT 
stage 1 blade and HPT stage 1 blade damper. 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 
ADDRESSES.

Other Related Service Information

    The FAA reviewed RRD Service Bulletin (SB) SB-BR700-72-102005, 
dated March 20, 2018; RRD NMSB SB-BR700-72-900118, dated June 6, 2017; 
and RRD SB SB-BR700-72-101671, dated January 29, 2010. RRD SB SB-BR700-
72-102005, dated March 20, 2018, introduces a new HPT stage 1 blade 
damper with a front restrictor that reduces the average airflow into 
the blade shank cavity, thereby reducing deposition of particles in the 
cavity. RRD NMSB SB-BR700-72-900118, dated June 6, 2017, describes 
procedures for recording the serial numbers of the cleaned, crack 
tested, and examined HPT stage 1 blades. RRD SB SB-BR700-72-101671, 
dated January 29, 2010, introduces a redesigned HPT stage 1 blade that 
improves robustness and stress characteristics.

Costs of Compliance

    The FAA estimates that this AD affects 222 engines installed on 
airplanes of U.S. registry. The agency estimates that the service life 
of both the HPT stage 1 blade and HPT stage 1 blade damper are 5.5 
years. Based on this life estimate, the agency is providing an 
estimated annual cost to replace these parts.
    The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                    Annualized
                Action                         Labor cost           Parts cost       Cost per      cost on U.S.
                                                                                      product        operators
----------------------------------------------------------------------------------------------------------------
Replace HPT stage 1 blade and HPT       20 work-hours x $85 per         $692,000        $693,700     $28,000,524
 stage 1 blade damper.                   hour = $1,700.
----------------------------------------------------------------------------------------------------------------

    The FAA has included all known costs in its cost estimate. 
According to the manufacturer, however, all of the costs of this AD may 
be covered under warranty, thereby reducing the cost impact on affected 
individuals.

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

[[Page 37228]]

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.

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:

2021-14-03 Rolls-Royce Deutschland Ltd & Co KG (Type Certificate 
previously held by BMW Rolls-Royce GmbH and BMW Rolls-Royce Aero 
Engines): Amendment 39-21630; Docket No. FAA-2020-1025; Project 
Identifier MCAI-2020-00757-E.

(a) Effective Date

    This airworthiness directive (AD) is effective August 19, 2021.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to all Rolls-Royce Deutschland Ltd. & Co KG 
(Type Certificate previously held by BMW Rolls-Royce GmbH and BMW 
Rolls-Royce Aero Engines) (RRD) BR700-715A1-30, BR700-715B1-30, and 
BR700-715C1-30 model turbofan engines with high-pressure turbine 
(HPT) stage 1 blade, part number (P/N) BRH17133, BRH19984, BRH20011, 
BRH20237, BRH20351, FW35594, FW45914, FW64379, or FW75735, and with 
HPT stage 1 blade damper, P/N BRH10943, BRH20353, or FW45770, 
installed.

(d) Subject

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

(e) Unsafe Condition

    This AD was prompted by reports of HPT stage 1 blades failing in 
service due to sulphidation and subsequent crack initiation. The FAA 
is issuing this AD to prevent failure of the HPT stage 1 blade. The 
unsafe condition, if not addressed, could result in the release of 
the HPT stage 1 blade, failure of the engine, in-flight shutdown, 
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 engines that have not operated exclusively 
under the Hawaiian Flight Mission:
    (i) Before an affected HPT stage 1 blade exceeds 10,000 flight 
cycles (FCs) since first installation of that affected HPT stage 1 
blade, or within 50 FCs after the effective date of this AD, 
whichever occurs later, remove the affected HPT stage 1 blade and 
the affected HPT stage 1 blade damper from service and replace with 
parts eligible for installation using the Accomplishment 
Instructions, paragraph 3.R. through T., of RRD Alert Non-
Modification Service Bulletin (NMSB) SB-BR700-72-A900640, Revision 
1, dated August 31, 2018 (NMSB SB-BR700-72-A900640).
    (ii) If an HPT stage 1 blade has been cleaned and examined 
before the effective date of this AD using RRD NMSB SB-BR700-72-
900118, dated June 6, 2017, within 1,500 FCs from the last cleaning 
and examination, or within 10 FCs after the effective date of this 
AD, whichever occurs later, remove the affected HPT stage 1 blade 
and affected HPT stage 1 blade damper from service and replace with 
parts eligible for installation using Accomplishment Instructions, 
paragraph 3.R. through T., of RRD NMSB SB-BR700-72-A900640.
    (2) For affected engines operated exclusively under the Hawaiian 
Flight Mission:
    (i) At the next change of the flight mission after the effective 
date of this AD, replace the affected HPT stage 1 blade and affected 
HPT stage 1 blade damper in accordance with paragraphs (g)(1)(i) and 
(ii) of this AD.
    (ii) [Reserved]

(h) Installation Prohibition

    After the effective date of this AD, do not install any HPT 
stage 1 blade, P/N BRH17133, BRH19984, BRH20011, BRH20237, BRH20351, 
FW35594, FW45914, FW64379, or FW75735, with any HPT stage 1 blade 
damper, P/N BRH10943, BRH20353, or FW45770, in any engine.

(i) Definitions

    (1) For the purpose of this AD, ``parts eligible for 
installation'' are an HPT stage 1 blade, P/N FW75735, or a P/N 
approved for installation in accordance with paragraph 2.C of RRD 
NMSB SB-BR700-72-A900640, installed with HPT stage 1 blade damper, 
P/N KH82098, or a P/N approved for installation in accordance with 
paragraph 2.C of RRD NMSB SB-BR700-72-A900640.
    (2) For the purpose of this AD, the ``Hawaiian Flight Mission'' 
are flights operated by Hawaiian Airlines.

(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 
certification office, send it to the attention of the person 
identified in Related Information. 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) Barbara Caufield, Aviation Safety Engineer, ECO Branch, FAA, 
1200 District Avenue, Burlington, MA 01803; phone: (781) 238-7146; 
fax: (781) 238-7199; email: [email protected].
    (2) Refer to European Aviation Safety Agency (EASA) AD 2018-
0194, dated September 4, 2018, for more information. You may examine 
the EASA AD in the AD docket at https://www.regulations.gov by 
searching for and locating it in Docket No. FAA-2020-1025.

(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 Deutschland Ltd. & Co KG (RRD) BR700 Series 
Alert Non-Modification Service Bulletin SB-BR700-72-A900640, 
Revision 1, dated August 31, 2018.
    (ii) [Reserved]
    (3) For RRD 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: 
rrd.techhelp@rolls-

[[Page 37229]]

royce; website: 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 June 21, 2021.
Gaetano A. Sciortino,
Deputy Director for Strategic Initiatives, Compliance & Airworthiness 
Division, Aircraft Certification Service.
[FR Doc. 2021-15055 Filed 7-14-21; 8:45 am]
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