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

[Federal Register Volume 87, Number 97 (Thursday, May 19, 2022)]
[Rules and Regulations]
[Pages 30411-30413]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2022-10755]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2021-1004; Project Identifier MCAI-2021-00480-E; 
Amendment 39-22030; AD 2022-09-10]
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) RB211 Trent 875-17, 877-17, 
884-17, 884B-17, 892-17, 892B-17, and 895-17 model turbofan engines. 
This AD was prompted by findings during engine overhaul of corrosion on 
the low-pressure compressor (LPC) front case assembly. This AD requires 
inspection of the LPC front case assembly and, depending on the result 
of the inspection, accomplishment of the applicable corrective 
action(s), as specified in a European Union Aviation Safety Agency 
(EASA) AD, which is incorporated by reference. The FAA is issuing this 
AD to address the unsafe condition on these products.

DATES: This AD is effective June 23, 2022.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of June 23, 
2022.

ADDRESSES: For material incorporated by reference in this AD, contact 
EASA, Konrad-Adenauer-Ufer 3, 50668 Cologne, Germany; phone: +49 221 
8999 000; email: [email protected]. You may find this material on the 
EASA website at https://ad.easa.europa.eu. You may view this material 
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 (817) 222-5110. It is 
also available at https://www.regulations.gov by searching for and 
locating Docket No. FAA-2021-1004. For RRD service information 
identified in this AD, contact Rolls-Royce plc, Corporate 
Communications, P.O. Box 31, Derby, DE24 8BJ, United Kingdom; phone: 
+44 (0)1332 242424 fax: +44 (0)1332 249936; website: https://www.rolls-royce.com/contact-us.aspx.

Examining the AD Docket

    You may examine the AD docket at https://www.regulations.gov by 
searching for and locating Docket No. FAA-2021-1004; 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 
EASA AD, 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: Nicholas Paine, Aviation Safety 
Engineer, ECO Branch, FAA, 1200 District Avenue, Burlington, MA 01803; 
phone: (781) 238-7116; email: [email protected].

SUPPLEMENTARY INFORMATION:

Background

    EASA, which is the Technical Agent for the Member States of the 
European Union, has issued EASA AD 2021-0114, dated April 23, 2021 
(EASA AD 2021-0114), to address an unsafe condition for certain RRD 
RB211 Trent 875-17, 877-17, 884-17, 884B-17, 892-17, 892B-17, and 895-
17 model turbofan engines.
    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to RRD RB211 Trent 875-17, 
877-17, 884-17, 884B-17, 892-17, 892B-17, and 895-17 model turbofan 
engines. The NPRM published in the Federal Register on November 16, 
2021 (86 FR 63319). The NPRM was prompted by findings during engine 
overhaul of corrosion on the LPC front case assembly caused by 
excessive movement between the Kevlar wrap and the fan case, which 
resulted in the anti-corrosion paint fretting away. In the NPRM, the 
FAA proposed to require the performance of all required actions within 
the compliance times specified in, and in accordance with EASA AD 2021-
0114, except for any differences identified as exceptions in the 
regulatory text of this AD and except as discussed under ``Differences 
Between this Proposed AD and the EASA AD.'' The FAA is issuing this AD 
to address the unsafe condition on these products. See EASA AD 2021-
0114 for additional background information.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from three commenters. The commenters 
were American Airlines (American), The Boeing Company (Boeing), and 
Rolls-Royce plc (RR). The following presents the comments received on 
the NPRM and the FAA's response to each comment.

Request To Revise Applicability

    American requested that the FAA revise paragraph (c), 
Applicability, of this AD to replace ``as identified in EASA AD 2021-
0114'' with ``RB211 Trent 875-17, 877-17, 884-17, 884B-17, 892-17, 
892B-17 and 895-17 engines with Low Pressure (LP) Compressor front 
(fan) case assemblies having Part Number (P/N) FK33097, P/N FK26850, P/
N FK26853, P/N FK26915, P/N FK26692 or P/N FK28577.'' American stated 
that certain engines identified in the EASA AD applicability section 
have already performed rework on the LPC front case assembly to provide 
additional corrosion protection using RR RB211 Trent 800 Series 
Propulsion Systems Service Bulletin (SB) RB.211-72-G634

[[Page 30412]]

(RR SB RB.211-72-G634) or RR RB211 Trent 800 Series Propulsion Systems 
SB RB.211-72-G856 (RR SB RB.211-72-G856) and the LPC front case 
assembly subsequently received a new P/N. American explained that, in 
addition to the new LPC front case assembly introduced by RR SB RB.211-
72-G581, the new reworked LPC front case assembly P/Ns are not 
identified in the affected part list of the EASA AD.
    The FAA disagrees with revising paragraph (c), Applicability of 
this AD. Paragraph (c) lists engines affected by this AD and refers to 
EASA AD 2021-0114, which identifies the affected P/Ns of the LPC front 
case assemblies. The Credit paragraph (4) in EASA AD 2021-0114 
provides, ``Corrective action(s) on an engine, accomplished in 
accordance with the instructions of Rolls-Royce SB RB.211-72-G634 or SB 
RB.211-72-G856, are acceptable to comply with the requirements of 
paragraph (2) of this [EASA] AD for that engine.'' The FAA notes that 
this AD requires compliance with EASA AD 2021-0114 in its entirety, 
including any credit for previous actions. The FAA did not change this 
AD as a result of this comment.

Request To Revise Exceptions to EASA AD Paragraph

    RR requested that the FAA revise paragraph (h)(3) of this AD to 
ensure consistency with the Credit paragraph in EASA AD 2021-0114 or to 
provide an alternative means to accomplish the same intent. RR 
explained that the service information cited in EASA AD 2021-0114 
requires inspecting the affected part and contacting the manufacturer 
for repair instructions if corrosion exceeds the criteria in RR Alert 
Non-Modification Service Bulletin (NMSB) RB.211-72-G774. RR also 
explained that the NPRM proposed to require the removal of an affected 
LPC front case assembly if corrosion exceeds the criteria in RR Alert 
NMSB RB.211-72-G774. RR noted that this difference is inconsistent with 
the Credit paragraph of the EASA AD.
    In response to this comment the FAA has revised paragraph (h)(3) of 
this AD to include a repair option for the LPC front case assembly in 
lieu of removal. This revision allows operators to repair the affected 
LPC front case assembly using a method approved by the Manager, 
International Validation Branch, FAA; or EASA; or Rolls-Royce's EASA 
Design Organization Approval (DOA). The FAA has also updated the 
Estimated Costs section of this preamble to include the estimated costs 
for repairing the LPC front case assembly.

Support for the AD

    Boeing expressed support for the AD as written.

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 an 
update to the language in paragraph (h)(3), 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 EASA AD 2021-0114. EASA AD 2021-0114 specifies 
instructions for inspecting the LPC front case assembly and, depending 
on the result of the inspection, corrective action. This material 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 Rolls-Royce RB211 Trent 800 Series Propulsion 
Systems Alert NMSB RB.211-72-AG774, Revision 4, dated October 13, 2020 
(the NMSB). The NMSB specifies procedures for inspecting the LPC front 
case assembly for corrosion and taking corrective action.

Costs of Compliance

    The FAA estimates that this AD affects 98 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
----------------------------------------------------------------------------------------------------------------
Perform ultrasonic inspection.........  8 work-hours x $85 per                $0            $680         $66,640
                                         hour = $680.
Rework the LPC front case assembly....  200 work-hours x $85 per          18,724          35,724       3,500,952
                                         hour = $17,000.
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    The FAA estimates the following costs to do any necessary 
replacement or repair that would be required based on the results of 
the inspection. The agency has no way of determining the number of 
aircraft that might need this replacement or repair:

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                    Action                                 Labor cost               Parts cost        product
----------------------------------------------------------------------------------------------------------------
Replace the LPC front case assembly...........  140 work-hours x $85 per hour =         $932,000        $943,900
                                                 $11,900.
Repair the LPC front case assembly............  200 work-hours x $85 per hour =           18,724          35,724
                                                 $17,000.
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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 30413]]

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:

2022-09-10 Rolls-Royce Deutschland Ltd & Co KG (Type Certificate 
previously held by Rolls-Royce plc): Amendment 39-22030; Docket No. 
FAA-2021-1004; Project Identifier MCAI-2021-00480-E.

(a) Effective Date

    This airworthiness directive (AD) is effective June 23, 2022.

(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) RB211 Trent 
875-17, RB211 Trent 877-17, RB211 Trent 884-17, RB211 Trent 884B-17, 
RB211 Trent 892-17, RB211 Trent 892B-17, and RB211 Trent 895-17 
model turbofan engines, as identified in EASA AD 2021-0114, dated 
April 23, 2021 (EASA AD 2021-0114).

(d) Subject

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

(e) Unsafe Condition

    This AD was prompted by findings during engine overhaul of 
corrosion on the low-pressure compressor (LPC) front case assembly 
caused by excessive movement between the Kevlar wrap and the fan 
case, which resulted in the anti-corrosion paint fretting away. The 
FAA is issuing this AD to address corrosion on the LPC front case 
assembly. The unsafe condition, if not addressed, could result in 
reduced integrity of the LPC front case assembly during a fan blade 
release, resulting in damage to the airplane or reduced control of 
the airplane.

(f) Compliance

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

(g) Required Actions

    Except as specified in paragraph (h) of this AD: Perform all 
required actions within the compliance times specified in, and in 
accordance with EASA AD 2021-0114.

(h) Exceptions to EASA AD 2021-0114

    (1) Where EASA AD 2021-0114 requires compliance from its 
effective date, this AD requires using the effective date of this 
AD.
    (2) Where EASA AD 2021-0114 defines a qualified shop visit as 
``any scheduled shop visit where the affected part is exposed and 
substantial rebuild has not yet started, except shop visits for 
serviceability only,'' for this AD replace that phrase with ``the 
induction of an engine into the shop after the effective date of 
this AD for maintenance involving the separation of pairs of major 
mating engine flanges, with the exception of the separation of 
engine flanges solely for the purposes of transportation of the 
engine without subsequent engine maintenance, which does not 
constitute an engine shop visit.''
    (3) Where paragraph (3) of EASA AD 2021-0114 specifies ``if, 
during the inspection as required by paragraph (1) of this AD, any 
corrosion is found exceeding the criteria as specified in the NMSB, 
before release to service of the engine, contact Rolls-Royce for 
approved repair instructions and accomplish those instructions 
accordingly,'' for this AD replace that phrase with ``remove the 
affected LPC front case assembly from service if corrosion is found 
that exceeds the criteria specified in Appendix 2 of the NMSB.'' In 
lieu of removal of the affected LPC front case assembly, operators 
may repair the affected LPC front case assembly using a method 
approved by the Manager, International Validation Branch, FAA; or 
EASA; or Rolls-Royce's EASA Design Organization Approval (DOA). If 
approved by the DOA, the approval must include the DOA-authorized 
signature.
    (4) This AD does not mandate compliance with the ``Remarks'' 
section of EASA AD 2021-0114.

(i) No Reporting Requirement

    Although the service information referenced in EASA AD 2021-0114 
specifies to submit certain information to the manufacturer, this AD 
does not include that requirement.

(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) of this AD. Information may be emailed 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

    For more information about this AD, contact Nicholas Paine, 
Aviation Safety Engineer, ECO Branch, FAA, 1200 District Avenue, 
Burlington, MA 01803; phone: (781) 238-7116; email: 
[email protected].

(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 this AD specifies otherwise.
    (i) European Union Aviation Safety Agency (EASA) AD 2021-0114, 
dated April 23, 2021.
    (ii) [Reserved]
    (3) For more information about EASA AD 2021-0114, contact EASA, 
Konrad-Adenauer-Ufer 3, 50668 Cologne, Germany; phone: +49 221 8999 
000; email: [email protected]. You may find this material on the 
EASA website at https://ad.easa.europa.eu.
    (4) You may view this material 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 (817) 222-5110. This material may be found 
in the AD docket at https://www.regulations.gov by searching for and 
locating Docket No. FAA-2021-1004.
    (5) You may view this material 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 13, 2022.
Gaetano A. Sciortino,
Deputy Director for Strategic Initiatives, Compliance & Airworthiness 
Division, Aircraft Certification Service.
[FR Doc. 2022-10755 Filed 5-18-22; 8:45 am]
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