Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan Engines

[Federal Register Volume 71, Number 163 (Wednesday, August 23, 2006)]
[Rules and Regulations]
[Pages 49339-49343]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E6-13910]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2006-25584; Directorate Identifier 2000-NE-62-AD; 
Amendment 39-14733; AD 2006-17-12]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

-----------------------------------------------------------------------

SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD), that is applicable to Rolls-Royce plc (RR) models RB211-535E4-37, 
RB211-535E4--37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4-C, and 
RB211-22B-02 turbofan engines. That AD currently requires inspecting 
certain high pressure (HP) turbine discs, manufactured between 1989 and 
1999, for cracks in the rim cooling air holes, and, if necessary, 
replacing the discs with serviceable parts. The manufacturer identified 
reaming-induced machining anomalies (RIMA) as the cause for the 
cracking. This amendment requires the same inspections, and reduces the 
compliance times for eddy current inspection (ECI) for the RR RB211-
22B-02 engines. This amendment results from the manufacturer reducing 
their recommended compliance times for inspections on RB211-22B-02 
engines. We are issuing this AD to prevent possible disc failure, which 
could result in an uncontained engine failure and damage to the 
airplane.

DATES: This AD becomes effective September 27, 2006. The Director of 
the Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of September 27, 2006.
    The Director of the Federal Register approved the incorporation by 
reference of RR Alert Service Bulletin (ASB) No. RB211-72-AE651, dated 
November 22, 2004, as of January 13, 2005 (69 FR 77881, December 29, 
2004) and RR Service Bulletin (SB) No. RB211-72-C877, Revision 1, dated 
March 7, 2001, listed in the AD, as of December 24, 2001 (66 FR 57859, 
November 19, 2001).

ADDRESSES: You can get the service information identified in this 
proposed AD from Rolls-Royce plc, PO Box 31, Derby, England; telephone: 
011 44 1332-249428, fax: 011 44 1332-249223.
    You may examine the AD docket on the Internet at http://dms.dot.gov 
or in Room PL-401 on the plaza level of the Nassif Building, 400 
Seventh Street, SW., Washington, DC.

FOR FURTHER INFORMATION CONTACT: Ian Dargin, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; telephone (781) 238-7178, 
fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39 
with a proposed airworthiness directive (AD). The proposed AD applies 
to RR models RB211-535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-
535E4-B-75, and RB211-22B-02 turbofan engines. We published the 
proposed AD in the Federal Register on January 30, 2006 (71 FR 4832). 
That action proposed to reduce the inspection schedules required by AD 
2004-26-03, for the high risk discs installed on model RB211-22B-02 
engines.

Examining the AD Docket

    You may examine the docket that contains the AD, any comments 
received, and any final disposition in person at the Docket Management 
Facility Docket Offices between 9 a.m. and 5 p.m., Monday through 
Friday, except Federal holidays. The Docket Office (telephone (800) 
647-5227) is located on the plaza level of the Department of 
Transportation Nassif Building at the street address stated in 
ADDRESSES. Comments will be available in the AD docket shortly after 
the DMS receives them.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We received no comments on the proposal or on 
the determination of the cost to the public.

Editorial Change To Add Background Information to the Summary

    After we issued the NPRM, RR informed us that they identified 
reaming-induced machining anomalies (RIMA) as the cause for the 
cracking.

[[Page 49340]]

Docket Number Change

    We are transferring the docket for this AD to the Docket Management 
System as part of our on-going docket management consolidation efforts. 
The new Docket No. is FAA-2006-25584. The old Docket No. became the 
Directorate Identifier, which is 2000-NE-62-AD. This final rule might 
get logged into the DMS docket, ahead of the proposed AD and comments 
received, as we are in the process of sending those items to the DMS.

Conclusion

    We have carefully reviewed the available data and determined that 
air safety and the public interest require adopting the AD as proposed.

Costs of Compliance

    We estimate that this AD will affect six RR RB211-22B engines 
installed on airplanes of U.S. registry. We also estimate that it will 
take about 4.0 work-hours per engine to perform the actions, and that 
the average labor rate is $65 per work-hour. There are no required 
parts. Based on these figures, we estimate the total cost of the AD to 
U.S. operators to be $1,560.

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.
    We are 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

    We have determined that 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) Is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979); 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.
    We prepared a summary of the costs to comply with this AD and 
placed it in the AD Docket. You may get a copy of this summary at the 
address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the Federal Aviation Administration 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 removing Amendment 39-13915 (69 FR 
77881, December 29, 2004) and by adding a new airworthiness directive, 
Amendment 39-14733, to read as follows:

2006-17-12 Rolls-Royce plc: Amendment 39-14733. Docket No. FAA-2006-
25584; Directorate Identifier 2000-NE-62-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective 
September 27, 2006.

Affected ADs

    (b) This AD supersedes AD 2004-26-03, Amendment 39-13915.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) models RB211-535E4-
37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4-
C, and RB211-22B-02 turbofan engines with turbine discs having part 
numbers and serial numbers listed in the following Tables 1, 3, and 
5 of this AD. These turbofan engines are installed on, but not 
limited to, Boeing 757, Tupolev Tu204, and Lockheed L-1011 series 
airplanes.

Unsafe Condition

    (d) This AD results from the manufacturer reducing the 
inspection compliance times for the RB211-22B-02 turbofan engines. 
We are issuing this AD to prevent possible disc failure, which could 
result in an uncontained engine failure and damage to the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.

Eddy Current Inspection for All Except Model RB211-22B-02 Engines

    (f) For all except model RB211-22B-02 engines, do the following:
    (1) Perform an eddy current inspection of the high pressure (HP) 
turbine discs listed in Table 1 of this AD, for cracks in the rim 
cooling air holes. Use paragraph 3. of the Accomplishment 
Instructions of RR Alert Service Bulletin (ASB) No. RB.211-72-AE651, 
dated November 22, 2004, to perform the eddy current inspection.

                    Table 1.--Affected HP Turbine Discs Using Compliance Schedule in Table 2
----------------------------------------------------------------------------------------------------------------
            Part No.                       Serial No.                 Part No.                Serial No.
----------------------------------------------------------------------------------------------------------------
LK80623.........................  CQDY6397                      UL27681............  LDRCZ12893
LK80623.........................  CQDY6504                      UL27681............  LDRCZ12985
UL27680.........................  CQDY6451                      UL27681............  LDRCZ13044
UL27680.........................  CQDY6452                      UL27681............  LDRCZ13047
UL27680.........................  CQDY6466                      UL27681............  LQDY6803
UL27680.........................  CQDY6468                      UL27681............  LQDY6814
UL27680.........................  CQDY6471                      UL27681............  LQDY6847
UL27680.........................  CQDY6496                      UL27681............  LQDY6868
UL27680.........................  CQDY6505                      UL27681............  LQDY6875
UL27680.........................  CQDY6653                      UL27681............  LQDY6892
UL27680.........................  CQDY6656                      UL27681............  LQDY6898
UL27680.........................  CQDY6657                      UL27681............  LQDY6904
UL27680.........................  CQDY6684                      UL27681............  LQDY6909

[[Page 49341]]

 
UL27680.........................  CQDY6883                      UL27681............  LQDY6910
UL27681.........................  CQDY6465                      UL27681............  LQDY9133
UL27681.........................  LAQDY6002                     UL27681............  LQDY9574
UL27681.........................  LAQDY6083                     UL27681............  LQDY9579
UL27681.........................  LAQDY6087                     UL27681............  LQDY9672
UL27681.........................  LDRCZ10247                    UL27681............  LQDY9770
UL27681.........................  LDRCZ10277                    UL27681............  LQDY9783
UL27681.........................  LDRCZ10318                    UL27681............  LQDY9786
UL27681.........................  LDRCZ10335                    UL27681............  LQDY9900
UL27681.........................  LDRCZ10430                    UL27681............  LQDY9902
UL27681.........................  LDRCZ10531                    UL27681............  LQDY9929
UL27681.........................  LDRCZ10750                    UL27681............  LQDY9957
UL27681.........................  LDRCZ10899                    UL27681............  LQDY9982
UL27681.........................  LDRCZ11616                    UL27681............  LQDY9992
UL27681.........................  LDRCZ11720                    UL27681............  WGQDY90005
UL27681.........................  LDRCZ11893
----------------------------------------------------------------------------------------------------------------

    (2) Use the compliance schedule in Table 2 of this AD.

  Table 2.--Compliance Schedule for HP Turbine Discs Listed in Table 1
------------------------------------------------------------------------
   If disc Cycles-Since-New
(CSN) on October 8, 2004 are:          Then eddy current inspect:
------------------------------------------------------------------------
(i) 12,750 CSN or more.......  Within 250 cycles-in-service (CIS) from
                                October 8, 2004 or within 14,500 CSN,
                                whichever occurs first.
(ii) Fewer than 12,750 CSN     Within 500 CIS from October 8, 2004.
 but 10,500 CSN or more.
(iii) Fewer than 10,500 CSN..  Before 11,000 CSN or at next shop visit
                                after the effective date of this AD,
                                whichever occurs first.
------------------------------------------------------------------------

    (3) On discs that pass inspection, use paragraph 3. of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AE651, dated 
November 22, 2004, to permanently etch NMSB 72-AE651 onto the disc, 
adjacent to the part number.
    (4) Perform an eddy current inspection of the HP turbine discs 
listed in Table 3 of this AD, for cracks in the rim cooling air 
holes. Use paragraph 3. of the Accomplishment Instructions of RR ASB 
No. RB.211-72-AE651, dated November 22, 2004, to perform the eddy 
current inspection.

Table 3.--Affected HP Turbine Discs Using Compliance Schedule in Table 4
------------------------------------------------------------------------
             Part No.                            Serial No.
------------------------------------------------------------------------
UL10323...........................  CQDY6070 and higher.
UL27680...........................  All.
UL27681...........................  All.
LK80622...........................  LQDY6316 and higher.
LK80623...........................  CQDY5945 and higher.
UL28267...........................  All.
------------------------------------------------------------------------

    (5) Use the compliance schedule in Table 4 of this AD.

  Table 4.--Compliance Schedule for HP Turbine Discs Listed in Table 3
------------------------------------------------------------------------
  If disc CSN on January 29,
          2001 are:                    Then eddy current inspect:
------------------------------------------------------------------------
(i) Fewer than 13,700 CSN....  Before reaching 14,500 CSN, or at the
                                next shop visit after the effective date
                                of this AD, whichever occurs first.
(ii) 13,700 CSN or more......  Before reaching one of the following,
                                whichever occurs first after the
                                effective date of this AD:
                               (A) 15,300 CSN.
                               (B) Within 800 CIS since January 29,
                                2001.
                               (C) At next shop visit.
------------------------------------------------------------------------

    (6) For discs that pass inspection, use paragraph 3. of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AE651, dated 
November 22, 2004, to permanently etch NMSB 72-AE651 onto the disc, 
adjacent to the part number.

Eddy Current Inspection for Model RB211-22B-02 Engines

    (g) For model RB211-22B-02 engines, do the following:
    (1) Perform an eddy current inspection of the HP turbine discs 
listed in Table 5 of this AD, for cracks in the rim cooling air 
holes. Use paragraph 3. of the Accomplishment Instructions of RR ASB 
No. RB.211-72-AE717, dated January 21, 2005, to perform the eddy 
current inspection.

[[Page 49342]]



    Table 5.--Affected HP Turbine Discs in RR Model RB211-02 Turbofan
                                 Engines
------------------------------------------------------------------------
             Part No.                            Serial No.
------------------------------------------------------------------------
LK80622...........................  LQDY6316 and higher.
LK80623...........................  CQDY5945 and higher.
UL28267...........................  All.
------------------------------------------------------------------------

    (2) Use the compliance schedule in Table 6 of this AD.

  Table 6.--Compliance Schedule for HP Turbine Discs Listed in Table 5
------------------------------------------------------------------------
  If disc CSN on January 1,
          2005 are:                    Then eddy current inspect:
------------------------------------------------------------------------
(i) More than 9,000 CSN......  Within 500 CIS after January 1, 2005, but
                                before 11,000 CSN, whichever is sooner.
(ii) More than 1,500, but      Before exceeding 9,500 CSN, or at the
 fewer than 9,001 CSN.          next shop visit after the effective date
                                of this AD, whichever occurs first.
------------------------------------------------------------------------

    (3) For discs that pass inspection, use paragraph 3. of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AE717, dated 
January 21, 2005, to permanently etch NMSB 72-AE717 onto the disc, 
adjacent to the part number.

Other Conditions for All Engines

    (h) Do not perform the actions of this AD to a disc until that 
disc has reached at least 1,500 CSN.
    (i) Engines with an affected HP turbine disc at shop visit on 
the effective date of this AD and without the HP turbine rotor 
installed in the combustor outer case, must have the disc eddy 
current inspected before assembling the engine.
    (j) Engines with an affected HP turbine disc at shop visit on 
the effective date of this AD with the HPT rotor installed in the 
combustor case need not have the disc eddy current inspected at this 
time.
    (k) HP turbine discs previously eddy current inspected at fewer 
than 1,500 CSN must be inspected again using this AD.
    (l) Replace cracked HP turbine discs with a serviceable disc.

Definition

    (m) For the purpose of this AD, next shop visit is defined as 
the first shop visit opportunity when the HPT rotor is removed from 
the combustion case.
    (n) For the purpose of this AD, a serviceable part is one with 
cyclic life remaining and either not listed in any of the preceding 
tables or one listed in a preceding table, but previously eddy 
current inspected and permanently etch marked with the Service 
Bulletin (SB) number NMSB 72-AE651 or NMSB 72-C877 on the disc.

Previous Credit

    (o) Previous credit is allowed for the actions in this AD for HP 
turbine discs with 1,500 CSN or more that were eddy current 
inspected using applicable RR SB No. RB.211-72-C817, Revision 2, 
dated March 7, 2001, RR TSD 594-J, Overhaul Processes Manual, Task 
70-00-00-200-223, or RR SB No. RB.211-72-C877, Revision 1, dated 
March 7, 2001.

Reporting Requirements

    (p) For all except model RB211-22B-02 engines, report findings 
of the inspection using paragraph 3.E. of the Accomplishment 
Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004. The 
Office of Management and Budget (OMB) has approved the reporting 
requirements specified in paragraph 3.E. of the Accomplishment 
Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004, and 
assigned OMB control number 2120-0056.
    (q) For model RB211-22B-02 engines, report findings of the 
inspection using paragraph 3.E. of the Accomplishment Instructions 
of RR ASB RB.211-72-AE717, dated January 21, 2005. The OMB has 
approved the reporting requirements specified in paragraph 3.E. of 
the Accomplishment Instructions of RR ASB RB.211-72-AE717, dated 
January 21, 2005, and assigned OMB control number 2120-0056.

Alternative Methods of Compliance

    (r) The Manager, Engine Certification Office, has the authority 
to approve alternative methods of compliance for this AD if 
requested using the procedures found in 14 CFR 39.19.

Material Incorporated by Reference

    (s) You must use the service information specified in Table 7 of 
this AD to perform the inspections required by this AD. The Director 
of the Federal Register approved the incorporation by reference of 
RR ASB RB.211-72-AE717, dated January 21, 2005, listed in Table 7 of 
this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. The 
incorporation by reference of RR ASB No. RB.211-72-AE651, dated 
November 22, 2004, was approved previously by the Director of the 
Federal Register as of January 13, 2005 (69 FR 77881, December 29, 
2004). The incorporation by reference of RR SB No. RB.211-72-C877, 
Revision 1, dated March 7, 2001, was approved previously by the 
Director of the Federal Register as of December 24, 2001 (66 FR 
57859, November 19, 2001). You can get a copy from Rolls-Royce plc, 
PO Box 31, Derby, England; telephone: 011 44 1332-249428, fax: 011 
44 1332-249223, for a copy of this service information. You may 
review copies at the FAA, New England Region, Office of the Regional 
Counsel, 12 New England Executive Park, Burlington, MA; or the 
National Archives and Records Administration (NARA). For information 
on the availability of this material at NARA, call 202-741-6030, or 
go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

                                      Table 7.--Incorporation by Reference
----------------------------------------------------------------------------------------------------------------
         Service Bulletin                Page Nos.             Revision                       Date
----------------------------------------------------------------------------------------------------------------
RB.211-72-AE651..................  All.................  Original............  November 22, 2004.
  Total Pages--7
RB.211-72-AE717..................  All.................  Original............  January 21, 2005.
  Total Pages--8
RB.211-72-C877...................  All.................  1...................  March 7, 2001.
  Total Pages--5
----------------------------------------------------------------------------------------------------------------


[[Page 49343]]

Related Information

    (t) CAA Airworthiness Directive G-2004-0027, dated November 19, 
2004, and CAA Airworthiness Directive G-2005-0003, dated January 24, 
2005, also address the subject of this AD.

    Issued in Burlington, Massachusetts, on August 15, 2006.
Thomas A. Boudreau,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
 [FR Doc. E6-13910 Filed 8-22-06; 8:45 am]
BILLING CODE 4910-13-P

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