[Federal Register: February 2, 2005 (Volume 70, Number 21)]
[Proposed Rules]
[Page 5390-5393]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr02fe05-16]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2002-NE-40-AD]
RIN 2120-AA64
Airworthiness Directives; Rolls-Royce plc RB211-524 Series
Turbofan Engines
AGENCY: Federal Aviation Administration, DOT.
ACTION: Supplemental notice of proposed rulemaking; reopening of
comment period.
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SUMMARY: This notice revises an earlier proposed airworthiness
directive (AD), applicable to Rolls Royce plc (RR) RB211-524 series
turbofan engines with certain part number (P/N) intermediate pressure
(IP) compressor stage 5 disks installed. That proposal required new
reduced IP compressor stage 5 disk cyclic limits. That proposal also
required removing from service affected disks that already exceed the
new reduced cyclic limit, and removing other affected disks before
exceeding their cyclic limits, using a drawdown schedule. That proposal
resulted from the discovery of cracks in the cooling air hole areas of
the disk front spacer arm. This Supplemental Notice of Proposed
Rulemaking (SNPRM) revises the proposed rule by correcting certain
cycle life limits specified in Table 3 of that AD and by clarifying
certain inspections. We are proposing this AD to prevent IP compressor
stage 5 disk failure, which could result in uncontained engine failure
and possible damage to the airplane.
DATES: Comments must be received by April 4, 2005.
ADDRESSES: Use one of the following addresses to comment on this
proposed AD:
By mail: Federal Aviation Administration (FAA), New
England Region, Office of the Regional Counsel, Attention: Rules Docket
No. 2002-NE-40-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
By fax: (781) 238-7055.
By e-mail: 9-ane-adcomment@faa.gov.
You can get the service information identified in this proposed AD
from Rolls-Royce plc, PO Box 31 Derby, DE248BJ, United Kingdom;
telephone 011-44-1332-242424; fax 011-44-1332-249936.
You may examine the AD docket, by appointment, at the FAA, New
England Region, Office of the Regional Counsel, 12 New England
Executive Park, Burlington, MA.
FOR FURTHER INFORMATION CONTACT: Ian Dargin, Aerospace Engineer, Engine
Certification Office, FAA, Engine and Propeller Directorate, 12 New
England Executive Park, Burlington, MA 01803-5299; telephone (781) 238-
7178; fax (781) 238-7199.
SUPPLEMENTARY INFORMATION:
Comments Invited
We invite you to submit any written relevant data, views, or
arguments regarding this proposal. Send your comments to an address
listed under ADDRESSES. Include ``AD Docket No. 2002-NE-40-AD'' in the
subject line of your comments. If you want us to acknowledge receipt of
your mailed comments, send us a self-addressed, stamped postcard with
the docket number written on it; we will date-stamp your postcard and
mail it back to you. We specifically invite comments on the overall
regulatory, economic, environmental, and energy aspects of the proposed
AD. If a person contacts us verbally, and that contact relates to a
substantive part of this proposed AD, we will summarize the contact and
place the summary in the docket. We will consider all comments received
by the closing date and may amend the proposed AD in light of those
comments.
Examining the AD Docket
You may examine the AD Docket (including any comments and service
information), by appointment, between 8 a.m. and 4:30 p.m., Monday
through Friday, except Federal holidays. See ADDRESSES for the
location.
Discussion
On October 21, 2003 we issued a proposal to amend part 39 of the
Federal Aviation Regulations (14 CFR part 39) to add an AD to apply to
RR RB211-524 series turbofan engines, with certain P/N IP compressor
stage 5 disks installed. The Office of the Federal Register published
that proposal as a notice of proposed rulemaking (NPRM) in the Federal
Register on October 27, 2003 (68 FR 61158). That NPRM would have
required new reduced IP compressor stage 5 disk cyclic limits. The NPRM
also required removing from service affected disks that already exceed
the new reduced cyclic limit, and removing other affected disks before
exceeding their cyclic limits, using a drawdown schedule. That NPRM
resulted from the discovery of cracks in the cooling air hole areas of
the disk front spacer arm. That condition, if not corrected, could
result in IP compressor stage 5 disk failure, which could result in
uncontained engine failure and possible damage to the airplane.
Since we issued that NPRM, we found an error in Table 3 at the date
December 1, 2008 row. The cycle life limits in columns 4 and 5 of this
row were written incorrectly as 12,000. We have corrected those cycle
life limits to 8,900 and 9,000 CIS, respectively. We have removed the
phrase ``one-time'' in reference to on-wing inspections. We also added
a sentence to clarify that an on-wing inspection may be used to extend
service life only once between shop visit inspections of the disk.
Since these changes expand the scope of the originally proposed
rule, we determined that it is necessary to reopen the comment period
to provide additional opportunity for public comment.
Manufacturer's Service Information
We have reviewed and approved the technical contents of RR
Mandatory Service Bulletin (MSB) No. RB.211-72-D428, Revision 3, dated
June 30, 2003, that specifies a drawdown schedule for
[[Page 5391]]
removing from service affected IP compressor stage 5 disks, using new
RR Time Limits Manual (TLM), 05-10-01 cyclic limits. The MSB also
describes procedures for optional inspections at each shop visit to
extend the disk life beyond the lives specified. The Civil Aviation
Authority (CAA), the airworthiness authority of the United Kingdom
(U.K.), has classified this service bulletin as mandatory and issued AD
006-04-2002 to ensure the airworthiness of these RR turbofan engines in
the U.K. We have also reviewed and approved the technical contents of
Service Bulletin (SB) No. RB.211-72-E148, dated March 13, 2003 and SB
No. RB.211-72-E150, Revision 1, dated June 4, 2003, that provide an
optional on-wing ECI of the affected disks, to extend the disk life
beyond the lives specified.
Differences Between This Proposed AD and the Manufacturer's Service
Information
This proposed AD adds a requirement to change the service cyclic
limits in the Time Limits Manual and to remove or inspect disks not
later than 30 days after the effective date of this AD.
FAA's Determination of an Unsafe Condition and Proposed Actions
These engine models, manufactured in the U.K., are type-
certificated for operation in the United States under the provisions of
section 21.29 of the Federal Aviation Regulations (14 CFR 21.29) and
the applicable bilateral airworthiness agreement. Under this bilateral
airworthiness agreement, the CAA has kept us informed of the situation
described above. We have examined the CAA's findings, reviewed all
available information, and determined that AD action is necessary for
products of this type design that are certificated for operation in the
United States. Therefore, we are proposing this AD, which would
require:
Establishing new reduced IP compressor stage 5 disk cyclic
limits.
Removing from service affected disks that already exceed
the new reduced cyclic limit.
Removing other affected disks before exceeding their
cyclic limits, using a drawdown schedule.
Allowing optional inspections at each shop visit or an on-
wing ECI to extend the disk life beyond the specified life.
The proposed AD would require you to use the service information
described previously to perform these actions.
Economic Analysis
There are about 939 RR RB211-524 series turbofan engines of the
affected design in the worldwide fleet. We estimate that 35 engines
installed on airplanes of U.S. registry will be affected by this
proposed AD. We also estimate that it will take about 8 work hours per
engine to perform an inspection, and 300 work hours per engine to
replace an IP compressor stage 5 disk. The average labor rate is $65
per work hour. Required parts will cost about $49,000 per engine. Based
on these figures, we estimate the total cost of the AD to U.S.
operators to be $2,415,700.
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 Analysis
We have determined that this proposed AD would not have federalism
implications under Executive Order 13132. This proposed AD would 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 the proposed
regulation:
1. Is not a ``significant regulatory action'' under Executive Order
12866;
2. Is not a ``significant rule'' under the DOT Regulatory Policies
and Procedures (44 FR 11034, February 26, 1979); 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.
We prepared a summary of the costs to comply with this proposal 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.
The Proposed Amendment
Under the authority delegated to me by the Administrator, the
Federal Aviation Administration proposes to amend 14 CFR part 39 as
follows:
PART 39--AIRWORTHINESS DIRECTIVES
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]
2. Section 39.13 is amended by adding the following new
airworthiness directive:
Rolls Royce plc: Docket No. 2002-NE-40-AD.
Comments Due Date
(a) The Federal Aviation Administration (FAA) must receive
comments on this airworthiness directive (AD) action by April 4,
2005.
Affected ADs
(b) None.
Applicability
(c) This AD applies to the Rolls-Royce plc (RR) RB211-524 series
turbofan engines listed in the following Table 1, with intermediate
pressure (IP) compressor stage 5 disk part numbers (P/Ns) listed in
Table 2 of this AD, installed.
Table 1.--Engine Models Affected
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-524B-02 -524B-B-02 -524B3-02 -524B4-02 -524B4-D-02
-524B2-19 -524B2-B-19 -524C2-19 -524C2-B-19 -524D4-19
-524D4-B-19 -524D4X-19 -524D4X-B-19 -524D4-39 -524D4-B-39
-524G2-19 -524G2-T-19 -524G3-19 -524G3-T-19 -524H2-19
-524H2-T-19 -524H-36 -524H-T-36 ..................... ....................
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These engines are installed on, but not limited to, Boeing 747,
767, and Lockheed L-1011 airplanes.
[[Page 5392]]
Table 2.--IP Compressor Stage 5 Disk P/Ns Affected
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LK60130 LK65932 LK69021 LK81269 LK83282
LK83283 UL12290 UL15743 UL15744 UL15745
UL19132 UL20785 UL20832 UL23291 UL25011
UL36821 UL36977 UL36978 UL36979 UL36980
UL36981 UL36982 UL36983 UL37078 UL37079
UL37080 UL37081 UL37082 UL37083 UL37084
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Unsafe Condition
(d) This AD results from discovery of cracks in the cooling air
hole areas of the disk front spacer arm. The actions specified in
this AD are intended to prevent IP compressor stage 5 disk failure,
which could result in uncontained engine failure and possible 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.
Cycle Limits
(f) Change the service cyclic limits contained in the Time
Limits Manual, 05-10-01, for the IP compressor stage 5 discs
installed in the engine models listed in the following Table 3,
within 30 days after the effective date of this AD.
Table 3.--Cyclic Life Limits Without Qualifying Magnetic Particle Inspection (MPI) Or Eddy Current Inspection (ECI)
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Engine Models
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Date of reduced life limit -524G2, G2-T, G3, G3-T, H2, -524D4, D4-B, D4-B-39, D4X, -524B-02, B-B-02, B3-02, B4-
H2-T, H-36, H-T-36 D4X-B, D4-39 -524B2, B2-B, C2, C2-B 02, B4-D-02
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November 30, 2002................ 13,500 cycles-in-service 16,150 CIS 16,000 CIS 16,200 CIS
(CIS)
April 1, 2003.................... 13,500 CIS 13,500 CIS 13,500 CIS 14,000 CIS
December 1, 2003................. 12,000 CIS 13,500 CIS 13,500 CIS 14,000 CIS
December 1, 2004................. 11,000 CIS 13,500 CIS 12,000 CIS 12,000 CIS
December 1, 2005................. 11,000 CIS 12,000 CIS 12,000 CIS 12,000 CIS
December 1, 2008................. 7,830 CIS 8,700 CIS 8,900 CIS 9,000 CIS
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Optional Inspections
(g) Before December 1, 2008, optional inspections are allowed at
each shop visit or on-wing to extend the disk life. Guidance for
these inspections is provided in paragraphs (h) or (i) of this AD.
Optional Inspections at Shop Visit
(h) Perform optional inspections at shop visit, as follows:
(1) Remove corrosion protection from IP stage 5 disk.
Information on corrosion protection removal can be found in the
Engine Manual.
(2) Visual-inspect and binocular-inspect the IP stage 5 disk for
corrosion pitting at the cooling air holes and defender holes in the
disk front spacer arm. Follow paragraph 3.C. of the Accomplishment
Instructions of RR MSB No. RB.211-72-D428, Revision 3, dated June
30, 2003. Information on disk corrosion pitting limits can be found
in the Engine Manual.
(i) If the disk has corrosion pitting in excess of limits,
remove the disk from service.
(ii) If the disk is free from corrosion pitting, MPI the entire
disk. Information on MPI can be found in the Engine Manual. If the
disk passes MPI and no cracks are found, complete all other
inspections, re-apply corrosion protection to disk, and return the
disk to service in accordance with the cyclic limits allowed by
paragraph (k) of this AD. Information on MPI limits can be found in
the Engine Manual. Information on re-applying corrosion protection
can be found in RR Repair FRS5900.
(iii) If the disk has corrosion pitting within limits, ECI all
disk cooling air holes, defender holes, and inner and outer faces.
Follow paragraph 3.D. of the Accomplishment Instructions of RR MSB
No. RB.211-72-D428, Revision 3, dated June 30, 2003. Information on
corrosion pitting limits can be found in the Engine Manual. If the
disk passes ECI and no cracks are found, MPI the entire disk.
Information on MPI can be found in the Engine Manual. If the disk
passes MPI and no cracks are found, re-apply corrosion protection to
disk, and return the disk to service in accordance with the cyclic
limits allowed by paragraph (k) of this AD.
Optional On-Wing EC Inspections
(i) For RB211-524B2/C2 and RB211-524B4/D4 engine models, an on-
wing ECI of the IP compressor stage 5 disk may be performed only
once between shop visit inspections. Follow paragraphs 3.A. through
3.F. of the Accomplishment Instructions of RR SB No. RB.211-72-E148,
dated March 13, 2003, and RR SB No. RB.211-72-E150, Revision 1,
dated June 4, 2003, respectively, to do the ECI. If the disk passes
the ECI and no cracks are found, an extension is allowed as
specified in paragraph (k) of this AD.
Definition of Shop Visit
(j) For the purposes of this AD, a shop visit is defined as the
separation of an engine major case flange. This definition excludes
shop visits when only field maintenance type activities are
performed in lieu of performing them on-wing. (i.e., for purposes
such as to perform an on-wing inspection of a tail engine
installation on a Lockheed L-1011 airplane).
Cyclic Life Extension
(k) Disks that pass an optional inspection may remain in service
after that inspection for the additional cycles listed in the
following Table 4, until the next inspection, or December 1, 2008,
or until the cyclic life limit published in the Time Limits Manual
is reached, whichever occurs first.
Table 4.--Cyclic Life Extension
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-524G2, G2-T, G3, G3-T, H2, -524D4, D4-B, D4-B-39, D4X, -524B-02, B-B-02, B3-02, B4-
Engine models H2-T, H-36, H-T-36 D4X-B, D4-39 -524B2, B2-B, C2, C2-B 02, B4-D-02
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Extension After Passing MPI...... 1,600 cycles 2,000 cycles 2,000 cycles 2,000 cycles.
[[Page 5393]]
Extension After Passing In-Shop 3,800 cycles 4,500 cycles 4,500 cycles 4,500 cycles.
ECI.
Extension After Passing On-Wing 1,000 cycles 1,200 cycles 1,200 cycles 1,200 cycles.
ECI.
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Disks That Have Been Intermixed Between Engine Models
(l) Information on intermixing disks between engine models can
be found in the RR Time Limits Manual, 05-00-01.
Alternative Methods of Compliance
(m) 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.
Credit for Previous Inspections
(n) Inspections done using RR SB No. RB.211-72-E150, dated April
17, 2003 are acceptable in meeting the requirements of this AD.
Reporting Requirement
(o) Report findings of all inspections of the IP stage 5 disk
using paragraph 3.B.(2) of the Accomplishment Instructions of RR ASB
RB.211-72-D428, Revision 3, dated June 30, 2003. The Office of
Management and Budget (OMB) has approved the reporting requirements
specified in Paragraph 3.B. of the Accomplishment Instructions of RR
ASB RB.211-72-D428, Revision 3, dated June 30, 2003, and assigned
OMB control number 2120-0056.
Related Information
(p) CAA airworthiness directive 006-04-2002, dated April 2002,
also addresses the subject of this AD.
Issued in Burlington, Massachusetts, on January 25, 2005.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft
Certification Service.
[FR Doc. 05-1799 Filed 2-1-05; 8:45 am]
BILLING CODE 4910-13-P