P.O. Box 31, DERBY 

DE24 8BJ, UK 

Telephone: 44 (0) 1332 242424 

Fax: 44 (0) 1332 249936 

1 tan!H Rol Is-Royce 

TRANSMITTA 

The technical information contained in this document has been approved under the authority 

of - See Planning Information, Approval. 

Signed Date Nov. 4/11 

N. J. Wright 

RB211 TRENT 800 SERIES PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN 

ALERT 

This document transmits Revision 1 to Service Bulletin RB211-72-AG456 

Document History 

Service Bulletin Revision Status 

Initial Issue Sep. 9/10 

Bulletin Revision 1 

Remove 

Pages 1 to 11 of the 

Service Bulletin 

Supplement Revision Status 

Incorporate 

Pages 1 to 19 of the 

Service Bulletin 

ALERT 

Reason for change 

To introduce on-wing and 

in-shop cold side and hot 

side inspection procedures 

to 3.B. Accomplishment 

Instructions. Added Fig.4 

thru Fig.8. Updated 1.B. 

Reason, 1.D. Description, 

1.1. References and titles 

to Fig.1 thru Fig.3. Minor 

non-technical changes also 

made. 

Transmittal - Page 1 of 2 

CHECK THAT ALL PREVIOUS TRANSMIlTALS HAVE BEEN INCORPOWTED 

If any have not been received please advise Customer Data Services, Rolls-Royce plc, Derby, England 

O Rolls-Royce plc {date as above) Printed in Great Britain 
LIST OF EFFECTIVE PAGES

The effective pages to this Service Bulletin following incorporation of Revision

1 are as follows:

Page Revision Number Revision Date

Bulletin

R 1 1 Nov.4/11

R 2 1 Nov.4/11

R 3 1 Nov.4/11

R 4 1 Nov.4/11

R 5 1 Nov.4/11

R 6 1 Nov.4/11

R 7 1 Nov.4/11

R 8 1 Nov.4/11

R 9 1 Nov.4/11

R 10 1 Nov.4/11

R 11 1 Nov.4/11

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R 13 1 Nov.4/11

R 14 1 Nov.4/11

R 15 1 Nov.4/11

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R 18 1 Nov.4/11

R 19 1 Nov.4/11

Printed in Great Britain

RB.211−72−AG456

Transmittal - Page 2
1. Planning Information

A. Effectivity

Boeing 777

All RB211 TRENT 875-17, 877-17, 884-17, 884B-17, 892-17, 892B-17 and 895-17

Engines.

B. Reason

Cracking has been found on the head sections of two Trent 800 front combustion

liners during routine inspection at shop visit. The lives of the cracked

combustion liners were 1997 cycles and 7332 cycles since new. Laboratory

investigation concluded that the cracking had propagated circumferentially.

Analysis shows that cracking in this position could ultimately result in hot

gas breakout with the potential for downstream component distress.

Although there is already a Maintenance Planning Document (MPD) requirement to

borescope inspect the front combustion liner, this does not cover the front

combustion liner head section area.

Non-Modification Service Bulletin (NMSB) 72-AG073 was initially issued in May

2009 for a once around the fleet inspection of all engines incorporating the

affected type of combustor. The results from the inspection have been used to

complete a numerical risk assessment which shows the crack mechanism to be age

independent.

Revision 1 of this NMSB is issued to introduce on-wing and in-shop cold side

and hot side inspection procedures to 3.B. Accomplishment Instructions and to

add relevant figures (Fig.4 thru Fig.8).

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C. Description

This NMSB is issued to instruct a repeat inspection of the front combustion

liner head section for cracking and to provide acceptance limits and revised

inspection intervals in the event of such cracking being found. Repeat

inspection intervals have been based on current FCL inspection intervals in

line with MPD requirements and NMSB 72-AF458.

For convenience both hot and cold side on-wing borescope inspections are

included in this NMSB - only one method is required to accomplish the NMSB

intent. The hot side borescope inspection involves using the 8 borescope ports

at the combustion outer case for access. The cold side borescope inspection

involves removing one of the fuel spray nozzle bolts at 7 positions and using

the bolt hole for access. An alternative in-shop inspection is also provided.

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ENGINE - REPEAT BORESCOPE INSPECTION OF FRONT COMBUSTION LINER HEAD SECTION

NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-AG456

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Page 1 of 19

Sep 9/10

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Accomplishment of this NMSB must be recorded in the engine/module log book.

Provide details of any cracking found during these inspections. The details

should include combustor head section life and description of the crack size(s)

and circumferential location(s). The information should be returned to

Rolls-Royce Technical Services via your local field service representatives.

D. Compliance

ALERT

R the subject of an EASA Proposed This Non-Modification Service Bulletin is

R Airworthiness Directive (PAD:11-038).

R the hot side or cold side inspection specified in 3. Carry out either

Accomplishment Instructions. It is recommended that the inspections are aligned

where possible with existing scheduled combustion liner borescope inspections.

On-wing

(1) All Trent 800 variants listed in 1.A. Effectivity

(a) Inspect in accordance with 3.A. On-wing Accomplishment Instructions.

(i) Initial inspection within 1000 cycles of the issue date of this

R NMSB, or within 2000 cycles since last NMSB72-AG456 inspection.

(ii) Repeat inspections at intervals not exceeding 2000 cycles since

last inspection or since shop visit.

In-shop

(1) All Trent 800 variants listed in 1.A. Effectivity

(a) Inspect in accordance with 3.B. In-shop Accomplishment Instructions at

each shop visit.

E. Approval

The technical content of this Non-Modification Service Bulletin was approved

under the authority of Design Organisation Approval EASA.21J.035 on Sep.6/10

and was re-approved on Nov.2/11.

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F. Manpower

(1) Manpower

2 persons

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(2) Time to gain access

1.5 hours

(3) Time to inspect

1.5 hours

(4) Time to restore to serviceable condition

R 1 hour

G. Material Price and Availability

Not applicable.

H. Tooling

HU82292 Guide Tube - 1 off

I. References

(1) Rolls-Royce RB211 Non-Modification Service Bulletins:

(a) 72-AF458

Engine - Borescope Inspection of front combustion liner inner wall

(b) 72-AG073

Engine - Inspection of front combustion liner head section

R (2) Boeing 777 Aircraft Maintenance Manual, 70-51-00, Standard Practices,

R 72-00-00, Inspection/Check, 73-13-11, Removal/Installation

(3) Trent 800 Engine Manual, 72-00-00, Inspection/Check

R (4) Aircraft Illustrated Parts Catalogue (AIPC), 73-13-11

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2. Material Information

None

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R 3. Accomplishment Instructions

A. On-Wing Accomplishment Instructions

R Carry out the hot side or cold side inspection as follows:

CAUTION: IN ORDER TO REDUCE THE POTENTIAL FOR MULTIPLE ENGINE IN FLIGHT SHUTDOWN,

POWER LOSS OR OTHER ANOMALIES DUE TO MAINTENANCE ERROR, ROLLS-ROYCE

RECOMMENDS THAT OPERATORS AVOID PERFORMING MAINTENANCE ON MULTIPLE

ENGINES INSTALLED ON THE SAME AIRCRAFT AT THE SAME TIME. IF IT IS NOT

POSSIBLE TO AVOID MAINTENANCE ON MORE THAN ONE ENGINE AT THE SAME TIME,

ROLLS-ROYCE RECOMMENDS THAT ADDITIONAL CONTROLS ARE APPLIED IN ORDER TO

ENSURE THAT MAINTENANCE TASKS HAVE BEEN COMPLETED AS DEFINED.

MAINTENANCE GUIDELINES SHOULD BE REVISED, WHERE POSSIBLE, TO PROMOTE

THIS RECOMMENDATION.

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R (1) Hot side inspection:

(a) Carry out the inspection accessing via the combustion liner borescope

ports. This procedure requires a flexible borescope no greater than 6

mm diameter with straight ahead near focus viewing tip. Gain access

for the inspection in accordance with the following Aircraft

Maintenance Manual procedures.

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(i) The following Aircraft Maintenance Manual References apply for

this task:

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R Trent 800 Engines

R Boeing 777 Aircraft Maintenance Manual, 72-00-00, Inspection/Check

R Borescope inspection of combustion section

(b) Use a near focus forward view tip on the flexible borescope and insert

through the guide tube HU82292 so that the tip just protrudes through

the curved end. Position the tube through the first borescope position

to make sure the curved end points towards the inner joint of the fuel

spray nozzle heatshield tile as shown in Fig.1.

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(c) Feed the borescope towards the gap between the heatshield tile inner

edge and the Front Combustion Liner (FCL) inner wall. Refer to Fig.1.

Inspect the FCL head, in the corner of the gap for cracking at this

location. Refer to Fig.2. Slowly twist the guide tube and feed the

borescope along the heatshield lip to inspect the FCL across 4

heatshield tiles (2 either side of the borescope port).

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(d) Repeat the procedure for the remaining 7 borescope port positions to

make sure the FCL is inspected for cracks throughout the complete 360

degrees.

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NOTE: As there are 8 borescope ports and 24 burners, there will be

some overlap of the inspection, this will make sure no portions

of the FCL are missed.

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(e) If cracking is seen, carry out repeat inspections or engine removal in

accordance with Accomplishment Instructions (3.C.) for on-wing

acceptance standards of this NMSB.

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R (2) Cold side inspection:

This procedure requires a flexible borescope no greater than 4mm diameter

with straight ahead viewing tip.

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(a) Prepare the engine for inspection in accordance with AMM Task

73-13-11, Removal/Installation.

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(i) Remove one of the two rearmost bolts (AIPC 73-13-11, Fig./Item

No. 01-10) at Fuel Spray Nozzle (FSN) positions 1, 4, 7, 10,

16, 19 and 22. Refer to Fig.4.

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NOTE: Only one bolt should be removed from each FSN. This is to

preserve the integrity of the FSN seal. If the integrity of

the FSN seal is not preserved, then the seal must be

replaced resulting in the requirement for a high power

ground run.

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R (b) Begin the inspection at FSN position 1:

(i) Feed the borescope into the bolt hole, then along the side of

the FSN.

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(ii) Once past the end of the FSN, articulate the scope to the side

and feed along the annulus between the inner bore of the

combustion chamber and the outer surface of the outlet guide

vane case assembly (refer to Fig.6) until the tip reaches FSN

4. Refer to Fig.4 and Fig.5.

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(iii) Make sure that the borescope is fed past two FSNs and all the

way to the third FSN in order to make sure of complete

coverage, twisting and articulating the borescope tip to

prevent it falling down in front of the FSNs. Refer to Fig.6.

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(iv) Gradually withdraw the borescope, inspecting the weld at the

front edge of the combustion chamber inner bore for any cracks.

Refer to Fig.7 and Fig.8.

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(v) Once you have reached back to the point of entry, re-insert the

borescope and this time articulate the scope to the opposite

side and feed along the annulus between the inner bore of the

combustion chamber and the outer surface of the outlet guide

vane case assembly until the tip reaches FSN 22. Repeat the

inspection in this direction (steps (ii) to (iv) above).

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(c) Repeat the procedure detailed in steps ((b)(i) to (b)(iv)) above for

the following FSN positions.

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(i) FSN position 4, feeding the borescope along the annulus between

the inner bore of the combustion chamber and the outer surface

of the outlet guide vane case assembly until the tip reaches

FSN 7. Refer to Fig.4 and Fig.5.

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(ii) FSN position 7, feeding the borescope along the annulus between

the inner bore of the combustion chamber and the outer surface

of the outlet guide vane case assembly until the tip reaches

FSN 10. Refer to Fig.4 and Fig.5.

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(iii) FSN position 10, feeding the borescope along the annulus

between the inner bore of the combustion chamber and the outer

surface of the outlet guide vane case assembly until the tip

reaches FSN 13. Refer to Fig.4 and Fig.5.

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(iv) FSN position 16, feeding the borescope along the annulus

between the inner bore of the combustion chamber and the outer

surface of the outlet guide vane case assembly until the tip

reaches FSN 13. Refer to Fig.4 and Fig.5.

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(v) FSN position 19, feeding the borescope along the annulus

between the inner bore of the combustion chamber and the outer

surface of the outlet guide vane case assembly until the tip

reaches FSN 16. Refer to Fig.4 and Fig.5.

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(vi) FSN position 22, feeding the borescope along the annulus

between the inner bore of the combustion chamber and the outer

surface of the outlet guide vane case assembly until the tip

reaches FSN 19. Refer to Fig.4 and Fig.5.

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(d) If cracking is seen, carry out repeat inspections or engine removal in

accordance with Accomplishment Instructions for on-wing acceptance

standards of this NMSB.

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(e) Once the inspection is complete, refit the removed bolts (AIPC

73-13-11, Fig./Item No. 01-10) to each of the FSN positions. Torque

the bolts to 11,5 Nm (100 lbfin) in accordance with AMM 70-51-00,

Standard Practices.

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(f) Return the aircraft to its usual condition in accordance with AMM

73-13-11, Removal/Installation.

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NOTE: There is no requirement to accomplish Test2 - The Fuel and Oil

Leak test after returning the aircraft to its usual condition.

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B. In-shop Accomplishment Instructions

R Carry out the hot side or cold side inspection as follows:

R (1) Hot side inspection:

(a) Engines where the combustion section is to be stripped, and the FCL

exposed for inspection:

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(i) Where the combustion section is to be stripped and the FCL

exposed for inspection, inspection of the FCL head section in

accordance with Engine Manual, 72-41-13, satisfies requirements

of this NMSB.

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R (ii) If any cracking is seen reject the FCL.

(b) Engines where strip of the combustion section is not scheduled and the

FCL is not exposed for inspection.

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(i) Comply with this NMSB during the existing borescope inspection

at engine induction. This procedure requires a flexible

borescope no greater than 6 mm diameter with straight ahead

near focus viewing tip. Use the following procedures to gain

access.

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R (1) Trent 800 Engine Manual, 72-00-00, Inspection/Check

(ii) Use a near focus forward view tip on the flexible borescope and

insert through the guide tube HU82292 so that the tip just

protrudes through the curved end. Position the tube through the

first borescope position to make sure the curved end points

towards the inner joint of the fuel spray nozzle heatshield

tile as shown in Fig.1.

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(iii) Feed the borescope towards the gap between the heatshield tile

inner edge and the FCL inner wall. Refer to Fig.1. Inspect the

FCL head, in the corner of the gap for cracking at this

location. Refer to Fig.2. Slowly twist the guide tube and feed

the borescope along the heatshield lip to inspect the FCL

across 4 heatshield tiles (2 either side of the borescope

port).

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(iv) Repeat the procedure for the remaining 7 borescope port

positions to make sure the FCL is inspected for cracks

throughout the complete 360 degrees.

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NOTE: As there are 8 borescope ports and 24 burners, there will

be some overlap of the inspection, this will make sure no

portions of the FCL are missed.

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R (v) If cracking is seen, reject the FCL.

R (2) Cold side inspection:

(a) Engines where the combustion section is to be stripped, and the FCL

exposed for inspection:

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(i) Where the combustion section is to be stripped and the FCL

exposed for inspection, inspection of the FCL head section in

accordance with Engine Manual, 72-41-13, satisfies requirements

of this NMSB.

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R (ii) If any cracking is seen reject the FCL.

(b) Engines where strip of the combustion section is not scheduled and the

FCL is not exposed for inspection.

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(i) Remove one of the rearmost bolts (EIPC 73-13-11, Fig./Item No.

01-058/-088) at Fuel Spray Nozzle (FSN) positions 1, 4, 7, 10,

16, 19 and 22. Refer to Fig.4.

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NOTE: Only one bolt should be removed from each FSN. This is to

preserve the integrity of the FSN seal. If the integrity of

the FSN seal is not preserved, then the seal must be

replaced.

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(ii) This procedure requires a flexible borescope no greater than

4mm diameter with straight ahead viewing tip. Begin the

inspection at FSN position 1:

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(1) Feed the borescope into the bolt hole, then along the side of

the FSN.

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(2) Once past the end of the FSN, articulate the scope to the

side and feed along the annulus between the inner bore of the

combustion chamber and the outer surface of the outlet guide

vane case assembly (refer to Fig.6) until the tip reaches FSN

4. Refer to Fig.4 and Fig.5.

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(3) Make sure that the borescope is fed past two FSNs and all the

way to the third FSN in order to make sure of complete

coverage, twisting and articulating the borescope tip to

prevent it falling down in front of the FSNs. Refer to Fig.6.

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(4) Gradually withdraw the borescope, inspecting the weld at the

front edge of the combustion chamber inner bore for any

cracks. Refer to Fig.7 and Fig.8.

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(5) Once you have reached back to the point of entry, re-insert

the borescope and this time articulate the scope to the

opposite side and feed along the annulus between the inner

bore of the combustion chamber and the outer surface of the

outlet guide vane case assembly until the tip reaches FSN 22.

Repeat the inspection in this direction (steps (2) to (4)

above).

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(c) Repeat the procedure detailed in steps (b)(ii)(1) to (4) above for the

following FSN positions:

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(i) FSN position 4, feeding the borescope along the annulus between

the inner bore of the combustion chamber and the outer surface

of the outlet guide vane case assembly until the tip reaches

FSN 7. Refer to Fig.4 and Fig.5.

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(ii) FSN position 7, feeding the borescope along the annulus between

the inner bore of the combustion chamber and the outer surface

of the outlet guide vane case assembly until the tip reaches

FSN 10. Refer to Fig.4 and Fig.5.

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(iii) FSN position 10, feeding the borescope along the annulus

between the inner bore of the combustion chamber and the outer

surface of the outlet guide vane case assembly until the tip

reaches FSN 13. Refer to Fig.4 and Fig.5.

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(iv) FSN position 16, feeding the borescope along the annulus

between the inner bore of the combustion chamber and the outer

surface of the outlet guide vane case assembly until the tip

reaches FSN 13. Refer to Fig.4 and Fig.5.

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(v) FSN position 19, feeding the borescope along the annulus

between the inner bore of the combustion chamber and the outer

surface of the outlet guide vane case assembly until the tip

reaches FSN 16. Refer to Fig.4 and Fig.5.

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(vi) FSN position 22, feeding the borescope along the annulus

between the inner bore of the combustion chamber and the outer

surface of the outlet guide vane case assembly until the tip

reaches FSN 19. Refer to Fig.4 and Fig.5.

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R (d) If cracking is seen, reject the FCL.

(e) Once the inspection is complete, refit the removed bolts (EIPC

73-13-11, Fig./Item No. 01-058/-088) to each of the FSN positions.

Torque the bolts to 11,5 Nm (100 lbfin) in accordance with EM

70-51-00, Standard Practices.

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C. On-wing Acceptance Standards

(1) Circumferential cracking.

(a) Examine the front combustion liner head section for circumferential

cracking in the area immediately forward of the inner wall attaching

weld as shown in Fig.1, Fig.2 and Fig.3. The fly-on and rejection

criteria are shown in Table 1.

CUMULATIVE CRACK

LENGTH (see NOTES)

ACTION

No cracking Accept No action required

Cumulative crack

length up to 150 mm

(up to 2 heatshields)

Accept Repeat inspection at intervals

no more than 250 cycles

Cumulative crack

length 150 mm to 300

mm (up to 4

heatshields)

Accept Repeat inspection at intervals

no more than 100 cycles

Cumulative crack

length 300 mm to 450

mm (up to 6

heatshields)

Accept Remove the engine within 50

cycles

Cumulative crack

length 450 mm to 900

mm (up to 12

heatshields)

Accept Remove the engine within 5

cycles

Cumulative crack

length greater than

900 mm (more than 12

heatshields)

Reject Remove the engine immediately

Table 1

NOTE: Count the total length of all circumferential cracks seen

during inspection.

The width of the heatshield tiles at the inner wall diameter is

approximately 75 mm. Refer to Fig.3.

D. A record of accomplishment is required.

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R Hot Side Inspection Route - View Through Borescope (A) and Location of Cracks

R Fig.1

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R Example of Hot Side Front and Side Views Showing Area of Cracking

R Fig.2

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R with Heatshields Removed Example of Cracking from Hot Side

Fig.3

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R Cold Side inspection access FSN position

R Fig.4

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R Cold Side Inspection Borescope Inspection Route

R Fig.5

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R Cold Side Inpsection Region to be Inspected

R Fig.6

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R Location of Cracking

R Fig.7

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R Example of Cracking from Cold Side

R Fig.8

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Head 

Section 

FSN 

Location

Crack 

Inner 

Wall