This document transmits the Initial Issue of Service Bulletin RB211-72-J055 and

the Initial Issue of the Supplement

Bulletin Initial Issue

Remove Incorporate Reason for change

Pages 1 to 11 of the

Service Bulletin

Initial Issue

Supplement Initial Issue

Remove Incorporate Reason for change

Page 1 Initial Issue

Printed in Great Britain

Mar.22/16

RB211 TRENT 900 SERIES PROPULSION SYSTEMS SERVICE BULLETIN

RB.211−72−J055

Transmittal - Page 1 of 2

Date
LIST OF EFFECTIVE PAGES

The effective pages to this Service Bulletin are as follows:

Page Revision Number Revision Date

Bulletin

1 Mar.22/16

2 Mar.22/16

3 Mar.22/16

4 Mar.22/16

5 Mar.22/16

6 Mar.22/16

7 Mar.22/16

8 Mar.22/16

9 Mar.22/16

10 Mar.22/16

11 Mar.22/16

Supplement

1 Mar.22/16

Printed in Great Britain

RB.211−72−J055

Transmittal - Page 2
1. Planning Information

A. Effectivity

Airbus A380

RB211 TRENT970-84 Engines prior to Serial No.91409 excluding 91405 to 91407.

RB211 TRENT972-84 Engines prior to Serial No.91409 excluding 91405 to 91407.

RB211 TRENT900 SE100006, SE100444, SE100560, SE100562, SE100563, SE100577,

SE100578, SE100767, SE100768, SE100802, SE100803, SE100804, SE100828, SE100829,

SE100830, SE100831, SE100832, SE100885, SE100886, SE100887, SE100888, SE100889,

SE100897, SE100898, SE100899, SE100900, SE100904, SE100905, SE100906, SE100907,

SE100909, SE100910, SE100924 and SE100925 Core Engines.

RB211 TRENT900 M08100014, M08100443 and M08100911 M52 Modules.

B. Concurrent Requirements

None.

C. Reason

(1) Problem

The LP turbine exhaust case and support assembly can suffer premature

cracking at the radius of the leading edge of vanes 1 and 14. The problem

is attributed to Low Cycle Fatigue (LCF) as a result of the

thermo-mechanical loads experienced during the flight cycle. Engineering

analysis has established that there are differences between the actual

loads compared to the predicted loads used during the original

determination of fatigue life.

The Non Destructive Test (NDT) inspection process used at the manufacturer

may not detect all cracks in the welds of the turbine exhaust case and

support assembly. Cracks may subsequently be found during metallurgical

analysis of the component.

The outer skin stiffeners, located on the top of the turbine exhaust case

and support assembly, may be susceptible to cracking in the fillet weld.

The problem is attributed to insufficient contact between the end corners

of the stiffeners and the base material of the case assembly, during the

welding process. Consequently, a lack of full weld penetration may occur.

ENGINE - EXHAUST CASE - INTRODUCTION OF AN LP TURBINE EXHAUST CASE AND SUPPORT

ASSEMBLY WITH INCREASED STRENGTH CAPABILITY - MOD.72-J055

Printed in Great Britain

RB.211−72−J055

Page 1 of 11

Mar.22/16

Mar.22/16
Design best practice is to minimise the risk of contaminating critical

parts with silver residue. Engineering evaluation has determined that

there is a possibility of cross-contamination of silver onto the LP

turbine disc assembly, which is located forward of the baffle plate. The

disc is a critical part. The problem is attributed to self-locking plate

nuts, which contain silver plating, located on the front of the baffle

plate on the front inner support cone of the exhaust case and support

assembly. Cross-contamination may occur during assembly and overhaul

activities.

(2) Evidence

The problem of cracking has been identified during in-service Fluorescent

Penetrant Inspections (FPI) and subsequent laboratory examination of

sample components.

(3) Substantiation

The changes introduced by this modification have been the subject of

satisfactory engineering evaluation, including stress and thermal

analysis, using revised modelling methods. Analysis of the revised design

has shown that the outer skin stiffeners are not required to demonstrate

the buckling capability of the LP turbine exhaust case and support

assembly.

The results of the thermal modelling assessment verifies in-service and

development engine testing data.

The results of new thermal analysis, conducted by specialists at the

manufacturer, support the results of the stress analysis.

Furthermore, the accuracy of the revised modelling techniques has been

cross-validated. Examination of in-service components, found to be cracked

following the FPI, has taken place. Comparison with the predicted cracking

from the revised modelling methods confirms the modelling reflects actual

cracking experienced during in-service operations.

(4) Objective

Incorporation of this Service Bulletin (Modification) is designed to

maintain reliability.

(5) Effect of Bulletin on:

(a) Operation

Not affected.

(b) Maintenance

Not affected.

Printed in Great Britain

RB.211−72−J055

Page 2

Mar.22/16

Mar.22/16
(c) Overhaul

Affected (See 1.L Other Publications Affected).

(d) Repair Schemes

Affected (affected Repair Schemes will be revised to include the

part(s) introduced by this Service Bulletin).

(e) Interchangeability

Affected (See 1.M. Interchangeability of Parts).

D. Description

(1) This Service Bulletin introduces a revised LP Turbine exhaust case and

support assembly with changes to increase strength capability:

The changes are:

(a) A revised LP turbine exhaust case and support assembly is introduced

similar to the existing item except for:

(i) A revised machined profile in the engine mounting lugs.

(ii) The forward outer annulus is thickened locally over a sector

spanning the mount lugs and run outs.

(iii) A chamfer is included on the male catcher in order to increase

axial clearance with the aircraft mounting system.

(iv) Deletion of the four stiffener ribs on the outer skin.

(v) Standard rivets are introduced as an alternative option for

attaching the floating nuts of the tail bearing housing snubber

flange to facilate supply.

(vi) Scalloping is introduced on the rear inner flange, that

provides support for the exhaust cone.

(vii) Inspection capability has been improved at the manufacturer for

detectability of welding defects.

(viii) A revised orientation of scallops on the inner ring cone to

reduce local stress.

(b) A revised air baffle is introduced similar to the existing item except

for the deletion of sixteen anchor nut plates and thirty-two rivets.

Printed in Great Britain

RB.211−72−J055

Page 3

Mar.22/16

Mar.22/16
(c) The orientation of the existing sixteen air baffle attaching bolts is

reversed such that the bolt head is located in the LP turbine disc

cavity, in the forward engine axis attitude.

(d) Sixteen self-locking bi-hexagonal nuts and washers are introduced to

replace the deleted anchor nuts as described in (b) above.

(2) This Service Bulletin is in two parts as follows:

(a) Part 1

New production and in service applications.

(b) Part 2

Reserved for possible future use.

E. Compliance

(1) ON-WING

Not applicable

(2) IN-SHOP

OPTIONAL

This Service Bulletin introduces new parts that should be used when stocks

of the pre-Service Bulletin parts have been used up and/or when the part

involved requires renewal because of its condition.

F. Approval

The technical content of Modification 72-J055 was approved by a representative

of the European Aviation Safety Agency (EASA) on Jan.13/16, EASA certificate

No.EASA.C.10056268.

The technical content under the JAR 25 regulation of this document is approved

under the authority of DOA ref. EASA.21J.031.

G. Manpower

(1) On-wing

Not applicable

(2) In-shop

Not affected

NOTE: The parts affected by this Service Bulletin are accessible in-shop.

Printed in Great Britain

RB.211−72−J055

Page 4

Mar.22/16

Mar.22/16
H. Material Price and Availability

Modification kit not required; parts supplied as single line items.

For prices and availability of future spares see supplement to this bulletin.

I. Tooling Price and Availability

Special tools are not required.

J. Weight and Balance

(1) Weight change:

Plus 3,67 kg (8.1 lb)

(2) Moment arm:

2786 mm (109.7 in.) rearwards

(3) Datum:

Power Plant Station (PPS) 100

K. References

(1) This Service Bulletin is subject to aircraft Modification No. 75654 T85541

(classified minor).

(2) Engine Manual, 72-52-50, Assembly and Disassembly.

L. Other Publications Affected

(1) For effect on Illustrated Parts Catalogue (IPC) see 2. Material

Information.

(2) Engine Manual, 72-52-50, Assembly and Disassembly.

(3) Cleaning, Inspection and Repair Manual, 72-52-51, Clean and Examine the

Remaining Parts.

M. Interchangeability of Parts

It is essential that items within Part 1 are fitted as a set.

Printed in Great Britain

RB.211−72−J055

Page 5

Mar.22/16

Mar.22/16
2. Material Information

A. The kit required consists of the following parts:

None

B. Parts to be reworked:

None

C. New production parts:

The following parts will be made available as future spares:

All Engines, Core Engines and Modules

72-52-51

Part 1 of SB

FIG

ITEM

NO.

NEW

PART

NO.

QTY PART TITLE MAT OLD

PART

NO.

INSTR

DISP

03140 KH52692 1 Baffle, air QRW FW25495 (1)

03143 AS12944 16 Washer, flat, csk

(0.250 in. dia)

EBY - (2)

03144 AS20625 16 Nut, self-locking,

bihex

(0.250 in. dia)

EAR

ECL

(2)

03300 KH45091 1 Case and Support

Assy

FW51434 (1)

03523 NAS1399C3A3 56 Rivet, blind, 100

deg csk

- (3) (5)

D. Redundant parts:

All Engines, Core Engines and Modules

72-52-51

Part 1 of SB

Printed in Great Britain

RB.211−72−J055

Page 6

Mar.22/16

Mar.22/16
FIG

ITEM

NO.

NEW

PART

NO.

QTY PART TITLE MAT OLD

PART

NO.

INSTR

DISP

03148 AS46726 16 Nut,

self-locking,

plate

(0.250 in. dia)

EAR (6) (7)

03146 AS16646 32 Rivet, solid, csk

head

- (6) (7)

E. Other affected parts:

All Engines, Core Engines and Modules

72-52-51

Part 1 of SB

FIG

ITEM

NO.

NEW

PART

NO.

QTY PART TITLE MAT OLD

PART

NO.

INSTR

DISP

03141 AS48512 16 Bolt, bihex hd QZK AS48512 (4)

F. Instruction disposition codes:

(1) Not Interchangeable. The new part must not be replaced by the old part in

isolation, and the old part must not be replaced by the new part in

isolation.

(2) Additional.

(3) Alternative to part number CR2672-3-03 and AS16648.

(4) Part re-orientated.

(5) Sub assembly item, part of case and support assy located at

72-52-51-03-300

(6) Old part may be used up on other applications.

(7) Redundant sub-assembly item, previously part of case, and support assy

located at 72-52-51-03-300.

Printed in Great Britain

RB.211−72−J055

Page 7

Mar.22/16

Mar.22/16
3. Accomplishment Instructions

A. The revised LP turbine exhaust case and support assembly and the revised air

baffle introduced by this Service Bulletin are interchangeable with the

existing items only as a complete modification set (see 1.M. Interchangeability

of Parts). Remove the existing items in accordance with part B. of these

Accomplishment Instructions. Install the new items in accordance with part C.

of these Accomplishment Instructions.

B. Disassemble the LP turbine exhaust case and support assembly in accordance with

Engine Manual Task 72-52-50-040-801

C. Assemble the LP turbine exhaust case and support assembly in accordance with

Engine Manual Task 72-52-50-440-801, except use the following procedure to

assemble the air baffle (72-52-51,03-140) in the LP turbine exhaust case and

support assembly, in place of Subtask 72-52-50-440-020

(1) Refer to Fig.3

(2) Put the air baffle (72-52-51, 03-140) in the correct position in the LP

turbine exhaust case and support assembly (72-52-51, Fig./Item 03-300),

aligning the offset attachment holes in each component, see Note, below.

NOTE: The offset attachment holes (positioning features) are located at

the 6 o'clock (BDC) position

(3) Install the bolts (72-52-51, 03-142), 28 off and install the washers

(72-52-51, 03-143) 16 off, the bolts (72-52-51, 03-141) 16 off and the

nuts (72-52-51, Fig./Item 31-144) 16 off, to attach the air baffle

(72-52-51, 03-140) to the LP turbine exhaust case and support assembly

(72-52-51, 03-300).

(4) Torque tighten the bolts (72-52-51, Fig./Item 03-142) 28 off, to 4,5 Nm

(40 lbf.in.).

(5) Torque tighten the nuts (72-52-51, Fig./Item 03-144) 16 off to 11,5 Nm

(100 lbf.in.).

D. A record of accomplishment is required when this modification has been

embodied. The modification number and relevant modification part(s) shall be

recorded in the engine log book when the modification part is fitted in its

entirety.

Printed in Great Britain

RB.211−72−J055

Page 8

Mar.22/16

Mar.22/16
A

BEFORE ALTERATION

A

deh0014724

LP TURBINE

EXHAUST CASE

FW51434

72−52−51

03−300

BAFFLE

FW25495

72−52−51

03−140

BOLT

AS48512

72−52−51

03−141

(16 off)

BOLT

AS50209

72−52−51

03−142

(28 off)

NUT

AS46726

72−52−51

03−148

(16 off)

RIVET

AS16646

72−52−51

03−146

(32 off)

NUT

AS46725

72−52−51

03−525

(28 off)

RIVET

AS16648

OR

CR2672−3−03

72−52−51

03−523

(56 off)

LP turbine exhaust case and support assembly - Before alteration

Fig.1

Printed in Great Britain

RB.211−72−J055

Page 9

Mar.22/16

Mar.22/16
A

AFTER ALTERATION

deh0014725

LP TURBINE

EXHAUST CASE

KH45091

72−52−51

03−300

BAFFLE

KH52692

72−52−51

03−140

BOLT

AS48512

72−52−51

03−141

(16 off)

BOLT

AS50209

72−52−51

03−142

(28 off)

NUT

AS46725

72−52−51

03−525

(28 off)

WASHER

AS12944

72−52−51

03−143

NUT

AS20625

72−52−51

03−144

(16 off)

(16 off)

A

RIVET

NAS1399C3A3

OR

CR2672−3−03

72−52−51

03−523

(56 off)

AS16648

OR

LP turbine exhaust case and support assembly - After alteration

Fig.2

Printed in Great Britain

RB.211−72−J055

Page 10

Mar.22/16

Mar.22/16
A

AFTER ALTERATION

deh0014792

LP TURBINE

EXHAUST CASE

KH45091

72−52−51

03−300

BAFFLE

KH52692

72−52−51

03−140

BOLT

AS48512

72−52−51

03−141

(16 off)

BOLT

AS50209

72−52−51

03−142

(28 off)

WASHER

AS12944

72−52−51

03−143

NUT

AS20625

72−52−51

03−144

(16 off)

(16 off)

A

LP turbine exhaust case and support assembly - Install air baffle

Fig.3

Printed in Great Britain

RB.211−72−J055

Page 11

Mar.22/16

Mar.22/16

SUPPLEMENT - PRICES AND AVAILABILITY

This is a technical document not a quotation; any prices and delivery given are in

good faith without engagement.

Alternative parts may be supplied instead of parts listed. See Material Information

disposition instructions.

1. Modification Kit

Modification kit is not required; parts supplied as single line items.

2. Parts required to accomplish this Service Bulletin:

Part No Qty Unit Price

U.S. Dollars

AS12944 16 Price to be supplied on request

AS20625 16 Price to be supplied on request

KH45091 1 Price to be supplied on request

KH52692 1 Price to be supplied on request

NAS1399C3A3 56 Price to be supplied on request (see Note)

NOTE: NAS1399C3A3 is an alternative to existing part AS16648

3. Tools:

None

ENGINE - EXHAUST CASE - INTRODUCTION OF AN LP TURBINE EXHAUST CASE AND SUPPORT

ASSEMBLY WITH INCREASED STRENGTH CAPABILITY - MOD.72-J055

Printed in Great Britain

RB.211−72−J055

Supplement Page 1 of 1

Mar.22/16

Mar.22/16