P.O. Box 31, DERBY DE24 8BJ, UK Telephone: 44 (0) 1332 242424 Fax: 44 (0) 1332 249936 

# Rolls-Royce 

# -

PUBLICATION TRANSMITTA

The technical information contained in this document has been approved under the authority of - See Planning Information, Approval.

Signed 

# 4, Date Apr. 2/09

N. J. Wright

RB211-524 AND 535 SERIES PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN 

# ALERT

u 2 (3 This document transmits Revision 2 to Service Bulletin RB211-72-AF572

s .- m

cI Document History
s .- L n Service Bulletin Revision Status Supplement Revision Status Initial Issue Oct. 15/07 Revision 1 Oct .10/08

Bulletin Revision 2

Remove All pages of the Service Bulletin Incorporate Pages 1 to 10 of the Service Bulletin



# ALERT Reason for change Accomplishment Instructions revised to allow alternative power source for the electrochemical test

Transmittal - Page 1 of 2

CHECK THAT ALL PREVIOUS TRANSMITTALS HAVE BEEN INCORPORATED 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 BritainLIST OF EFFECTIVE PAGES

The effective pages to this Service Bulletin following incorporation of Revision 2 are as follows:

Page Revision Number Revision Date

Bulletin R 1 2 Apr.2/09 R 2 2 Apr.2/09 R 3 2 Apr.2/09 R 4 2 Apr.2/09 R 5 2 Apr.2/09 R 6 2 Apr.2/09 R 7 2 Apr.2/09 R 8 2 Apr.2/09 R 9 2 Apr.2/09 R 10 2 Apr.2/09Printed in Great Britain



# RB.211−72−AF572
Transmittal - Page 2

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No : 72-AF572 Revision 2

ISSUED BY THE ENGINEERING CONFIGURATION DEPARTMENT

 2009 Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied, or communicated to a third party, or used for any purpose other than that for which it is suppl ied without the express written consent of Rolls-Royce plc. ENGINE – COMBUSTION LINER – CHECK OF PHASE 2 FRONT COMBUSTION LINER METERING

PANEL MATERIAL – NON-MODIFICATION SERVICE BULLETIN – NON-MOD.72-AF572 1. Planning Information

A. Effectivity

(1) Boeing 757 All RB211-535C engines. All RB211-535E4 engines except: 535E4-37/25, 535E4-37/39, 535E4-37/43, 535E4-37/44.All RB211-535E4-B engines except: 535E4-B-37/25, 535E4-B-37/35, 535E4-B-37/39, 535E4-B37/41.

(2) Tupolev Tu204
RB211-535E4-B-75

(3) Boeing 747 RB211-524B2-19, 524C2-19, 524D4-19, 524D4-B-19, 524D4-39: only engines that are post SB72-7221. All RB211-524G2-19, 524G3-19, 524H2-19 engines.

(4) Boeing 767 All RB211-524H-36 engines.

(5) Lockheed L1011 RB211-524B-02, 524B3-02, 524B4-02: only engines that are post SB72-7221.

Note: This Non-Modification Service Bulletin (NMSB) inspection is applicable only to RB211-524 and RB211–535C/E4/E4-B engines that are installed with Phase 2 combustors that are specified with C263 material metering panels. This NMSB is not applicab le to Phase 5 combustors, hence it is not applicable to RB211-535E4/E4-B engines with SB 72-C230 inst alled, nor is it applicable to RB211-535E4-C engines that had a Phase 5 combustor at entry into service, nor is it applicable to RB211-524G/H-T engines that are post SB 72-C067.

B. Reason

During troubleshooting of a starting problem with an RB211-535E4-B engine, the Fuel Spray Nozzles (FSNs) appeared misaligned and the engine was removed. Strip inves tigation found that the FSNs were correctly positioned but that the Front Combustion Liner (FCL) metering panel (EIPC 72-41-13 02-324) was cracked and distorted. Laboratory investigation revealed that the FCL metering panel was to an incorrect material specification (‘N75’ material, rather than ‘C263’ material), which was determined to be the root cause of the FCL metering panel cracking and distortion.

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No: 72-AF572 Revision 2

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 2009 Rolls-Royce plc SB 72-7221 was issued, in 1984, to address the issue of Phase 2 FCL N75 metering panel cracking in the early marks of the RB211-524 engine; it replaced the N75 metering panel with one made from C263. The metering panel in Phase 2 combustors of the RB2 11-524G/H and RB211-535C/E4/E4-B engines was specified in C263 material from engine type entry into service.

The use of N75 metering panels, where C263 was the intended material, has the proven potential to lead to metering panel cracking. Significant metering panel cracking could result in a service event.

This Non-Modification Service Bulletin (NMSB) instru cts a check for correct metering panel material at engine shop visit, and the withdrawal from service an y parts that have been incorrectly manufactured from N75 material.

R Revision 1 of this NMSB was raised to remove the requirement to vibro-engrave the NMSB number onto the Front Combustion Liner after accomplishment and to amend the recording requirements.

R Revision 2 has been raised to allow the use of alternative power source for carrying out the R electrochemical test instructed. Revision 1 specified 2-off 9 volt PP9 batteries connected in series. R These batteries are becoming obsolete a nd difficult to procure; however, any 18 volt battery power supply R capable of producing a spark when tested as detailed in section 3.B.7 is acceptable.

C. Compliance

ALERT

The actions described in Section 3. Accomplishmen t Instructions of this Non-Modification Service Bulletin (NMSB) should be accomplished as detailed below:

a) Inspect any front combustion liner stock that can be fitted to those engines listed in Section A. Effectivity within 6 months of issue of this NMSB. b) Inspect engines at current shop visit where the HP Turbine Rotor ha s been removed from the Combustion Outer Casing and has not yet been reinstalled into the Combustion Outer Casing on the date of the first issue of this NMSB. c) Inspect at the next shop where the HP Turb ine Rotor is removed from the Combustion Outer Case. NOTE: This is a once-only inspection. This NMSB can be incorporated without carrying out the Accomplishment Instructions in Section 3 if either: i. TV75295 has been incorporated, or ii. The metering panel (Engine Illustra ted Parts Catalogue: 72-41-13-02-324) was delivered from Rolls-Royce after 23 April 2007.

D. Approval

The technical content of this Non-Modification Serv ice Bulletin was approved under the authority of R Design Organisation Approval EASA.21J.035 on Oct.15/07 and was re-approved on Oct.7/08 and R Apr. 2/09

E. Manpower

(1) Overhaul Shop

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No: 72-AF572 Revision 2

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 2009 Rolls-Royce plc (a) Time to gain access (1 person) 0.25 hour

(b) Time to inspect (1 person) 0.5 hour

(c) Time to restore to serviceable condition (1 person) 0.25 hour

(d) Total Time 1 hour

(2) On Wing

Not Required

F. Material Price and Availability

None

G. Tooling Price and Availability

None

H. References
(1) TV75295 - Inspection Of Front Com bustion Liner (FCL) Meterpanel Material (2) Engine Illustrated Parts Catalogue (EIP C), 72-41-13-02-324 Metering Panel Assembly (3) Rolls-Royce RB211 Service Bulletins: 72-7221 Engine – Combustion Section - Front Combustion Liner - Flexible Mounting (Hairpin Section) and Improved Cooling 72-C067 Engine - Module 4 - Introduction of Revised HP System 72-C230 Engine - Module 4 - Introduction of Revised HP System Incorporating an Improved Combustor (4) OP TASK 70-00-00-300-363 (Overhaul Process 363 - Marking Methods), Overhaul Processes Manual

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No: 72-AF572 Revision 2

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 2009 Rolls-Royce plc 2. Material Information

Chemical reagents: 5% sodium fluoride aqueous solution (50ml) – OMat 1/102 5% Potassium Thiocyanate in Acetone (50ml) – OMat 1/113

R 18 volt power supply. Any form of battery power may be used provided that it is able to produce a spark R when configured in accordance with this NMSB and tested in accordan ce with section 3.B.7. An 18 volt, R 2.4 Amp battery power source is ideal.

2m of insulated copper wires (e.g. 1.5mm gauge)

Filter paper (e.g. Whatman no. 2) – OMat 1/144

Crocodile clip (positive test electrode – “anode”)

Commercially pure cylindrical (approx 5mm dia) aluminium or titanium rod (negative test electrode – “cathode”) with PVC or rubber tubing insulating sleeve.

Abrasive grit paper:

SiC – OMat 5/37 or Emery paper – OMat 5/44 or Aluminium oxide abrasive cloth – OMat 5/71 or Aluminium oxide paper – OMat 5/62 Degreaser Acetone – OMat 150 or Isopropanol – OMat 1/40

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No : 72-AF572 Revision 2

ISSUED BY THE ENGINEERING CONFIGURATION DEPARTMENT

 2009 Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied, or communicated to a third party, or used for any purpose other than that for which it is suppl ied without the express written consent of Rolls-Royce plc. 3. Accomplishment instructions

A. Introduction

This procedure uses an electrochemic al process. The output is a colour difference on a filter paper, which identifies the difference in cobalt content of the two a lloys. The C263 material has a large cobalt content and gives a blue/green colour output. The N75 material has a low cobalt content and gives a yellow colour output. Figures 1a and 1b show a typical metering panel. Access to the metering panel can be attained through the FSN port (Figure 1c). Note that this procedure shoul d not be carried out in the presence of fuel vapour.

Figure 1a Figure 1b

Figure 1a and 1b show a typical metering panel sub assembly

Figure 1c shows the FSN port through wh ich the metering panel can be accessed. Metering panel through the port

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No: 72-AF572 Revision 2

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 2009 Rolls-Royce plc B. Procedure to check for N75/C263 Alloy.

WARNING: 1. MAKE SURE THAT YOU USE APPLICABLE GLOVES AND EYE PROTECTION WHEN HANDLING CHEMICALS TO PREVENT INJURY TO PERSONNEL.

2. DO NOT INGEST ANY CHEMICALS DESCRIBED IN THE FOLLOWING PROCEDURE

3. THE HEALTH AND SAFETY DATA GIVEN IN THIS PROCEDURE ARE GENERAL GUIDELINES IN USE AT ROLLS-ROYCE; IT IS THE RESPONSIBILITY OF THE OPERATOR/USER TO OBTAIN DETAILED HEALTH AND SAFETY DATA FOR THE MATERIALS IN USE
, AND TO LOCAL REGULATIONS
, TO ENSURE SAFE WORKING PRACTICE

RECOMMENDATION: 1. Before testing a single metering panel, carry out the following procedure on a sheet of N75 material and on a sheet of C263 supplied by Rolls-Royce. The two sheets provided by Rolls-Royce will be clearly marked with material type. This step will prove the test apparatus and set-up. If the two sheets do not give the expected result (i.e yellow for N75, blue /green for C263) then ensure that the procedure has been carried out correctly, and the apparatus is set up correctly. If the problem persists contact Rolls-Royce Service Engineering through your local field support office.

RECOMMENDATION: 2. If testing a batch of metering panels, prove the material test process – as per Recommendation 1 – before testing the fi rst and last metering panels in the batch. This will ensure the integrity of the test for the complete batch.

1. Clean the test area with dry 180 grade SiC ab rasive paper. If cleaning a test area on a built module make sure the strip of SiC paper is long enoug h to prevent release in to the assembly. On the assembled unit there will only be visi bility of the area show n in Figure 2. Figure 3 shows a typical view through a port.

Figure 2 shows a close up of the metering panel

Area that will

be visible through the

FSN port

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No: 72-AF572 Revision 2

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 2009 Rolls-Royce plc Figure 3 shows a view through a typical port.

2. Wipe over the area with an isopropano l wipe to degrease and remove debris.

3. Electrically connect (e.g. solder) the crocodile c lip to an insulated copper wire. Electrically connect R (e.g. solder) the other end of this copper wire to the positive terminal of the 18V battery power supply. The crocodile clip is now the positive test electrode (or “anode”).

4. Connect the positive test electrode to the metering panel as shown in Figure 4a and 4b. Ensure that the crocodile clip (the positive test electrode) is attach ed directly to the metering panel and not another component that is in contact with the metering panel. Ensure that the crocodile clip is within 20,0 mm of the area to be swab tested.

Figure 4a showing metering panel Figure 4b showing metering panel (RB211-524) connected to positive terminal in FC L assembly connected to positive terminal Metering panel

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No: 72-AF572 Revision 2

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 2009 Rolls-Royce plc Figure 4c showing metering panel (RB211-535) in FCL assembly connected to positive terminal

WARNING: MAKE SURE THERE ARE NO SOLVENTS AND FUELS IN THE AREA. TEST EQUIPMENT/PROCEDURE PRODUCES SPARKS THAT CAN IGNITE SOLVENTS/FUELS.

5. If the metering panel is assembled in the combus tion liner as shown in Figure 4b and 4c, it will be necessary to use a tweezers or adjust able pliers to attach the crocodile clip to the metering panel due to access constraints through the FSN port. See Figures 5a and 5b. The position on the metering panel where the crocodile clip can be easily attached will vary slightly depending on the standard of metering panel and burner seal ring. Figures 4b and 4c show typical attachment positions for the RB211-524 and RB211-535 respectively.

WARNING: ENSURE THAT NO FOREIGN OBJECT DEBRIS (E.G. ABRASIVE PAPER, FILTER PAPER, DEGREASANT WIPES) DROPS INTO THE ASSEMBLED FRONT COMBUSTION LINER.

Figure 5a showing crocodile clip in adjustable pliers Figure 5b showing use of adjustable pliers to attach crocodile clip

6. Electrically connect (e.g. solder) the cylindrical aluminium rod to an insulated copper wire. Cover the electrical join with an insu lating sleeve of rubber or PVC. Electrically connect (e.g. solder) the other R end of this copper wire to the negative terminal of the 18V battery power supply. The cylindrical aluminium rod is now the negative test electrode (or “cathode”).

7. Touch the aluminium rod (negative test electrode ) on to the metering panel to ensure a spark is generated as per Figure 6. Clean the area again if no spark is seen and check the battery voltage.

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No: 72-AF572 Revision 2

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 2009 Rolls-Royce plc Figure 6 shows a spark test

8. Wet a section of filter paper (e.g. Watman no 2) w ith 2-3 drops of 5% sodium fluoride solution, so the filter paper is just damp.

9. Put the damp filter paper against the metering pane l and press on with the negative test electrode to make a full electric circuit. Hold in position for 2-3 seconds.

Figure 7 shows the full electrochemical cell test with the Sodium Fluoride damp filter paper between the metering panel and the –ve electrode.

10. Remove the negative test electrode from the filter paper. Remove the filter paper from the metering panel. Within 30 seconds of removal, put 1-2 drop s of 5% Potassium Thiocyanate in Acetone on the damp filter paper where the filter paper has been in contact with the metering panel.

Figure 8 shows adding the Thiocyanate to the filter paper from step 10. Damp filter paper

# RB211 Propulsion System NON-MODIFICATION SERVICE BULLETIN 

## Mod No: 72-AF572 Revision 2

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 2009 Rolls-Royce plc NOTE: The colour change will start to fade within 20-30 seconds; therefore ensure a note of the colour is made immediately after adding the Potassium Thiocyanate

. 11. Observe the colour change on the filter paper test area. The C263 material gives a blue / green colour. The N75 material stays a yellow colour. See Figures 9a and 9b.

Figure 9a N75 colours Figure 9b C263 colours

12. Remove the test electrodes from the metering pane l. Clean the metering panel test area with an isopropanol wipe.

13. If the FCL metering panel is identified as N75 material, contact Rolls-Royce Technical Services immediately and quarantine the part.

14. If the FCL metering panel is identified as C263 material, record accomplishment of the testing procedure (NMSB) in Engine Log Book.

C. A record of accomplishment is required.

D. Contact Rolls-Royce Service Engineering with the results of the test through your local field support office (FSO).