LIST OF EFFECTIVE PAGES

The effective pages to this Service Bulletin following incorporation of Revision

3 are as follows:

Page Revision Number Revision Date

Bulletin

R 1 3 Jan.11/13

R 2 3 Jan.11/13

R 3 3 Jan.11/13

R 4 3 Jan.11/13

R 5 3 Jan.11/13

R 6 3 Jan.11/13

R 7 3 Jan.11/13

R 8 3 Jan.11/13

R 9 3 Jan.11/13

R 10 3 Jan.11/13

R 11 3 Jan.11/13

Printed in Great Britain

RB.211−72−AF964

Transmittal - Page 2
1. Planning Information

A. Effectivity

(1) RB211-TRENT 500 Engines - All HP Compressor Stage 1 to 4 Rotor Discs:

R FK30524 FW88340

(2) RB211-TRENT 700 Engines - All HP Compressor Rotor Shafts:

R FW20197 R FW88696 R FK22745 FK26185 FW88700

R FW20638 R FW88697 R FK23313 FK32129 FW88701

R FW20195 R FW23711 R FW88698 R FK24031 FW88702

R FW20196 R FW88695 R FW88699 R FK25502 FW88703

(3) RB211-TRENT 800 Engines - All HP Compressor Stage 1 to 4 Rotor Discs:

R FW61622 R FW88724 R FK24009 FK32580

R FW11590 R FW88723 R FW88725 R FK26167

(4) RB211-524G-T, 524H-T Engines - All HP Compressor Rotor Shafts:

R FK25502 FW20195 FW23711 FW88695 FW88696 FW88697

B. Reason

During manufacture of a small number of HP Compressor Stage 1 and 2 discs with

axial dovetail slots, anomalies at the disc post corners have been found.

Whilst no anomalies have been found on in-service discs, this Non-Modification

Service Bulletin (NMSB) has been raised to reduce the potential risk of a crack

propagating from an anomaly. An investigation of the root cause of the

anomalies is in progress. As a result, an inspection at the HP Compressor Stage

1 and 2 axial dovetail slots is required. This NMSB instructs a local

Fluorescent Penetrant Inspection (FPI) of the HP Compressor Stage 1 and 2 discs

axial dovetail slots, see Section 3. Accomplishment Instructions for engine

applicability.

Revision 1 of this NMSB was issued to correct a part number in 1.A.Effectivity,

to advise that the actions instructed would be contained within an EASA AD and

to revise Accomplishment Instructions to include Overhaul Process 104

references and changes to FPI parameters.

R issued to identify the applicable Airworthiness Revision 2 of this NMSB was

R Directive and to delete reference to NMSB 72-AF259 which was superseded by NMSB

R Figure 4 was amended to show the front face 72-AG330 and is managed separately.

of the axial dovetail slot.

ENGINE - HP COMPRESSOR DRUM - INSPECTION OF AXIAL DOVETAIL SLOTS - NON-MODIFICATION

SERVICE BULLETIN - NON - MOD.72-AF964

Printed in Great Britain

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R Revision 3 of this NMSB introduces three changes:

(1) 1.A., Effectivity is extended to include the part numbers introduced by

Service Bulletins 72-G612, 72-G613 and 72-G614 (see 1.H., References).

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(2) The requirement to complete the Record of Accomplishment sheet and return

it to Rolls-Royce is removed because sufficient data has now been

supplied.

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(3) When the FAA amends an Airworthiness Directive (AD), the new version is

given a different number. The previous version of this NMSB identified ADs

by number, which made it necessary to revise the NMSB when AD numbers

changed. This then made it necessary for operators to change their

compliance documentation.

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Revision 3 of this NMSB removes the AD numbers from section

1.C.,Compliance; this will make sure that subsequent changes to the

Airworthiness Directives will not make it necessary to revise this NMSB.

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C. Compliance

ALERT

Rolls-Royce recommends that the following action is undertaken to maintain

reliability.

The actions detailed in Section 3. Accomplishment Instructions must be

completed on all HP Compressor drums regardless of disposition, in accordance

with the following.

R Effectivity: For all hardware covered in Section 1.A.,

(1) At every engine Refurbishment (Level 3) shop visit, Overhaul (Level 4)

shop visit or when the HP compressor rotor is at piece part level, and the

life of the drum is greater than 1000 cycles since new, then complete the

R Accomplishment Instructions. action defined in Section 3.,

(2) For hardware currently at Refurbishment (Level 3) shop visit, Overhaul

(Level 4) visit or when the HP compressor is at piece part level on the

date of issue of this NMSB, if the HP compressor rotor assembly is not

completed and the life of the drum is greater than 1000 cycles since new,

R then complete the action defined in Section 3., Accomplishment

Instructions.

This NMSB does not instruct inspection on Time Expired HP Compressor drums.

R The actions instructed in this NMSB are mandated by EASA and FAA Airworthiness

R Directives.

Printed in Great Britain

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D. Approval

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

under the authority of Design Organisation Approval EASA.21J.035 on June 2/08

R and was re-approved on June 7/11 and Dec.12/12.

E. Manpower

In Service: Not applicable

At Overhaul: 20 man hours

F. Material Price and Availability

Not applicable

G. Tooling Price and Availability

R Not applicable

H. References

R Service Bulletins: (1) Rolls-Royce RB211

R (a) RB211-524G-T, 524H-T, RB211-TRENT 500, TRENT 700, TRENT 800 Engines

R 72-AG330

Engine - HP Compressor Stage 1 Drum Inspection - Non-Modification

Service Bulletin

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R

R (b) Trent 500 and 700 Engines

R 72-G612

Engine - HP Compressor Shaft - Introduction of a reworked HP

Compressor Shaft assembly with revised interference bush with improved

lead-in chamfer - Mod.72-G612

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R (c) RB211-524G-T, 524H-T Engines

R 72-G613

Engine - HP Compressor Shaft - Introduction of a reworked HP

Compressor Shaft assembly with revised interference bush with improved

lead-in chamfer - Mod.72-G613

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Printed in Great Britain

RB.211−72−AF964

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R (d) Trent 800 Engines

R 72-G614

Engine - HP compressor shaft - Introduction of a reworked HP

Compressor Shaft assembly with revised interference bush with improved

lead-in chamfer - Mod.72-G614

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(2) Trent 500 Engine Manual:

Task 72-41-31-200-803, Examine the HP Compressor Stage 1 to 4 Rotor Discs

Shaft Assembly.

(3) Trent 700 Engine Manual:

Task 72-41-31-200-801, Examine the High Pressure (HP) Compressor Rotor

Disks Shaft Assembly.

(4) Trent 800 Engine Manual:

Task 72-41-31-200-801, Examine the High Pressure (HP) Compressor Stage 1

to 4 Rotor Disks Shaft Assembly.

(5) RB211-524G-T and 524H-T Engine Manual:

Task 72-41-31-200-014, Inspect High Pressure (HP) Compressor Rotor Shaft

Assembly - Inspection/Check-00, Config-2

(6) Engine Overhaul Processes Manual TSD594-J:

(a) Overhaul Process OP101: Non-Aqueous Vapour and Liquid Degreasing

(b) Overhaul Process OP102: Primary Cleaning - Aqueous

(c) Overhaul Process OP104: Abrasive Blasting for Cleaning

(d) Overhaul Process OP136: Removal of Oxidation and Heat Discolouration

from Titanium Parts

(e) Overhaul Process OP210: Fluorescent Penetrant Inspection

(f) Overhaul Process OP335: Application Of Dry-Film Lubricants

2. Material Information

None

Printed in Great Britain

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3. Accomplishment Instructions

Only corners of the front faces of the following HP Compressor axial dovetail

slots are required to be inspected to accomplish this NMSB, see Figure 4:

Trent 500: Stage 1 and 2

Trent 700: Stage 1 only (except FK26185 and FK32129)

Trent 700: Stage 1 and 2 (FK26185 and FK32129 only)

Trent 800: Stage 1 and 2 (except FK24009)

Trent 800: Stage 1 (FK24009 only)

RB211-524G-T, 524H-T: Stage 1 only

NOTE: Figures 1 to 4 are for illustration only, Trent 700 Compressor Rotor

Shafts are shown as an example.

General

Tasks identified by OP (Overhaul Process) are in the Engine Overhaul Processes

Manual, TSD594-J.

CAUTION: COTTON GLOVES MUST BE WORN AT ALL TIMES WHEN HANDLING THE HP COMPRESSOR

DRUM.

A. Disassemble the HP Compressor Rotor Assembly following Engine Manual

requirements.

NOTE: To carry out this NMSB on Trent 500 and Trent 800 HP Compressor drums,

it is not required to remove the Stage 1 to 4 Compressor drum from the

Stage 5 and 6 Compressor drum.

B. Primary clean to OP101 (Non-Aqueous Vapour and Liquid Degreasing) or OP102

(Primary Cleaning - Aqueous).

C. Remove Dry Film Lubricant (DFL) to OP104 (Abrasive Blasting for Cleaning)

Subtask 70-00-00-120-104-004 or Subtask 70-00-00-120-104-005

D. Clean to OP136 (Removal of Oxidation and Heat Discolouration from Titanium

Parts) Subtask 70-00-00-110-136-002 if the surface is not sufficiently cleaned

to carry out the FPI inspection.

Printed in Great Britain

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E. Carry out local FPI to OP210 (Subtask 70-00-00-230-210-002) at applicable axial

dovetail slots following the steps that follow.

(1) Ensure part has cooled to 38 deg.C (100 deg.F) or less (comfortable to

touch)

(2) Apply OMat 652 Penetrant, 30 minutes minimum contact time. Check for full

coverage. Do not exceed 60 minutes.

(3) First wash at 25psi (0.17MPa) maximum (Max). Verify wash under UV light.

(4) Emulsify one minute plus or minus 15 seconds, including travel time.

(5) Second wash at 25psi (0.17MPa) Max. Verify wash under UV light.

(6) Blow off excess water at 25psi (0.17MPa) Max.

(7) Oven dry at 70 deg.C, plus or minus 10 deg. C (158 deg.F, plus or minus 18

deg.F) for 20 minutes Max. Move parts to next step immediately after

removing them from the oven.

(8) Apply OMat 606 (or approved alternative) developer for 30 to 60 minutes.

(9) Air blow off excess developer at 10psi (0.069MPa) Max.

(10) Inspection:

(a) Complete the inspection within two hours of application of developer.

(b) Ensure all curtains/doors are fully closed in the inspection booth.

Max 5 lux ambient white light.

(c) Ensure drum is correctly centred on a turntable or horizontal viewing

fixture. If a turntable is used, make sure the drum runs true when it

is rotated.

(d) Position UV lamps at 90 degrees apart, with the focal spot of both

lamps directed on the dovetail, as shown in Figure 1. Liquid guide

lights may be used instead of UV lamps as long as they are of an

approved type and meet minimum output requirement of

1000microWatts/sq.cm.

(e) Set binoculars to 6 to 8 x magnification.

(f) Use white light to aid focusing the binoculars onto the dovetails.

(g) Allow three minutes eye adaptation time.

(h) Carefully binocular inspect, at 6 to 8 x magnification, each dovetail

in turn under UV; pay particular attention to both acute and obtuse

angles, as shown in Figures 1 to 4. A mirror may be used as an aid.

Printed in Great Britain

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(i) If any cracks are found - Reject. For any other anomalies use Engine

Manual limits, see References (1.H.).

NOTE: Keep hands and items away from the area being inspected to

reduce excessive fluorescence.

(11) Re-apply the DFL to OP335 (Application Of Dry-Film Lubricants).

(12) Reassemble module and inspect in accordance with the Engine Manual

requirements.

Printed in Great Britain

RB.211−72−AF964

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Position of UV lamps

Figure 1

Printed in Great Britain

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Acute angle

Figure 2

Printed in Great Britain

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Obtuse angle

Figure 3

Printed in Great Britain

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Key Inspection Areas

Figure 4

Printed in Great Britain

RB.211−72−AF964

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