LIST 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 May 5/16 R 2 2 May 5/16 R 3 2 May 5/16 R 4 2 May 5/16 R 5 2 May 5/16 6 1 Sep.27/13 R 7 2 May 5/16 R 8 2 May 5/16 R 9 2 May 5/16 R 10 2 May 5/16 R 11 2 May 5/16 R 12 2 May 5/16 R 13 2 May 5/16 R 14 2 May 5/16 R 15 2 May 5/16 R 16 2 May 5/16 R 17 2 May 5/16 R 18 2 May 5/16 R 19 2 May 5/16 R 20 2 May 5/16 R 21 2 May 5/16 R 22 2 May 5/16 R 23 2 May 5/16 R 24 2 May 5/16 R 25 2 May 5/16 R 26 2 May 5/16 R 27 2 May 5/16 R 28 2 May 5/16 R 29 2 May 5/16 R 30 2 May 5/16 R 31 2 May 5/16 Appendix 1 R 1 2 May 5/16**Printed in Great Britain**



# RB.211−72−AG971 Transmittal - Page 21. Planning Information A. Effectivity Airbus A380 All RB211 TRENT 900 Engines with part numbers FW27718, FW35923, FW51434, KH46678, KH45090 or KH46677 only. R R
B. Reason Problem Re-analysis of Tail Bearing Housing (TBH) structural features identified a potential limitation to R R the TBH capability in the fail safe condition. To confirm intact capability, an on-wing and in-shop inspection regime was R defined for the Trent 900 TBH. The structural features to be inspected are the TBH mount lug run-outs and Top Core Vanes (TCV). In addition, the life of the TBH was R limited to 17200 cycles to make sure it did not enter in fail safe mode. Additionally, historical inspections of the TBH to initial issue of Non-Modification Service Bulletin (NMSB) 72-AG971 identified issues which required additional inspection criteria as part of a revised containment strategy. This has been addressed independently through NMSB 72-AH154. Revision 1 of this NMSB was R issued to provide additional clarity for some of the materials, tooling and cleaning tasks associated with inspections. It also revised R the acceptance criteria for the on-wing inspections (section 3.A.(2)) and introduced R the inspection of the fail safe catcher in-shop to inform root cause understanding for the issues addressed in NMSB 72-AH154. Revision 2 of this NMSB is issued to introduce eddy current inspection method as an alternative to the existing FP inspection of the mount lug run out region. It also removes the life limitation for the component following a re-assessment of the TBH that has demonstrated full limit load capability of the structure. The on-wing inspections of the mount lug run-outs are to be maintained until a pin check is introduced into the Maintenance Planning Document (MPD) every 3800 flight cycles. Finally, it also clarifies that the Central Male Catcher Run-Out is also addressed as part of the full FP inspection of the TBH in the shop. R R R R R R R R R C. Description This Non-Modification Service Bulletin (NMSB) instructs the following: TRENT 900 LP TURBINE EXHAUST CASE AND SUPPORT ASSEMBLY (TAIL BEARING HOUSING) MOUNT LUG RUN-OUT AND TOP CORE VANE INSPECTIONS - NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-AG971**Printed in Great Britain**



# RB.211−72−AG971 Page 1 of 31 Sep 20/12 May. 5/16 R(1) On-wing or in-shop TBH mount lug run-out inspections which are required on R Trent 900 Tail Bearing Housings with part numbers FW27718, FW35923, FW51434, KH46678, KH45090 or KH46677 R R every 2200 cycles. (2) The in-shop inspection of TBH top core vanes and central male catcher runout R R which are required on Trent 900 Tail Bearing Housings with part numbers FW27718, FW35923, FW51434, KH46678, KH45090 or KH46677 R R every 3800 cycles. On-wing a specified area on the mount lug run-outs is to be crack tested using a Fluorescent Penetrant Inspection (FPI) method or an alternative Eddy Current Method, R R see Fig.1. In shop, the mount lug run-outs can either be inspected using a local FPI, R local eddy current or through a full FPI of the TBH. In shop the top core vanes and central male catcher runout R are to be inspected by a full FPI of the TBH. Results of the Inspections are to be returned to Rolls-Royce. Return Appendix 1 (or similar form) to your Rolls-Royce Service representative. D. Compliance
ALERT This Non-Modification Service Bulletin is R the subject of an EASA Airworthiness Directive AD 2013-0240. R Rolls-Royce recommends that the following action is undertaken to maintain continued airworthiness. This NMSB applies to both on-wing and in-shop activities. (1) On-wing - Localised Mount Lug Run-Outs Inspection: Accomplish the first inspection in accordance with section 3.A. Accomplish the first inspection within 2200 cycles for the TBH mount lug run-outs if it is not to be done in-shop. Subsequent inspections whether in-shop or on-wing should be within 2200 cycles of previous inspection. Any TBH mount lug run-outs that were inspected to TV124801 or TV124851 prior to initial issue of this NMSB are deemed as compliant with the NMSB. (2) In-shop - Localised Mount Lug Run-outs Inspection: Accomplish the first inspection in accordance with section 3.B. Accomplish the first inspection within 2200 cycles for the TBH mount lug run-outs if it is not to be done on-wing or in-shop through full FPI of the TBH. Subsequent inspections whether in-shop or on-wing should be within 2200 cycles of previous inspection. Any TBH mount lug run-outs that were inspected to TV124801 or TV124851 prior to initial issue of this NMSB are deemed as compliant with the NMSB.**Printed in Great Britain**



# RB.211−72−AG971 Page 2 Sep 20/12 May. 5/16 R(3) In-shop - Top Core Vanes and Mount Lug Run-outs Inspection through full FPI of the TBH: Accomplish the first inspection of the Top Core Vanes and central male catcher runout R R in accordance with section 3.C. Accomplish the first inspection within 3800 cycles for the TBH top core vanes and central male catcher runout. R R Subsequent inspections should be within 3800 cycles of previous inspection. Inspection of the mount lug run-outs can also be accomplished in accordance with section 3.C. Accomplish the first inspection within 2200 cycles for the TBH mount lug run-outs if it is not to be done on-wing or through a localised in-shop inspection. Subsequent inspections whether in-shop or on-wing should be within 2200 cycles of previous inspection. 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.4/12, Sep.13/13 R R and was re-approved on Apr.29/16. The inspection procedures described in this SB are reviewed and technically accepted by Airbus Design Office to apply to the Airbus fleet affected. This SB does not contain any change information that revises the equipment definition covered by Airbus approved modifications. F. Manpower (1) On-wing: (a) Time to gain access 1 hour (1 person) (b) Time to inspect TBH Mount Lug Run-outs (FPI Method) R 3 hours (2 persons) (c) Time to inspect TBH Mount Lug Run-outs (Eddy Current Method) R 1 hour (1 person) R (d) Time to restore to serviceable condition 1 hour (1 person)**Printed in Great Britain**



# RB.211−72−AG971 Page 3 Sep 20/12 May. 5/16 R(2) In-shop: (a) Time to locally inspect TBH Mount Lug Run-outs (FPI Method) R 2 hours (2 persons) (b) Time to locally inspect TBH Mount Lug Run-outs (Eddy Currrent Method) R 1 hour (1 person) R (c) Inspection of TBH through full FPI Level 2 workscope The FPI defined in this NMSB R shall only be performed by personnel qualified to FPI level 2 or higher and in possession of an up to date eyesight record in accordance with EN4179/NAS410 or alternative standards/guidelines accepted by the applicable National Aviation Authority. The eddy current defined in this NMSB shall only be performed by personnel qualified to eddy current level 2 or higher and in possession of an up to date eyesight record in accordance with EN4179/NAS410 or alternative standards/guidelines accepted by the applicable National Aviation Authority. R R R R G. Material Price and Availability (1) For Local FPI R Material/ Compounds R R Description OMat 651 (Aerosol) R R Aerosol penetrant - Commercially available OMat 617 (Aerosol) R R Aerosol Developer - Commercially available OMat 150 R Acetone OMat 2/101 R Lint-Free Cloth OMat 677 R Penetrant Test Panel (2) For Eddy Current R Material/ Compounds R R Description OMat 2/30 R PTFE Tape - Minimum width of 10 mm H. Tooling Price and Availability (1) For Local FPI R Material/ Compounds R R Description**Printed in Great Britain**



# RB.211−72−AG971 Page 4 Sep 20/12 May. 5/16 RDark Non-reflective cover R R R To darken the area for inspection - Commercially available Ultra Violet (UV) light source R R 2 alternatives R Capable of providing a minimum UV radiation intensity of 1200 micro W/sq.cm at the inspection surface. R R Alternatively, Spectroline Tritan 365 UV/White LED Inspection Lamp, Portable, Battery Operated Version, Part Number - TRI-365MH series Kit R R R Unit Price - Approximately £ 1200, Supplier - RSL NDT Ltd. R R (2) For Eddy Current R Material/ Compounds R R Description HU82371 R Eddy Current Inspection Kit Rohmann Eddy current instrument capable of showing an X-Y display R R
NOTE : The eddy current instrument must be subject to annual calibration in accordance with the manufacturer instructions. R R I. References (1) Aircraft Maintenance Manual (AMM) (a) 71-13-00, Maintenance Practices, Opening of Fan Cowl Doors (b) 78-26-00, Maintenance Practices, Opening/Closing of the Fan Exhaust Cowl or Thrust Reverser (c) 78-30-00, Deactivation/Reactivation, Make the Thrust Reverser Unserviceable for Maintenance (d) 70-20-02, Maintenance Processes - Inspection - Maintenance Practices, Fluorescent Penetrant Inspection (2) Engine Manual (EM) (a) 70-00-00, Overhaul Process 102, Primary Cleaning Aqueous, Overhaul Process 121, Alkaline Derusting and Descaling, Overhaul Process 134, Acidic Descalers, Overhaul Process 210, Fluorescent Penetrant Inspection. (b) 72-52-00-030-802, Engine Data Task, Disassemble the LP Turbine (c) 72-52-51-200-801, Cleaning/Inspection and Repair Data Task, Examine the LP Turbine Exhaust Case**Printed in Great Britain**



# RB.211−72−AG971 Page 5 Sep 20/12 May. 5/16 R2. Material Information
A. None**Printed in Great Britain**



# RB.211−72−AG971 Page 6 Sep 20/12 Sep.27/13 R3. Accomplishment Instructions A. On-wing - Localised Mount Lug Run-outs Inspection R

WARNING : YOU MUST BE CAREFUL WHEN YOU WORK ON THE ENGINE AFTER THE ENGINE IS SHUTDOWN. THE ENGINE CAN STAY HOT FOR ALMOST ONE HOUR. R R
WARNING : YOU MUST NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT PARTS CAN CAUSE INJURY. IF YOU GET AN INJURY, PUT IT IN COLD WATER FOR 10 MINUTES. THEN GET MEDICAL AID. R R R
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. R R R R R R R R R (1) Flourescent Penetrant Inspection R
NOTE : Eddy current inspections in accordance with step 3.A.(2) is a valid alternative inspection method to the local FPI of the mount lug run-outs. R R R (a) To get access to the Tail Bearing Housing (TBH) mount lug run-outs: R (i) Open the fan cowl doors in accordance with AMM Task 71-13-00, Maintenance Practices to get access R R (ii) Make the thrust reverser unserviceable for maintenance in accordance with AMM 78-30-00, Deactivation/Activation. R R
WARNING : YOU MUST MAKE THE THRUST REVERSER UNSERVICEABLE (INSTALL AND SAFETY THE INHIBITION DEVICE) BEFORE YOU DO WORK ON OR AROUND THE THRUST REVERSER. IF YOU DO NOT INSTALL AND SAFETY THE INHIBITION DEVICE, THERE IS A RISK THAT THE THRUST REVERSER CAN OPERATE ACCIDENTALLY. THIS CAN CAUSE INJURY TO PERSON AND/OR DAMAGE TO THE EQUIPMENT. R R R R R R (iii) Open the fan exhaust cowls in accordance with the AMM, 78-26-00. R R (iv) Use appropriate staging to gain access to the TBH. R (b) Carry out the inspection on the mount lug run-outs: R**Printed in Great Britain**



# RB.211−72−AG971 Page 7 Sep 20/12 May. 5/16 RWARNING : PROTECTIVE GLOVES AND SAFETY GLASSES MUST BE WORN AT ALL TIMES DURING THE INSPECTION. IF YOU GET AN INJURY, SEEK MEDICAL AID IMMEDIATELY R R R (i) This inspection must be performed in accordance with the requirements of AMM 70-20-02, Maintenance Processes - Inspection - Maintenance Practices, Fluorescent Penetrant Inspection. R R R R (ii) Clean the inspection areas (see Fig.1) with a clean OMat 2/101 lint-free cloth moistened with OMat 150 acetone. R R (iii) Discard the soiled cloth after use. R (iv) Repeat the swabbing using fresh OMat 150 acetone and a fresh OMat 2/101 lint-free cloth until all deposits have been removed. R R R
NOTE: The inspection surface, must be clean, dry and free from soils, oil, grease, paint, coatings, corrosion products, scale, smeared metal, welding flux, chemical residues or any other material that could prevent penetrant from entering a discontinuity, affect process performance or produce an unacceptable background. R R R R R R (v) Allow five minutes for the area to completely dry prior to penetrant application. R R (vi) Penetrant application - Apply OMat 651 penetrant to the inspection areas (Fig.1) by brush or sponge applicator. The penetrant must be dispensed from a sealed aerosol can and any unused penetrant must go to waste. R R R R (vii) Make sure that the inspection area is fully covered with penetrant with the aid of a UV lamp. R R (viii) Apply OMat 651 penetrant to the OMat 677 penetrant test panel. R (ix) Leave the penetrant in contact with the components for 30 minutes. R R
NOTE : The penetrant contact time must not exceed one hour. If it does, the penetrant must be re-applied and 5 minutes contact time allowed. R R R (x) Penetrant Removal - After the 30 minutes contact time, remove the excess penetrant from the inspection surface and the OMat 677 penetrant test panel by wiping thoroughly with a clean OMat 2/101 lint-free cloth. R R R R**Printed in Great Britain**



# RB.211−72−AG971 Page 8 Sep 20/12 May. 5/16 R(xi) Whilst illuminating with UV light, wipe off the penetrant with a clean OMat 2/101 lint-free cloth moistened with OMat 150 acetone. Use the minimum application necessary to achieve acceptable background fluorescence and make sure that acetone is not allowed to flow on the inspection surface. R R R R R (xii) Make sure that all traces of the OMat 150 acetone have been completely removed. R R (xiii) Develop - Apply a light, even coating of OMat 617 non-aqueous wet developer from a sealed aerosol can to the inspection area and the OMat 677 penetrant test panel. R R R (xiv) Allow 10 minutes contact time for the developer prior to inspection. R R (xv) Cover the region of the engine with a dark non-reflective cover in order to reduce the white light levels. R R (xvi) Make sure there are no white light sources or fluorescent items (including clothing) within the inspection area or the inspector's field of vision. R R R (xvii) Do not wear darkened or light sensitive glasses. R (xviii)Allow one minute for eye adaptation to the darkened area. R (xix) Illuminate the OMat 677 penetrant test panel in the darkened area with one of the allowed UV light sources listed in 1.H. Tooling Price and Availability. R R R (xx) Inspect the OMat 677 penetrant test panel and check that the four largest indications are visible and match the control photograph for that individual panel. R R R (xxi) Illuminate the inspection surface with the same UV light in the darkened area. R R (xxii) Inspect the mount lug run-outs for crack indications. R (xxiii)The Wipe Off technique can be used to aid the evaluation of any indications: R R (1) Dampen a cotton swab with acetone. R (2) Wipe once across the indication. R (3) Allow the acetone to evaporate and inspect immediately. R**Printed in Great Britain**



# RB.211−72−AG971 Page 9 Sep 20/12 May. 5/16 R(4) If the indication reappears then record it is a crack. If the indications does not reappear then apply a light, even coating of OMat 617 non-aqueous wet developer from a sealed aerosol can to the area. R R R R (5) Allow the solvent in the developer to evaporate and inspect immediately. R R (6) If the indication reappears then record it as a crack. If the indication does not reappear then allow 10 minutes contact time for the developer. R R R (7) If the indication reappears after the 10 minutes contact time then record it as a crack. If the indication does not reappear then that area is acceptable. R R R (xxiv) The cause of all indications must be evaluated under white light using visual aids, such as magnification, as appropriate. R R (xxv) Photograph any suspected crack indications and record them in Appendix 1. R R (1) No cracks detected - Accept R (2) Any cracks less than or equal to 2mm length - Remove engine within 10 flight cycles R R (3) Any cracks greater than 2mm length - Remove engine or refer to Rolls-Royce R R
NOTE : Any findings outside the above limits can be referred to Rolls-Royce to determine if up to 10 flight cycles additional fly on can be granted in order to facilitate engine removal. R R R R

(xxvi) Post Clean - Once all indications have been evaluated and recorded, remove the penetrant processing materials from the inspection surface by wiping with a clean OMat 2/101, lint-free cloth moistened with OMat 150 acetone. R R R R (xxvii)Restore the OMat 677 penetrant test panel to a completely clean condition and make sure there is no residual fluorescence. R R (c) Close access to the tail bearing housing: R (i) Make sure the work area is clean and clear of tools and other items. R R**Printed in Great Britain**



# RB.211−72−AG971 Page 10 Sep 20/12 May. 5/16 R(ii) Close the fan exhaust cowls in accordance with AMM 78-26-00, Maintenance Practices. R R (iii) Make the thrust reverser serviceable after maintenance in accordance with AMM 78-30-00, Deactivation/Activation as necessary. R R R (iv) Close the fan exhaust cowls in accordance with AMM 71-13-00, Maintenance Practices. R R (d) Accomplishment of this Non-Modification Service Bulletin should be recorded in accordance with local SB tracking system procedures. R R (2) Eddy Current Inspection R
NOTE : FPI inspection in accordance with step 3.A.(1) is a valid alternative inspection to this eddy current procedure for the mount lug run-outs. R R R (a) Pre Inspection Calibration R (i) Check the equipment before use for any signs of wear or damage and, if necessary, rectify before use. R R (ii) Use the following nominal instrument settings for the initial setup: R R - Frequency - 2 MHz R - Gain - 40 dB R - Angle - 250 deg. R - Low Pass Filter - 65 Hz R - High Pass Filter - Static R - Spot Position - Centre R (iii) Apply a strip of PTFE (OMat 2/30) tape along the length of the working standard, HU82372, on the edge containing the EDM notch (Fig.3) and apply a disc of PTFE tape on the face of the eddy current probe (Fig.4). R R R R Make sure that there are no creases in the tape as this will cause the probe to move away from the surface and produce lift-off signals. R R R The disc of PTFE tape on the eddy current probe must not extend over the edge of the probe face as this will affect the ability of the spring loaded mechanism to compress. R R R**Printed in Great Britain**



# RB.211−72−AG971 Page 11 Sep 20/12 May. 5/16 R(iv) Place the probe on the edge of the working standard containing the EDM notch. Make sure the probe is away from the EDM notch (see Fig.5) and then balance the instrument. Make sure the probe is at 45 degrees to the corner and the spring is fully compressed (see Fig.6). R R R R R (v) Slide the probe over the 1 mm x 1 mm corner EDM notch and identify the signal on the eddy current instrument display. The scanning speed must be between 15 mm per second and 30 mm per second. R R R R (vi) Make sure that the probe is kept at 45 degrees to the corner with the spring fully compressed (see Fig.6). If the probe is off-axis then the phase angle and signal amplitude will be affected. R R R R (vii) Adjust the phase angle so that the signal rises and falls vertically from the centre of the screen. R R (viii) Adjust the gain so that the signal amplitude covers 80 per cent of the full screen height, see Fig.7. R R (b) Inspection R (i) Using suitable staging, access the Tail Bearing Housing Mount Lug Run-Out inspection areas (see Fig.1 for the inspection areas). Both edges of all 4 Mount Lug Run-Outs are to be inspected. R R R R (ii) Remove any loose dirt and debris from the inspection areas with an OMat 2/101 - Lint-free cloth in order to allow PTFE tape to adhere well to the inspection surface. R R R (iii) Make sure the inspection area is clean, dry and free from contaminants that could affect process performance. R R (iv) Place PTFE tape along each of the eight edges of the Mount Lug Run-Outs requiring eddy current inspection (see Fig.8). Make sure that the full 120 mm of the inspection area is covered by the tape by applying it 20 mm beyond each end of the inspection area and make sure that there are no creases in the tape that would provide lift-off signals. R R R R R R (v) Check the condition of the tape on the eddy current probe face. If it is torn or damaged then replace it before continuing with the inspection. R R R**Printed in Great Britain**



# RB.211−72−AG971 Page 12 Sep 20/12 May. 5/16 R(vi) Place the probe on the edge of the first Mount Lug Run-Out (see Fig.8) and balance the instrument. Make sure that the probe is kept at 45 degrees to the edge with the spring fully compressed (see Fig.6). If the probe is off-axis then the phase angle and signal amplitude will be affected. R R R R R (vii) Slide the probe along the edge of the Mount Lug Run-Out, covering the full extent of the inspection area. The scanning speed must be between 15 mm per second and 30 mm per second. R R R (viii) Monitor the instrument display for any indications. R
NOTE: Crack signals will appear as a figure-of-eight rising and falling vertically from the centre of the screen, as seen on the working standard during calibration, see Fig.7. R R R
NOTE : Indications of mechanical damage, for example burrs or grooves, may also produce indications. These indications will have a different phase angle that is aligned further from the vertical axis and will often be a wider figure-of-eight or a single loop, some examples are shown in Fig.9. R R R R R R (ix) If there are tears or damage to the tape on the Mount Lug Run-Outs or on the probe face then the tape must be replaced before continuing the inspection in order to avoid damage to the probe. R R R R (x) Repeat the inspection for the remaining seven Mount Lug Run-Out corners. R R (xi) Mark the location of any crack indications. R (c) Post Inspection Calibration R (i) Make sure the PTFE tape is still in place and in good condition on the corner of the working standard, HU82372, and on the probe face. If not, replace the tape prior to the post inspection calibration and make sure there are no creases. R R R R (ii) Place the probe on the edge of the working standard containing the EDM notch. Make sure the probe is away from the EDM notch (Fig.5) and then balance the instrument. Make sure the probe is at 45 degrees to the corner and the spring is fully compressed (see Fig.6). R R R R R (iii) Slide the probe over the 1 mm x 1 mm corner EDM notch and identify the signal on the eddy current instrument display. The scanning speed must be between 15 mm per second and 30 mm per second. R R R R**Printed in Great Britain**



# RB.211−72−AG971 Page 13 Sep 20/12 May. 5/16 R(iv) Make sure that the probe is kept at 45 degrees to the corner with the spring fully compressed (see Fig.6). If the probe is off-axis then the phase angle and signal amplitude will be affected. R R R R (v) Check that the signal from the EDM notch is still 80 per cent full screen height, as seen in Fig.7. If the signal is less than 80 per cent full screen height, then the equipment must be recalibrated and the inspection repeated. R R R R (d) Accept/Reject R (i) Any indications leading to a signal with an amplitude less than 50 per cent full screen height - Accept R R (ii) Any crack indications leading to a signal with an amplitude of 50 per cent full screen height or more (see Fig.10) - Remove engine or refer to Rolls-Royce. R R R
NOTE: Crack indications will rise and fall vertically from the centre of the screen with a similar form to the signal from the EDM notch in the working standard and will be repeatable. R R R R
NOTE : Any findings outside the above limits can be referred to Rolls-Royce to determine if up to 10 flight cycles additional fly on can be granted in order to facilitate engine removal. R R R R (e) Photograph any suspected crack indications and record them in Appendix 1. R R B. In-shop - Localised Mount Lug Run-outs Inspection R (1) Flourescent Penetrant Inspection R (a) Carry out the inspection on the mount lug run-outs (local inspection only) R R
NOTE : Eddy current inspections in accordance with step 3.B.(2) is a valid alternative inspection method to the local FPI of the mount lug run-outs. R R R
WARNING : PROTECTIVE GLOVES AND SAFETY GLASSES MUST BE WORN AT ALL TIMES DURING THE INSPECTION. IF YOU GET AN INJURY, SEEK MEDICAL AID IMMEDIATELY R R R (i) This inspection must be performed in accordance with the requirements of 70-00-00 Overhaul Process 210, Fluorescent Penetrant Inspection. R R R**Printed in Great Britain**



# RB.211−72−AG971 Page 14 Sep 20/12 May. 5/16 R(ii) Clean the inspection areas (see Fig.1) with a clean OMat 2/101 lint-free cloth moistened with OMat 150 acetone. R R (iii) Discard the soiled cloth after use. R (iv) Repeat the swabbing using fresh OMat 150 acetone and a fresh OMat 2/101 lint-free cloth until all deposits have been removed. R R R
NOTE: The inspection surface, must be clean, dry and free from soils, oil, grease, paint, coatings, corrosion products, scale, smeared metal, welding flux, chemical residues or any other material that could prevent penetrant from entering a discontinuity, affect process performance or produce an unacceptable background. R R R R R R (v) Allow five minutes for the area to completely dry prior to penetrant application. R R (vi) Penetrant application - Apply OMat 651 penetrant to the inspection areas (see Fig.1) by brush or sponge applicator. The penetrant must be dispensed from a sealed aerosol can and any unused penetrant must go to waste. R R R R (vii) Make sure that the inspection area is fully covered with penetrant with the aid of a UV lamp. R R (viii) Apply OMat 651 penetrant to the OMat 677 penetrant test panel. R (ix) Leave the penetrant in contact with the components for 30 minutes. R R
NOTE : The penetrant contact time must not exceed one hour. If it does, the penetrant must be re-applied and 5 minutes contact time allowed. R R R (x) Penetrant Removal - After the 30 minutes contact time, remove the excess penetrant from the inspection surface and the OMat 677 penetrant test panel by wiping thoroughly with a clean OMat 2/101 lint-free cloth. R R R R (xi) Whilst illuminating with UV light, wipe off the penetrant with a clean OMat 2/101 lint-free cloth moistened with OMat 150 acetone. Use the minimum application necessary to achieve acceptable background fluorescence and make sure that acetone is not allowed to flow on the inspection surface. R R R R R (xii) Make sure that all traces of the OMat 150 acetone have been completely removed. R R**Printed in Great Britain**



# RB.211−72−AG971 Page 15 Sep 20/12 May. 5/16 R(xiii) Develop - Apply a light, even coating of OMat 617 non-aqueous wet developer from a sealed aerosol can to the inspection area and the OMat 677 penetrant test panel. R R R (xiv) Allow 10 minutes contact time for the developer prior to inspection. R R (xv) Cover the region of the engine with a dark non-reflective cover in order to reduce the white light levels. R R (xvi) Make sure there are no white light sources or fluorescent items (including clothing) within the inspection area or the inspector's field of vision. R R R (xvii) Do not wear darkened or light sensitive glasses. R (xviii)Allow one minute for eye adaptation to the darkened area. R (xix) Illuminate the OMat 677 penetrant test panel in the darkened area with one of the allowed UV light sources listed in 1.H. Tooling Price and Availability. R R R (xx) Inspect the OMat 677 penetrant test panel and check that the four largest indications are visible and match the control photograph for that individual panel. R R R (xxi) Illuminate the inspection surface with the same UV light in the darkened area. R R (xxii) Inspect the mount lug run-outs for crack indications. R (xxiii)The Wipe Off technique can be used to aid the evaluation of any indications: R R (1) Dampen a cotton swab with acetone. R (2) Wipe once across the indication. R (3) Allow the acetone to evaporate and inspect immediately. R (4) If the indication reappears then record it is a crack. If the indications does not reappear then apply a light, even coating of OMat 617 non-aqueous wet developer from a sealed aerosol can to the area. R R R R (5) Allow the solvent in the developer to evaporate and inspect immediately. R R (6) If the indication reappears then record it as a crack. If the indication does not reappear then allow 10 minutes contact time for the developer. R R R**Printed in Great Britain**



# RB.211−72−AG971 Page 16 Sep 20/12 May. 5/16 R(7) If the indication reappears after the 10 minutes contact time then record it as a crack. If the indication does not reappear then that area is acceptable. R R R (xxiv) The cause of all indications must be evaluated under white light using visual aids, such as magnification, as appropriate. R R (xxv) Photograph any suspected crack indications and record them in Appendix 1. R R (1) No cracks detected - Accept R (2) Any cracks detected - Reject R (xxvi) Post Clean - Once all indications have been evaluated and recorded, remove the penetrant processing materials from the inspection surface by wiping with a clean OMat 2/101, lint-free cloth moistened with OMat 150 acetone. R R R R (xxvii)Restore the OMat 677 penetrant test panels to a completely clean condition and make sure there is no residual fluorescence. R R R (2) Eddy Current Inspection R
NOTE: FPI inspection in accordance with step 3.B.(1) is a valid alternative inspection to this eddy current procedure for the mount lug run-outs. R R R (a) Pre Inspection Calibration R (i) Check the equipment before use for any signs of wear or damage and, if necessary, rectify before use. R R (ii) Use the following nominal instrument settings for the initial setup: R R - Frequency - 2 MHz R - Gain - 40 dB R - Angle - 250 deg. R - Low Pass Filter - 65 Hz R - High Pass Filter - Static R - Spot Position - Centre R**Printed in Great Britain**



# RB.211−72−AG971 Page 17 Sep 20/12 May. 5/16 R(iii) Apply a strip of PTFE tape along the length of the working standard, HU82372, on the edge containing the EDM notch (Fig.3) and apply a disc of PTFE tape on the face of the eddy current probe (Fig.4). R R R R Make sure that there are no creases in the tape as this will cause the probe to move away from the surface and produce lift-off signals. R R R The disc of PTFE tape on the eddy current probe must not extend over the edge of the probe face as this will affect the ability of the spring loaded mechanism to compress. R R R (iv) Place the probe on the edge of the working standard containing the EDM notch. Make sure the probe is away from the EDM notch (see Fig.5) and then balance the instrument. Make sure the probe is at 45 degrees to the corner and the spring is fully compressed (see Fig.6). R R R R R (v) Slide the probe over the 1 mm x 1 mm corner EDM notch and identify the signal on the eddy current instrument display. The scanning speed must be between 15 mm per second and 30 mm per second. R R R R (vi) Make sure that the probe is kept at 45 degrees to the corner with the spring fully compressed (see Fig.6). If the probe is off-axis then the phase angle and signal amplitude will be affected. R R R R (vii) Adjust the phase angle so that the signal rises and falls vertically from the centre of the screen. R R (viii) Adjust the gain so that the signal amplitude covers 80 per cent of the full screen height, see Fig.7. R R (b) Inspection R (i) Using suitable staging, access the Tail Bearing Housing Mount Lug Run-Out inspection areas (see Fig.1 for the inspection areas). Both edges of all 4 Mount Lug Run-Outs are to be inspected. R R R R (ii) Remove any loose dirt and debris from the inspection areas with an OMat 2/101 - Lint-free cloth in order to allow PTFE tape to adhere well to the inspection surface. R R R (iii) Make sure the inspection area is clean, dry and free from contaminants that could affect process performance. R R**Printed in Great Britain**



# RB.211−72−AG971 Page 18 Sep 20/12 May. 5/16 R(iv) Place PTFE tape along each of the eight edges of the Mount Lug Run-Outs requiring eddy current inspection (see Fig.8). Make sure that the full 120 mm of the inspection area is covered by the tape by applying it 20 mm beyond each end of the inspection area and make sure that there are no creases in the tape that would provide lift-off signals. R R R R R R (v) Check the condition of the tape on the eddy current probe face. If it is torn or damaged then replace it before continuing with the inspection. R R R (vi) Place the probe on the edge of the first Mount Lug Run-Out (see Fig.9) and balance the instrument. Make sure that the probe is kept at 45 degrees to the edge with the spring fully compressed (see Fig.6). If the probe is off-axis then the phase angle and signal amplitude will be affected. R R R R R (vii) Slide the probe along the edge of the Mount Lug Run-Out, covering the full extent of the inspection area. The scanning speed must be between 15 mm per second and 30 mm per second. R R R (viii) Monitor the instrument display for any indications. R
NOTE: Crack signals will appear as a figure-of-eight rising and falling vertically from the centre of the screen, as seen on the working standard during calibration, see Fig.7. R R R
NOTE : Indications of mechanical damage, for example burrs or grooves, may also produce indications. These indications will have a different phase angle that is aligned further from the vertical axis and will often be a wider figure-of-eight or a single loop, some examples are shown in Fig.10. R R R R R R (ix) If there are tears or damage to the tape on the Mount Lug Run-Outs or on the probe face then the tape must be replaced before continuing the inspection in order to avoid damage to the probe. R R R R (x) Repeat the inspection for the remaining seven Mount Lug Run-Out corners. R R (xi) Mark the location of any crack indications. R (c) Post Inspection Calibration R (i) Make sure the PTFE tape is still in place and in good condition on the corner of the working standard, HU82372, and on the probe face. If not, replace the tape prior to the post inspection calibration and make sure there are no creases. R R R R**Printed in Great Britain**



# RB.211−72−AG971 Page 19 Sep 20/12 May. 5/16 R(ii) Place the probe on the edge of the working standard containing the EDM notch. Make sure the probe is away from the EDM notch (Fig.5) and then balance the instrument. Make sure the probe is at 45 degrees to the corner and the spring is fully compressed (see Fig.6). R R R R R (iii) Slide the probe over the 1 mm x 1 mm corner EDM notch and identify the signal on the eddy current instrument display. The scanning speed must be between 15 mm per second and 30 mm per second. R R R R (iv) Make sure that the probe is kept at 45 degrees to the corner with the spring fully compressed (see Fig.6). If the probe is off-axis then the phase angle and signal amplitude will be affected. R R R R (v) Check that the signal from the EDM notch is still 80 per cent full screen height, as seen in Fig.7. If the signal is less than 80 per cent full screen height, then the equipment must be recalibrated and the inspection repeated. R R R R (d) Accept/Reject R (i) Any indications leading to a signal with an amplitude less than 50 per cent full screen height - Accept R R (ii) Any crack indications leading to a signal with an amplitude of 50 per cent full screen height or more (see Fig.10) - Reject. R R
NOTE: Crack indications will rise and fall vertically from the centre of the screen with a similar form to the signal from the EDM notch in the working standard and will be repeatable. R R R R (e) Photograph any suspected crack indications and record them in Appendix 1. R R (3) Accomplishment of this Non-Modification Service Bulletin should be recorded in the engine log book. R R C. In-shop - Top Core Vanes, Mount Lug Run-outs and Central Male Catcher Run-out Inspection through Full FPI of the TBH R R (1) Carry out the inspection on the Top Core Vanes (TCV) and mount lug run-outs and central male catcher run-out. R R (a) Remove the tail bearing housing in accordance with Engine Data Task 72-52-00-030-802, Disassemble the LP Turbine. R R**Printed in Great Britain**



# RB.211−72−AG971 Page 20 Sep 20/12 May. 5/16 R(b) Disassemble the TBH in accordance with Engine Data Task 72-52-50-040-801, Disassemble the LP Turbine Bearing Housing (TBH) Support and Exhaust Case. R R R (c) Clean the TBH in accordance with Overhaul Process 134, Acidic Descalers, Subtask 70-00-00-110-134-002: R R (i) In accordance with Subtask 70-00-00-110-134-002, Degrease the part in accordance with Overhaul Process 102, Primary Cleaning Aqueous. R R R (ii) In accordance with Subtask 70-00-00-110-134-002, perform the optional Alkali Derust in accordance with Overhaul Process 121, Alkaline Derusting and Descaling, Subtask 70-00-00-110-121-001. R R R (iii) In accordance with remainder of Subtask 70-00-00-110-134-002, perform the Acidic Descale (step 1), Scale Condition Acidic Descale (step 2). R R R (d) Carry out a full FPI crack test in line with Cleaning/Inspection and Repair Data Task 72-52-51-200-801, Subtask 72-52-51-230-023. Use a high sensitivity penetrant as the minimum sensitivity. R R R (e) Inspect the entire TBH for crack indications, including the areas for the mount lug run-outs highlighted in Fig.1 and the areas of the TCV and the areas of the central male catcher highlighted in Fig.2. R R R (f) Record inspection results and any crack indications in Appendix 1. R (i) No Cracks R ACCEPT R (ii) Cracks on the Mount Lug Leading Edge area of Vanes 1 or 14 R R R REJECT or repair in accordance with CIR Task 72-52-51-300-023 and repeat a local flourescent penetrant crack test of this area. Use OMat 632 flourescent penetrant, high sensitivity water washable. Refer to OP Task 70-00-00-200-210. Reject if cracked. R R R R R R R R (iii) Cracks on any other location R R REJECT

(2) Accomplishment of this Non-Modification Service Bulletin should be recorded in the engine log book. R R**Printed in Great Britain**



# RB.211−72−AG971 Page 21 Sep 20/12 May. 5/16 Rdeh0014561 

## A



## A **B**

**C**

5.0 mm (0.20 in) 

## B 60.0 mm (2.36 in) INSPECTION AREAS

IN ADDITION APPROXIMATELY

5.0 mm (0.20 in) COVERAGE

IS REQUIRED AROUND THE CORNERS 120.0 mm (4.72 in) 

## B

THE 4 EDGES OF THE MOUNT LUGS ON BOTH SIDES OF THE TBH MUST BE INSPECTED R

Mount Lug Run Outs - Inspection Areas R Fig.1 R**Printed in Great Britain**



# RB.211−72−AG971 Page 22 Sep 20/12 May. 5/16 Rdeh0013071 TOP CORE VANES



## C REQUIRING INSPECTION CENTRAL MALE CATCHER RUN OUT AREA

R

Top Core Vanes Requiring Inspection R Fig.2 R**Printed in Great Britain**



# RB.211−72−AG971 Page 23 Sep 20/12 May. 5/16 Rdeh0014396 WORKING STANDARD HU82372

EDM NOTCH

PTFE TAPE ALONG THE EDGE R

Apply a strip of PTFE Tape along the Edge of the Working Standard containing the EDM Notch R Fig.3 R**Printed in Great Britain**



# RB.211−72−AG971 Page 24 Sep 20/12 May. 5/16 Rdeh0014397 PTFE TAPE ACROSS THE PROBE FACE AND NOT EXTENDING OVER THE EDGES

ROHMANN EDDY CURRENT PROBE

KD−1 H−373.01E

R

Apply a Disc of PTFE Tape across the Probe Face R Fig.4 R**Printed in Great Britain**



# RB.211−72−AG971 Page 25 Sep 20/12 May. 5/16 Rdeh0014398 WORKING STANDARD HU82372

EDM NOTCH PROBE PLACED ON THE EDGE AWAY FROM THE EDM NOTCH

R

Place the Probe on the Edge of the Working Standard and Balance the Instrument R Fig.5 R**Printed in Great Britain**



# RB.211−72−AG971 Page 26 Sep 20/12 May. 5/16 Rdeh0014399 WORKING STANDARD/ COMPONENT EDDY CURRENT PROBE

R

The Probe must be fully Pressed on to the Edge R Fig.6 R**Printed in Great Britain**



# RB.211−72−AG971 Page 27 Sep 20/12 May. 5/16 Rdeh0014400a 100%

0 100%

80%

80% R

Gain adjusted so that the Signal Amplitude covers 80 per cent of the Full Screen Height R Fig.7 R**Printed in Great Britain**



# RB.211−72−AG971 Page 28 Sep 20/12 May. 5/16 Rdeh0014402 PTFE TAPE ON BOTH EDGES OF THE MOUNT LUG RUN OUTS

PROBE PLACED ON THE EDGE R

Place the Probe on the Edge of the Mount Lug Run-Out R Fig.8 R**Printed in Great Britain**



# RB.211−72−AG971 Page 29 Sep 20/12 May. 5/16 Rdeh0014403 INDICATIONS OF MECHANICAL DAMAGE WILL HAVE A PHASE ANGLE

ALIGNED FURTHER FROM

VERTIVAL AXIS THAN A

CRACK INDICATION INDICATIONS OF MECHANICAL DAMAGE WILL HAVE A PHASE ANGLE

ALIGNED FURTHER FROM

VERTIVAL AXIS THAN A

CRACK INDICATION

R

Examples of Signals that may be caused by Mechanical Damage R Fig.9 R**Printed in Great Britain**



# RB.211−72−AG971 Page 30 Sep 20/12 May. 5/16 Rdeh0014404a 100%

0 100%

50%

50% R

Reject Crack Indications of 50 Per cent Full Screen Height or Greater R Fig.10 R**Printed in Great Britain**



# RB.211−72−AG971 Page 31 Sep 20/12 May. 5/16 RThis form (or similar) is to be completed for every component. Results and photographs to be sent to Rolls-Royce via your Service Representative.

Feedback Sheet NMSB 72-AG971 Overhaul Base Operator Engine Mark Date of Inspection Engine Serial Number Engine Hours Since New Engine Cycles Since New 08 Module Serial Number

08 Module Hours Since new

08 Module Cycles Since New Component Part Number / Component Serial Number Component Hours Since New / Component Cycles Since New Inspection Result and Comments On-wing Inspection of Mount Lug Run-outs (if applicable)

In-shop Inspection of Mount Lug Run-outs (if applicable)

In-shop Inspection of Top Core Vanes and central male catcher run-out R R (if applicable)

In-shop Inspection of Fail Safe Catcher (if applicable)

Any other finding during In-shop Inspection (Full FPI) APPENDIX 1**Printed in Great Britain**



# RB.211−72−AG971 Appendix 1 - Page 1 of 1 Sep 20/12 May. 5/16 R