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 2
1. 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

R confirm intact capability, an on-wing and in-shop inspection regime was 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

R limited to 17200 cycles to make sure it did not enter in fail safe mode. was

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.

R issued to provide additional clarity for some of Revision 1 of this NMSB was

the materials, tooling and cleaning tasks associated with inspections. It also

R the acceptance criteria for the on-wing inspections (section 3.A.(2)) revised

R the inspection of the fail safe catcher in-shop to inform root and introduced

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

R May. 5/16
R (1) On-wing or in-shop TBH mount lug run-out inspections which are required on

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

R local eddy current or through a full FPI of the TBH. using a local FPI,

R In shop the top core vanes and central male catcher runout 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

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

R Directive AD 2013-0240.

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

R May. 5/16
(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)

R (b) Time to inspect TBH Mount Lug Run-outs (FPI Method)

3 hours (2 persons)

R (c) Time to inspect TBH Mount Lug Run-outs (Eddy Current Method)

R 1 hour (1 person)

(d) Time to restore to serviceable condition

1 hour (1 person)

Printed in Great Britain

RB.211−72−AG971

Page 3

Sep 20/12

R May. 5/16
(2) In-shop:

R (a) Time to locally inspect TBH Mount Lug Run-outs (FPI Method)

2 hours (2 persons)

R (b) Time to locally inspect TBH Mount Lug Run-outs (Eddy Currrent Method)

R 1 hour (1 person)

(c) Inspection of TBH through full FPI

Level 2 workscope

R shall only be performed by personnel qualified to The FPI defined in this NMSB

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

R (1) For Local FPI

Material/

Compounds

R

R

Description

OMat 651

(Aerosol)

R

R

Aerosol penetrant - Commercially available

OMat 617

(Aerosol)

R

R

Aerosol Developer - Commercially available

R OMat 150 Acetone

R OMat 2/101 Lint-Free Cloth

R OMat 677 Penetrant Test Panel

R (2) For Eddy Current

Material/

Compounds

R

R

Description

R OMat 2/30 PTFE Tape - Minimum width of 10 mm

H. Tooling Price and Availability

R (1) For Local FPI

Material/

Compounds

R

R

Description

Printed in Great Britain

RB.211−72−AG971

Page 4

Sep 20/12

R May. 5/16
Dark

Non-reflective

cover

R

R

R

To darken the area for inspection - Commercially

available

Ultra Violet (UV)

light source

R

R

R 2 alternatives

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

R (2) For Eddy Current

Material/

Compounds

R

R

Description

R HU82371 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

R May. 5/16
2. Material Information

A. None

Printed in Great Britain

RB.211−72−AG971

Page 6

Sep 20/12

R Sep.27/13
3. Accomplishment Instructions

R A. On-wing - Localised Mount Lug Run-outs Inspection

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

R (1) Flourescent Penetrant Inspection

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

R (a) To get access to the Tail Bearing Housing (TBH) mount lug run-outs:

(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

R (iv) Use appropriate staging to gain access to the TBH.

R (b) Carry out the inspection on the mount lug run-outs:

Printed in Great Britain

RB.211−72−AG971

Page 7

Sep 20/12

R May. 5/16
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 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

R (iii) Discard the soiled cloth after use.

(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

R (viii) Apply OMat 651 penetrant to the OMat 677 penetrant test panel.

(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

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(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

R (xvii) Do not wear darkened or light sensitive glasses.

R (xviii)Allow one minute for eye adaptation to the darkened area.

(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

R (xxii) Inspect the mount lug run-outs for crack indications.

(xxiii)The Wipe Off technique can be used to aid the evaluation of any

indications:

R

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.

Printed in Great Britain

RB.211−72−AG971

Page 9

Sep 20/12

R May. 5/16
(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

R (1) No cracks detected - Accept

(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

R (c) Close access to the tail bearing housing:

(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

R May. 5/16
(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

R (2) Eddy Current Inspection

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

R (a) Pre Inspection Calibration

(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

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

(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

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(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

R (b) Inspection

(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

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(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

R (viii) Monitor the instrument display for any indications.

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

R (xi) Mark the location of any crack indications.

R (c) Post Inspection Calibration

(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

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(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

R (d) Accept/Reject

(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

R B. In-shop - Localised Mount Lug Run-outs Inspection

R (1) Flourescent Penetrant Inspection

(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

R May. 5/16
(ii) Clean the inspection areas (see Fig.1) with a clean OMat 2/101

lint-free cloth moistened with OMat 150 acetone.

R

R

R (iii) Discard the soiled cloth after use.

(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

R (viii) Apply OMat 651 penetrant to the OMat 677 penetrant test panel.

(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

R May. 5/16
(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

R (xvii) Do not wear darkened or light sensitive glasses.

R (xviii)Allow one minute for eye adaptation to the darkened area.

(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

R (xxii) Inspect the mount lug run-outs for crack indications.

(xxiii)The Wipe Off technique can be used to aid the evaluation of any

indications:

R

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.

(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

R May. 5/16
(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

R (1) No cracks detected - Accept

R (2) Any cracks detected - Reject

(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

R (2) Eddy Current Inspection

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

R (a) Pre Inspection Calibration

(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

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

Printed in Great Britain

RB.211−72−AG971

Page 17

Sep 20/12

R May. 5/16
(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

R (b) Inspection

(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

R May. 5/16
(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

R (viii) Monitor the instrument display for any indications.

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

R (xi) Mark the location of any crack indications.

R (c) Post Inspection Calibration

(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

R May. 5/16
(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

R (d) Accept/Reject

(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

R May. 5/16
(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

R (f) Record inspection results and any crack indications in Appendix 1.

R ACCEPT R (i) No Cracks

(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

R May. 5/16
deh0014561

A

A

B

C

5.0 mm

B (0.20 in)

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

R Mount Lug Run Outs - Inspection Areas

R Fig.1

Printed in Great Britain

RB.211−72−AG971

Page 22

Sep 20/12

R May. 5/16
deh0013071

TOP CORE VANES

C

REQUIRING

INSPECTION

CENTRAL MALE

CATCHER RUN OUT AREA

R

R Top Core Vanes Requiring Inspection

R Fig.2

Printed in Great Britain

RB.211−72−AG971

Page 23

Sep 20/12

R May. 5/16
deh0014396

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

R Fig.3

Printed in Great Britain

RB.211−72−AG971

Page 24

Sep 20/12

R May. 5/16
deh0014397

PTFE TAPE

ACROSS THE PROBE FACE

AND NOT EXTENDING OVER

THE EDGES

ROHMANN EDDY

CURRENT PROBE

KD−1 H−373.01E

R

R Apply a Disc of PTFE Tape across the Probe Face

R Fig.4

Printed in Great Britain

RB.211−72−AG971

Page 25

Sep 20/12

R May. 5/16
deh0014398

WORKING STANDARD

HU82372

EDM NOTCH

PROBE PLACED

ON THE EDGE

AWAY FROM THE

EDM NOTCH

R

R Place the Probe on the Edge of the Working Standard and Balance the Instrument

R Fig.5

Printed in Great Britain

RB.211−72−AG971

Page 26

Sep 20/12

R May. 5/16
deh0014399

WORKING STANDARD/

COMPONENT

EDDY CURRENT

PROBE

R

R The Probe must be fully Pressed on to the Edge

R Fig.6

Printed in Great Britain

RB.211−72−AG971

Page 27

Sep 20/12

R May. 5/16
deh0014400a

100%

0

100%

80%

80%

R

Gain adjusted so that the Signal Amplitude covers 80 per cent of the Full Screen

Height R

R Fig.7

Printed in Great Britain

RB.211−72−AG971

Page 28

Sep 20/12

R May. 5/16
deh0014402

PTFE TAPE ON

BOTH EDGES OF THE

MOUNT LUG RUN OUTS

PROBE PLACED

ON THE EDGE

R

R Place the Probe on the Edge of the Mount Lug Run-Out

R Fig.8

Printed in Great Britain

RB.211−72−AG971

Page 29

Sep 20/12

R May. 5/16
deh0014403

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

R Examples of Signals that may be caused by Mechanical Damage

R Fig.9

Printed in Great Britain

RB.211−72−AG971

Page 30

Sep 20/12

R May. 5/16
deh0014404a

100%

0

100%

50%

50%

R

R Reject Crack Indications of 50 Per cent Full Screen Height or Greater

R Fig.10

Printed in Great Britain

RB.211−72−AG971

Page 31

Sep 20/12

R May. 5/16
This 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

R May. 5/16