r::: P.O. Box 31, DERBY DE24 8BJ, UK Telephone: 44 (0) 1332242424 Fax: 44 (0) 1332249936 

# II Roiis-Royce
PUB L CAT 

# o N TRA N 

# S M T TAL
The technical information contained in this document has been approved under the authority of

- See Planning Information, Approval.

Signed Date 

### Sep. 9/1 0
N. J. Wright



### RB211 TRENT 800 SERIES PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN 

# ALERT

This document transmits the InitiaL Issue of Service BuLLetin RB211-72-AG456 BuLLetin InitiaL Issue Remove Incorporate Pages 1 to 11 of the Service Bulletin



# ALERT Reason for change InitiaL issue



# RB.211-72-AG456 TransmittaL

- Page 1 of 2

CHECK THAT ALL PREVIOUS TRANSMITTALS HAVE BEEN INCORPORATED lf any have not been reeeived please advise Customer Data Services, Rolls-Royee pie, Derby, England © Rolls-Royee pie (date as above) Printed in Great BritainLIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin are as follows: Page Revision Number Revision Date

Bulletin 1 Sep.9/10 2 Sep.9/10 3 Sep.9/10 4 Sep.9/10 5 Sep.9/10 6 Sep.9/10 7 Sep.9/10 8 Sep.9/10 9 Sep.9/10 10 Sep.9/10 11 Sep.9/10Printed in Great Britain



# RB.211−72−AG456 Transmittal - Page 21. Planning Information A. Effectivity Boeing 777 All RB211 TRENT 875-17, 877-17, 884-17, 884B-17, 892-17, 892B-17 and 895-17 Engines.
B. Reason Cracking has been found on the head sections of two Trent 800 front combustion liners during routine inspection at shop visit. The lives of the cracked combustion liners were 1997 cycles and 7332 cycles since new. Laboratory investigation concluded that the cracking had propagated circumferentially. Analysis shows that cracking in this position could ultimately result in hot gas breakout with the potential for downstream component distress. Although there is already a Maintenance Planning Document (MPD) requirement to borescope inspect the front combustion liner, this does not cover the front combustion liner head section area. Non-Modification Service Bulletin (NMSB) 72-AG073 was initially issued in May 2009 for a once around the fleet inspection of all engines incorporating the affected type of combustor. The results from the inspection have been used to complete a numerical risk assessment which shows the crack mechanism to be age independent. C. Description This NMSB is issued to instruct a repeat inspection of the front combustion liner head section for cracking and to provide acceptance limits and revised inspection intervals in the event of such cracking being found. Repeat inspection intervals have been based on current FCL inspection intervals in line with MPD requirements and NMSB 72-AF458. Accomplishment of this NMSB must be recorded in the engine/module log book. Provide details of any cracking found during these inspections. The details should include combustor head section life and description of the crack size(s) and circumferential location(s). The information should be returned to Rolls-Royce Technical Services via your local field service representatives. D. Compliance
ALERT

ENGINE - REPEAT BORESCOPE INSPECTION OF FRONT COMBUSTION LINER HEAD SECTION NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-AG456Printed in Great Britain



# RB.211−72−AG456 Page 1 of 11 Sep. 9/10 Sep. 9/10This Non-Modification Service Bulletin is anticipated to be the subject of an EASA Airworthiness Directive (AD). Carry out the action specified in 3. Accomplishment Instructions. It is recommended that the inspections are aligned where possible with existing scheduled combustion liner borescope inspections. On-wing (1) All Trent 800 variants listed in 1.A. Effectivity (a) Inspect in accordance with 3.A. On-wing Accomplishment Instructions. (i) Initial inspection within 1000 cycles of the issue date of this NMSB. (ii) Repeat inspections at intervals not exceeding 2000 cycles since last inspection or since shop visit. In-shop (1) All Trent 800 variants listed in 1.A. Effectivity (a) Inspect in accordance with 3.B. In-shop Accomplishment Instructions at each shop visit. 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.6/10. F. Manpower (1) Manpower 2 persons (2) Time to gain access 1.5 hours (3) Time to inspect 1.5 hours (4) Time to restore to serviceable condition 2 hoursPrinted in Great Britain



# RB.211−72−AG456 Page 2 Sep. 9/10 Sep. 9/10G. Material Price and Availability Not applicable. H. Tooling HU82292 Guide Tube - 1 off I. References (1) Rolls-Royce RB211 Non-Modification Service Bulletins: (a) 72-AF458 Engine - Borescope Inspection of front combustion liner inner wall (b) 72-AG073 Engine - Inspection of front combustion liner head section (2) Boeing 777 Aircraft Maintenance Manual, 72-00-00, Inspection/Check (3) Trent 800 Engine Manual, 72-00-00, Inspection/CheckPrinted in Great Britain



# RB.211−72−AG456 Page 3 Sep. 9/10 Sep. 9/102. Material Information
NonePrinted in Great Britain



# RB.211−72−AG456 Page 4 Sep. 9/10 Sep. 9/10 

# RB211
SERVICE BULLETIN PROPULSION SYSTEM



## © Rolis-Royee pie3. Accomplishment instructions A. On-Wing Accomplishment Instructions

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. (1) Carry out the inspection accessing via the combustion liner borescope ports. This procedure requires a flexible borescope no greater than 6 mm diameter with straight ahead near focus viewing tip. Gain access for the inspection in accordance with the following Aircraft Maintenance Manual procedures. (a) The following Aircraft Maintenance Manual References apply for this task: (i) Trent 800 Engines Boeing 777 Aircraft Maintenance Manual, 72-00-00, Inspection/Check Borescope inspection of combustion section (2) Use a near focus forward view tip on the flexible borescope and insert through the guide tube HU82292 so that the tip just protrudes through the curved end. Position the tube through the first borescope position to make sure the curved end points towards the inner joint of the fuel spray nozzle heatshield tile as shown in Fig.1. (3) Feed the borescope towards the gap between the heatshield tile inner edge and the Front Combustion Liner (FCL) inner wall. Refer to Fig.1. Inspect the FCL head, in the corner of the gap for cracking at this location. Refer to Fig.2. Slowly twist the guide tube and feed the borescope along the heatshield lip to inspect the FCL across 4 heatshield tiles (2 either side of the borescope port). (4) Repeat the procedure for the remaining 7 borescope port positions to make sure the FCL is inspected for cracks throughout the complete 360 degrees.
NOTE : As there are 8 borescope ports and 24 burners, there will be some overlap of the inspection, this will make sure no portions of the FCL are missed.Printed in Great Britain



# RB.211−72−AG456 Page 5 Sep. 9/10 Sep. 9/10(5) If cracking is seen, carry out repeat inspections or engine removal in accordance with Accomplishment Instructions (3.C.) for on-wing acceptance standards of this NMSB. B. In-shop Accomplishment Instructions (1) Engines where the combustion section is to be stripped, and the FCL exposed for inspection: Where the combustion section is to be stripped and the FCL exposed for inspection, inspection of the FCL head section in accordance with Engine Manual, 72-41-13, satisfies requirements of this NMSB. If any cracking is seen reject the FCL. (2) Engines where strip of the combustion section is not scheduled and the FCL is not exposed for inspection. (a) Comply with this NMSB during the existing borescope inspection at engine induction. This procedure requires a flexible borescope no greater than 6 mm diameter with straight ahead near focus viewing tip. Use the following procedures to gain access. (i) Trent 800 Engine Manual, 72-00-00, Inspection/Check (b) Use a near focus forward view tip on the flexible borescope and insert through the guide tube HU82292 so that the tip just protrudes through the curved end. Position the tube through the first borescope position to make sure the curved end points towards the inner joint of the fuel spray nozzle heatshield tile as shown in Fig.1. (c) Feed the borescope towards the gap between the heatshield tile inner edge and the FCL inner wall. Refer to Fig.1. Inspect the FCL head, in the corner of the gap for cracking at this location. Refer to Fig.2. Slowly twist the guide tube and feed the borescope along the heatshield lip to inspect the FCL across 4 heatshield tiles (2 either side of the borescope port). (d) Repeat the procedure for the remaining 7 borescope port positions to make sure the FCL is inspected for cracks throughout the complete 360 degrees. NOTE : As there are 8 borescope ports and 24 burners, there will be some overlap of the inspection, this will make sure no portions of the FCL are missed. (e) If cracking is seen, reject the FCL.Printed in Great Britain



# RB.211−72−AG456 Page 6 Sep. 9/10 Sep. 9/10C. On-wing Acceptance Standards (1) Circumferential cracking. (a) Examine the front combustion liner head section for circumferential cracking in the area immediately forward of the inner wall attaching weld as shown in Fig.1, Fig.2 and Fig.3. The fly-on and rejection criteria are shown in Table 1. CUMULATIVE CRACK LENGTH (see NOTES) ACTION
No cracking Accept No action required Cumulative crack length up to 150 mm (up to 2 heatshields) Accept Repeat inspection at intervals no more than 250 cycles

Cumulative crack length 150 mm to 300 mm (up to 4 heatshields) Accept Repeat inspection at intervals no more than 100 cycles

Cumulative crack length 300 mm to 450 mm (up to 6 heatshields) Accept Remove the engine within 50 cycles

Cumulative crack length 450 mm to 900 mm (up to 12 heatshields) Accept Remove the engine within 5 cycles

Cumulative crack length greater than 900 mm (more than 12 heatshields) Reject Remove the engine immediately

Table 1 NOTE : Count the total length of all circumferential cracks seen during inspection. The width of the heatshield tiles at the inner wall diameter is approximately 75 mm. Refer to Fig.3.Printed in Great Britain



# RB.211−72−AG456 Page 7 Sep. 9/10 Sep. 9/10D. A record of accomplishment is required.Printed in Great Britain



# RB.211−72−AG456 Page 8 Sep. 9/10 Sep. 9/10 

# RB211
SERVICE BULLETIN PROPULSION SYSTEM



## © Rolis-Royee pieBorescope Inspection Route - View Through Borescope (A) and Location of Cracks Fig.1Printed in Great Britain



# RB.211−72−AG456 Page 9 Sep. 9/10 Sep. 9/10 

## L FUELSPRAY NOZZLE



# - RB211
SERVICE BULLETIN PROPULSION SYSTEM

FEED BORESCOPE THROUGH COMBUSTION BORESCOPE PORTS AND GUlDE TUBE 

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# ~ HEADSECTION

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# L**~~ERWALL** HEATSHIELD TILE COMBUSTION LlNER

# ~~ CRACK/ LOCATION HEATSHIELD LIP



## © Rolis-Royee pie dee0009123Example of Borescope Front and Side Views Showing Area of Cracking Fig.2Printed in Great Britain



# RB.211−72−AG456 Page 10 Sep. 9/10 Sep. 9/10 

## L CRACK LOCATION 

# RB211
SERVICE BULLETIN

HEATSHIELD PROPULSION SYSTEM**.is~~~~~:::::::::::=-** HEATSHIELD

CRACK LOCATION

SIDEVIEW



## © Rolis-Royee pie LIP

dee0009124Example of Cracking with Heatshields Removed Fig.3Printed in Great Britain



# RB.211−72−AG456 Page 11 Sep. 9/10 Sep. 9/10 

## L 

# RB211
SERVICE BULLETIN PROPULSION SYSTEM

HEATSHIELD WIDTH 75mm

INNERWALL



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