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 Britain 
LIST 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.9/10

Printed in Great Britain

RB.211−72−AG456

Transmittal - Page 2
1. 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-AG456

Printed in Great Britain

RB.211−72−AG456

Page 1 of 11

Sep. 9/10

Sep. 9/10
This 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 hours

Printed in Great Britain

RB.211−72−AG456

Page 2

Sep. 9/10

Sep. 9/10
G. 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/Check

Printed in Great Britain

RB.211−72−AG456

Page 3

Sep. 9/10

Sep. 9/10
2. Material Information

None

Printed in Great Britain

RB.211−72−AG456

Page 4

Sep. 9/10

Sep. 9/10

RB211 

SERVICE 

BULLETIN 

PROPULSION 

SYSTEM 

© Rolis-Royee pie 
3. 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. 9/10
C. 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. 9/10
D. A record of accomplishment is required.

Printed in Great Britain

RB.211−72−AG456

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Sep. 9/10

Sep. 9/10

RB211 

SERVICE 

BULLETIN 

PROPULSION 

SYSTEM 

© Rolis-Royee pie 
Borescope Inspection Route - View Through Borescope (A) and Location of Cracks

Fig.1

Printed 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 

+ 

HEADSECTION 

~ ~ ~~ L ~~ERWALL 

HEATSHIELD TILE COMBUSTION 

LlNER 

~~ 

CRACK/ 

LOCATION HEATSHIELD LIP 

© Rolis-Royee pie 

dee0009123 
Example of Borescope Front and Side Views Showing Area of Cracking

Fig.2

Printed in Great Britain

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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 

dee0009124 
Example of Cracking with Heatshields Removed

Fig.3

Printed 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 

© Rolis-Royce pie 

dee0009125