# Repeater Technical Variance

© Rolls

- Royce plc (date as shown below).

The information in this document is the property of Rolls

- Royce plc and may not be copied, communicated to a third party, or

used for any purpose other than that which it is supplied without the express written consent of Rolls

- Royce plc.

This is a repeat application technical variance. It is the responsibility of the operator / overhaul base to control the application

of this document.

This document is supplemental to the Manual(s) specified below and should be suitably stored in accordance with local

airworthiness requireme nts.

Declaration of Approval

This document is approved under the authority of Airbus EASA Design Organisation Approval no. EASA.21J.031.

Refer to Repair Design Approval Sheet reference no

Rolls

- Royce plc. Proprietary Information

– Not for Manuf acture

Page 1 of 11 Pages Technical Variance No. 132043 Issue 1 Date 2 5 MAR 2013

Operator / Applicant ALL OPERATORS /

ALL APPLICANTS Original Request No. DK_08_03_2013

Engine Type RB211 Engine Mark(s) TRENT 9 00 ALL ENGINE MARKS

Part Description LP TURBINE EXHAUST CASE (TAIL BEARING HOUSING)

Part No. FW35923

, FW51434 , FW27718

Manual Title EM Ref. NA ATA Ref. 72

- 5 2

- 51

TV Title MOUNT LUG FORGING LEADING EDGE INSPECTIONS

Hours NA Cycles NA

Existing Requirement

The Engine Manual (E M) do es not contain a procedure to inspect the Tail Beari ng Housing (TBH) Mount

Lug Forging Leading Edge (LE) area for crack indications in shop

Requested Variance

Currently there is a requirement to inspect the TBH Mount Lug Forging LE area on T rent 900 engines in

shop.

NMSB72

- AH154 will follow the issue of this repeater TV and will include details of the new inspection. This

repeater TV includes the details of the inspection until NMSB72

- AH154 is finalised and issued. This

Technical Variance may be applied until 28 th June 2013

.

The results of this inspecti on are to be reported to Rolls

- Royce.

Summary of Investigation and Conclusions

Rolls

- Royce Engineering has reviewed the above requirement and a n inspection t echnique has been

developed . This TV is issued to instruct the inspection of the TBH Mount Lug Fo rging LE area

.

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 2 of 11 Pages A. Compliance

This TV should be applied on all Engines where the Module 52 is Level 1 ( Serviceability ). The inspection

should be carried out whilst the part is at module level and strip of the module to piece part is not

required.

Fo r Engines where the Module 52 is Level 2 (Check and Repair) the TV is not required as the TBH will

receive a full Fluorescent Penetrant Inspection (FPI) in accordance with NMSB 72

- AG971.

For all Engines currently in shop, this TV should be applied regardl ess of rebuild status

.

For engines that are hospital shop visit, this TV can be applied.

For all Engines not currently installed on an Aircraft and not planned for induction into an overhaul shop,

this TV can be applied

.

B

. Manpower Requirements

1 ) In Shop

(a) Time to inspect Mount Lug Forging LE Areas

2 hours (2 persons)

The FPI defined in this Technical Instruction shall only be performed by personnel qualified to Fluorescent

Penetrant Inspection 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.

C

. Material Price and Availability

OMat 632

– Aerosol p enetrant

- Commercially Available

OMat 617

– Aerosol developer

- Commercially Available

OMat 150

– Acetone

- Commercially Available

OMat 2/101

– Lint Free Cloths

- Commercially Available

OMat 677

– Penetrant Test Panel

- Commercially Available

D

. Tooling Price and Availability

Dark Non

- Ref lective cover to darken the area for inspection

– Commercially Available

UV Light source

– Commercially Available

Mirror

– Commercially Available

E

. References

(1 ) Engine Manual (EM):

(a ) 72

- 52

- 51

- 200

- 801 Cleaning/Inspection and Repair Data Task, Examine the LP

Turbine Exhaust Case.

(b ) 70

- 00

- 00, Overhaul Process 210, Fluorescent Penetrant Inspection

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 3 of 11 Pages F

. In

- Shop

– Local Inspection Mount Lug Forging LE

1) Processing the penetrant test panel

(i) The OMat 677

– penetrant test panel must be processed at the beginning of

each shift and viewed in each engine that is to be inspected during the shift in

order to ensure that the test environment and materials are acceptable.

(ii) Ensure the OMat 677

– penetrant test panel is clean and there i s no residual

fluorescence.

(iii) Cover the region of the engine to be inspected with a dark non

- reflective cover in

order to reduce the white light levels in the leading edge inspection area.

(iv) Apply OMat 632 penetrant to the OMat 677

– penetrant test panel by sponge

applicator or brush. The penetrant must be dispensed from a sealed aerosol can

and any unused penetrant must go to waste following the inspection.

(v) Leave the penetrant in contact with the panel for 20 minutes.

(vi) After t he 20 minutes contact time, take the OMat 677 penetrant test panel inside

the darkened area to process. Allow 3 minutes for eye adaptation to the low light

levels.

(vii) Remove the excess penetrant from the panel surface by wiping thoroughly with a

clea n, dry OMat 2/101

– lint free cloth whilst illuminating the panel with UV light.

(viii) Soak a clean OMat 2/10

- lint free cloth in water and then gently squeeze the

excess water out to reduce the flow of water on the panel surface.

(ix) Whilst illu minating the OMat 677

– penetrant test panel with UV light, wipe off the

penetrant with the wet cloth before immediately wiping over with a clean, dry

OMat2/10 lint free cloth. Repeat this process using the minimum application

necessary to achieve acceptab le background fluorescence.

(x) Ensure that the panel is dry by wiping with a clean, dry OMat2/10 lint free cloth.

(xi) Apply a light, even coating of OMat 617

– non

- aqueous wet developer from a

sealed aerosol can to the OMat 677

– penetrant test pan el.

(xii) Allow 10 minutes contact time for the developer prior to inspecting the panel.

(xiii) Ensure there are no white light sources or fluorescent items (including clothing)

within the darkened area.

(xiv) Hold the OMat 677

– penetrant test panel alongside the leading edge of the Top

Core Vanes and illuminate it with UV light.

(xv) Inspect the OMat 677

– penetrant test panel and check that the visible

indications match the control photograph for that panel.

(xvi) If the panel matches th e photograph then the inspection materials and

environment are acceptable and the inspections can be performed.

(xvii) Repeat steps (xiii) to (xvi) for each engine to be inspected during the shift.

Ensure that the inspection area is darkened for each e ngine.

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 4 of 11 Pages (xviii) Restore the OMat 677

– penetrant test panel to a completely clean condition and

ensure there is no residual fluorescence and store in acetone.

2) Carry out the inspection of the Mount Lug Forging LE Area

WARNING: PROTECTIVE GLOVES A ND SAFETY GLASSES MUST BE WORN AT ALL

TIMES DURING THE INSPECTION. IF YOU GET AN INJURY, SEEK MEDICAL

AID IMMEDIATELY.

(i) Clean the inspection areas (See Fig. 2) with a clean OMat 2/101

– lint free cloth

moistened with OMat 150

– acetone.

(ii) Discar d the soiled cloth after use.

(iii) Repeat the swabbing using fresh OMat 150

– acetone and a fresh OMat 2/101

– lint free cloth until all deposits have been removed.

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.

(iv) Allow 5 minutes for the area to completely dry prior to penetrant application.

(v) Apply OMat 632 penetrant to the inspection areas in Fig.2. The penetrants must

be dispensed from a sealed aerosol can and any unused penetrant must go to

waste.

(vi) Ensure that the inspection areas are fully covered with penetrant with the aid of

the UV lamp and mirror.

(vii) Leave the penetrant in contact with the components for 20 minutes.

NOTE: THE PENETRANT CONTACT TIME MUST NOT EXCEED 1 HOUR. IF IT DOES

THE PE NETRANT MUST BE REAPPLIED AND 5 MINUTES CONTACT TIME

ALLOWED.

(viii) After the 20 minutes contact time, remove the excess penetrant from the

inspection surface by wiping thoroughly with a clean OMat 2/101

– lint free cloth.

(ix) Soak a clean OMat 2/ 10

- lint free cloth in water and then gently squeeze the

excess water out to reduce the flow of water on the component surface.

(x) Whilst illuminating the inspection area with UV light, wipe off the penetrant with

the wet cloth before immediately wip ing over with a clean, dry OMat2/10 lint free

cloth. Repeat this process using the minimum application necessary to achieve

acceptable background fluorescence.

(xi) Ensure that the inspection area is dry by wiping with a dry OMat2/10 lint free

cloth.

(xii) 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.

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 5 of 11 Pages (xiii) Allow a minimum of 10 minutes and a maximum of 15 minutes contact time for

the developer prior to inspection.

(xiv) Cover the region of the engine with a dark non

- reflective cover in order to reduce

the white light levels.

(xv) Ensure there are no white light sources or fluorescent items (including clothing)

within the insp ection area.

(xvi) Positioned inside the darkened area, allow 3 minutes for eye adaptation to the

low light levels.

(xvii) Illuminate the inspection surfaces with UV light in the darkened area and view by

line of sight or by using the mirror as neces sary.

(xviii) Assess the Inspection areas for crack indications. White light may be used to aid

assessment

(xix) The “Wipe Off” technique shall be used to determine the nature of any

indications.

1. Dampen a cotton swab with acetone.

2. Wipe once across th e indication.

3. Allow the acetone to evaporate and inspect immediately.

4. If the indication reappears then record it as a crack. If the indication does

not reappear then apply a light, even coating of OMat 617

– non

aqueous wet developer from a sealed aeroso l can to the area.

5. Allow the solvent in the developer to evaporate and inspect immediately.

6. If the indication reappears record it as a crack. If the indication does not

reappear then allow 10 minutes contact time for the developer.

7. If the indication rea ppears after the 10 minutes contact time then record

it as a crack. If the indication does not reappear then that area is

acceptable.

(xx) Record any suspected crack indication in Appendix 1.

Photograph any crack indications.

(xxi) No cracks detected ACCEPT

Any Cracks REJECT

(xxii) 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

– Aceton e.

3 ) Inspect the fail safe catcher for signs of contact

(i) Visually inspect the LE face of the fail safe catcher (see Fig.3 ) f or examples of

damage (see Fig.4 ).

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 6 of 11 Pages (ii) Inspect in accordance with

CIR: 72

- 52

- 51

- 200

- 801 Examine the LP Turbine Exhaust

SUBTASK 7 2

- 52

- 51

- 210

- 110

18. Examine the LP Turbine Engine Mounting Lug at Location 10

(ii) Photograph any damage and note location of the damage on the fail safe

catcher. See Fig.4 for example photographs of typical damage.

# Technical Variance

Continuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 7 of 11 Pages

Figure 1

– Tail Bearing Housing

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 8 of 11 Pages Figure 2

- Mount Lug Forging LE Area

VIEW LOOKING AFT

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 9 of 11 Pages Figure 3

- In Shop

- Fail Safe Catcher Inspection Locations Inspect LE face of

Fail Safe Catcher

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 10 of 11 Pages Figure 4

- In Shop

- Fail Safe Catcher Damage

# Technical Variance

Con tinuation Sheet TV No. 132043

Issue 1

Rolls

- Royce plc. Proprietary Information

– Not for Manufacture

Page 11 of 11 Pages

APPENDIX 1

This form (or similar) to be completed for every engine/component inspected

Results to be sent to Rolls

- Royce via your Service Representative



## Feedback Sheet TV 132043

Overhaul Base

O perator

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

Comp onent Hours Since

New

Component Cycles Since

New

Inspection result and comments

In Shop i nspection of

Mount Lug Forging

Leading Edge Area Any crack indications?

Photographs of crack

indications



### In Shop i n spection of

Fail Safe Catcher LE

f ace and any

photographs of damage