Pages 1 to 8 of the

Service Bulletin

Pages 1 to 10 of the

Service Bulletin

Revised 3. Accomplishment

Instructions to introduce a

best cleaning process and

inspection. Renumbered

existing Appendix 4 to

Appenidx 5 and added

pictures of acceptable and

unacceptable process

cleaned discs to Appendix

4. Revised Appendix A.

Updated 1.B. Reason, 1.D.

Compliance, 1.E. Approval,

1.F. Manpower, 1.G. Tooling

and 1.I. References.

Revised Figure in Appendix

3 to add a note. Minor

non-technical changes also

made.

All pages of

Appendix 1

Page 1 and 2 of

Appendix 1

Revised 3. Accomplishment

Instructions to introduce a

best cleaning process and

inspection. Renumbered

existing Appendix 4 to

Appenidx 5 and added

pictures of acceptable and

unacceptable process

cleaned discs to Appendix

4. Revised Appendix A.

Updated 1.B. Reason, 1.D.

Compliance, 1.E. Approval,

1.F. Manpower, 1.G. Tooling

and 1.I. References.

Revised Figure in Appendix

3 to add a note. Minor

non-technical changes also

made.

All pages of

Appendix 2

Pages 1 to 10 of

Appendix 2

Revised 3. Accomplishment

Instructions to introduce a

best cleaning process and

inspection. Renumbered

existing Appendix 4 to

Appenidx 5 and added

pictures of acceptable and

unacceptable process

cleaned discs to Appendix

4. Revised Appendix A.

Updated 1.B. Reason, 1.D.

Compliance, 1.E. Approval,

1.F. Manpower, 1.G. Tooling

and 1.I. References.

Revised Figure in Appendix

3 to add a note. Minor

non-technical changes also

made.

Printed in Great Britain

RB.211−72−AG493

Transmittal - Page 2
All pages of

Appendix 3

Page 1 and 2 of

Appendix 3

Revised 3. Accomplishment

Instructions to introduce a

best cleaning process and

inspection. Renumbered

existing Appendix 4 to

Appenidx 5 and added

pictures of acceptable and

unacceptable process

cleaned discs to Appendix

4. Revised Appendix A.

Updated 1.B. Reason, 1.D.

Compliance, 1.E. Approval,

1.F. Manpower, 1.G. Tooling

and 1.I. References.

Revised Figure in Appendix

3 to add a note. Minor

non-technical changes also

made.

All pages of

Appendix 4

Pages 1 to 17 of

Appendix 4

Revised 3. Accomplishment

Instructions to introduce a

best cleaning process and

inspection. Renumbered

existing Appendix 4 to

Appenidx 5 and added

pictures of acceptable and

unacceptable process

cleaned discs to Appendix

4. Revised Appendix A.

Updated 1.B. Reason, 1.D.

Compliance, 1.E. Approval,

1.F. Manpower, 1.G. Tooling

and 1.I. References.

Revised Figure in Appendix

3 to add a note. Minor

non-technical changes also

made.

Pages 1 to 6 of

Appendix 5

Revised 3. Accomplishment

Instructions to introduce a

best cleaning process and

inspection. Renumbered

existing Appendix 4 to

Appenidx 5 and added

pictures of acceptable and

unacceptable process

cleaned discs to Appendix

4. Revised Appendix A.

Updated 1.B. Reason, 1.D.

Compliance, 1.E. Approval,

1.F. Manpower, 1.G. Tooling

and 1.I. References.

Revised Figure in Appendix

3 to add a note. Minor

non-technical changes also

made.

Printed in Great Britain

RB.211−72−AG493

Transmittal - Page 3
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 Oct.12/12

R 2 2 Oct.12/12

R 3 2 Oct.12/12

R 4 2 Oct.12/12

R 5 2 Oct.12/12

R 6 2 Oct.12/12

R 7 2 Oct.12/12

R 8 2 Oct.12/12

R 9 2 Oct.12/12

R 10 2 Oct.12/12

Appendix 1

R 1 2 Oct.12/12

R 2 2 Oct.12/12

Appendix 2

R 1 2 Oct.12/12

R 2 2 Oct.12/12

R 3 2 Oct.12/12

R 4 2 Oct.12/12

R 5 2 Oct.12/12

R 6 2 Oct.12/12

R 7 2 Oct.12/12

R 8 2 Oct.12/12

R 9 2 Oct.12/12

R 10 2 Oct.12/12

Appendix 3

R 1 2 Oct.12/12

R 2 2 Oct.12/12

Appendix 4

R 1 2 Oct.12/12

R 2 2 Oct.12/12

R 3 2 Oct.12/12

R 4 2 Oct.12/12

R 5 2 Oct.12/12

R 6 2 Oct.12/12

R 7 2 Oct.12/12

R 8 2 Oct.12/12

R 9 2 Oct.12/12

R 10 2 Oct.12/12

R 11 2 Oct.12/12

R 12 2 Oct.12/12

Printed in Great Britain

RB.211−72−AG493

Transmittal - Page 4
R 13 2 Oct.12/12

R 14 2 Oct.12/12

R 15 2 Oct.12/12

R 16 2 Oct.12/12

R 17 2 Oct.12/12

Appendix 5

R 1 2 Oct.12/12

R 2 2 Oct.12/12

R 3 2 Oct.12/12

R 4 2 Oct.12/12

R 5 2 Oct.12/12

R 6 2 Oct.12/12

Printed in Great Britain

RB.211−72−AG493

Transmittal - Page 5
1. Planning Information

A. Effectivity

(1) Boeing 747

RB211-524G2-19, 524G2-19/11, 524G2-19/15, 524G2-T-19, 524G2-T-19/11,

524G2-T-19/15 Engines with IP turbine disc serial numbers listed in

Appendix 1.

RB211-524G3-19, 524G3-19/15, 524G3-T-19, 524G3-T-19/15 Engines with IP

turbine disc serial numbers listed in Appendix 1.

RB211-524H2-19, 524H2-19/11, 524H2-19/15, 524H2-T-19, 524H2-T-19/11,

524H2-T-19/15 Engines with IP turbine disc serial numbers listed in

Appendix 1.

(2) Boeing 757

RB211-535E4-37, 535E4-37/10, 535E4-37/11, 535E4-37/12, 535E4-37/14,

535E4-37/16, 535E4-37/17, 535E4-37/19, 535E4-37/20, 535E4-37/23,

535E4-37/24, 535E4-37/25, 535E4-37/39, 535E4-37/43, 535E4-37/44 Engines

with IP turbine disc serial numbers listed in Appendix 2

RB211-535E4-B-37/15, 535E4-B-37/19, 535E4-B-37/20, 535E4-B-37/21,

535E4-B-37/25, 535E4-B-37/35, 535E4-B-37/39, 535E4-B-37/41, 535E4-B-37/44

Engines with IP turbine disc serial numbers listed in Appendix 2

RB211-535E4-C-37, 535E4-C-37/43 Engines with IP turbine disc serial

numbers listed in Appendix 2

(3) Boeing 767

RB211-524H-36, 524H-36/11, 524H-T-36, 524H-T-36/11 Engines with IP turbine

disc serial numbers listed in Appendix 1.

(4) Tupolev Tu204

RB211-535E4-B-75, 535E4-B-75/25 Engines with IP turbine disc serial

numbers listed in Appendix 2.

ENGINE - IP TURBINE DISC - REMOVAL DUE TO STEEL INCLUSION CONCERNS - NON-MODIFICATION

SERVICE BULLETIN - NON - MOD.72-AG493

Printed in Great Britain

RB.211−72−AG493

Page 1 of 10

Oct. 8/10

R Oct.12/12
B. Reason

The inspection of 3-off IP Turbine discs at engine overhaul, in the period

1998-2001, identified the presence of a steel inclusion. IP turbine discs are

manufactured from forgings of Waspaloy (Nickel) material. Following the

discovery of the steel inclusions an investigation was launched in 1999, this

identified several other discs with steel contamination. The investigation

concluded that all the contaminated discs were manufactured from billets

produced pre 1997 at a supplier who also melted steel in the same furnaces. In

1997 procedures were changed to introduce dedicated furnaces for Waspaloy

production.

An analysis of the effect of the steel inclusions on the disc life concluded

that the lives would be unaffected.

This analysis has recently been repeated utilising the improved stress models

now available, it is now concluded that the Declared Safe Cyclic Life (DSCL)

cannot be supported for some discs with an inclusion.

Four forgings are generally produced from a billet of Waspaloy material. The

Waspaloy material was generally melted in campaigns using several consecutive

melts of Waspaloy. Analysis of the melt data for the discs containing

inclusions has concluded that the Waspaloy melts produced immediately after a

steel melt have the highest risk of containing an inclusion. Material from the

same source was utilised to manufacture RB211-524G, 524H and 535E4 discs.

Non-Modification Service Bulletin (NMSB) 72-AG418 was raised to remove three

discs from service, from batches known to have been contaminated; the discs

from NMSB72-AG418 are also included in this NMSB.

Revision 1 introduces an inspection of IP turbine discs to allow discs

withdrawn in accordance with the initial issue of this NMSB to be returned to

service.

R Revision 2 introduces a number of changes:

(1) A best practice cleaning process and inspection standard to make sure that

discs are cleaned to a sufficient level to allow the SQUID inspection to

be completed.

R

R

R

(2) A best practice packaging process to reduce the risk of contamination

after the disc has been cleaned.

R

R

R (3) A note that this NMSB is subject to an Airworthiness Directive.

R (4) A correction to a part number, typographical error in Table 1.

R (5) Changes to reflect issue 2 of QCTP BRR0144 in Appendix 4.

R (6) A clarification in 1.D. Compliance section.

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Page 2

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C. Description

This NMSB instructs the removal and inspection of the potentially affected

discs.

The applicable Part Numbers (EIPC 72-51-31, Fig/Item 01-150) are:

(1) RB211-524G and 524H series Engines: LK82335, UL27958, UL37681, UL37721.

(2) RB211-524G-T and 524H-T series Engines: UL38383, UL38384, UL38467,

UL38929, UL38930.

(3) RB211-535E4 series Engines: UL17774, UL19818, UL27940.

D. Compliance

ALERT

Rolls-Royce recommends that:

(1) RB211-535E4 IP turbine discs as listed in Appendix 2 are to be removed

from service prior to reaching the maximum life (cycles) as defined in the

Appendix.

NOTE: The maximum life (cycles) for all the RB211-524G/H discs listed in

Appendix 1 is the declared safe cyclic life as defined in the Time

Limits Manual.

(2) IP turbine discs exposed at a shop visit (Engine level 3 or 4 shop visit

or 05 module level 2 shop visit), with a cyclic life greater than the

inspection threshold as defined in Appendix 1 or 2. These IP turbine discs

must be inspected in accordance with 3. Accomplishment Instructions prior

to further use.

NOTE: Refer to example shown in Appendix 3.

(3) Discs exposed at a shop visit (Engine level 3 or 4 or 05 module level 2)

R after the initial issue date of this NMSB, should be inspected but may

continue in service without inspection provided:

(a) The cyclic life at that shop visit exposure is less than the

inspection threshold as defined in Appendix 1 or 2.

Printed in Great Britain

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R Oct.12/12
(b) The disc is planned to be removed for inspection prior to the

inspection threshold as defined in Appendix 1 or 2.

NOTE: Installed engines fitted with IP turbine discs at lives above

the inspection threshold, at the date of issue of this NMSB,

may continue in service until next shop visit or until reaching

the maximum life (cycles) whichever occurs first.

NOTE: Refer to example shown in Appendix 3.

NOTE: Discs listed in Appendix 1 or 2 fitted into engines, that have

had an engine level 3 or 4 or 05 module level 2 shop visit,

after the initial issue date of this Service Bulletin, must not

be operated above the inspection threshold life defined in

Appendix 1 or 2.

(4) For steps (1), (2) or (3) above, once a disc has been inspected in

accordance with 3. Accomplishment Instructions,

R

R and has passed the

R the disc can be returned to service for the remainder of the inspection,

R the applicable Time Limits Manual. declared safe cyclic life as defined by

E. Approval

The technical content of Non-Modification Service Bulletin 72-AG493 was

approved under the authority of EASA Design Organisational Approval

R and was re-approved on Oct.12/12. No.EASA.21J.035 on Oct. 5/10, Oct.27/11

The actions contained within this NMSB are the subject of an EASA Airworthiness

Directive. It is anticipated that an FAA Airworthiness Directive will follow.

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R

F. Manpower

(1) On-wing:

Removal and installation of engine - 48 manhours

(2) At overhaul:

R (a) IPT disc cleaning

R hours elapsed time 16

R man hours 5.5

(b) SQUID (Superconductive Quantitative Induction Device) inspection

10 man hours

R defined in section 3. The Personnel for NOTE: The SQUID inspection is

the SQUID inspection should be qualified and approved to the

requirements of the NDE Training Pack TP0044.

Printed in Great Britain

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Page 4

Oct. 8/10

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G. Tooling

FITMHT01 - IPT Disc Lifting and turnover tool

SQUID Equipment - Refer to Appendix 4

H. Consumable Materials

None

I. References

(1) Rolls-Royce RB211 Service Bulletin

72-AG418 Engine - IP Turbine Disc - Removal Due To Steel Contamination

Concerns - Non-Modification Service Bulletin

(2) Time Limits Manual (TLM)

(a) T-211(524)-7RR (RB211-524G/H Engines)

(b) T-211(535)-6RR (RB211-535E4-37 Engines)

(c) T-211(535)-4RR (RB211-535E4-75 Engines)

(3) Standard Practices Manual

TSD594J Task 72-00-00-300-363

2. Material Information

None

Printed in Great Britain

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Page 5

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3. Accomplishment Instructions

A. Review Group A parts records to confirm the location of the affected discs

B. Remove the discs from service prior to reaching the limits defined in 1.D.

Compliance

C. Inspect the disc for evidence of previous inspection accomplishment - Refer to

R section 3.H.

NOTE: The inspection is not required to be repeated

R IPT disc in preparation for the inspection for steel D. Clean and examine the

R inclusions using SQUID. Clean and examine the disc in accordance with:

(1) Degrease disc in accordance with TSD594J 70-00-00-100-101 or TSD594J

70-00-00-100-102 or TSD594J 70-00-00-100-118.

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(2) Immerse the parts fully in an OMat 173 alkaline deruster to TSD594J Task

70-00-00-100-121, Subtask 70-00-00-110-121-001 for between 25 and 35

minutes.

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(3) Rinse the parts fully in clean, cold, running water and pressure wash with

an air/water gun or water lance at pressures up to 14 MPa (2000 psi) to

remove all traces of process solution.

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(4) Remove Heat Oxidation/Corrosion via an Acid descale, step (1). Immerse the

parts fully in the OMat 1/152 or OMat 1/153 (acid descaler) for between 25

and 30 minutes. Refer to TSD594J Task 70-00-00-100-134, Subtask

70-00-00-180-134-002 for the make-up and typical operation parameters for

some OMat 1/152 solutions and Subtask 70-00-00-180-134-001 for the make-up

and typical operation parameters for some OMat 1/153 solutions.

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(5) Rinse the parts fully in clean, cold, running water and pressure wash with

an air/water gun or water lance at pressures up to 14 MPa (2000 psi) to

remove all traces of process solution.

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(6) Scale condition with OMat 198. Immerse the parts fully in OMat 198

alkaline permanganate for a minimum of 1 hour and maximum of 2 hours. The

solution made up as specified in TSD594J Task 70-00-00-100-134 Subtask

70-00-00-180-134-003.

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(7) Rinse the parts fully in clean, cold, running water and pressure wash with

an air/water gun or water lance at pressures up to 14 MPa (2000 psi) to

remove all traces of process solution.

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(8) Remove Heat Oxidation/Corrosion via an Acid descale, step (2). Immerse the

parts fully in the OMat 1/152 or OMat 1/153 (acid descaler) for between 25

and 30 minutes. Refer to TSD594J Task 70-00-00-100-134, Subtask

70-00-00-180-134-002 for the make-up and typical operation parameters for

some OMat 1/152 solutions and Subtask 70-00-00-180-134-001 for the make-up

and typical operation parameters for some OMat 1/153 solutions.

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(9) Rinse the parts fully in clean, cold, running water and pressure wash with

an air/water gun or water lance at pressures up to 14 MPa (2000 psi) to

remove all traces of process solution.

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(10) Repeat steps (6), (7), (8) and (9) (Scale Condition, Rinse, Acid Descale

and Rinse).

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(11) Dry the disc by immersing fully in clean, hot water at 80 deg. C minimum.

Allow the parts to reach the water temperature. Remove the parts from the

hot water and dry fully with a blast of clean, dry, oil free compressed

air.

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(12) Plastic media blast the entire disc once in accordance with TSD594J Task

70-00-00-100-104 Subtask 70-00-00-120-104-005.

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NOTE: Make sure difficult to clean areas such as firtree serrations and

the bores of bolt holes are not missed during the plastic media

blast operation.

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CAUTION: DO NOT DWELL IN ANY AREA FOR TOO LONG. IF YOU DWELL FOR TOO LONG

YOU CAN CAUSE UNACCEPTABLE METAL REMOVAL

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(13) Repeat steps (6), (7), (8) and (9) (Scale Condition, Rinse, Acid Descale

and Rinse).

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(14) Dry the disc by immersing fully in clean, hot water at 80 deg.C minimum.

Allow the parts to reach the water temperature. Remove the parts from the

hot water and dry fully with a blast of clean, dry, oil free compressed

air.

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(15) Examine the disc to make sure the oxidation and corrosion is removed. Use

the pictures in Appendix 5 to assist in making an assessment:

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(a) Examine the whole disc for general cleanliness. The general surface

finish should appear shiny with no oxide scale, corrosion or

contamination evident.

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(b) Examine the firtree serrations for excessive oxide scale, corrosion or

other contamination.

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(c) Examine the bores of bolt holes and cooling air holes in the front

flange/disc drive arm for excessive oxide scale, corrosion or other

contamination.

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(d) Examine the web to rim filet radius for excessive oxide scale,

corrosion or other contamination.

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(e) Examine the drive arm, disc bore and disc web areas for excessive

oxide scale, corrosion or other contamination.

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If excessive oxide, corrosion or contamination remain and the disc is

judged not to be clean enough to attempt a SQUID inspection then

repeat steps (6), (7), (8) and (9) up to a maximum of 2 further times

(5 times in total). If the cleaning process has been repeated to a

maximum of 5 times total and the disc is still not judged to be clean

enough contact Rolls-Royce for further advice. If the disc is judged

to be clean enough go to step (16) below.

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NOTE: For oxidation or corrosion that is difficult to remove, the

immersion time in the OMat 198 alkaline permanganate can be

increased to 16 hours maximum.

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NOTE: For oxidation or corrosion that is difficult to remove,

ultrasonic agitation can be used to assist the cleaning

process. Refer to TSD594J Task 70-00-00-100-134 Subtask

70-00-00-270-134-001.

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NOTE: The SQUID inspection is highly sensitive to any remaining

ferro-magnetic contamination (including oxide scale). Failure

to clean the disc to the required standard will lead to delays

in the SQUID inspection process and may require the disc to be

returned for further process cleaning. If doubts exist on

whether the disc has achieved the required cleanliness

standard, photos of the applicable areas can be sent to

Rolls-Royce Deutschland for further advice. The contact address

is CoTES@Rolls-Royce.com.

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NOTE: The multiple number of Scale Conditioning and Acid Descale

cycles defined in the procedure above has been determined based

on the anticipated life consumed of the disc and a trial to

confirm cleaning best practice.

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(16) Degrease in accordance with TSD594J 70-00-00-100-102 or TSD594J

70-00-00-100-118

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NOTE: Rinse thoroughly, preferably with demineralised water to prevent

staining.

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R NOTE: Handle whilst wearing clean cotton gloves after cleaning.

R E. Package the disk for transportation:

(1) Make sure transportation box is cleaned before use and free from any

debris.

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R (2) Cover the bottom of the box with a clean polythene sheet (or equivalent).

NOTE: Do not use anti-corrosion VCI paper to inhibit the disc. This can

contaminate the disc by leaving a greasy residue.

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(3) Place disc in box, using clean cotton gloves, and secure to prevent

movement during transportation.

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NOTE: Make sure the disc is not contaminated when being secured within

the box.

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R (4) Cover disc with a clean polythene sheet (or equivalent).

(5) Make sure transportation box is sealed at the earliest opportunity to

reduce risk of contamination.

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R F. Send the disc to:

R Rolls-Royce Deutschland Ltd & Co KG

R Materials Laboratory - FAO SQUID Logistics Co-ordinator (ET-M1)

R Eschenweg 11

R 15827 Blankenfelde-Mahlow

R Brandenburg

R Germany

NOTE: It is recommended that Rolls-Royce Deutschland are advised in advance

that an inspection will be required, this will minimise the turnaround

time. The contact address is CoTES@Rolls-Royce.com.

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G. Inspect the disc in accordance with the SQUID procedure defined in Appendix 4.

If necessary (due to the sensitivity of the inspection equipment to

contamination) the component can be cleaned locally at the inspection facility

using a cloth (OMat 2/101) and Acetone (OMat 150).

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H. Record of accomplishment

(1) Discs that have successfully completed the inspection should be marked

with NMSB 72-AG493 as detailed in Fig.1.

NOTE: The marking of the disc will not be completed by Roll-Royce

Deutschland. The receiving overhaul shop will need to review the

results provided by Rolls-Royce Deutschland and mark the disc as

appropriate.

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Location for Identity Markings

Fig.1

Printed in Great Britain

RB.211−72−AG493

Page 10

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RB211-524G, 524G-T, 524H, 524H-T Engines - IP Turbine Discs

Disc

Serial No.

Inspection Threshold

(Cycles)

Disc

Serial No.

Inspection Threshold

(Cycles)

ADQDY 131 16500 ADQDY 859 16500

ADQDY 236 16500 ADQDY 860 16500

ADQDY 360 16250 ADQDY 869 16500

ADQDY 363 16500 ADQDY 872 16500

ADQDY 378 16500 ADQDY 885 16500

ADQDY 513 16250 ADQDY 887 16500

ADQDY 533 16250 ADQDY 1087 16500

ADQDY 544 16250 ADQDY 1096 16500

ADQDY 551 16500 ADQDY 1097 16500

ADQDY 555 16500 ADQDY 1098 16500

ADQDY 560 16250 ADQDY 1099 16500

ADQDY 565 16500 ADQDY 1111 16500

ADQDY 690 16500 ADQDY 1112 16500

ADQDY 691 16500 ADQDY 1113 16500

ADQDY 698 16500 ADQDY 1130 16500

ADQDY 699 16500 ADQDY 1144 16500

ADQDY 700 16500 ADQDY 1145 16500

ADQDY 701 16500 ADQDY 1146 16500

ADQDY 717 16500 ADQDY 1147 16500

ADQDY 724 16500 ADQDY 1148 16500

ADQDY 725 16500 ADQDY 1177 16500

ADQDY 726 16500 ADQDY 1178 16500

ADQDY 727 16500 ADQDY 1179 16500

ADQDY 728 16500 ADQDY 1180 16500

ADQDY 729 16500 ADQDY 1181 16500

ADQDY 733 16500 ADQDY 1182 16500

ADQDY 734 16500 ADQDY 1183 16500

ADQDY 738 16500 ADQDY 1184 16500

ADQDY 739 16500 ADQDY 1212 16500

ADQDY 760 16500 ADQDY 1213 16500

ADQDY 761 16500 ADQDY 1217 16250

ADQDY 779 16500 ADQDY 1218 16250

ADQDY 780 16500 ADQDY 1220 16250

ADQDY 781 16500 ADQDY 1225 16250

ADQDY 782 16500 ADQDY 1226 16250

ADQDY 799 16500 ADQDY 1227 16250

ADQDY 800 16500 ADQDY 1228 16250

ADQDY 801 16500 ADQDY 1229 16500

ADQDY 802 16500 ADQDY 1230 16500

ADQDY 834 16500 ADQDY 1231 16500

ADQDY 835 16500 ADQDY 1232 16500

ADQDY 836 16500 ADQDY 1254 16250

ADQDY 837 16500 ADQDY 1255 16250

APPENDIX 1

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RB211-524G, 524G-T, 524H, 524H-T Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection Threshold

(Cycles)

Disc

Serial No.

Inspection Threshold

(Cycles)

ADQDY 1268 16500 ADREB 33 16250

ADQDY 1270 16500 ADREB 34 16250

ADQDY 1274 16500 ADREB 36 16250

ADQDY 1502 16500 ADREB 54 16250

ADQDY 1503 16500 ADREB 55 16250

ADQDY 1504 16500 ADREB 56 16250

ADQDY 1520 16250 ADREB 57 16250

ADQDY 1521 16250 ADREB 58 16500

ADQDY 1522 16250 ADREB 71 14000

ADQDY 1523 16250 - -

Printed in Great Britain

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Appendix 1 - Page 2

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RB211-535E4 Engines - IP Turbine Discs

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADQDY 209 19500 Refer to TLM

ADQDY 210 19500 Refer to TLM

ADQDY 211 19500 Refer to TLM

ADQDY 212 19500 Refer to TLM

ADQDY 213 19500 Refer to TLM

ADQDY 215 19500 Refer to TLM

ADQDY 216 19500 Refer to TLM

ADQDY 217 19500 Refer to TLM

ADQDY 218 19500 Refer to TLM

ADQDY 219 19500 Refer to TLM

ADQDY 220 19500 Refer to TLM

ADQDY 222 19500 Refer to TLM

ADQDY 223 19500 Refer to TLM

ADQDY 224 19500 Refer to TLM

ADQDY 225 19500 Refer to TLM

ADQDY 226 19500 Refer to TLM

ADQDY 227 19500 Refer to TLM

ADQDY 229 19500 Refer to TLM

ADQDY 230 19500 Refer to TLM

ADQDY 231 19500 Refer to TLM

ADQDY 232 19500 Refer to TLM

ADQDY 233 19500 Refer to TLM

ADQDY 234 19500 Refer to TLM

ADQDY 235 19500 Refer to TLM

ADQDY 238 19500 Refer to TLM

ADQDY 239 19500 Refer to TLM

ADQDY 240 19500 Refer to TLM

ADQDY 241 19500 Refer to TLM

ADQDY 242 19500 Refer to TLM

ADQDY 244 19500 Refer to TLM

ADQDY 245 19500 Refer to TLM

ADQDY 246 19500 Refer to TLM

ADQDY 247 19500 Refer to TLM

ADQDY 248 19500 Refer to TLM

ADQDY 249 19500 Refer to TLM

ADQDY 251 19500 Refer to TLM

ADQDY 252 19500 Refer to TLM

ADQDY 253 19500 Refer to TLM

ADQDY 254 19500 Refer to TLM

ADQDY 255 19500 Refer to TLM

ADQDY 256 19500 Refer to TLM

ADQDY 258 19500 Refer to TLM

ADQDY 259 19500 Refer to TLM

APPENDIX 2

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 1 of 10

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADQDY 260 19500 Refer to TLM

ADQDY 261 19500 Refer to TLM

ADQDY 262 19500 Refer to TLM

ADQDY 263 19500 Refer to TLM

ADQDY 264 19500 Refer to TLM

ADQDY 265 19500 Refer to TLM

ADQDY 266 19500 Refer to TLM

ADQDY 267 19500 Refer to TLM

ADQDY 269 19500 Refer to TLM

ADQDY 270 19500 Refer to TLM

ADQDY 271 19500 Refer to TLM

ADQDY 272 19500 Refer to TLM

ADQDY 273 19500 Refer to TLM

ADQDY 274 19500 Refer to TLM

ADQDY 275 19500 Refer to TLM

ADQDY 276 19500 Refer to TLM

ADQDY 277 19500 Refer to TLM

ADQDY 279 19500 Refer to TLM

ADQDY 282 19500 Refer to TLM

ADQDY 283 19500 Refer to TLM

ADQDY 284 19500 Refer to TLM

ADQDY 285 19500 Refer to TLM

ADQDY 286 19500 Refer to TLM

ADQDY 287 19500 Refer to TLM

ADQDY 288 19500 Refer to TLM

ADQDY 289 19500 Refer to TLM

ADQDY 290 19500 Refer to TLM

ADQDY 291 19500 Refer to TLM

ADQDY 292 19500 Refer to TLM

ADQDY 293 19500 Refer to TLM

ADQDY 294 19500 Refer to TLM

ADQDY 295 19500 Refer to TLM

ADQDY 296 19500 Refer to TLM

ADQDY 297 19500 Refer to TLM

ADQDY 298 19500 Refer to TLM

ADQDY 299 19500 Refer to TLM

ADQDY 301 19500 Refer to TLM

ADQDY 302 19500 Refer to TLM

ADQDY 303 19500 Refer to TLM

ADQDY 304 19500 Refer to TLM

ADQDY 305 19500 Refer to TLM

ADQDY 308 19500 Refer to TLM

ADQDY 309 19500 Refer to TLM

ADQDY 311 19500 Refer to TLM

ADQDY 312 19500 Refer to TLM

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 2

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADQDY 313 19500 Refer to TLM

ADQDY 314 19500 Refer to TLM

ADQDY 315 19500 Refer to TLM

ADQDY 401 21500 Refer to TLM

ADQDY 402 21500 Refer to TLM

ADQDY 405 19500 Refer to TLM

ADQDY 406 19500 Refer to TLM

ADQDY 407 19500 Refer to TLM

ADQDY 408 19500 Refer to TLM

ADQDY 410 19500 Refer to TLM

ADQDY 411 19500 Refer to TLM

ADQDY 413 21500 Refer to TLM

ADQDY 416 19500 Refer to TLM

ADQDY 417 19500 Refer to TLM

ADQDY 418 19500 Refer to TLM

ADQDY 419 21500 Refer to TLM

ADQDY 420 21500 Refer to TLM

ADQDY 421 21500 Refer to TLM

ADQDY 422 19500 Refer to TLM

ADQDY 423 19500 Refer to TLM

ADQDY 424 19500 Refer to TLM

ADQDY 425 19500 Refer to TLM

ADQDY 426 19500 Refer to TLM

ADQDY 427 19500 Refer to TLM

ADQDY 429 19500 Refer to TLM

ADQDY 430 21500 Refer to TLM

ADQDY 431 19500 Refer to TLM

ADQDY 432 21500 Refer to TLM

ADQDY 433 21500 Refer to TLM

ADQDY 435 19500 Refer to TLM

ADQDY 436 21500 Refer to TLM

ADQDY 437 21500 Refer to TLM

ADQDY 440 19500 Refer to TLM

ADQDY 441 19500 Refer to TLM

ADQDY 443 21500 Refer to TLM

ADQDY 444 21500 Refer to TLM

ADQDY 449 19500 Refer to TLM

ADQDY 458 21500 Refer to TLM

ADQDY 459 21500 Refer to TLM

ADQDY 460 21500 Refer to TLM

ADQDY 461 21500 Refer to TLM

ADQDY 466 21500 Refer to TLM

ADQDY 474 19500 Refer to TLM

ADQDY 475 19500 Refer to TLM

ADQDY 486 18500 25500

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 3

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADQDY 487 21500 Refer to TLM

ADQDY 488 21500 Refer to TLM

ADQDY 489 19500 Refer to TLM

ADQDY 592 19500 Refer to TLM

ADQDY 593 19500 Refer to TLM

ADQDY 594 19500 Refer to TLM

ADQDY 595 19500 Refer to TLM

ADQDY 596 19500 Refer to TLM

ADQDY 597 21500 Refer to TLM

ADQDY 598 21500 Refer to TLM

ADQDY 599 21500 Refer to TLM

ADQDY 618 19500 Refer to TLM

ADQDY 620 19500 Refer to TLM

ADQDY 621 19500 Refer to TLM

ADQDY 626 19500 Refer to TLM

ADQDY 627 19500 Refer to TLM

ADQDY 628 19500 Refer to TLM

ADQDY 629 19500 Refer to TLM

ADQDY 634 21500 Refer to TLM

ADQDY 635 21500 Refer to TLM

ADQDY 636 21500 Refer to TLM

ADQDY 637 21500 Refer to TLM

ADQDY 648 19500 Refer to TLM

ADQDY 649 19500 Refer to TLM

ADQDY 669 20000 20000 Refer to NMSB72-AG418

ADQDY 671 20000 20000 Refer to NMSB72-AG418

ADQDY 674 21500 Refer to TLM

ADQDY 675 21500 Refer to TLM

ADQDY 676 21500 Refer to TLM

ADQDY 677 21500 Refer to TLM

ADQDY 893 21500 Refer to TLM

ADQDY 894 21500 Refer to TLM

ADQDY 895 21500 Refer to TLM

ADQDY 896 21500 Refer to TLM

ADQDY 897 21500 Refer to TLM

ADQDY 935 19500 Refer to TLM

ADQDY 937 19500 Refer to TLM

ADQDY 938 19500 Refer to TLM

ADQDY 939 21500 Refer to TLM

ADQDY 940 21500 Refer to TLM

ADQDY 941 21500 Refer to TLM

ADQDY 942 21500 Refer to TLM

ADQDY 955 21500 Refer to TLM

ADQDY 956 21500 Refer to TLM

ADQDY 957 21500 Refer to TLM

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 4

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADQDY 981 19500 Refer to TLM

ADQDY 982 19500 Refer to TLM

ADQDY 983 19500 Refer to TLM

ADQDY 984 19500 Refer to TLM

ADQDY 997 19500 Refer to TLM

ADQDY 998 19500 Refer to TLM

ADQDY 999 19500 Refer to TLM

ADQDY 1000 19500 Refer to TLM

ADQDY 1001 19500 Refer to TLM

ADQDY 1002 21500 Refer to TLM

ADQDY 1003 21500 Refer to TLM

ADQDY 1004 21500 Refer to TLM

ADQDY 1005 21500 Refer to TLM

ADQDY 1010 21500 Refer to TLM

ADQDY 1011 21500 Refer to TLM

ADQDY 1012 21500 Refer to TLM

ADQDY 1013 21500 Refer to TLM

ADQDY 1014 21500 Refer to TLM

ADQDY 1022 21500 Refer to TLM

ADQDY 1023 21500 Refer to TLM

ADQDY 1024 21500 Refer to TLM

ADQDY 1025 21500 Refer to TLM

ADQDY 1026 19500 Refer to TLM

ADQDY 1027 19500 Refer to TLM

ADQDY 1028 19500 Refer to TLM

ADQDY 1029 19500 Refer to TLM

ADQDY 1046 21500 Refer to TLM

ADQDY 1047 21500 Refer to TLM

ADQDY 1052 18500 25500

ADQDY 1053 18500 25500

ADQDY 1054 18500 25500

ADQDY 1055 18500 25500

ADQDY 1056 18500 26500

ADQDY 1057 18500 25500

ADQDY 1058 18500 25500

ADQDY 1059 18500 26000

ADQDY 1060 18500 25500

ADQDY 1061 18500 25500

ADQDY 1062 19500 Refer to TLM

ADQDY 1063 19500 Refer to TLM

ADQDY 1064 19500 Refer to TLM

ADQDY 1065 19500 Refer to TLM

ADQDY 1066 19500 Refer to TLM

ADQDY 1067 19500 Refer to TLM

ADQDY 1068 19500 Refer to TLM

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 5

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADQDY 1069 19500 Refer to TLM

ADQDY 1070 19500 Refer to TLM

ADQDY 1071 21500 Refer to TLM

ADQDY 1072 21500 Refer to TLM

ADQDY 1073 21500 Refer to TLM

ADQDY 1074 21500 Refer to TLM

ADQDY 1075 19500 Refer to TLM

ADQDY 1076 19500 Refer to TLM

ADQDY 1077 19500 Refer to TLM

ADQDY 1078 19500 Refer to TLM

ADQDY 1082 19500 Refer to TLM

ADQDY 1085 21500 Refer to TLM

ADQDY 1086 21500 Refer to TLM

ADQDY 1287 21500 Refer to TLM

ADQDY 1288 21500 Refer to TLM

ADQDY 1289 19500 Refer to TLM

ADQDY 1290 19500 Refer to TLM

ADQDY 1291 19500 Refer to TLM

ADQDY 1292 19500 Refer to TLM

ADQDY 1293 21500 Refer to TLM

ADQDY 1294 21500 Refer to TLM

ADQDY 1295 21500 Refer to TLM

ADQDY 1296 21500 Refer to TLM

ADQDY 1299 18500 25500

ADQDY 1300 19500 Refer to TLM

ADQDY 1301 19500 Refer to TLM

ADQDY 1302 19500 Refer to TLM

ADQDY 1303 19500 Refer to TLM

ADQDY 1316 19500 Refer to TLM

ADQDY 1317 18500 25500

ADQDY 1319 19500 Refer to TLM

ADQDY 1320 19500 Refer to TLM

ADQDY 1321 19500 Refer to TLM

ADQDY 1322 19500 Refer to TLM

ADQDY 1323 19500 Refer to TLM

ADQDY 1324 19500 Refer to TLM

ADQDY 1325 19500 Refer to TLM

ADQDY 1326 18500 25500

ADQDY 1327 18500 25500

ADQDY 1329 18500 25500

ADQDY 1330 18500 26500

ADQDY 1331 18500 25500

ADQDY 1332 18500 25500

ADQDY 1333 18500 25500

ADQDY 1334 21500 Refer to TLM

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 6

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADQDY 1335 21500 Refer to TLM

ADQDY 1336 21500 Refer to TLM

ADQDY 1341 18500 25500

ADQDY 1347 21500 Refer to TLM

ADQDY 1348 21500 Refer to TLM

ADQDY 1349 21500 Refer to TLM

ADQDY 1350 21500 Refer to TLM

ADQDY 1361 21500 Refer to TLM

ADQDY 1362 21500 Refer to TLM

ADQDY 1363 18500 25500

ADQDY 1364 18500 26000

ADQDY 1366 18500 25500

ADQDY 1367 18500 25500

ADQDY 1368 18500 25500

ADQDY 1369 18500 25500

ADQDY 1370 18500 25500

ADQDY 1371 18500 25500

ADQDY 1372 18500 25500

ADQDY 1373 18500 25500

ADQDY 1374 18500 25500

ADQDY 1375 18500 25500

ADQDY 1376 18500 25500

ADQDY 1377 19500 Refer to TLM

ADQDY 1378 19500 Refer to TLM

ADQDY 1379 19500 Refer to TLM

ADQDY 1380 19500 Refer to TLM

ADQDY 1381 21500 Refer to TLM

ADQDY 1382 21500 Refer to TLM

ADQDY 1383 21500 Refer to TLM

ADQDY 1384 21500 Refer to TLM

ADQDY 1385 21500 Refer to TLM

ADQDY 1386 21500 Refer to TLM

ADQDY 1387 21500 Refer to TLM

ADQDY 1388 21500 Refer to TLM

ADQDY 1389 18500 25500

ADQDY 1390 18500 25500

ADQDY 1391 19500 Refer to TLM

ADQDY 1392 19500 Refer to TLM

ADQDY 1393 19500 Refer to TLM

- - -

ADREB 2 18500 25500

ADREB 4 18500 25500

ADREB 5 18500 26000

ADREB 6 19500 Refer to TLM

ADREB 7 19500 Refer to TLM

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 7

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADREB 8 19500 Refer to TLM

ADREB 9 19500 Refer to TLM

ADREB 12 19500 Refer to TLM

ADREB 14 19500 Refer to TLM

ADREB 15 19500 Refer to TLM

ADREB 16 18500 25500

ADREB 17 18500 25500

ADREB 18 18500 25500

ADREB 19 18500 25500

ADREB 35 18500 25500

ADREB 130 21500 Refer to TLM

ADREB 131 21500 Refer to TLM

ADREB 135 19500 Refer to TLM

ADREB 136 19500 Refer to TLM

ADREB 137 19500 Refer to TLM

ADREB 139 18500 26000

ADREB 140 18500 25500

ADREB 141 18500 25500

ADREB 142 18500 26000

ADREB 143 19500 Refer to TLM

ADREB 144 19500 Refer to TLM

ADREB 145 19500 Refer to TLM

ADREB 146 19500 Refer to TLM

ADREB 153 19500 Refer to TLM

ADREB 154 19500 Refer to TLM

ADREB 155 19500 Refer to TLM

ADREB 156 19500 Refer to TLM

ADREB 157 19500 Refer to TLM

ADREB 158 19500 Refer to TLM

ADREB 159 19500 Refer to TLM

ADREB 160 21500 Refer to TLM

ADREB 161 21500 Refer to TLM

ADREB 162 21500 Refer to TLM

ADREB 163 21500 Refer to TLM

ADREB 164 21500 Refer to TLM

ADREB 165 21500 Refer to TLM

ADREB 166 21500 Refer to TLM

ADREB 167 21500 Refer to TLM

ADREB 168 19500 Refer to TLM

ADREB 169 19500 Refer to TLM

ADREB 170 19500 Refer to TLM

ADREB 171 19500 Refer to TLM

ADREB 172 19500 Refer to TLM

ADREB 173 18500 25500

ADREB 174 18500 25500

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 8

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADREB 175 18500 25500

ADREB 176 18500 25500

ADREB 177 18500 25500

ADREB 178 18500 25500

ADREB 179 18500 25500

ADREB 180 21500 Refer to TLM

ADREB 181 21500 Refer to TLM

ADREB 182 21500 Refer to TLM

ADREB 183 21500 Refer to TLM

ADREB 184 21500 Refer to TLM

ADREB 185 21500 Refer to TLM

ADREB 186 20000 20000 Refer to NMSB72-AG418

ADREB 188 18500 25500

ADREB 190 18500 25500

ADREB 191 18500 25500

ADREB 192 18500 25500

ADREB 193 18500 25500

ADREB 194 18500 25500

ADREB 195 18500 25500

ADREB 196 18500 25500

ADREB 197 18500 25500

ADREB 198 18500 25500

ADREB 199 18500 25500

ADREB 200 19500 Refer to TLM

ADREB 201 19500 Refer to TLM

ADREB 202 19500 Refer to TLM

ADREB 203 19500 Refer to TLM

ADREB 204 19500 Refer to TLM

ADREB 205 19500 Refer to TLM

ADREB 206 19500 Refer to TLM

ADREB 207 19500 Refer to TLM

ADREB 208 19500 Refer to TLM

ADREB 209 19500 Refer to TLM

ADREB 210 18500 25500

ADREB 211 18500 25500

ADREB 212 18500 25500

ADREB 213 18500 25500

ADREB 214 18500 25500

ADREB 215 18500 25500

ADREB 216 18500 25500

ADREB 217 18500 25500

ADREB 218 18500 25500

ADREB 219 19500 Refer to TLM

ADREB 220 19500 Refer to TLM

ADREB 221 19500 Refer to TLM

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 9

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - IP Turbine Discs - continued

Disc

Serial No.

Inspection

Threshold

(Cycles)

Maximum Life

(Cycles)

Remarks

ADREB 222 21500 Refer to TLM

ADREB 223 21500 Refer to TLM

ADREB 224 21500 Refer to TLM

ADREB 225 21500 Refer to TLM

Printed in Great Britain

RB.211−72−AG493

Appendix 2 - Page 10

Oct. 8/10

R Oct.12/12
RB211-535E4 Engines - High Risk IP Turbine Discs examples

See over

APPENDIX 3

Printed in Great Britain

RB.211−72−AG493

Appendix 3 - Page 1 of 2

Oct. 8/10

R Oct.12/12
R

R Examples of RB211-535E4 high risk IP turbine discs

Printed in Great Britain

RB.211−72−AG493

Appendix 3 - Page 2

Oct. 8/10

R Oct.12/12
SQUID inspection of RB211 IP Turbine Disc QCTP

Part numbers covered by this Document

Engine

(RB211)

Part

Reference

Date Makes Detail

Number

Date Limitations

Agreed by

Engineering

535E4 UL17774 23.08.10 N/A N/A N/A

535E4 UL19818 23.08.10 N/A N/A N/A

535E4 UL27940 26.04.10 N/A N/A N/A

R 524G/H LK82335 23.08.10 N/A N/A N/A

524G/H UL27958 26.04.10 N/A N/A N/A

524G/H UL37681 23.08.10 N/A N/A N/A

524G/H UL37721 23.08.10 N/A N/A N/A

524G/H-T UL38383 23.08.10 N/A N/A N/A

524G/H-T UL38384 23.08.10 N/A N/A N/A

524G/H-T UL38467 23.08.10 N/A N/A N/A

524G/H-T UL38929 23.08.10 N/A N/A N/A

524G/H-T UL38930 23.08.10 N/A N/A N/A

This QCTP covers the SQUID inspection of the RB211-524 and RB211-535 ITP discs

The NDT techniques specified herin are mandatory for the components covered in

this procedure. No alterations or alternatives to this procedure shall be

allowed unless prior to written permission is obtained from the Materials and

Technology Dahlewitz

Originator

D.Ruschenbaum

R Date: 13.02.2012

NDT Approval

K.Griffiths

Date: 21.02.2012

Copyright:

This document is the property of Rolls-Royce plc and may not be copied or

communicated to a third party or used for any purpose other than that for which

it is supplied without the express written authority of Rolls-Royce plc.

APPENDIX 4

Printed in Great Britain

RB.211−72−AG493

Appendix 4 - Page 1 of 8

Oct. 8/10

R Oct.12/12
Content

Chapter Description Page

1 Scope and Purpose 4

2 Reference Documents 4

3 Definitions and Abbreviations 4

3.1 Definitions 4

3.2 Abbreviations 4

4 Responsibilities 4

4.1 Qualification and approval of SQUID

inspection personnel

4

5 Test Procedures 5

5.1 Handling of Turbine Discs 5

5.2 Equipment Requirements 5

5.3 Calibration Reference 6

5.4 Calibration Procedure 7

5.5 Disc Test Procedure 7

5.6 Evaluation Procedure 8

Printed in Great Britain

RB.211−72−AG493

Appendix 4 - Page 2

Oct. 8/10

R Oct.12/12
R and Tables Appendix A Figures 1

A.1.1 Calibration Unit 2

A.2 Plot Sheet RB211-524 3

A.2 Plot Sheet RB211-535 4

A.2.1 Scan Plan IPT Disc RB211-535 5

A.2.2 Scan Plan IPT Disc RB211-524 6

A.3.1 Dependency measurement-signal of inner

width between part surface to fluxgate

- gradiometer bottom edge of a 10 mg

defect

7

A.3.2 Distance determination of a defect to

fluxgate gradiometer bottom edge

8

A.3.3 SQUID Evaluation Sheet 9

Printed in Great Britain

RB.211−72−AG493

Appendix 4 - Page 3

Oct. 8/10

R Oct.12/12
1. Scope and Purpose

This specification covers SQUID inspection for the detection of ferromagnetic

inclusions in RB211 IP Turbine discs.

2. Reference Documents

For dated references subsequent amendments, or revisions of any of these

publications, apply to this specification only when incorporated in it by

amendment or revision. For undated references, the latest edition of the

publication is applicable.

3. Definitions and Abbreviations

3.1 - Definitions

RRD - Rolls-Royce Deutschland Ltd. and Co KG

The word SQUID defines the measurement with fluxgate gradiometer and the

electronics of the gradiometer.

Abbreviations

GM02 - Basic Magnetic Measuring System

CB01 - Calibration Ring working standard

DT01 - Turntable

MH02 - Magnetising System

DM01 - Demagnetiser

ME01 - Electronic measuring equipment

AN01 - Drive Unit

DS01 - Distance Piece

DH01 - Distance Bush

4. Responsibilities

In accordance to Quality Agreement No.

01041327

4.1 - Qualification and approval of SQUID - Inspection personnel

Printed in Great Britain

RB.211−72−AG493

Appendix 4 - Page 4

Oct. 8/10

R Oct.12/12
Personnel for the SQUID - Inspection should be qualified and approved to the

requirements of the NDE Training Pack TP0044.

5. Test Procedure

5.1 - Handling of turbine discs

The handling should be restricted to the minimum requirements.

The turbine discs must be handled with maximum care.

At all times the handling of turbine discs must be undertaken by two persons.

Clean cotton gloves must be worn when handling the turbine discs.

Turbine discs should not be slid over surfaces.

Incoming turbine discs must be stored in a dry closed room.

Only one single turbine disc box may be open at a time.

Turbine disc box should only be opened immediately prior to SQUID inspection

process.

No foreign material may contact the turbine discs.

In the case of disc damage or any peculiarity, it must be reported to RRD ET-M

in writing.

Damage - any surface imperfection (dent, scratch, score) that is clearly visible

with the naked eye under good lighting conditions.

Peculiarity - visible indication of some foreign matter in contact with the

surface of the component, e.g. liquid or solid, or any apparent discolouration

that is not consistent with general visible appearance of the component.

5.2 - Test Equipment

5.2.1 - SQUID measuring system GM02

5.2.1.1 - Gradiometer (MAG-03IEL100)

5.2.1.2 - Electronics of gradiometer

(MAG-03PSU)

5.2.1.3 - Electronics measuring equipment (ME01) codec:

- Adaption electronics AE01

- Preamplifier (VV01) with

voltage gain of 1000

Printed in Great Britain

RB.211−72−AG493

Appendix 4 - Page 5

Oct. 8/10

R Oct.12/12
- Low-pass filter (TP01) with cut -off frequency of 10 Hz

5.2.1.4 - Digital oscillioscope Vellemann

- PCSU 1000

Channel 1 (measurement signal)

Input signal: DC

Sensitivity: variable

Time-base 1s/div

Channel 2 (trigger signal at 360 deg.)

Input signal: DC

Sensitivity: 100 mV/div

5.2.1.5 - Laptop with software PCSU 1000 and printer

5.2.1.6 - Calibration ring working standard (CB01) for inline system set up

5.2.1.7 - Turntable DT01, made of thermo plastic

5.2.1.8 - SQUID handling unit

5.2.2 - Magnetising system (550 Gauss) MH02

5.2.3 - Demagnetiser DM01

5.2.4 - Direct current motor with toothed belt (AN01), (3m distance to

turntable)

5.2.5 - Distance piece DS01 (50x23x3 mm)

5.2.6 - Distance Bush DH01 (inner diameter 20,00 and height 50 mm)

Gauge RB211-524/2

Gauge RB211-535/1

Gauge RB211-535/2

5.3 - Calibration Reference

Cubic block of 1.6604 ( MSRR6017) material with 10 mg mass, magnetised to 550

Gauss (0,055T). The sample is glued in the thermoplastic calibration ring (CB01)

see Appendix A1.1.

Printed in Great Britain

RB.211−72−AG493

Appendix 4 - Page 6

Oct. 8/10

R Oct.12/12
5.4 - Calibration Procedure

The calibration procedure is to be carried out before and after each test

session and shall be documented.

If the inspection will be stopped for longer than two hours, a new calibration

should be done.

Check the equipment in accordance to internal procedure FITM 1 at the beginning

of the inspection.

5.4.1 - Demagnetise the calibration sample with demagnetiser (DM01). Fix the

calibration ring in the magnet with the 20 mm bore and the distance bush (DH01)

of 50 mm height onto the bearing pin of the magnetising system (MH02). The

calibration sample (red point) should be above.

R The permanent magnet shall be navigated to adjustment hole 18. Turn the

turntable 4 revolutions by hand, each round should require approx. 3 seconds.

R now and take the calibration block to the The calibration sample is magnetised

turntable (DT01).

5.4.2 - Centralise calibration ring (CB01) on the turntable 50 plus or minus 1

mm below GM02.

Switch on the motor. The disk will rotate at approx. 20 RPM.

Rotate minimum two revolutions, then store the data on the oscilloscope.

Switch off the motor.

The calibration is valid, if the SQUID signal is 140mV plus or minus 7mV.

5.5 - Turbine Disc Test Procedure

5.5.1 - Calibrate the whole equipment in accordance to chapter 5.4.

5.5.2 - Mount the turbine disc on the turntable of the magnetiser (MH02) with

R the disc with permanent magnet (550 Gauss) in 30 mm the flange upward. Magnetise

steps from

R

R the middle completely.

Turn the turbine disc 4 revolutions by hand for each position. Each revolution

should be about 3 seconds. Magnetise the disc per position as described above.

The turbine disc is magnetised now.

5.5.3 - Remove the permanent magnet and put the turbine disc with the flange

downward on the turntable (DT01). The firtree No. 1 has to be positioned on the

trigger signal.

5.5.4 - Regarding the radius, the gradiometer has to be positioned with aid of

the gauges in accordance to scan plan appendix A2.1/2.2 (3mm above the surface)

Printed in Great Britain

RB.211−72−AG493

Appendix 4 - Page 7

Oct. 8/10

R Oct.12/12
5.5.5 - Switch on the motor. The disc will rotate clockwise respectively

anti-clockwise at approx. 0,3 Hz. in accordance to the scan plan.

5.5.6 - When two consecutive revolutions give the same SQUID signal, store the

scan, switch off the motor and plot the scan, see Appendix A1.2.

R than 80mV a second scan 20 mm above is 5.5.7 - If the defect signal is greater

required (3mm + 20 mm above the surface) - procedure in accordance to chapter

5.5.4 to 5.5.6.

5.5.8 - The procedure in accordance with chapter 5.5.4 to 5.5.7 must be repeated

for each scan (see Appendix A2.1/A2.2).

5.5.9 - The disc will be turned, so that the flange side is upwards.

The firtree no.1 has to be positioned on the trigger signal. Application flow in

accordance to 5.5.4 to 5.5.8 for each receivable scan (see appendix A2.1/A2.2)

5.6 - Evaluation Procedure

5.6.1 - The defect signal of each scan must be determined and written in the

table (see Appendix A3.3).

5.6.2 - Depending on the defect signal heights (see chapter 5.5.7), a +20 mm

scan, may be necessary.

5.6.3 - Determine the ratio of Signal: signal +20 mm

and enter in the column signal ratio. Determine in diagram (see Appendix A 3.2)

the corresponding distance and enter in column distance.

For defect size determination enter values of signal and distance out of

evaluation sheet A3.3 in diagram (see Appendix A3.1). If the coordinates are

above the 10mg-3sigma line the turbine disc is rejected, below the line the

turbine disc is passed.

Printed in Great Britain

RB.211−72−AG493

Appendix 4 - Page 8

Oct. 8/10

R Oct.12/12
Illustrations and Tables

APPENDIX A

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 1 of 9

Oct. 8/10

R Oct.12/12
A1.1 - Calibration Ring (CB01)

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 2

Oct. 8/10

R Oct.12/12
A1.2 - Plot Sheet RB211-524G/H & RB211-524G/H-T

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 3

Oct. 8/10

R Oct.12/12
A1.2 - Plot Sheet RB211-535E4

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 4

Oct. 8/10

R Oct.12/12
R

R A2.1 - Scan - Plan RB211-535E4

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 5

Oct. 8/10

R Oct.12/12
R

R A2.2 - Scan - Plan RB211-524G/H (&-T)

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 6

Oct. 8/10

R Oct.12/12
A3.1 - Dependency measurement signal of inner width between part surface to fluxgate

- gradiometer bottom edge for 10 mg defect

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 7

Oct. 8/10

R Oct.12/12
A3.2 - Distance determination of a defect to fluxgate gradiometer bottom edge

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 8

Oct. 8/10

R Oct.12/12
A3.3

SQUID Evaluation Sheet

Facility: FITM

Magdeburg

Datum: Inspector: Signature:

Trigger

Signal:

Firtree No 1

RB211-524G/H; 524G/H-T

RB211-535E4

Turn: Scan

1-9=anticlockwise

Turn: Scan

1-8=anticlockwise

Scan 10-14=clockwise

Scan 10-12=clockwise

Part No:

Part Description: IP turbine disc

S/N No.:

Reference Document: QCTP BRR

0144

R

R

R RB211 72-AG493

Magnetic Status of Test Piece:

Magnetised with 0,0550 T (550

Gauss)

Calibration carried out before test session:

Calibration carried out after test session:

Signal (mV) Signal (mV)

Scan X + 20

mm

Signal

ratio

Distance

(mm)

Comments

Scan 1:

Scan 2:

Scan 3:

Scan 4:

Scan 5:

Scan 6:

Scan 7:

Scan 8:

Scan 9:

Scan 10:

Scan 11:

Scan 12:

Scan 13:

Scan 14:

Test Result:

Authorised Signature:

Date:

Printed in Great Britain

RB.211−72−AG493

Appendix A - Page 9

Oct. 8/10

R Oct.12/12
R Pictures of acceptable and unacceptable process cleaned discs

APPENDIX 5

Printed in Great Britain

RB.211−72−AG493

Appendix 5 - Page 1 of 6

Oct. 8/10

R Oct.12/12
R

R Example of the general surface finish of an acceptable disc after process cleaning

R Fig.1

Printed in Great Britain

RB.211−72−AG493

Appendix 5 - Page 2

Oct. 8/10

R Oct.12/12

Surface finish appears shiny. No 

oxide, corrosion or other 

contamination evident 
R

R Example of an acceptable disc firtree process cleaning

R Fig.2

Printed in Great Britain

RB.211−72−AG493

Appendix 5 - Page 3

Oct. 8/10

R Oct.12/12

No other oxide, corrosion 

or other contamination 

present 

Very minor oxide deposits 

are acceptable in firtree 

serrations
R

R Example of the general surface finish of an unacceptable disc after process cleaning

R Fig.3

Printed in Great Britain

RB.211−72−AG493

Appendix 5 - Page 4

Oct. 8/10

R Oct.12/12

Surface finish dull - oxide layer still 

present. Other visible contamination 

evident. Disc not protected in 

transportation box (to keep clean) 
R

R Example of an unacceptable disc firtree serration and rim after process cleaning

R Fig.4

Printed in Great Britain

RB.211−72−AG493

Appendix 5 - Page 5

Oct. 8/10

R Oct.12/12

Excessive oxide scale still 

present in and around firtree 

serrations, disc post and disc rim 
R

R Example of an unacceptable flange bolt and cooling air hole after process cleaning

R Fig.5

Printed in Great Britain

RB.211−72−AG493

Appendix 5 - Page 6

Oct. 8/10

R Oct.12/12

Excessive oxide scale still present 

in disc bolt/cooling hole bore