This document transmits Revision 4 of Non-Modification Service Bulletin SB-BR700-72-A900503. This Non-Modification Service Bulletin can be embodied "In Service" or "At Overhaul/Shop Visit". Document History Non-Modification Service Bulletin Revision Status Initial Issue Dec.11/09 Revision 1 Mar.24/10 Revision 2 Jun.18/10 Revision 3 Apr.15/11**Printed in Great Britain** Jun.16/11

BR700 SERIES PROPULSION SYSTEM SERVICE BULLETIN



# ALERT SB−BR700−72−A900503 Transmittal - Page 1 of 2 

# ALERTNon-Modification Service Bulletin Revision 4 Remove Incorporate Reason for change All pages of the Non-Modification Service Bulletin. Pages 1 to 18 of the Non-Modification Service Bulletin. To include the inspection of the Low Pressure (LP) compressor booster rotor front flange scallops for engines at overhaul/shop visit, if the level of engine or module disassembly does not allow the LP compressor booster rotor to be reworked in accordance with Service Bulletin SB-BR700-72-101683.**Printed in Great Britain**



# SB−BR700−72−A900503 Transmittal - Page 2 of 21. Planning Information A. Effectivity BR700-715A1-30, BR700-715B1-30 and BR700-715C1-30 Engines. For all engines which do not have the Service Bulletin SB-BR700-72-101155 standard and do not have the Service Bulletin SB-BR700-72-101683 standard incorporated. Non-Modular. B. Concurrent Requirements
None.
C. Reason A crack was detected on a Low Pressure (LP) compressor booster rotor during a spin test at high life. The LP compressor booster rotor was part of the first production batch installed on BR715 engines. There is the requirement to instruct a precautionary local Fluorescent Penetrant Inspection (FPI) of the potentially affected LP compressor booster rotors. Revision 1 of this Non-Modification Service Bulletin had been issued to extend the quantity of potentially affected LP compressor booster rotors in the Description and to revise the Compliance. Revision 2 of this Non-Modification Service Bulletin had been issued to add the use of alternative fluorescent high sensitivity post-emulsified penetrant (Material No. 6/155) for the Fluorescent Penetrant Inspection (FPI) for engines "In Service". Revision 3 of this Non-Modification Service Bulletin had R been issued to include PART 2 which instructs the rework of the Low Pressure (LP) compressor booster rotor front flange scallops for engines at overhaul/shop visit in accordance with Service Bulletin SB-BR700-72-101683. Revision 4 of this Non-Modification Service Bulletin has been issued to include the inspection of the Low Pressure (LP) compressor booster rotor front flange scallops for engines at overhaul/shop visit, if the level of engine or module disassembly does not allow the LP compressor booster rotor to be reworked in accordance with Service Bulletin SB-BR700-72-101683. R R R R R ENGINE - LOW PRESSURE (LP) COMPRESSOR BOOSTER ROTOR - LOCAL FLUORESCENT PENETRANT INSPECTION (FPI) OF THE LP COMPRESSOR BOOSTER ROTOR FRONT FLANGE SCALLOPS - NON-MODIFICATION SERVICE BULLETIN**Printed in Great Britain**



# SB−BR700−72−A900503 Page 1 of 18 Dec.11/09 Jun.16/11 Revision 4D. Description This Non-Modification Service Bulletin instructs a local Fluorescent Penetrant Inspection (FPI) and the rework of the front flange scallops of all potentially affected LP compressor booster rotors with the part numbers BRH19215 and BRH19871 which have a serial number in the range of 118 to 255. This Non-Modification Service Bulletin is divided into two PARTs as follows: PART 1 - Local Fluorescent Penetrant Inspection (FPI) of the Low Pressure (LP) compressor booster rotor front flange scallops.
NOTE : The Accomplishment Instruction for PART 1 of this Service Bulletin is applicable for engines "In Service" and for engines "At Overhaul/Shop Visit", if the level of engine or module disassembly does not allow the LP compressor booster rotor to be reworked in accordance with Service Bulletin SB-BR700-72-101683. R R R R R PART 2 - Rework of the Low Pressure (LP) compressor booster rotor front flange scallops in accordance with Service Bulletin SB-BR700-72-101683.
NOTE : The Accomplishment Instruction for PART 2 of this Service Bulletin is applicable for engines At R Overhaul/Shop Visit" only. R E. Compliance
ALERT This Non-Modification Service Bulletin must be accomplished on all engines within 500 cycles after receipt of this Non-Modification Service Bulletin. PART 1 In Service If one of the LP compressor booster rotor serial numbers quoted in paragraph 1.D. Description is recorded in the engine log book as currently installed on the engine, this LP compressor booster rotor must be inspected in accordance with this Non-Modification Service Bulletin as follows: (1) For engines operating to Hawaiian Flight Mission only: (a) The LP compressor booster rotor must be inspected on or before the LP compressor booster rotor achieves a threshold life of 36000 cycles and must be inspected at repeat intervals of not more than 6000 cycles after the previous inspection.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 2 of 18 Dec.11/09 Jun.16/11 Revision 4(b) If the LP compressor booster rotor has exceeded the threshold life of 36000 cycles, the LP compressor booster rotor must be inspected at the next aircraft scheduled maintenance opportunity, but not later than 500 cycles after receipt of this Non-Modification Service Bulletin. (c) If the LP compressor booster rotor has been previously inspected in accordance with this Non-Modification Service Bulletin, the LP compressor booster rotor must be inspected at repeat intervals of not more than 6000 cycles after the previous inspection. (2) For engines operating to all other ratings (Design, Tropical, De-rated Tropical or De-rated Design Flight Missions): (a) The LP compressor booster rotor must be inspected on or before the LP compressor booster rotor achieves a threshold life of 18000 cycles and must be inspected at repeat intervals of not more than 4000 cycles after the previous inspection. (b) If the LP compressor booster rotor has exceeded the threshold life of 18000 cycles, the LP compressor booster rotor must be inspected at the next aircraft scheduled maintenance opportunity, but not later than 500 cycles after receipt of this Non-Modification Service Bulletin. (c) If the LP compressor booster rotor has been previously inspected in accordance with this Non-Modification Service Bulletin, the LP compressor booster rotor must be inspected at repeat intervals of not more than 4000 cycles after the previous inspection. (3) For engines operating to both to Hawaiian Flight Mission and to any other rating (Design, Tropical, De-rated Tropical or De-rated Design Flight Missions): (a) The LP compressor booster rotor must be inspected on or before the LP compressor booster rotor achieves a threshold life of 18000 cycles and must be inspected at repeat intervals of not more than 4000 cycles after the previous inspection. (b) If the LP compressor booster rotor has exceeded the threshold life of 18000 cycles, the LP compressor booster rotor must be inspected at the next aircraft scheduled maintenance opportunity, but not later than 500 cycles after receipt of this Non-Modification Service Bulletin. (c) If the LP compressor booster rotor has been previously inspected in accordance with this Non-Modification Service Bulletin, the LP compressor booster rotor must be inspected at repeat intervals of not more than 4000 cycles after the previous inspection.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 3 of 18 Dec.11/09 Jun.16/11 Revision 4At Overhaul/Shop Visit R If one of the LP compressor booster rotor serial numbers quoted in paragraph 1.D. Description is recorded in the engine log book as currently installed on the engine and the level of engine or module disassembly does not allow the LP compressor booster rotor to be reworked in accordance with Service Bulletin SB-BR700-72-101683, this LP compressor booster rotor must be inspected in accordance with this Non-Modification Service Bulletin. R R R R R R PART 2 At Overhaul/Shop Visit If one of the LP compressor booster rotor serial numbers quoted in paragraph 1.D. Description is recorded in the engine log book as currently installed on the engine and the level of engine or module disassembly allows the LP compressor booster rotor to be reworked in accordance with Service Bulletin SB-BR700-72-101683, R R R this LP compressor booster rotor must be reworked in accordance with Service Bulletin SB-BR700-72-101683. R F. Approval The technical content of this document is approved under the authority of EASA Design Organisation Approval No. EASA.21J.065. G. Manpower Estimated Man-hours: (1) PART 1 (a) In Service R 5 hours. R (b) At Overhaul/Shop Visit R 5 hours. R (2) PART 2 (a) At Overhaul/Shop Visit R Refer to Service Bulletin SB-BR700-72-101683. R H. Material Price and Availability Not applicable.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 4 of 18 Dec.11/09 Jun.16/11 Revision 4I. Tooling Price and Availability New tools are not required. J. Industry Support Information The incorporation of this Non-Modification Service Bulletin is not free of charge.
NOTE : For further information contact your local Rolls-Royce Representative. K. Weight and Balance (1) Weight Change
None. (2) Moment Arm No effect. (3) Datum ES2540 (PPS100). L. Electrical Load Data The aircraft electrical load is not affected by this Non-Modification Service Bulletin. M. Software Accomplishment Summary Not applicable.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 5 of 18 Dec.11/09 Jun.16/11 Revision 4N. References (1) Aircraft Maintenance Manual, Chapters 70-20-01, 70-30-01, 72-38-01 and 72-38-15. (2) Engine Manual - E-715-3BR, Chapter 72-38-15. R (3) Standard Practices Manual - SP-700-BR, Chapter 70-20-01. R (4) Engine Overhaul Processes Manual - TSD594-J, Chapter 70-00-00. R (5) Service Bulletin SB-BR700-72-101155
ENGINE - LP COMPRESSOR BOOSTER ROTOR - INTRODUCTION OF A NEW BOOSTER BLISK ROTOR WITH DECREASED TIP CLEARANCE (6) Service Bulletin SB-BR700-72-101683 ENGINE - LOW PRESSURE (LP) COMPRESSOR BOOSTER ROTOR - INTRODUCTION OF A LP COMPRESSOR BOOSTER ROTOR WITH REPROFILED SCALLOPS BY REWORK O. Other Publications Affected
None. P. Interchangeability of Parts Not affected.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 6 of 18 Dec.11/09 Jun.16/11 Revision 42. Material Information A. Parts to be Replaced
None. B. Expendable Parts Refer to the related Manual tasks given in the Accomplishment Instruction of this Non-Modification Service Bulletin. C. Instruction/Disposition Codes
None.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 7 of 18 Dec.11/09 Jun.16/11 Revision 43. Accomplishment Instruction
APPLICABLE FOR ENGINES "IN SERVICE" A. Verify the engine log book to determine if a potentially affected Low Pressure (LP) compressor booster rotor with one of the serial numbers quoted in paragraph 1.D. Description is installed on the engine (1) If none of the LP compressor booster rotor serial numbers quoted in paragraph 1.D. Description is recorded in the engine log book as currently installed on the engine, a local Fluorescent Penetrant Inspection (FPI) of the LP compressor booster rotor is not required. Continue with step B. R (2) If one of the LP compressor booster rotor serial numbers quoted in paragraph 1.D. Description is recorded in the engine log book as currently installed on the engine, a local Fluorescent Penetrant Inspection (FPI) of the LP compressor booster rotor is required. Continue with step D. (PART 1). R B. Complete the Accomplishment Form on page 18 and send it to Rolls-Royce Deutschland, Engineering for Services. R R C. A record of accomplishment is required. Rolls-Royce Deutschland suggests to put an entry into the engine log book R R (1) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 in the Engine Service Record. R R (2) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 in the Service Bulletins list of the Non-Modular Log Card. R R R**Printed in Great Britain**



# SB−BR700−72−A900503 Page 8 of 18 Dec.11/09 Jun.16/11 Revision 4PART 1 - Local Fluorescent Penetrant Inspection (FPI) of the Low Pressure (LP) compressor booster rotor front flange scallops R R D. General
NOTE : In order to reduce the potential for multiple-engine in-flight shutdown, power loss, or other anomaly due to maintenance error, Rolls-Royce Deutschland 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 of an aircraft at the same time, Rolls-Royce Deutschland recommends that additional controls are applied in order to ensure that maintenance tasks have been completed as defined.
WARNING : YOU MUST BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE IS STOPPED. THE ENGINE PARTS CAN STAY HOT FOR ALMOST ONE HOUR.
WARNING : DO NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT PARTS CAN CAUSE AN INJURY. IF YOU GET AN INJURY, PUT IT IN COLD WATER FOR TEN MINUTES AND GET MEDICAL AID. (1) Obey all the WARNINGS and CAUTIONS in the procedures that are referred to. (2) Consumable Materials (a) Refer to the related Manual tasks given in this instruction. (3) Tools and Equipment (a) Refer to the related Manual tasks given in this instruction. (4) Refer to the Aircraft Maintenance Manual, TASK 70-20-01-100-801 for the procedure to clean engine parts. E. Get access to the LP compressor booster rotor that is installed in the front area of the engine (1) Remove the air intake rotating fairing and the nose cone from the engine (Refer to the Aircraft Maintenance Manual, TASK 72-38-01-000-801). (2) Remove the LP compressor blades from the engine (Refer to the Aircraft Maintenance Manual, TASK 72-38-15-000-801). (3) Remove the LP compressor annulus fillers from the engine (Refer to the Aircraft Maintenance Manual, TASK 72-38-15-000-803).**Printed in Great Britain**



# SB−BR700−72−A900503 Page 9 of 18 Dec.11/09 Jun.16/11 Revision 4F. Locally clean the LP compressor booster rotor in the area of the 24 front flange scallops (Refer to Figure 1).
NOTE : If loose Dry Film Lubricant (DFL) coating from the LP compressor blades or the LP compressor rotor disc is visible in the area of the 24 front flange scallops, the DFL coating must be removed. G. Do a detailed, local visual inspection on all 24 front flange scallops of the LP compressor booster rotor (Refer to Figure 1) (1) Record the inspection results in the Accomplishment Form R on page 18. (2) If damage is found, contact Rolls-Royce Deutschland, Engineering for Services. H. Do a local Fluorescent Penetrant Inspection (FPI) on all 24 front flange scallops of the LP compressor booster rotor (Refer to the Aircraft Maintenance Manual, TASK 70-30-01-230-801 and to Figure 1 of this Non-Modification Service Bulletin) (1) Use the fluorescent high sensitivity post-emulsified penetrant (Material No. 6/155) or the fluorescent ultra high sensitivity post-emulsified penetrant (Material No. 6/160) for the Fluorescent Penetrant Inspection (FPI). (2) Record the inspection results in the Accomplishment Form R on page 18. (3) If any crack is found, reject the engine. I. Close the access to the LP compressor booster rotor (1) Install the LP compressor annulus fillers on the engine (Refer to the Aircraft Maintenance Manual, TASK 72-38-15-400-803). (2) Install the LP compressor blades on the engine (Refer to the Aircraft Maintenance Manual, TASK 72-38-15-400-801). (3) Install the nose cone and the air intake rotating fairing on the engine (Refer to the Aircraft Maintenance Manual, TASK 72-38-01-400-801). J. Make sure that the work area is clean and clear of tools, equipment and other unwanted materials. K. Complete the Accomplishment Form R on page 18 and send it to Rolls-Royce Deutschland, Engineering for Services.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 10 of 18 Dec.11/09 Jun.16/11 Revision 4L. A record of accomplishment is required. Rolls-Royce Deutschland suggests to put an entry into the engine log book (1) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 (PART 1) in the Engine Service Record. (2) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 (PART 1) in the Service Bulletins list of the Non-Modular Log Card.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 11 of 18 Dec.11/09 Jun.16/11 Revision 4APPLICABLE FOR ENGINES "AT OVERHAUL/SHOP VISIT" R M. Verify the engine log book to determine if a potentially affected Low Pressure (LP) compressor booster rotor with one of the serial numbers quoted in paragraph 1.D. Description is installed on the engine R R R (1) If none of the LP compressor booster rotor serial numbers quoted in paragraph 1.D. Description is recorded in the engine log book as currently installed on the engine, a local Fluorescent Penetrant Inspection (FPI) of the LP compressor booster rotor or a rework of the LP compressor booster rotor in accordance with Service Bulletin SB-BR700-72-101683 is not required. Continue with step N. R R R R R R (2) If one of the LP compressor booster rotor serial numbers quoted in paragraph 1.D. Description is recorded in the engine log book as currently installed on the engine and the level of engine or module disassembly does not allow the LP compressor booster rotor front flange scallops to be reworked in accordance with Service Bulletin SB-BR700-72-101683, a local Fluorescent Penetrant Inspection (FPI) of the LP compressor booster rotor is required. Continue with step P. (PART 1). R R R R R R R (3) If one of the LP compressor booster rotor serial numbers quoted in paragraph 1.D. Description is recorded in the engine log book as currently installed on the engine and the level of engine or module disassembly allows the LP compressor booster rotor front flange scallops to be reworked in accordance with Service Bulletin SB-BR700-72-101683, a rework of the LP compressor booster rotor in accordance with Service Bulletin SB-BR700-72-101683 is required. Continue with step Y. (PART 2). R R R R R R R N. Complete the Accomplishment Form on page 18 and send it to Rolls-Royce Deutschland, Engineering for Services. R R O. A record of accomplishment is required. Rolls-Royce Deutschland suggests to put an entry into the engine log book R R (1) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 in the Engine Service Record. R R (2) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 in the Service Bulletins list of the Non-Modular Log Card. R R R**Printed in Great Britain**



# SB−BR700−72−A900503 Page 12 of 18 Dec.11/09 Jun.16/11 Revision 4PART 1 - Local Fluorescent Penetrant Inspection (FPI) of the Low Pressure (LP) compressor booster rotor front flange scallops R R P. General R (1) Obey all the WARNINGS and CAUTIONS in the procedures that are referred to. R R (2) Consumable Materials R (a) Refer to the related Manual tasks given in this instruction. R (3) Tools and Equipment R (a) Refer to the related Manual tasks given in this instruction. R (4) Refer to the Standard Practices Manual, TASK 70-20-01-100-801 for the procedure to clean engine parts. R R Q. Get access to the LP compressor booster rotor that is installed in the front area of the engine R R (1) Remove the air intake rotating fairing, the nose cone, the LP compressor blades and the LP compressor annulus fillers from the engine (Refer to the Engine Manual, TASK 72-38-01-000-801). R R R R. Locally clean the LP compressor booster rotor in the area of the 24 front flange scallops (Refer to Figure 1). R R
NOTE : If loose Dry Film Lubricant (DFL) coating from the LP compressor blades or the LP compressor rotor disc is visible in the area of the 24 front flange scallops, the DFL coating must be removed. R R R S. Do a detailed, local visual inspection on all 24 front flange scallops of the LP compressor booster rotor (Refer to Figure 1) R R (1) Record the inspection results in the Accomplishment Form on page 18. R (2) If damage is found, contact Rolls-Royce Deutschland, Engineering for Services. R R**Printed in Great Britain**



# SB−BR700−72−A900503 Page 13 of 18 Dec.11/09 Jun.16/11 Revision 4T. Do a local Fluorescent Penetrant Inspection (FPI) on all 24 front flange scallops of the LP compressor booster rotor (Refer to the Engine Overhaul Processes Manual, TASK 70-00-00-200-210 and to Figure 1 of this Non-Modification Service Bulletin) R R R R (1) Use the fluorescent high sensitivity post-emulsified penetrant (OMat 651) or the fluorescent ultra high sensitivity post-emulsified penetrant (OMat 652) for the Fluorescent Penetrant Inspection (FPI). R R R (2) Record the inspection results in the Accomplishment Form on page 18. R (3) If any crack is found, reject the engine. R U. Close the access to the LP compressor booster rotor R (1) Install the LP compressor annulus fillers, the LP compressor blades, the nose cone and the air intake rotating fairing on the engine (Refer to the Engine Manual, TASK 72-38-15-400-801). R R R V. Make sure that the work area is clean and clear of tools, equipment and other unwanted materials. R R W. Complete the Accomplishment Form on page 18 and send it to Rolls-Royce Deutschland, Engineering for Services. R R X. A record of accomplishment is required. Rolls-Royce Deutschland suggests to put an entry into the engine log book R R (1) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 (PART 1) in the Engine Service Record. R R (2) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 (PART 1) in the Service Bulletins list of the Non-Modular Log Card. R R R**Printed in Great Britain**



# SB−BR700−72−A900503 Page 14 of 18 Dec.11/09 Jun.16/11 Revision 4PART 2 - Rework of the Low Pressure (LP) compressor booster rotor front flange scallops in accordance with Service Bulletin SB-BR700-72-101683 Y. Rework the LP compressor booster rotor front flange scallops in accordance with Service Bulletin SB-BR700-72-101683. Z. Complete the Accomplishment Form R on page 18 and send it to Rolls-Royce Deutschland, Engineering for Services. AA.A record of accomplishment is required. Rolls-Royce Deutschland suggests to put an entry into the engine log book (1) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 (PART 2) in the Engine Service Record. (2) Record the incorporation of Non-Modification Service Bulletin SB-BR700-72-A900503 (PART 2) in the Service Bulletins list of the Non-Modular Log Card.**Printed in Great Britain**



# SB−BR700−72−A900503 Page 15 of 18 Dec.11/09 Jun.16/11 Revision 4Local Fluorescent Penetrant Inspection (FPI) of the Low Pressure (LP) Compressor Booster Rotor Front Flange Scallops Figure 1 (Sheet 1 of 2)**Printed in Great Britain**



# SB−BR700−72−A900503 Page 16 of 18 Dec.11/09 Jun.16/11 Revision 4Local Fluorescent Penetrant Inspection (FPI) of the Low Pressure (LP) Compressor Booster Rotor Front Flange Scallops Figure 1 (Sheet 2 of 2)**Printed in Great Britain**



# SB−BR700−72−A900503 Page 17 of 18 Dec.11/09 Jun.16/11 Revision 4R

Accomplishment Form R**Printed in Great Britain**



# SB−BR700−72−A900503 Page 18 of 18 Dec.11/09 Jun.16/11 Revision 4