P.O. Box 31, DERBY DE24 8BJ, UK Telephone: 44 (0) 1332 242424 Fax: 44 (0) 1332 249936 

# Rolls-Royce 

# -
TRANSMITTA The technical information contained in this document has been approved underthe authority of - See Planning Information,Approval.
Signed Date Jun. 6/08
N. J. Wright

RB211-524G-T, 524H-T, TRENT 500, TRENT 700 AND TRENT 800 PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN 

# ALERT

This document transmits Revision 1 to Service Bulletin RB211-72-AF964 Document History Service Bulletin Revision Status Initial Issue Jun. 3/08 Bulletin Revision 1 Remove All pages of the Service Bulletin Supplement Revision Status

Incorporate Pages 1 to 11 of the Service Bulletin



# ALERT Reason for change To correct Part No. in I.A.(4) and to revise Accomplishment Instructions to include OP104 Subtask references and changes to FPI parameters (RR RMRs 7735 and SB0053).

Transmittal 

### - Page 1 of 2

CHECK THATALL PREVIOUS TRANSMITTALS HAVE BEEN INCORPORATED If any have not been received please advise Customer Data Services, Rolls-Royce plc, Derby, England O Rolls-Royce plc (date as above) Printed in Great BritainLIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin following incorporation of Revision 1 are as follows: Page Revision Number Revision Date

Bulletin R 1 1 Jun.6/08 R 2 1 Jun.6/08 R 3 1 Jun.6/08 R 4 1 Jun.6/08 R 5 1 Jun.6/08 R 6 1 Jun.6/08 R 7 1 Jun.6/08 R 8 1 Jun.6/08 R 9 1 Jun.6/08 R 10 1 Jun.6/08 R 11 1 Jun.6/08Printed in Great Britain



# RB.211−72−AF964 Transmittal - Page 21. Planning Information A. Effectivity (1) RB211-TRENT 500 Engines - All HP Compressor Stage 1 to 4 Rotor Discs: FK30524 (2) RB211-TRENT 700 Engines - All HP Compressor Rotor Shafts: FK22745 FK24031 FK26185 FW20195 FW20197 FW23711 FK23313 FK25502 FK32129 FW20196 FW20638 - (3) RB211-TRENT 800 Engines - All HP Compressor Stage 1 to 4 Rotor Discs: FK24009 FK26167 FK32580 FW11590 FW61622 (4) RB211-524G-T, 524H-T Engines - All HP Compressor Rotor Shafts: FK25502 FW20195 R FW23711
B. Reason During manufacture of a small number of HP Compressor Stage 1 and 2 discs with axial dovetail slots, anomalies at the disc post corners have been found. Whilst no anomalies have been found on in-service discs, this Non-Modification Service Bulletin (NMSB) has been raised to reduce the potential risk of a crack propagating from an anomaly. An investigation of the root cause of the anomalies is in progress. As a result, an inspection at the HP Compressor Stage 1 and 2 axial dovetail slots is required. This NMSB instructs a local Fluorescent Penetrant Inspection (FPI) of the HP Compressor Stage 1 and 2 discs axial dovetail slots, see Section 3. Accomplishment Instructions for engine applicability. C. Compliance
ALERT Rolls-Royce recommends that the following action is undertaken to maintain reliability. The actions detailed in Section 3. Accomplishment Instructions must be completed on all HP Compressor drums regardless of disposition, in accordance with the following. For all hardware covered in Section 1.A. Effectivity: ENGINE - HP COMPRESSOR DRUM - INSPECTION OF AXIAL DOVETAIL SLOTS - NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-AF964Printed in Great Britain



# RB.211−72−AF964 Page 1 of 11 Jun 3/08 Jun. 6/08 R(1) At every engine Refurbishment (Level 3) shop visit, Overhaul (Level 4) shop visit or when the HP compressor rotor is at piece part level, and the life of the drum is greater than 1000 cycles since new, then complete the action defined in Section 3. Accomplishment Instructions. (2) For hardware currently at Refurbishment (Level 3) shop visit, Overhaul (Level 4) visit or when the HP compressor is at piece part level on the date of issue of this NMSB, if the HP compressor rotor assembly is not completed and the life of the drum is greater than 1000 cycles since new, then complete the action defined in Section 3. Accomplishment Instructions. This NMSB does not instruct inspection on Time Expired HP Compressor drums. It is anticipated that the actions instructed in this NMSB will be contained within an EASA Airworthiness Directive R R NMSB72-AF259 HP Compressor Stage 1 Disc Inspection should be carried out at the same time as this NMSB. D. Approval The technical content of this Non-Modification Service Bulletin was approved under the authority of Design Organisation Approval EASA.21J.035 on June 2/08. E. Manpower In Service: Not applicable At Overhaul: 20 man hours F. Material Price and Availability Not applicable G. Tooling Price and Availability Not applicable. H. References (1) Rolls-Royce RB211 Non-Modification Service Bulletin: 72-AF259 Engine - HP Compressor Stage 1 Disc Inspection (2) Trent 500 Engine Manual: Task 72-41-31-200-803, Examine the HP Compressor Stage 1 to 4 Rotor Discs Shaft Assembly.Printed in Great Britain



# RB.211−72−AF964 Page 2 Jun 3/08 Jun. 6/08 R(3) Trent 700 Engine Manual: Task 72-41-31-200-801, Examine the High Pressure (HP) Compressor Rotor Disks Shaft Assembly. (4) Trent 800 Engine Manual: Task 72-41-31-200-801, Examine the High Pressure (HP) Compressor Stage 1 to 4 Rotor Disks Shaft Assembly. (5) RB211-524G-T and 524H-T Engine Manual: Task 72-41-31-200-014, Inspect High Pressure (HP) Compressor Rotor Shaft Assembly - Inspection/Check-00, Config-2 (6) Engine Overhaul Processes Manual TSD594-J: (a) Overhaul Process OP101: Non-Aqueous Vapour and Liquid Degreasing (b) Overhaul Process OP102: Primary Cleaning - Aqueous (c) Overhaul Process OP104: Abrasive Blasting for Cleaning (d) Overhaul Process OP136: Removal of Oxidation and Heat Discolouration from Titanium Parts (e) Overhaul Process OP210: Fluorescent Penetrant Inspection (f) Overhaul Process OP335: Application Of Dry-Film Lubricants 2. Material Information
NonePrinted in Great Britain



# RB.211−72−AF964 Page 3 Jun 3/08 Jun. 6/08 R3. Accomplishment Instructions Only corners of the front faces of the following HP Compressor axial dovetail slots are required to be inspected to accomplish this NMSB, see Figure 4: Trent 500: Stage 1 and 2 Trent 700: Stage 1 only (except FK26185 and FK32129) Trent 700: Stage 1 and 2 (FK26185 and FK32129 only) Trent 800: Stage 1 and 2 (except FK24009) Trent 800: Stage 1 (FK24009 only) RB211-524G-T, 524H-T: Stage 1 only
NOTE : Figures 1 to 4 are for illustration only, Trent 700 Compressor Rotor Shafts are shown as an example. General Tasks identified by OP (Overhaul Process) are in the Engine Overhaul Processes Manual, TSD594-J.
CAUTION : COTTON GLOVES MUST BE WORN AT ALL TIMES WHEN HANDLING THE HP COMPRESSOR DRUM. A. Disassemble the HP Compressor Rotor Assembly following Engine Manual requirements.

NOTE : To carry out this NMSB on Trent 500 and Trent 800 HP Compressor drums, it is not required to remove the Stage 1 to 4 Compressor drum from the Stage 5 and 6 Compressor drum. B. Primary clean to OP101 (Non-Aqueous Vapour and Liquid Degreasing) or OP102 (Primary Cleaning - Aqueous).
C. Remove Dry Film Lubricant (DFL) to OP104 (Abrasive Blasting for Cleaning) Subtask 70-00-00-120-104-004 or Subtask 70-00-00-120-104-005 R R

D. Clean to OP136 (Removal of Oxidation and Heat Discolouration from Titanium Parts) Subtask 70-00-00-110-136-002 if the surface is not sufficiently cleaned to carry out the FPI inspection.Printed in Great Britain



# RB.211−72−AF964 Page 4 Jun 3/08 Jun. 6/08 RE. Carry out local FPI to OP210 (Subtask 70-00-00-230-210-002) at applicable axial dovetail slots following the steps that follow. (1) Ensure part has cooled to 38 deg.C (100 deg.F) or less (comfortable to touch) (2) Apply OMat 652 Penetrant, 30 minutes minimum contact time. Check for full coverage. Do not exceed 60 minutes. (3) First wash at 25psi (0.17MPa) maximum (Max). Verify wash under UV light. (4) Emulsify one minute plus or minus 15 seconds, including travel time. (5) Second wash at 25psi (0.17MPa) Max. Verify wash under UV light. (6) Blow off excess water at 25psi (0.17MPa) Max. (7) Oven dry at 70 deg.C, plus or minus 10 deg. C (158 deg.F, plus or minus 18 R deg.F) R for 20 minutes Max. Move parts to next step immediately after removing them from the oven. (8) Apply OMat 606 (or approved alternative) developer for 30 to 60 minutes. (9) Air blow off excess developer at 10psi (0.069MPa) R Max. (10) Inspection: (a) Complete the inspection within two hours of application of developer. (b) Ensure all curtains/doors are fully closed in the inspection booth. Max 5 lux ambient white light. (c) Ensure drum is correctly centred on a turntable or horizontal viewing fixture. If a turntable is used, make sure the drum runs true when it is rotated. (d) Position UV lamps at 90 degrees apart, with the focal spot of both lamps directed on the dovetail, as shown in Figure 1. Liquid guide lights may be used instead of UV lamps as long as they are of an approved type and meet minimum output requirement of 1000microWatts/sq.cm. R (e) Set binoculars to 6 to 8 x magnification. (f) Use white light to aid focusing the binoculars onto the dovetails. (g) Allow three minutes R eye adaptation time. (h) Carefully binocular inspect, at 6 to 8 x magnification, each dovetail in turn under UV; pay particular attention to both acute and obtuse angles, as shown in Figures 1 to 4. A mirror may be used as an aid.Printed in Great Britain



# RB.211−72−AF964 Page 5 Jun 3/08 Jun. 6/08 R(i) If any cracks are found - Reject. For any other anomalies use Engine Manual limits, see References (1.H.).
NOTE : Keep hands and items away from the area being inspected to reduce excessive fluorescence. (11) Re-apply the DFL to OP335 (Application Of Dry-Film Lubricants). (12) Reassemble module and inspect in accordance with the Engine Manual requirements. (13) Complete the Record of Accomplishment sheet (Figure 5) and return to Rolls-Royce via your local Rolls-Royce Field Service Office.Printed in Great Britain



# RB.211−72−AF964 Page 6 Jun 3/08 Jun. 6/08 RPosition of UV lamps Figure 1Printed in Great Britain



# RB.211−72−AF964 Page 7 Jun 3/08 Jun. 6/08 RAcute angle Figure 2Printed in Great Britain



# RB.211−72−AF964 Page 8 Jun 3/08 Jun. 6/08 RObtuse angle Figure 3Printed in Great Britain



# RB.211−72−AF964 Page 9 Jun 3/08 Jun. 6/08 RKey Inspection Areas Figure 4Printed in Great Britain



# RB.211−72−AF964 Page 10 Jun 3/08 Jun. 6/08 RRecord of Accomplishment (Inspection) Sheet Figure 5Printed in Great Britain



# RB.211−72−AF964 Page 11 Jun 3/08 Jun. 6/08 R