Document ID: FAA-2010-0821-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Rolls-Royce plc RB211-Trent 800 Series Turbofan Engines
Posted Date: 2011-01-14T05:00Z

[Federal Register Volume 76, Number 10 (Friday, January 14, 2011)]
[Proposed Rules]
[Pages 2605-2607]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2011-775]

 ========================================================================
 Proposed Rules
                                                 Federal Register
 ________________________________________________________________________
 
 This section of the FEDERAL REGISTER contains notices to the public of 
 the proposed issuance of rules and regulations. The purpose of these 
 notices is to give interested persons an opportunity to participate in 
 the rule making prior to the adoption of the final rules.
 
 ========================================================================
 

  Federal Register / Vol. 76, No. 10 / Friday, January 14, 2011 / 
Proposed Rules  

[[Page 2605]]

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2010-0821; Directorate Identifier 2010-NE-30-AD]
RIN 2120-AA64

Airworthiness Directives; Rolls-Royce plc RB211-Trent 800 Series 
Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: We propose to adopt a new airworthiness directive (AD) for the 
products listed above. This proposed AD results from mandatory 
continuing airworthiness information (MCAI) issued by an aviation 
authority of another country to identify and correct an unsafe 
condition on an aviation product. The MCAI describes the unsafe 
condition as:

    In January 2009 a Trent 895 powered Boeing 777-200 aircraft 
experienced release of a low pressure (LP) compressor blade which 
failed due to fatigue cracking in the root section of the blade. The 
released blade (undercut root standard) had received a part life 
processing to apply a compression layer to the blade root (Service 
Bulletin SB 72-D672--Introduction of Laser Shock Peening (LSP)) and 
also a part life upgrade to the retention feature lubrication 
system. Investigation has revealed that the effectiveness of this 
upgraded blade root lubrication coating system may be reduced 
dependant on the extent of previous running with the earlier 
standard, leading to increased blade root stress levels. In the 
specific case of the released blade, a review of its in-service 
modification history has shown that it operated for a relatively 
high number of flight cycles prior to the compression layer 
processing and the new retention feature lubrication system. A 
review of the Engine Health Monitoring data has also identified it 
operated at high N1 speeds compared to the Trent 800 fleet average 
N1 speeds. The combination of these factors has resulted in 
increased fatigue life usage which is considered to have led to 
crack initiation and propagation prior to reaching the blades 
declared life limit. A review of all in-service undercut/LSP 
standard Trent 800 LP compressor blades has identified specific 
blades that carry a similar increased susceptibility to cracking.
    This AD is issued to mitigate the risk of possible multiple fan 
blades failure affecting those blades identified as described above 
which could lead to high energy non contained debris from the 
engine.

We are proposing this AD to prevent LP compressor blades from failing 
due to blade root cracks, which could lead to uncontained engine 
failure and damage to the airplane.

DATES: We must receive comments on this proposed AD by February 28, 
2011.

ADDRESSES: You may send comments by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 1200 New Jersey Avenue, SE., West Building Ground 
Floor, Room W12-140, Washington, DC 20590-0001.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
     Fax: (202) 493-2251.
    Contact Rolls-Royce plc, P.O. Box 31, DERBY, DE24 8BJ, UK; 
telephone 44 (0) 1332 242424; fax 44 (0) 1332 249936, for the service 
information identified in this proposed AD.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Operations office 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this proposed AD, the regulatory 
evaluation, any comments received, and other information. The street 
address for the Docket Operations office (phone (800) 647-5527) is the 
same as the Mail address provided in the ADDRESSES section. Comments 
will be available in the AD docket shortly after receipt.

FOR FURTHER INFORMATION CONTACT: Alan Strom, Aerospace Engineer, Engine 
Certification Office, FAA, Engine & Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; e-mail: 
alan.strom@faa.gov; telephone (781) 238-7143; fax (781) 238-7199.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposed AD. Send your comments to an address 
listed under the ADDRESSES section. Include ``Docket No. FAA-2010-0821; 
Directorate Identifier 2010-NE-30-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this proposed AD. We 
will consider all comments received by the closing date and may amend 
this proposed AD based on those comments.
    We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact 
with FAA personnel concerning this proposed AD. Using the search 
function of the Web site, anyone can find and read the comments in any 
of our dockets, including, if provided, the name of the individual who 
sent the comment (or signed the comment on behalf of an association, 
business, labor union, etc.). You may review the DOT's complete Privacy 
Act Statement in the Federal Register published on April 11, 2000 (65 
FR 19477-78).

Discussion

    The European Aviation Safety Agency (EASA), which is the Technical 
Agent for the Member States of the European Community, has issued EASA 
Airworthiness Directive 2010-0097, dated May 26, 2010 (referred to 
after this as ``the MCAI''), to correct an unsafe condition for the 
specified products. The MCAI states:

    In January 2009 a Trent 895 powered Boeing 777-200 aircraft 
experienced release of a low pressure (LP) compressor blade which 
failed due to fatigue cracking in the root section of the blade. The 
released blade (undercut root standard) had received a part life 
processing to apply a compression layer to the blade root (Service 
Bulletin SB 72-D672--Introduction of Laser Shock Peening (LSP)) and 
also a part life upgrade to the retention feature lubrication 
system. Investigation has revealed that the effectiveness of this 
upgraded blade root lubrication coating system may be reduced 
dependant on the extent of previous running with the earlier 
standard, leading to

[[Page 2606]]

increased blade root stress levels. In the specific case of the 
released blade, a review of its in-service modification history has 
shown that it operated for a relatively high number of flight cycles 
prior to the compression layer processing and the new retention 
feature lubrication system. A review of the Engine Health Monitoring 
data has also identified it operated at high N1 speeds compared to 
the Trent 800 fleet average N1 speeds. The combination of these 
factors has resulted in increased fatigue life usage which is 
considered to have led to crack initiation and propagation prior to 
reaching the blades declared life limit. A review of all in-service 
undercut/LSP standard Trent 800 LP compressor blades has identified 
specific blades that carry a similar increased susceptibility to 
cracking.
    This AD is issued to mitigate the risk of possible multiple fan 
blades failure affecting those blades identified as described above 
which could lead to high energy non contained debris from the 
engine.

    You may obtain further information by examining the MCAI in the AD 
docket.

Relevant Service Information

    Rolls-Royce plc has issued Alert Service Bulletin No. RB.211-72-
AG244, Revision 1, dated January 26, 2010. The actions described in 
this service information are intended to correct the unsafe condition 
identified in the MCAI.

FAA's Determination and Requirements of This Proposed AD

    This product has been approved by the aviation authority of the 
United Kingdom, and is approved for operation in the United States. 
Pursuant to our bilateral agreement with the United Kingdom, they have 
notified us of the unsafe condition described in the MCAI and service 
information referenced above. We are proposing this AD because we 
evaluated all information provided by EASA, and determined the unsafe 
condition exists and is likely to exist or develop on other products of 
the same type design.

Costs of Compliance

    Based on the service information, we estimate that this proposed AD 
would affect about 20 engines installed on airplanes of U.S. registry. 
We also estimate that it would take about 18 work-hours per engine to 
perform the inspections in one year's time. The average labor rate is 
$85 per work-hour. We estimate that one LP compressor blade per year 
would need replacement, at a cost of about $82,000. Based on these 
figures, we estimate the annual cost of the proposed AD on U.S. 
operators to be $112,600. Our cost estimate is exclusive of possible 
warranty coverage.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, section 106, describes the 
authority of the FAA Administrator. ``Subtitle VII: Aviation 
Programs,'' describes in more detail the scope of the Agency's 
authority.
    We are issuing this rulemaking under the authority described in 
``Subtitle VII, Part A, Subpart III, Section 44701: General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
rulemaking action.

Regulatory Findings

    We determined that this proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would not 
have a substantial direct effect on the States, on the relationship 
between the national Government and the States, or on the distribution 
of power and responsibilities among the various levels of government.
    For the reasons discussed above, I certify this proposed 
regulation:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979); and
    3. Will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this proposed AD and placed it in the AD docket.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

The Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA proposes to amend 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.

Sec.  39.13  [Amended]

    2. The FAA amends Sec.  39.13 by adding the following new AD:

Rolls-Royce plc: Docket No. FAA-2010-0821; Directorate Identifier 
2010-NE-30-AD.

Comments Due Date

    (a) We must receive comments by February 28, 2011.

Affected Airworthiness Directives (ADs)

    (b) None.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) RB211-Trent 875-17, 
RB211-Trent 877-17, RB211-Trent 884-17, RB211-Trent 884B-17, RB211-
Trent 892-17, RB211-Trent 892B-17, and RB211-Trent 895-17 turbofan 
engines.

Reason

    (d) This AD results from mandatory continuing airworthiness 
information (MCAI) issued by an aviation authority of another 
country to identify and correct an unsafe condition on an aviation 
product. We are issuing this AD to prevent low-pressure (LP) 
compressor blades from failing due to blade root cracks, which could 
lead to uncontained engine failure and damage to the airplane.

Actions and Compliance

    (e) Unless already done, do the following actions.
    (1) Using the corresponding compliance threshold in Table 1 of 
this AD, perform an initial ultrasonic inspection (UI) of the 
affected LP compressor blades identified by serial number (S/N) in 
Appendices 3A through 3F of RR Alert Service Bulletin (ASB) No. 
RB.211-72-AG244, Revision 1, dated January 26, 2010.

                                     Table 1--Initial Inspection Thresholds
----------------------------------------------------------------------------------------------------------------
   Appendix number of RR ASB No. RB.211-72-AG244, Revision 1, that
          identifies affected LP compressor blades by  S/N                   Initial inspection threshold
----------------------------------------------------------------------------------------------------------------
3A..................................................................  120 flight cycles after the effective date
                                                                       of this AD.

[[Page 2607]]

 
3B..................................................................  Blades shown in RR ASB No. RB.211-72-
                                                                       AG244, Revision 1 as fitted to engine
                                                                       serial number (ESN) 51039--802 flight
                                                                       cycles after the effective date of this
                                                                       AD.
                                                                      ESNs 51146, 51177, 51145, and 51149--380
                                                                       flight cycles after the effective date of
                                                                       this AD.
3C..................................................................  Blades shown in RR ASB No. RB.211-72-
                                                                       AG244, Revision 1 as fitted to ESNs
                                                                       51001, 51137 and blade S/N RGG16694--
                                                                       1,680 flight cycles after the effective
                                                                       date of this AD.
                                                                      ESN 51145, 51149, 51150 and 51204--796
                                                                       flight cycles after the effective date of
                                                                       this AD.
                                                                      ESN 51160--1,160 flight cycles after the
                                                                       effective date of this AD.
3D..................................................................  Blades shown in RR ASB No. ASB RB.211-72-
                                                                       AG244, Revision 1 as fitted to ESN 51193
                                                                       and blade S/N RGG20216--1,212 flight
                                                                       cycles after the effective date of this
                                                                       AD.
                                                                      ESN 51200--1,237 flight cycles after the
                                                                       effective date of this AD.
                                                                      ESN 51280--1,551 flight cycles after the
                                                                       effective date of this AD.
3E..................................................................  Blades shown in RR ASB No. RB.211-72-
                                                                       AG244, Revision 1 as fitted to ESN 51004,
                                                                       ``na'' and blade S/Ns RGG12590, RGG14081,
                                                                       and RGG15419--3,433 flight cycles after
                                                                       the effective date of this AD.
                                                                      ESN 51156--1,627 flight cycles after the
                                                                       effective date of this AD.
3F..................................................................  Blades shown in RR ASB No. RB.211-72-
                                                                       AG244, Revision 1 as fitted to ESN 51175,
                                                                       51194, 51201, 51205, and 51228--2,042
                                                                       flight cycles after the effective date of
                                                                       this AD.
                                                                      ESN 51264--4,309 flight cycles after the
                                                                       effective date of this AD.
                                                                      ESN 51443--2,636 flight cycles after the
                                                                       effective date of this AD.
                                                                      Blade S/N RGG15698--2,638 flight cycles
                                                                       after the effective date of this AD.
----------------------------------------------------------------------------------------------------------------

     (2) Thereafter, perform repetitive UIs of the affected LP 
compressor blades within every 100 flight cycles.
    (3) Use paragraph 3 of Accomplishment Instructions of RR ASB No. 
RB.211-72-AG244, Revision 1, dated January 26, 2010, and Appendix 1 
of that ASB to perform the UIs.
    (4) Remove blades from service before further flight that fail 
the inspection criteria in Appendix 1 of RR ASB No. RB.211-72-AG244, 
Revision 1, dated January 26, 2010.
    (5) After the effective date of this AD, do not install any 
affected LP compressor blade unless it has passed the initial and 
repetitive UIs required by this AD.

FAA AD Differences

    (f) This AD differs from MCAI European Aviation safety Agency 
(EASA) AD 2010-0097, dated May 26, 2010. The EASA AD uses calendar 
dates for initial inspection thresholds. This AD uses flight cycles.

Alternative Methods of Compliance

    (g) The Manager, Engine Certification Office, FAA, has the 
authority to approve AMOCs for this AD, if requested using the 
procedures found in 14 CFR 39.19.

Related Information

    (h) Refer to EASA AD 2010-0097, dated May 26, 2010, and RR Alert 
SB No. RB.211-72-AG244, Revision 1, dated January 26, 2010, for 
related information. Contact Rolls-Royce plc, P.O. Box 31, DERBY, 
DE24 8BJ, UK; telephone 44 (0) 1332 242424; fax 44 (0) 1332 249936, 
for a copy of this service information.
    (i) Contact Alan Strom, Aerospace Engineer, Engine Certification 
Office, FAA, Engine & Propeller Directorate, 12 New England 
Executive Park, Burlington, MA 01803; e-mail: alan.strom@faa.gov; 
telephone (781) 238-7143; fax (781) 238-7199.

    Issued in Burlington, Massachusetts, on January 10, 2011.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2011-775 Filed 1-13-11; 8:45 am]
BILLING CODE 4910-13-P