Document ID: FAA-2009-0162-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Rolls-Royce plc (RR) RB211-524 Series Turbofan Engines
Posted Date: 2009-03-02T05:00Z

[Federal Register: March 2, 2009 (Volume 74, Number 39)]
[Proposed Rules]               
[Page 9050-9053]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr02mr09-4]                         

========================================================================
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.

========================================================================

[[Page 9050]]

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0162; Directorate Identifier 2004-NE-19-AD]
RIN 2120-AA64

 
Airworthiness Directives; Rolls-Royce plc (RR) RB211-524 Series 
Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Notice of proposed rulemaking (NPRM).

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

SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) for certain RR RB211-524 series turbofan engines. That 
AD currently requires initial and repetitive borescope inspections of 
the head section and meterpanel assembly of the combustion liner, and 
replacement if necessary with serviceable parts. This proposed AD would 
require those same inspections, and replacement if necessary with 
serviceable parts. This proposed AD would also add more part number (P/
N) combustion liners to the applicability of this proposed AD. This 
proposed AD results from an inquiry submitted by an operator, which 
resulted in RR performing a complete review of the affected front 
combustion liner part numbers. We are proposing this AD to prevent 
deterioration of the engine combustion liner, which can result in 
combustion liner breakup, case burn-through, engine fire, and damage to 
the airplane.

DATES: We must receive any comments on this proposed AD by May 1, 2009.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     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, United 
Kingdom; telephone: 011-44-1332-242424; fax: 011-44-1332-249936, for 
the service information identified in this proposed AD.

FOR FURTHER INFORMATION CONTACT: Ian Dargin, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; e-mail: 
ian.dargin@faa.gov; telephone (781) 238-7178; fax (781) 238-7199.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2009-0162; Directorate 
Identifier 2004-NE-19-AD'' in the subject line of your comments. We 
specifically invite comments on the overall regulatory, economic, 
environmental, and energy aspects of the proposed AD. We will consider 
all comments received by the closing date and may amend the proposed AD 
in light of 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).

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 (telephone (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.

Discussion

    On December 20, 2004, the FAA issued AD 2004-26-05, Amendment 39-
13917 (70 FR 680, January 5, 1005). That AD requires initial and 
repetitive borescope inspections of the combustion liner head section 
and meterpanel assembly of the combustion liner and replacement if 
necessary, with serviceable parts. That action also reduces the 
inspection intervals of certain RB211-524 engine models that have not 
been repaired to RR Field Repair Scheme FRS5367/B, and requires a 
mandatory terminating action to be completed by a certain date. The 
Civil Aviation Authority (CAA), which is the airworthiness authority 
for the United Kingdom, notified the FAA that an unsafe condition may 
exist on RR RB211-524 series turbofan engines. The CAA advises that in 
August 2002, an RB211-524B engine suffered a combustion case burn-
through as a result of combustor head breakup. The combustor head was 
previously inspected within the inspection interval specified in RR 
Service Bulletin (SB) No. RB.211-72-B482, Revision 8, dated November 
15, 2001, only 228 cycles before the event. Subsequent to the original 
AD, RR has issued several revisions to SB No. RB.211-72-B482 to expand 
the applicability and clarify or revise the inspection requirements. In 
2003, RR issued Alert Service Bulletin (ASB) No. RB.211-72-AB482, 
Revision 9, dated July 28, 2003, to reduce the inspection interval for 
RB211-524B-02, -524B2, -524B3, and -524B4 engines that have not been 
repaired to RR Field Repair Scheme FRS5367/B. This condition, if not 
corrected, could result in deterioration of the engine combustion 
liner, which can result in

[[Page 9051]]

combustion liner breakup, case burn-through, and engine fire.

Actions Since AD 2004-26-05 Was Issued

    Since that AD was issued, an operator submitted an inquiry which 
resulted in RR performing a complete review of the affected front 
combustion liner part numbers. Rolls-Royce identified a number of P/Ns 
that must be included in the inspection requirements of this proposed 
AD.

Relevant Service Information

    We have reviewed and approved the technical contents of the 
following RR SBs:
     RR ASB No. RB.211-72-AB482, Revision 9, dated July 28, 
2003, which describes the initial inspection procedures to detect 
cracking of the combustion liner head section and the meterpanel. This 
ASB also describes the compliance intervals to do the initial and 
repetitive inspections.
     RR SB No. RB.211-72-9670, dated August 27, 1993, which 
describes the procedures to incorporate the improved combustion liner 
head with C263 material, and to incorporate local thickened diffuser 
walls around the struts for engine models -524B-02, -524B2, -524B3, -
524B4, -524C2 and -524D4.
     RR SB No. RB.211-72-9764, Revision 3, dated January 16, 
1998, which describes the procedures to incorporate the improved 
combustion liner with strengthened head and improved heat shields for 
engine models -524G and -524H.
    The CAA classified ASB No. RB.211-72-AB482, Revision 9, dated July 
28, 2003, as mandatory and issued AD G-2003-0011 (previously 005-07-
95), dated October 1, 2003, in order to ensure the airworthiness of 
these RR engines in the United Kingdom.

Bilateral Agreement Information

    This engine model is manufactured in the United Kingdom and is type 
certificated for operation in the United States under the provisions of 
Section 21.29 of the Federal Aviation Regulations (14 CFR 21.29) and 
the applicable bilateral airworthiness agreement. Under this bilateral 
airworthiness agreement, the CAA kept us informed of the situation 
described above. We have examined the findings of the CAA, reviewed all 
available information, and determined that AD action is necessary for 
products of this type design that are certificated for operation in the 
United States.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design. We are proposing this AD, which would 
require:
     Initial and repetitive borescope inspections of the 
combustion liner head section and meterpanel assembly of the combustion 
liner and, if necessary, replacement.
     Reduction of the inspection intervals of certain RB211-524 
engine models that have not been repaired to RR Field Repair Scheme 
FRS5367/B, and
     A mandatory terminating action to the repetitive 
inspections to be completed no later than December 31, 2012.
    The proposed AD would require that you do these actions using the 
service information described previously.

Costs of Compliance

    We estimate that this proposed AD would affect 18 engines installed 
on airplanes of U.S. registry. We also estimate that it would take 
about 2 work-hours per engine to perform the proposed actions, and that 
the average labor rate is $80 per work-hour. No parts are required, so 
parts would cost about $0. Based on these figures, we estimate the 
total cost of the proposed AD to U.S. operators to be $2,880.

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 have 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 that the proposed AD:
    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. Would 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. See the ADDRESSES section for a location 
to examine the regulatory evaluation.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the Federal Aviation Administration 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 removing Amendment 39-13917 (70 FR 
680, January 5, 2005, and by adding a new airworthiness directive, to 
read as follows:

Rolls-Royce plc: Docket No. FAA-2009-0162; Directorate Identifier 
2004-NE-19-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by May 1, 2009.

Affected ADs

    (b) This AD supersedes AD 2004-26-05, Amendment 39-13917.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) engine models RB211-
524B-02, -524B2, -524B3, -524B4, -524C2, and -524D4 series engines 
that incorporate RR Service Bulletin (SB) No. RB.211-72-7221 or RR 
SB No. RB.211-72-7998 with front combustion liner assembly, part 
number (P/N) UL16078, UL16885, UL21441, UL24898, UL26916, UL27107, 
UL27108, UL27109, UL27875,

[[Page 9052]]

UL27876, UL28971, UL28972, UL28973, UL28974, UL28975, UL28976, 
UL28977, UL28978, UL28979, UL28980, UL28981, UL28982, or UL28983, 
installed but not incorporating RR SB No. RB.211-72-9670 or RR SB 
No. RB.211-72-9764, and engine models RB211-524G and -524H series 
engines with front combustion liner assembly P/N UL27659, UL23992, 
UL22988, UL37874, and UL37882, but not incorporating RR SB No. 
RB.211-72-9764. These engines are installed on, but not limited to, 
Boeing 747 and Lockheed L1011 series airplanes.

Unsafe Condition

    (d) This AD results from an inquiry submitted by an operator 
which resulted in RR performing a complete review of the affected 
front combustion liner part numbers. We are issuing this AD to 
prevent deterioration of the engine combustion liner, which can 
result in combustion liner breakup, case burn-through, engine fire, 
and damage to the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.

Credit for Previous Inspections

    (f) Engine inspections previously made to RR Service Bulletin 
No. RB.211-72-B482, Revision 8, meet the requirements of this AD for 
the initial or repetitive inspections specified in paragraphs (f) 
through (f)(3) and (g) through (g)(3) of this AD.

Inspections of Combustion Liner Head Sections--Not Previously Repaired

    (g) Borescope-inspect combustion liner head sections that have 
not been previously repaired. Use paragraphs 3.A.(1) through 3.A.(5) 
of the Accomplishment Instructions of RR Alert Service Bulletin 
(ASB) No. RB.211-72-AB482, Revision 9, dated July 28, 2003, and the 
cycles-since-new (CSN), cycles-since-last inspection (CSLI), and 
cycles-in-service (CIS) compliance thresholds in Table 1 of this AD.

                         Table 1--Combustion Liner Head Section--Not Previously Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
            Engine series                 Initial inspection     Repetitive inspection      inspection cycles
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 1,400 to 1,600    Within 200 CSLI........  Within 100 CIS after
 524H.                                  CSN.                                              the effective date of
                                                                                          this AD.
(2) RB211-524B-02, -524B2, -524B3,     Within 3,000 to 3,200    Within 200 CSLI........  Within 200 CIS after
 and -524B4.                            CSN.                                              the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Combustion Liner Head Sections--Previously Repaired 
Using RR Field Repair Scheme FRS5367/B

    (h) Borescope-inspect combustion liner head sections previously 
repaired using RR Field Repair Scheme FRS5367/B. Use paragraphs 
3.A.(1) through 3.A.(5) of the Accomplishment Instructions of RR ASB 
No. RB.211-72-AB482, Revision 9, dated July 28, 2003, and the 
cycles-since-last repair (CSLR), CSLI, and CIS compliance thresholds 
in Table 2 of this AD.

       Table 2--Combustion Liner Head Section--Previously Repaired Using RR Field Repair Scheme FRS5367/B
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
            Engine series                 Initial inspection     Repetitive inspection      inspection cycles
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 1,800 to 2,200    Within 400 CSLI........  Within 200 CIS after
 524H.                                  CSLR.                                             the effective date of
                                                                                          this AD.
(2) RB211-524B-02, -524B2, -524B3,     Within 3,000 to 3,200    Within 400 CSLI........  Within 200 CIS after
 and -524B4.                            CSLR.                                             the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Combustion Liner Head Sections That Have Been Repaired 
But Did Not Use RR Field Repair Scheme FRS5367/B

    (i) Borescope-inspect combustion liner head sections that have 
been repaired using a method other than RR Field Repair Scheme 
FRS5367/B. Use paragraphs 3.A.(1) through 3.A.(5) of the 
Accomplishment Instructions of RR ASB No. RB.211-72-AB482, Revision 
9, dated July 28, 2003, and the CSLR, CSLI, and CIS compliance 
thresholds in Table 3 of this AD.

       Table 3--Combustion Liner Head Section--Repaired, But Did Not Use RR Field Repair Scheme FRS5367/B
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
            Engine series                 Initial inspection     Repetitive inspection      inspection cycles
----------------------------------------------------------------------------------------------------------------
(1) RB211-524C2, -524D4, -524G, and -  Within 500 to 700 CSLR.  Within 200 CSLI........  Within 100 CIS after
 524H.                                                                                    the effective date of
                                                                                          this AD.
(2) RB211-524B-02, -524B2, -524B3,     Within 2,000 to 2,200    Within 200 CSLI........  Within 200 CIS after
 and -524B4.                            CSLR.                                             the effective date of
                                                                                          this AD.
----------------------------------------------------------------------------------------------------------------

    (3) For an installed front combustion liner that is subject to 
RR ASB No. RB.211-72-AB482, Revision 9, dated July 28, 2003, if the 
operator can confirm with the relevant overhaul base or repair 
vendor that the nicrobraze repair RR Field Repair Scheme FRS5367 has 
been applied to all 18 struts, then this is equivalent to compliance 
with RR Field Repair Scheme FRS5367/B.
    (4) Head sections repaired by replacement of all 18 struts using 
RR Field Repair Scheme FRS6548 are considered as equivalent to 
fitting a new head section for inspection purposes.

Inspections of Meterpanel Assemblies--Not Repaired

    (j) Borescope-inspect meterpanel assemblies that incorporate SB 
No. RB.211-72-7998, that have not been previously repaired. Use 
paragraphs 3.B.(1) through 3.B.(7) of the Accomplishment 
Instructions of RR ASB No. RB.211-72-AB482, Revision 9, dated July 
28, 2003, and the CSN, CSLI, and CIS compliance thresholds in Table 
4 of this AD.

[[Page 9053]]

                                    Table 4--Meterpanel Assembly--Not Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
            Engine series                 Initial inspection     Repetitive inspection      inspection cycles
----------------------------------------------------------------------------------------------------------------
(1) RB211-524D4, -524G, and -524H....  Within 1,000 to 1,200    Within 400 CSLI........  Within 50 CIS after the
                                        CSN.                                              effective date of this
                                                                                          AD.
(2) RB211-524D4, -524G, and -524H      Within 1,800 to 2,000    Within 400 CSLI........  Within 50 CIS after the
 that have not used RB211-524H          CSN.                                              effective date of this
 ratings at any time.                                                                     AD.
----------------------------------------------------------------------------------------------------------------

Inspections of Meterpanel Assemblies--Repaired

    (k) Borescope-inspect meterpanel assemblies that incorporate SB 
No. RB.211-72-7998, that have been previously repaired. Use 
paragraphs 3.B.(1) through 3.B.(7) of the Accomplishment 
Instructions of RR ASB No. RB.211-72-AB482, Revision 9, dated July 
28, 2003, and the CSLR, CSLI, and CIS compliance thresholds in Table 
5 of this AD.

                                     Table 5--Meterpanel Assembly--Repaired
----------------------------------------------------------------------------------------------------------------
                                                                                         Parts exceeding initial
            Engine series                 Initial inspection     Repetitive inspection      inspection cycles
----------------------------------------------------------------------------------------------------------------
(1) RB211-524D4, -524G, and -524H....  Within 500 to 700 CSLR.  Within 400 CSLI........  Within 50 CIS after the
                                                                                          effective date of this
                                                                                          AD.
----------------------------------------------------------------------------------------------------------------

Reject Parts

    (l) Replace parts that exceed the acceptance criteria. 
Information about the acceptance criteria can be found in the 
Aircraft Maintenance Manual, 72-00-00, Inspection/Check.

Mandatory Terminating Action

    (m) Replace any front combustion liner assembly that has a P/N 
listed in paragraph (c) of this AD at the next shop visit, but no 
later than December 31, 2012.
    (n) For RB211-524B02, -524B2, -524B3, -524B4, -524C2 and -524D4 
engines, replacing the front combustion liner assembly with a front 
combustion liner assembly that incorporates the modifications in RR 
SB No. RB.211-72-9670, Original Issue, dated August 27, 1993; or RR 
SB No. RB.211-72-9764, Revision 3, dated January 16, 1998, 
constitutes terminating action to the repetitive inspections in 
paragraphs (f), (g), (h), (i), and (j), of this AD.
    (o) For RB211-524G and -524H engines, replacing the front 
combustion liner assembly with a front combustion liner assembly 
that incorporates the modifications in RR SB No. RB.211-72-9764, 
Revision 3, dated January 16, 1998, constitutes terminating action 
to the repetitive inspections in paragraphs (f), (g), (h), (i), and 
(j) of this AD.

Definition of Shop Visit

    (p) For the purpose of this AD, a shop visit is any time that 
the 04 module is removed for refurbishment or overhaul.

Related Information

    (q) Contact Ian Dargin, Aerospace Engineer, Engine Certification 
Office, FAA, Engine and Propeller Directorate, 12 New England 
Executive Park, Burlington, MA 01803; e-mail: ian.dargin@faa.gov; 
telephone (781) 238-7178; fax (781) 238-7199, for more information 
about this AD.
    (r) Rolls-Royce ASB No. RB.211-72-AB482, Revision 9, dated July 
28, 2003; SB No. RB.211-72-9764, Revision 3, dated January 16, 1998; 
and SB No. RB.211-72-9670, Original Issue, dated August 27, 1993, 
pertain to the subject of this AD. Contact Rolls-Royce plc, P.O. Box 
31, Derby, DE24 8BJ, United Kingdom; telephone: 011-44-1332-242424; 
fax: 011-44-1332-249936, for a copy of this service information.

    Issued in Burlington, Massachusetts, on February 19, 2009.
Colleen M. D'Alessandro,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E9-4317 Filed 2-27-09; 8:45 am]

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