Document ID: FAA-2011-0273-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Rolls-Royce Corp. Turbofan Engines
Posted Date: 2011-11-02T04:00Z

[Federal Register Volume 76, Number 212 (Wednesday, November 2, 2011)]
[Rules and Regulations]
[Pages 67591-67594]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2011-28352]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2011-0273; Directorate Identifier 2011-NE-08-AD; 
Amendment 39-16845; AD 2011-22-03]
RIN 2120-AA64

Airworthiness Directives; Rolls-Royce Corporation Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: We are adopting a new airworthiness directive (AD) for Rolls-
Royce Corporation (RRC) AE 3007A, AE 3007A1/1, AE 3007A1, AE 3007A1/3, 
AE 3007A1E, AE 3007A1P, and AE 3007A3 turbofan engines. This AD 
requires initial and repetitive eddy current inspections (ECI) of 
certain 6th-through-13th stage compressor wheel knife edge seals, and 
initial and repetitive ECIs of the compressor wheel outer 
circumference, for cracks. This AD was prompted by reports of low-cycle 
fatigue cracks found during shop visits, in the 6th-through-13th stage 
compressor wheels having chrome-carbide coated or uncoated knife edge 
seals. We are issuing this AD to prevent uncontained failure of the 
6th-through-13th stage compressor wheel, leading to damage to the 
airplane.

DATES: This AD is effective November 17, 2011.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in the AD as of November 17, 
2011.
    We must receive comments on this AD by December 19, 2011.

ADDRESSES: You may send comments by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
     Fax: (202) 493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
     Hand Delivery: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590, between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays.
    For service information identified in this AD, contact Rolls-Royce 
Corporation, P.O. Box 420, Indianapolis, IN 46206; phone: (317) 230-
3774; fax: (317) 230-6084; email: royce.com">indy.pubs.services@rolls-royce.com. 
You may review copies of the referenced service information at the FAA, 
Engine & Propeller Directorate, 12 New England Executive Park, 
Burlington, MA. For information on the availability of this material at 
the FAA, call (781) 238-7125.

Examining the AD Docket

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

[[Page 67592]]

FOR FURTHER INFORMATION CONTACT: Kyri Zaroyiannis, Aerospace Engineer, 
Chicago Aircraft Certification Office, Small Airplane Directorate, FAA, 
2300 E. Devon Ave., Des Plaines, IL 60018; phone: (847) 294-7836; fax: 
(847) 294-7834; email: kyri.zaroyiannis@faa.gov.

SUPPLEMENTARY INFORMATION:

Discussion

    We received reports of low-cycle fatigue cracks found during shop 
visits, in the 6th-through-13th stage compressor wheels having chrome-
carbide coated or uncoated knife edge seals, on RRC AE 3007A, AE 
3007A1/1, AE 3007A1, AE 3007A1/3, AE 3007A1E, AE 3007A1P, and AE 3007A3 
turbofan engines. These cracks can deteriorate the integrity of the 
compressor wheel by lengthening into the outer circumference of the 
wheel. This condition, if not corrected, could result in uncontained 
failure of the 6th-through-13th stage compressor wheel, leading to 
damage to the airplane.

Relevant Service Information

    We reviewed RRC Alert Service Bulletin (ASB) No. AE 3007A-A-72-386, 
Revision 4, dated June 27, 2011, which describes procedures for 
performing a one-time comprehensive ECI of the compressor wheel outer 
circumference, for cracks. We also reviewed RRC ASB No. AE 3007A-A-72-
390, Revision 3, dated June 27, 2011, which describes procedures for 
initial and repetitive inspections of affected 6th-through-13th stage 
compressor wheel knife edge seals and the compressor wheel outer 
circumference, for cracks.

FAA's Determination

    We are issuing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design.

AD Requirements

    This AD requires accomplishing the actions specified in the service 
information described previously. The AD also requires sending the 
inspection results to AE Service Data, Rolls-Royce Corporation, Attn: 
AE Service Data Manager, P.O. Box 420, Speed Code U17, Indianapolis, IN 
46206-0420, email: royce.com">cra.rel.data@rolls-royce.com.

FAA's Justification and Determination of the Effective Date

    An unsafe condition exists that requires the immediate adoption of 
this AD. The FAA has found that the risk to the flying public justifies 
waiving notice and comment prior to adoption of this rule because our 
risk assessment indicates these parts, uninspected, pose an 
unacceptable level of risk to the traveling public. Therefore, we find 
that notice and opportunity for prior public comment are impracticable 
and that good cause exists for making this amendment effective in less 
than 30 days.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment. However, we invite you to send any written data, views, or 
arguments about this AD. Send your comments to an address listed under 
the ADDRESSES section. Include the docket number FAA-2011-0273 and 
Directorate Identifier 2011-NE-08-AD at the beginning of your comments. 
We specifically invite comments on the overall regulatory, economic, 
environmental, and energy aspects of this AD. We will consider all 
comments received by the closing date and may amend this AD because 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 we 
receive about this AD.

Costs of Compliance

    We estimate that this AD will affect 1,402 RRC AE 3007A, AE 3007A1/
1, AE 3007A1, AE 3007A1/3, AE 3007A1E, AE 3007A1P, and AE 3007A3 
turbofan engines installed on 616 airplanes of U.S. registry. We also 
estimate that it will take about 6 hours to perform one inspection of 
the affected 6th-through-13th stage compressor wheel knife edge seals 
and the compressor wheel outer circumference, for each engine. The 
average labor rate is $85 per work-hour. We anticipate required parts 
costs to be $35,546,000. Based on these figures, we estimate the total 
cost of the AD to U.S. operators to be $36,259,926.

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

    This AD will not have federalism implications under Executive Order 
13132. This AD will 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 this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866,
    (2) Is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979),
    (3) Will not affect intrastate aviation in Alaska, and
    (4) 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.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

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

PART 39--AIRWORTHINESS DIRECTIVES

0
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]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive (AD):

2011-22-03 Rolls-Royce Corporation (Formerly Allison Engine 
Company): Amendment 39-16845; Docket No. FAA-2011-0273; Directorate 
Identifier 2011-NE-08-AD.

(a) Effective Date

    This AD is effective November 17, 2011.

[[Page 67593]]

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to Rolls-Royce Corporation (RRC) AE 3007A, AE 
3007A1/1, AE 3007A1, AE 3007A1/3, AE 3007A1E, AE 3007A1P, and AE 
3007A3 turbofan engines, with any of the 6th-through-13th stage 
compressor wheel part numbers (P/Ns) in Table 1 of this AD 
installed.

                    Table 1--6th-Through-13th Stage Compressor Wheel P/Ns Affected by This AD
----------------------------------------------------------------------------------------------------------------
                                                     Wheel P/Ns with chrome-
               Compressor wheel stage                  carbide coated knife     Wheel P/Ns with uncoated knife
                                                              seals                          seals
----------------------------------------------------------------------------------------------------------------
6th................................................                 23074717        23062666, 23071261, 23071396
7th................................................       23074719, 23074217        23062667, 23071262, 23071397
8th................................................                 23074721                  23061628, 23071263
9th................................................                 23074722                  23061629, 23071264
10th...............................................                 23074723                  23061630, 23071265
11th...............................................                 23074724                  23061631, 23066231
12th...............................................                 23074725                  23061632, 23071267
13th...............................................       23074213, 23074726                  23061633, 23071268
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(d) Unsafe Condition

    This AD was prompted by reports of low-cycle fatigue cracks 
found during shop visits, in the 6th-through-13th stage compressor 
wheels having chrome-carbide coated or uncoated knife edge seals. We 
are issuing this AD to prevent uncontained failure of the 6th-
through-13th stage compressor wheel, leading to damage to the 
airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(f) Initial Inspection

    The initial inspection compliance times for the 6th-through-13th 
stage compressor wheels are based on cycles-since-new (CSN) and 
cycles-in-service (CIS) of their 12th and 13th stage compressor 
wheels. For engines that one or both 12th and 13th stage compressor 
wheels have chrome-carbide coated knife edge seals, use the 
compliance times listed in Table 2 of this AD. For engines that both 
12th and 13th stage compressor wheels do not have chrome-carbide 
coated knife edge seals, use the compliance times listed in Table 3 
of this AD.
    (1) Perform a one-time comprehensive eddy current inspection 
(ECI) of the 6th-through-13th stage compressor wheel knife edge 
seals for cracks, using paragraph 2, Accomplishment Instructions, of 
RRC Alert Service Bulletin (ASB) No. AE 3007A-A-72-386, Revision 4, 
dated June 27, 2011 (Completion of this one-time comprehensive ECI 
relieves you thereafter of the repetitive inspection requirements of 
this AD); or
    (2) Perform an initial ECI of the 6th-through-13th stage 
compressor wheel outer circumferences for cracks, using paragraph 2, 
Accomplishment Instructions, of RRC ASB No. AE 3007A-A-72-390, 
Revision 3, dated June 27, 2011.

  Table 2--Initial Inspection Compliance Times for Engines, That One or
  Both 12th and 13th Stage Compressor Wheels Have Chrome-Carbide Coated
                            Knife Edge Seals
------------------------------------------------------------------------
    For 12th and or 13th stage
    compressor wheels with the           Initially inspect after the
  following CSN on the effective          effective date of this AD
          date of this AD
------------------------------------------------------------------------
(i) 18,185 or more CSN............  Within 15 CIS.
(ii) 16,700 to 18,184 CSN.........  Before accumulating 18,200 CSN.
(iii) 16,000 to 16,699 CSN........  Within 1,500 CIS.
(iv) 15,100 to 15,999 CSN.........  Within 2,000 CIS.
(v) 14,300 to 15,099 CSN..........  Within 2,800 CIS.
(vi) 13,000 to 14,299 CSN.........  Within 3,400 CIS.
(vii) 12,300 to 12,999 CSN........  Within 4,000 CIS.
(viii) 11,200 to 12,299 CSN.......  Within 4,600 CIS.
(ix) 9,700 to 11,199 CSN..........  Within 5,300 CIS.
(x) Fewer than 9,700 CSN..........  Before accumulating 15,000 CSN or at
                                     the next shop visit when the engine
                                     has more than 7,000 cycles,
                                     whichever occurs first.
------------------------------------------------------------------------

Table 3--Initial Inspection Compliance Times for Engines, That Both 12th
and 13th Stage Compressor Wheels Do Not Have Chrome-Carbide Coated Knife
                               Edge Seals
------------------------------------------------------------------------
    For 12th and or 13th stage
    compressor wheels with the           Initially inspect after the
  following CSN on the effective         effective date of this AD:
         date of this AD:
------------------------------------------------------------------------
(i) 18,300 or more CSN............  Within 200 CIS.
(ii) 16,000 to 18,299 CSN.........  Within 1,500 CIS.
(iii) 15,100 to 15,999 CSN........  Within 2,000 CIS.
(iv) 14,300 to 15,099 CSN.........  Within 2,800 CIS.
(v) 13,000 to 14,299 CSN..........  Within 3,400 CIS.
(vi) 12,300 to 12,999 CSN.........  Within 4,000 CIS.
(vii) 11,200 to 12,299 CSN........  Within 4,600 CIS.
(viii) 9,700 to 11,199 CSN........  Within 5,300 CIS.

[[Page 67594]]

 
(ix) Fewer than 9,700 CSN.........  Before accumulating 15,000 CSN or at
                                     the next shop visit when the engine
                                     has more than 7,000 cycles,
                                     whichever occurs first.
------------------------------------------------------------------------

(g) Repetitive Inspections

    (1) After passing the initial inspection, perform repetitive 
ECIs of the compressor wheel outer circumference, for cracks, within 
every 5,000 cycles-since-last-inspection (CSLI), using paragraph 2, 
Accomplishment Instructions, of RRC ASB No. AE 3007A-A-72-390, 
Revision 3, dated June 27, 2011; or
    (2) Perform a one-time comprehensive ECI of the 6th-through-13th 
stage compressor wheel knife edge seals for cracks, within 5,000 
CSLI using paragraph 2, Accomplishment Instructions, of RRC ASB No. 
AE 3007A-A-72-386, Revision 4, dated June 27, 2011. Completion of 
this one-time ECI comprehensive inspection relieves you thereafter 
of the repetitive inspection requirements of this AD.

(h) 6th-Through-13th Stage Compressor Wheels Found Cracked

    Remove from service before further flight 6th-through-13th stage 
compressor wheels that are found cracked.

(i) Special Flight Permits

    Special Flight Permits are limited to essential flight crew 
only.

(j) Reporting Requirements

    Report all inspection results within 10 days, to AE Service 
Data, Rolls-Royce Corporation, Attn: AE Service Data Manager, P.O. 
Box 420, Speed Code U17, Indianapolis, IN 46206-0420, email: 
royce.com">cra.rel.data@rolls-royce.com. Use the reporting instructions in:
    (1) Paragraph 2.D. of ASB No. AE 3007A-A-72-386, Revision 4, 
dated June 27, 2011.
    (2) Service Bulletin Compliance Form of RRC ASB No. AE 3007A-A-
72-390, Revision 3, dated June 27, 2011.

(k) Paperwork Reduction Act Burden Statement

    A federal agency may not conduct or sponsor, and a person is not 
required to respond to, nor shall a person be subject to a penalty 
for failure to comply with a collection of information subject to 
the requirements of the Paperwork Reduction Act unless that 
collection of information displays a current valid OMB Control 
Number. The OMB Control Number for this information collection is 
2120-0056. Public reporting for this collection of information is 
estimated to be approximately 5 minutes per response, including the 
time for reviewing instructions, completing and reviewing the 
collection of information. All responses to this collection of 
information are mandatory. Comments concerning the accuracy of this 
burden and suggestions for reducing the burden should be directed to 
the FAA at: 800 Independence Ave. SW., Washington, DC 20591, Attn: 
Information Collection Clearance Officer, AES-200.

(l) Previous Inspection Credit

    (1) If you previously performed an ECI of the 6th-through-13th 
stage compressor wheels using RRC ASB No. AE 3007A-A-390, Revision 
1, dated February 14, 2011 or Revision 2, dated June 10, 2011, or 
Revision 3, dated June 27, 2011, you met the initial inspection 
requirements of this AD.
    (2) If you previously performed a one-time comprehensive ECI of 
the 6th-through-13th stage compressor wheel knife edge seals, using 
RRC ASB No. AE 3007A-A-72-386, dated October 20, 2010, or Revision 
1, dated December 17, 2010, or Revision 2 dated January 10, 2011, or 
Revision 3, dated June 10, 2011, you met the initial inspection 
requirements of paragraph (f) of this AD. Completion of this one-
time comprehensive inspection relieves you of the repetitive 
inspection requirements of this AD.
    (3) If you previously performed an ultrasonic inspection of the 
compressor wheel knife edge seals, using RRC Service Bulletin No. AE 
3007A-72-382, dated April 6, 2010, prior to publication of RRC ASB 
No. AE 3007A-A-72-386, dated October 20, 2010, you met the initial 
inspection requirements of this AD. Completion of this one-time 
ultrasonic inspection relieves you of the repetitive inspection 
requirements of this AD.

(m) Alternative Methods of Compliance (AMOCs)

    The Manager, Chicago Aircraft Certification Office, may approve 
AMOCs for this AD. Use the procedures found in 14 CFR 39.19 to make 
your request.

(n) Related Information

    For more information about this AD, contact Kyri Zaroyiannis, 
Aerospace Engineer, Chicago Aircraft Certification Office, Small 
Airplane Directorate, FAA, 2300 E. Devon Ave., Des Plaines, IL 
60018; phone: (847) 294-7836; fax: (847) 294-7834; email: 
kyri.zaroyiannis@faa.gov.

(o) Material Incorporated by Reference

    You must use the following service information to do the actions 
required by this AD, unless the AD specifies otherwise. The Director 
of the Federal Register approved the incorporation by reference 
(IBR) under 5 U.S.C. 552(a) and 1 CFR part 51 of the following 
service information on the date specified:
    (1) Rolls-Royce Corporation Alert Service Bulletin No. AE 3007A-
A-72-386, Revision 4, dated June 27, 2011, approved for IBR November 
17, 2011.
    (2) Rolls-Royce Corporation Alert Service Bulletin No. AE 3007A-
A-72-390, Revision 3, dated June 27, 2011, approved for IBR November 
17, 2011.
    (3) For service information identified in this AD, contact 
Rolls-Royce Corporation, P.O. Box 420, Indianapolis, IN 46206; 
phone: (317) 230-3774; fax: (317) 230-6084; email: 
royce.com">indy.pubs.services@rolls-royce.com.
    (4) You may review copies of the service information at the FAA, 
Engine & Propeller Directorate, 12 New England Executive Park, 
Burlington, MA. For information on the availability of this material 
at the FAA, call (781) 238-7125.
    (5) You may also review copies of the service information that 
is incorporated by reference at the National Archives and Records 
Administration (NARA). For information on the availability of this 
material at an NARA facility, call (202) 741-6030, or go to http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.

    Issued in Burlington, Massachusetts, on October 25, 2011.
Peter A. White,
Manager, Engine & Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 2011-28352 Filed 11-1-11; 8:45 am]
BILLING CODE 4910-13-P