Document ID: FAA-2018-1034-0007
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Rolls-Royce Deutschland Ltd&Co KG (Type Certificate Previously Held by Rolls-Royce plc) Turbofan Engines
Posted Date: 2020-04-13T04:00Z

[Federal Register Volume 85, Number 71 (Monday, April 13, 2020)]
[Rules and Regulations]
[Pages 20399-20402]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2020-07675]

[[Page 20399]]

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

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2018-1034; Project Identifier 2018-NE-38-AD; Amendment 
39-21109; AD 2020-08-03]
RIN 2120-AA64

Airworthiness Directives; Rolls-Royce Deutschland Ltd & Co KG 
(Type Certificate Previously Held by Rolls-Royce plc) Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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

SUMMARY: The FAA is superseding Airworthiness Directive (AD) 2008-22-24 
for certain Rolls-Royce Deutschland Ltd. & Co KG (RRD) RB211-535E4-37, 
RB211-535E4-B-37, and RB211-535E4-B-75 model turbofan engines. AD 2008-
22-24 required initial and repetitive ultrasonic inspections (USIs), 
both on-wing and during overhaul, to detect cracks on the installed 
low-pressure compressor (LPC) fan blade roots. AD 2008-22-24 also 
required re-lubrication of the fan blade roots according to accumulated 
life cycles. This AD retains the requirements of AD 2008-22-24 and 
extends these requirements to engines operating under additional flight 
profiles and adds the RB211-535E4-C-37 model turbofan engines to the 
applicability of this AD. This AD requires initial and repetitive USIs 
to detect cracks on the installed LPC fan blade roots, both on-wing and 
at engine overhaul, and replacement of certain blades that exceed the 
criteria established by the manufacturer. This AD was prompted by small 
cracks found in the LPC fan blade roots on the concave root flank 
during an engine overhaul. The FAA is issuing this AD to address the 
unsafe condition on these products.

DATES: This AD is effective May 18, 2020.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in this AD as of May 18, 2020.

ADDRESSES: For service information identified in this final rule, 
contact Rolls-Royce plc, Corporate Communications, P.O. Box 31, Derby, 
England, DE24 8BJ; phone: 011-44-1332-242424; fax: 011-44-1332-249936; 
email: https://www.rolls-royce.com/contact/civil_team.jsp; internet: 
https://www.aeromanager.com. You may view this service information at 
the FAA, Engine and Propeller Standards Branch, 1200 District Avenue, 
Burlington, MA, 01803. For information on the availability of this 
material at the FAA, call 781-238-7759. It is also available on the 
internet at https://www.regulations.gov by searching for and locating 
Docket No. FAA-2018-1034.

Examining the AD Docket

    You may examine the AD docket on the internet at https://www.regulations.gov by searching for and locating Docket No. FAA-2018-
1034; or in person at Docket Operations between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays. The AD docket contains 
this AD, the mandatory continuing airworthiness information (MCAI), any 
comments received, and other information. The address for Docket 
Operations is U.S. Department of Transportation, Docket Operations, M-
30, West Building Ground Floor, Room W12-140, 1200 New Jersey Avenue 
SE, Washington, DC, 20590.

FOR FURTHER INFORMATION CONTACT: Scott Stevenson, Aerospace Engineer, 
ECO Branch, FAA, 1200 District Avenue, Burlington, MA, 01803; phone: 
781-238-7132; fax: 781-238-7199; email: scott.m.stevenson@faa.gov.

SUPPLEMENTARY INFORMATION: 

Discussion

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 to supersede AD 2008-22-24, Amendment 39-15721 (73 FR 
65511, November 4, 2008), (``AD 2008-22-24''). AD 2008-22-24 applied to 
certain RRD RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 
model turbofan engines. The NPRM published in the Federal Register on 
May 20, 2019 (84 FR 22738). The NPRM was prompted by small cracks found 
in the LPC fan blade roots on the concave root flank during an engine 
overhaul. The NPRM proposed to require retaining the requirements of AD 
2008-22-24. The NPRM proposed to extend the requirements to engines 
operating under additional flight profiles and add the RB211-535E4-C-37 
model turbofan engines to the applicability of this AD. The NPRM 
proposed to require initial and repetitive USIs of LPC fan blade roots 
on-wing or at engine overhaul to detect cracks, and replacement of 
blades that exceed the criteria in Rolls-Royce (RR) Alert Non-
Modification Service Bulletin (NMSB) RB211-72-AC879, Revision 9, dated 
April 23, 2018. The FAA is issuing this AD to address the unsafe 
condition on these products.
    The European Union Aviation Safety Agency (EASA), which is the 
Technical Agent for the Member States of the European Community, has 
issued EASA AD 2018-0202R1, dated September 25, 2018 (referred to after 
this as ``the MCAI''), to address the unsafe condition on these 
products. The MCAI states:

    During engine overhaul, inspection of a high life set of low 
pressure compressor (LPC) fan blades revealed small cracks in the 
blade roots on the concave root flank. These cracks had originated 
at the edge of bedding from multiple origins. Root cause analysis 
indicated the cause of the crack initiation to be the absence of the 
anti-frettage coating.
    This condition, if not detected and corrected, could lead to fan 
blade failure, possibly resulting in release of high energy non-
contained debris from the engine, with consequent damage to the 
aeroplane.
    To address this condition, RR issued NMSB RB.211-72-AC879 
(original issue, later revised), providing instructions to inspect 
high life blades, either on-wing or during engine overhaul. 
Depending on flight profile flown, different inspection intervals 
were introduced. Consequently, the UK CAA classified that NMSB as 
mandatory and issued AD 002-01-2000 accordingly, requiring those 
repetitive inspections.
    Since that [UK CAA] AD was issued, it was reported that some 
engines were operated outside the profiles initially specified, and 
new flight profiles were introduced to mitigate the risk of 
overflying the recommended flight profiles. Consequently, the 
inspection intervals were extended for engines operating within 
RB211-535E4-B-37 flight profiles C, D and E, and RR issued the NMSB 
accordingly. Additionally, RR introduced inspection instructions for 
engines operating within RB211-535E4-C-37 flight profile F and 
RB211-535E4-37 flight profile G in the NMSB. For the reasons 
described above, EASA issued AD 2018-0202, retaining the 
requirements of UK CAA AD 002-01-2000, which was superseded, 
amending the compliance times and adding repetitive inspections for 
RB211-535E4-37, RB211-535E4-B-37 and RB211-535E4-C-37 engines 
operating within flight profiles C, D, E, F and G. That [EASA] AD 
also provided a modification as optional terminating action for the 
repetitive inspections.
    This [EASA] AD is revised to correct paragraph (1), indicating 
that only affected fan blades must be inspected.

    You may obtain further information by examining the MCAI in the AD 
docket on the internet at https://www.regulations.gov by searching for 
and locating Docket No. FAA-2018-1034.

Comments

    The FAA gave the public the opportunity to participate in 
developing this AD. The following presents the comments received on the 
NPRM and the FAA's response to each comment.

[[Page 20400]]

Request To Correct Typographical Error

    RRD requested that the FAA correct the typographical error 
``conclave'' to ``concave'' in paragraph (e) of this AD.
    The FAA agrees and corrected the typographical error as suggested.

Revised the Name of the Type Certificate (TC) Holder

    The FAA determined that the name of the TC design approval used in 
the NPRM should have been revised to ``Rolls-Royce Deutschland Ltd & Co 
KG'' to match TCDS Number E12EU, Revision 26, dated April 25, 2019. The 
FAA has revised references in this AD from ``Rolls-Royce plc'' to 
``Rolls-Royce Deutschland Ltd. & Co KG'' when the FAA refers to the 
name of the TC design approval holder.

Support for the AD

    United Airlines agreed with the modified inspection intervals 
listed in the NPRM.

No Comments on the AD

    Boeing Commercial Airplanes commented that it has no comments.

Conclusion

    The FAA reviewed the relevant data, considered the comments 
received, and determined that air safety and the public interest 
require adopting this AD with the change described previously and minor 
editorial changes. The FAA has determined that these minor changes:
     Are consistent with the intent that was proposed in the 
NPRM for addressing the unsafe condition; and
     Do not add any additional burden upon the public than was 
already proposed in the NPRM.
    The FAA also determined that these changes will not increase the 
economic burden on any operator or increase the scope of this AD.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed RR Alert NMSB No. RB.211-72-AC879, Revision 9, 
dated April 23, 2018, and RR Service Bulletin (SB) RB.211-72-C946, 
Revision 4, dated June 22, 2010. RR NMSB RB.211-72-AC879 describes 
procedures for performing inspections of high cyclic life LPC fan blade 
roots on-wing or at overhaul, and re-lubrication of the LPC fan blade 
roots during overhaul. RR SB RB.211-72-C946 introduces a revised LPC 
fan blade featuring a redefined dry film lubricant application. This 
service information is reasonably available because the interested 
parties have access to it through their normal course of business or by 
the means identified in the ADDRESSES section.

Costs of Compliance

    The FAA estimates that this AD affects 512 engines installed on 
airplanes of U.S. registry.
    The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
Inspection of LPC fan blade set.......  7 work-hours x $85 per                $0            $595        $304,640
                                         hour = $595.
----------------------------------------------------------------------------------------------------------------

    The FAA estimates the following costs to do any necessary 
replacements that would be required based on the results of the 
required inspections. The FAA has no way of determining the number of 
aircraft that might need these replacements:

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                    Action                                 Labor cost               Parts cost        product
----------------------------------------------------------------------------------------------------------------
Replacement of LPC fan blade..................  4 work-hours x $85 per hour =            $77,916         $78,256
                                                 $340.
----------------------------------------------------------------------------------------------------------------

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.
    The FAA is 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) Will not affect intrastate aviation in Alaska, 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.

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 part 39 of the Federal Aviation 
Regulations (14 CFR part 39) as follows:

[[Page 20401]]

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 removing Airworthiness Directive (AD) 
2008-22-24, Amendment 39-15721 (73 FR 65511, November 4, 2008), and 
adding the following new AD:

2020-08-03 Rolls-Royce Deutschland Ltd & Co KG (Type Certificate 
Previously Held by Rolls-Royce plc): Amendment 39-21109; Docket No. 
FAA-2018-1034; Project Identifier 2018-NE-38-AD.

(a) Effective Date

    This AD is effective May 18, 2020.

(b) Affected ADs

    This AD replaces AD 2008-22-24, Amendment 39-15721 (73 FR 65511, 
November 4, 2008).

(c) Applicability

    This AD applies to Rolls-Royce Deutschland Ltd. & Co KG (RRD) 
(Type Certificate previously held by Rolls-Royce plc) RB211-535E4-
37, RB211-535E4-B-37, RB211-535E4-C-37, and RB-211-535E4-B-75 model 
turbofan engines except those with fan blades that have all 
incorporated Rolls-Royce (RR) Service Bulletin (SB) RB.211-72-C946, 
Revision 4, dated June 22, 2010 (or any earlier revision).

(d) Subject

    Joint Aircraft System Component (JASC) Code 7230, Turbine Engine 
Compressor Section.

(e) Unsafe Condition

    This AD was prompted by small cracks found in the low-pressure 
compressor (LPC) fan blade roots on the concave root flank during an 
engine overhaul. The FAA is issuing this AD to detect cracks in the 
LPC fan blade roots. The unsafe condition, if not addressed, could 
result in uncontained LPC fan blade release, damage to the engine, 
and damage to the airplane.

(f) Compliance

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

(g) Required Actions

    (1) For engine models being used in the flight profiles 
indicated in Table 1 to paragraph (g)(1) of this AD, perform initial 
and repetitive ultrasonic inspections (USIs) of the affected fan 
blades in accordance with the Accomplishment Instructions, 
paragraphs 3.A., 3.B., and 3.C., of RR Alert Non-Modification 
Service Bulletin (NMSB) RB211-72-AC879, Revision 9, dated April 23, 
2018, as follows:
    (i) Perform an initial ultrasonic root or surface wave 
inspection of each LPC fan blade before exceeding the inspection 
threshold as indicated in Table 1 to paragraph (g)(1) of this AD, or 
within 30 days after the effective date of this AD, whichever occurs 
later.
    (ii) Thereafter, perform a repetitive ultrasonic root or surface 
wave inspection of each LPC fan blade at intervals not to exceed 
engine flight cycles (EFCs) since the previous inspection using the 
applicable EFCs specified in Table 1 to paragraph (g)(1) of this AD.
[GRAPHIC] [TIFF OMITTED] TR13AP20.001

    (2) For engine models that, after the effective date of this AD, 
change flight profiles, inspect the affected fan blades before 
exceeding the initial threshold of the new flight profile or 
reinspection interval, as applicable, or within 200 EFCs after 
changing flight profiles, whichever occurs later, without exceeding 
the previous flight profile initial inspection threshold or 
reinspection interval.
    (3) If, during any inspection required by paragraph (g)(1) or 
(2) of this AD, any crack is found in the affected fan blades that 
exceeds the criteria in the Accomplishment Instructions, paragraphs 
3.A., 3.B., or 3.C., of RR Alert NMSB RB211-72-AC879, Revision 9, 
dated April 23, 2018, before the next flight, replace the LPC fan 
blade with a LPC fan blade eligible for installation.

(h) Optional Terminating Action

    Modification of any RRD RB211-535E4-37, RB211-535E4-B-37, RB211-
535E4-C-37, and RB-211-535E4-B-75 model turbofan engine in 
accordance with RR SB RB.211-72-C946, Revision 4, dated June 22, 
2010, constitutes terminating action to this AD.

(i) Credit for Previous Actions

    Any initial USI accomplished before the effective date of this 
AD that uses RR NMSB No. RB.211-72-C879, Revision 8, dated November 
18, 2015, or earlier versions, meets the requirement of the initial 
inspection, as applicable. Any repetitive USI accomplished before 
the effective date of this AD that uses RR NMSB No. RB.211-72-C879, 
Revision 8, dated November 18, 2015, or earlier versions, meets the 
requirement of that single repetitive inspection, as applicable. 
Further repetitive inspections, as mandated by paragraph (g) of this 
AD, are still required.

(j) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, ECO Branch, FAA, has the authority to approve 
AMOCs for this AD, if requested using the procedures found in 14 CFR 
39.19. In accordance with 14 CFR 39.19, send your request to your 
principal inspector or local Flight Standards District Office, as

[[Page 20402]]

appropriate. If sending information directly to the manager of the 
ECO Branch, send it to the attention of the person identified in 
paragraph (k)(1) of this AD. You may email your request to: ANE-AD-AMOC@faa.gov.
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.

(k) Related Information

    (1) For more information about this AD, contact Scott Stevenson, 
Aerospace Engineer, ECO Branch, FAA, 1200 District Avenue, 
Burlington, MA, 01803; phone: 781-238-7132; fax: 781-238-7199; 
email: scott.m.stevenson@faa.gov.
    (2) Refer to European Union Aviation Safety Agency (EASA) AD 
2018-0202R1, dated September 25, 2018, for more information. You may 
examine the EASA AD in the AD docket on the internet at https://www.regulations.gov by searching for and locating Docket No. FAA-
2018-1034.

(l) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Rolls-Royce (RR) Alert Non-Modification Service Bulletin No. 
RB.211-72-AC879, Revision 9, dated April 23, 2018.
    (ii) RR Service Bulletin RB.211-72-C946, Revision 4, dated June 
22, 2010.
    (3) For RR service information identified in this AD, contact 
Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; telephone: 011-
44-1332-242424; fax: 011-44-1332-249936.
    (4) You may view this service information at FAA, Engine and 
Propeller Standards Branch, 1200 District Avenue, Burlington, MA, 
01803. For information on the availability of this material at the 
FAA, call 781-238-7759.
    (5) You may view this service information at the National 
Archives and Records Administration (NARA). For information on the 
availability of this material at NARA, email: fedreg.legal@nara.gov, 
or go to: https://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued on April 7, 2020.
Lance T. Gant,
Director, Compliance & Airworthiness Division, Aircraft Certification 
Service.
[FR Doc. 2020-07675 Filed 4-10-20; 8:45 am]
 BILLING CODE 4910-13-P