Document ID: FAA-2009-0674-0012
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Rolls-Royce plc RB211-Trent 500, 700, and 800 Series Turbofan Engines
Posted Date: 2010-03-29T04:00Z

[Federal Register: March 29, 2010 (Volume 75, Number 59)]
[Rules and Regulations]               
[Page 15326-15328]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr29mr10-3]                         

[[Page 15326]]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0674; Directorate Identifier 2009-NE-25-AD; 
Amendment 39-16244; AD 2010-07-01]
RIN 2120-AA64

 
Airworthiness Directives; Rolls-Royce plc RB211-Trent 500, 700, 
and 800 Series Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for the products listed above. 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, and results from the risk of engine 
fuel-to-oil heat exchanger (FOHE) blockage. The MCAI describes the 
unsafe condition as:

    In January 2008, a Boeing 777 powered by RB211-Trent 800 engines 
crashed short of the runway as a result of dual loss of engine 
response during the final stages of approach. The investigation of 
the incident has established that, under certain ambient conditions, 
ice can accumulate on the walls of the fuel pipes within the 
aircraft fuel system, which can then be released downstream when 
fuel flow demand is increased. This released ice can then collect on 
the FOHE front face and limit fuel flow through the FOHE. This type 
of icing event was previously unknown and creates ice concentrations 
into the fuel system beyond those specified in the certification 
requirements.
    In May 2009, an Engine Indicating and Crew Alerting System 
(EICAS) surge message was set following a successful go-around 
maneuver on a single RB211-Trent 700 engine of an A330 aircraft. 
Subsequent analysis concluded the likely cause to be temporary ice 
accumulation causing fuel flow restriction in the FOHE. The incident 
has indicated the potential susceptibility to ice blockage for 
Airbus aircraft in combination with Rolls-Royce engines that feature 
similar fuel systems to the RB211-Trent 800.

We are issuing this AD to prevent ice from blocking the FOHE, which 
could result in an unacceptable engine power loss and loss of control 
of the airplane.

DATES: This AD becomes effective May 3, 2010. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in this AD as of May 3, 2010. The Director of the 
Federal Register previously approved the incorporation by reference of 
certain publications listed in the regulations as of January 4, 2010 
(74 FR 6222, November 27, 2009).

ADDRESSES: The Docket Operations office is located at Docket Management 
Facility, U.S. Department of Transportation, 1200 New Jersey Avenue, 
SE., West Building Ground Floor, Room W12-140, Washington, DC 20590-
0001.
    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 AD.

FOR FURTHER INFORMATION CONTACT: James Lawrence, Aerospace Engineer, 
Engine Certification Office, FAA, Engine and Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803; e-mail: 
james.lawrence@faa.gov; telephone (781) 238-7176; fax (781) 238-7199.

SUPPLEMENTARY INFORMATION:

Discussion

    The FAA proposed to amend 14 CFR part 39 by superseding AD 2009-24-
05, Amendment 39-16092 (74 FR 62222, November 27, 2009), with a 
proposed AD. The proposed AD applies to Rolls-Royce plc RB211-Trent 
500, 700, and 800 series turbofan engines. We published the proposed AD 
in the Federal Register on January 6, 2010 (75 FR 801). That action 
proposed to correct an unsafe condition for the specified products. The 
MCAI states:

    In January 2008, a Boeing 777 powered by RB211-Trent 800 engines 
crashed short of the runway as a result of dual loss of engine 
response during the final stages of approach. The investigation of 
the incident has established that, under certain ambient conditions, 
ice can accumulate on the walls of the fuel pipes within the 
aircraft fuel system, which can then be released downstream when 
fuel flow demand is increased. This released ice can then collect on 
the FOHE front face and limit fuel flow through the FOHE. This type 
of icing event was previously unknown and creates ice concentrations 
into the fuel system beyond those specified in the certification 
requirements.
    In May 2009, an EICAS surge message was set following a 
successful go-around maneuver on a single Trent 700 engine of an 
A330 aircraft. Subsequent analysis concluded the likely cause to be 
temporary ice accumulation causing fuel flow restriction in the 
FOHE. The incident has indicated the potential susceptibility to ice 
blockage for Airbus aircraft in combination with Rolls-Royce engines 
that feature similar fuel systems to the RB211-Trent 800.

    To mitigate the risk of engine FOHE blockage, this AD requires, for 
RB211-Trent 500, 700, and 800 series turbofan engines, replacing the 
existing FOHE with a FOHE incorporating the modifications specified in 
the applicable Rolls-Royce plc Alert Service Bulletin.

Comments

    We gave the public the opportunity to participate in developing 
this AD. We considered the comments received.

Request To Allow Use of Later Revisions of Service Bulletins

    One commenter, Deutsche Lufthansa AG, requests that we add language 
to the AD that allows the use of later revisions of the service 
bulletins incorporated by reference. This change would make the AD more 
consistent with the related European Aviation Safety Agency ADs.
    We do not agree. Rulemaking requirements do not permit advance 
approval of unknown future revisions to service bulletins. We did not 
change the AD.

Request To Change the Compliance Period

    Airline Pilots Association, International, (ALPA) requests that we 
change the proposed AD compliance time from ``Within 6,000 flight hours 
after the effective date of this AD, but no later than January 1, 
2011'', to ``Within six months after the effective date of the AD or 
within 6,000 flight hours after receipt of the Service Bulletin.'' ALPA 
believes that the decreased compliance times are important since, in 
the event a blockage of the FOHE, the current procedure requires an 
immediate idle descent to melt the blockage. Due to this aircraft's 
design mission of long range flight, it often operates over oceanic and 
geographically remote areas where radar surveillance may not exist and 
communications with the air traffic control is encumbered by language 
limits, poor radio reception, and third party communication relay 
services. These areas may concentrate traffic on specific routes or 
tracks. This creates the potential for traffic conflicts during the 
descent, without the ability to receive timely Air Traffic Control 
clearance or the additional safety oversight provided by radar 
separation. This engine rollback is very insidious to the crew and 
creates the potential for a pilot to be faced with an immediate descent 
without adequate time to compensate for traffic, weather, or terrain.
    We do not agree. For the RB211-Trent 800 series engines, on 
February 17, 2009, the Transport Airplane Directorate issued AD 2009-
05-11 that revises the airplane flight manual to include in-flight 
procedures for pilots to follow in

[[Page 15327]]

certain cold weather conditions. That AD also includes mandating fuel 
circulation procedures on the ground when certain conditions exist. 
These procedures are considered adequate to assure continued safe 
operation through all environments and conditions, including those 
expressed by ALPA, until hardware modifications become available. Those 
procedures also reduce hazardous amounts of ice buildup within the fuel 
feed system and eliminate ice accumulation on the face of the FOHE. For 
the RB211-Trent 500 series and 700 series engines, changing the 
compliance time to 6 months would not result in a significant benefit 
to the level of safety. We did not change the AD.

Conclusion

    We reviewed the available data, including the comments received, 
and determined that air safety and the public interest require adopting 
the AD as proposed.

Differences Between This AD and the MCAI or Service Information

    The European Aviation Safety Agency (EASA) AD 2009-0142, dated July 
13, 2009, and EASA AD 2009-0257, dated December 3, 2009, require 
replacing the FOHE within 6,000 flight hours from July 10, 2009 or 
before January 1, 2011, whichever occurs first. This AD requires 
replacing the FOHE on RB211-Trent 500 and RB211-Trent 700 series 
turbofan engines within 6,000 flight hours after the effective date of 
this AD, or before January 1, 2011, whichever occurs first, and on 
RB211-Trent 800 series turbofan engines, replacing the FOHE within 
6,000 flight hours after January 4, 2010 (the effective date of AD 
2009-24-05), or before January 1, 2011, whichever occurs first.

Costs of Compliance

    Based on the service information, we estimate that this AD will 
affect about 138 RB211-Trent 800 series engines, and about 10 RB211-
Trent 700 series engines, installed on airplanes of U.S. registry. 
There are currently no RB211-Trent 500 series engines installed on 
airplanes of U.S. registry. We also estimate that it will take about 
8.5 work-hours per product to comply with this AD. The average labor 
rate is $80 per work-hour. Required parts will cost about $58,005 per 
product. Based on these figures, we estimate the cost of the AD on U.S. 
operators to be $8,685,380.

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 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 this 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. 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 AD and placed it in the AD docket.

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 AD, the regulatory evaluation, 
any comments received, and other information. The street address for 
the Docket Operations office (telephone (800) 647-5527) is provided in 
the ADDRESSES section. Comments will be available in the AD docket 
shortly after receipt.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

0
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 removing Amendment 39-16092 (74 FR 
62222, November 27, 2009), and by adding a new airworthiness directive, 
Amendment 39-16244, to read as follows:

2010-07-01 Rolls-Royce plc: Amendment 39-16244. Docket No. FAA-2009-
0674; Directorate Identifier 2009-NE-25-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective May 3, 
2010.

Affected Airworthiness Directives (ADs)

    (b) This AD supersedes AD 2009-24-05, Amendment 39-16092.

Applicability

    (c) This AD applies to:
    (1) Rolls-Royce plc models RB211-Trent 553-61, 556-61, 556B-61, 
560-61, 553A2-61, 556A2-61, 556B2-61, and 560A2-61 turbofan engines 
with fuel-to-oil heat exchangers (FOHEs) part number (P/N) 55027001-
1 or 55027001-11 installed; and
    (2) Rolls-Royce plc models RB211-Trent 768-60, 772-60, 772B-60, 
and RB211-Trent 875-17, 877-17, 884-17, 884B-17, 892-17, 892B-17, 
and 895-17 turbofan engines with FOHEs P/N 55003001-1 or 55003001-11 
installed.
    (3) The RB211-Trent 500 series engines are installed on, but not 
limited to, Airbus A340-500 and -600 series airplanes. The RB211-
Trent 700 series engines are installed on, but not limited to, 
Airbus A330-200 and -300 series airplanes. The RB211-Trent 800 
series engines are installed on, but not limited to, Boeing 777 
series airplanes.

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, and results from the risk of engine FOHE blockage. We are 
issuing this AD to prevent ice from blocking the FOHE, which could 
result in an unacceptable engine power loss and loss of control of 
the airplane.

Actions and Compliance

    (e) For RB211-Trent 500 series turbofan engines and RB211-Trent 
700 series turbofan engines, unless already done, within 6,000 
flight hours after the effective date of this AD, or before January 
1, 2011, whichever occurs first, do the following:

[[Page 15328]]

    (1) For RB211-Trent 500 series turbofan engines, replace the 
FOHE P/N 55027001-1 or 55027001-11, with an FOHE that incorporates 
the modifications specified in Rolls-Royce plc Alert Service 
Bulletin (ASB) No. RB.211-79-AG346, dated October 23, 2009.
    (2) For RB211-Trent 700 series turbofan engines, replace the 
FOHE, P/N 55003001-1 or 55003001-11, with an FOHE that incorporates 
the modifications specified in Rolls-Royce plc ASB No. RB.211-79-
AG338, Revision 1, dated December 2, 2009.
    (f) For RB211-Trent 800 series turbofan engines, unless already 
done, replace the FOHE, P/N 55003001-1 or 55003001-11, with an FOHE 
that incorporates the modifications specified in Rolls-Royce plc ASB 
No. RB.211-79-AG257, Revision 1, dated September 14, 2009 within 
6,000 flight hours from January 4, 2010 (the effective date of FAA 
AD 2009-24-05), or before January 1, 2011, whichever comes first.

FAA AD Differences

    (g) This AD differs from the Mandatory Continuing Airworthiness 
Information (MCAI) by requiring replacing the FOHE within 6,000 
flight hours after the effective date of this AD for RB211-Trent 500 
and RB211-Trent 700 series turbofan engines or January 4, 2010 for 
RB211-Trent 800 series turbofan engines, rather than within 6,000 
flight hours from July 10, 2009.

Previous Credit

    (h) For RB211-Trent 700 series engines, replacement of the FOHE 
with an FOHE that incorporates the modifications specified in Rolls-
Royce plc ASB No. RB.211-79-AG338, dated September 29, 2009, 
complies with the replacement requirement specified in paragraph 
(e)(2) of this AD.
    (i) For RB211-Trent 800 series engines, replacement of the FOHE 
with an FOHE that incorporates the modifications specified in Rolls-
Royce plc ASB No. RB.211-79-AG257, dated June 24, 2009, complies 
with the replacement requirement specified in paragraph (f) of this 
AD.

Alternative Methods of Compliance (AMOCs)

    (j) 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

    (k) Refer to European Aviation Safety Agency MCAI AD 2009-0142, 
dated July 13, 2009, and MCAI AD 2009-0257, dated December 3, 2009, 
for related information.
    (l) Contact James Lawrence, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; e-mail: 
james.lawrence@faa.gov; telephone (781) 238-7176; fax (781) 238-
7199, for more information about this AD.

Material Incorporated by Reference

    (m) You must use the service information specified in Table 1 of 
this AD to perform the FOHE modifications required by this AD, 
unless the AD specifies otherwise.
    (1) The Director of the Federal Register approved the 
incorporation by reference of Rolls-Royce plc Alert Service Bulletin 
No. RB.211-79-AG346, dated October 23, 2009, and Rolls-Royce plc 
Alert Service Bulletin No. RB. 211-79-AG338, Revision 1, dated 
December 2, 2009 under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) The Director of the Federal Register previously approved the 
incorporation by reference of Rolls-Royce plc ASB No. RB.211-79-
AG257, Revision 1, dated September 14, 2009, as of January 4, 2010.
    (3) For service information identified in this AD, contact 
Rolls-Royce plc, P.O. Box 31, DERBY, DE24 8BJ, UK; telephone 44 (0) 
1332 242424; fax 44 (0) 1332 249936.
    (4) You may review copies at the FAA, New England Region, 12 New 
England Executive Park, Burlington, MA; or at the National Archives 
and Records Administration (NARA). For information on the 
availability of this material at NARA, call (202) 741-6030, or go 
to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

                                   Table 1--Material Incorporated by Reference
----------------------------------------------------------------------------------------------------------------
  Rolls-Royce plc Alert Service
           Bulletin No.                    Page                Revision                       Date
----------------------------------------------------------------------------------------------------------------
RB.211-79-AG346..................
    Total Pages: 28.               All.................  Original............  October 23, 2009.
RB.211-79-AG338..................
    Total Pages: 25.               All.................  1...................  December 2, 2009.
RB.211-79-AG257..................  All.................  1...................  September 14, 2009.
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    Issued in Burlington, Massachusetts, on March 17, 2010.
Francis A. Favara,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 2010-6311 Filed 3-26-10; 8:45 am]
BILLING CODE 4910-13-P