Document ID: FAA-2007-29343-0007
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Rolls-Royce plc RB211-535E4-37, RB211- 535E4-B-37, and RB211-535E4-B-75 Series Turbofan Engines
Posted Date: 2008-11-04T05:00Z

[Federal Register: November 4, 2008 (Volume 73, Number 214)]
[Rules and Regulations]               
[Page 65511-65514]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr04no08-8]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2007-29343; Directorate Identifier 2000-NE-13-AD; 
Amendment 39-15721; AD 2008-22-24]
RIN 2120-AA64

 
Airworthiness Directives; Rolls-Royce plc RB211-535E4-37, RB211-
535E4-B-37, and RB211-535E4-B-75 Series Turbofan Engines

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

ACTION: Final rule.

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

SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD) for Rolls-Royce plc (RR) RB211-535E4-37, RB211-535E4-B-37, and 
RB211-535E4-B-75 series turbofan engines. That AD currently requires 
initial and repetitive ultrasonic inspections of installed low pressure 
compressor (LPC) fan blade roots on-wing and during overhaul, and 
relubrication according to accumulated life cycles. Also, that AD 
introduces application of Metco 58 blade root coating as an optional 
terminating action. This AD requires the same actions but adds 
compliance paragraphs to relax the compliance schedule for repetitive 
inspections for fan blades operating within RB211-535E4 flight profiles 
A and B, if certain requirements are met. This AD also relaxes the 
initial compliance threshold by extending the cycles at which an 
initial inspection is required. This AD results from RR issuing 
Mandatory Service Bulletin (MSB) No. RB.211-72-C879, Revision 5 and 
Revision 6, that introduced a relaxed repetitive compliance schedule 
for fan blades operating within RB211-535E4 flight profiles A and B, if 
certain requirements are met, and introduced a relaxed initial 
compliance threshold. We are issuing this AD to detect cracks in LPC 
fan blade roots, which if not detected, could lead to uncontained 
multiple fan blade failure, and damage to the airplane.

DATES: This AD becomes effective December 9, 2008. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of December 9, 2008.

ADDRESSES: You can get the service information identified in this AD 
from Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; telephone: 
011-44-1332-242-424; fax: 011-44-1332-249-936.
    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.

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: The FAA proposed to amend 14 CFR part 39 by 
superseding AD 2005-02-05, Amendment 39-13950 (70 FR 3863, January 27, 
2005), with a proposed AD. The proposed AD applies to RR RB211-535E4-
37, RB211-535E4-B-37, and RB211-535E4-B-75 series turbofan engines. We 
published the proposed AD in the Federal Register on October 25, 2007 
(72 FR 60606). That action proposed to require initial and repetitive 
ultrasonic inspections of installed LPC fan blade roots on-wing and 
during overhaul, and relubrication according to accumulated life 
cycles. That action also proposed to add compliance paragraphs to relax 
the compliance schedule for repetitive inspections for RB211-535E4 
engines operating in flight profiles A and B, if certain requirements 
are met.

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.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comment received.
    One commenter states that Rolls-Royce plc issued Mandatory Service 
Bulletin No. RB.211-72-C879, Revision 6, dated December 14, 2007, while 
the proposed AD comment period was still open, and the AD should 
reference Revision 6.
    We agree. Revision 6 contains the changes from Revision 5, and 
relaxes the initial compliance threshold by extending the cycles at 
which an inspection is required. We changed the AD to reference 
Revision 6, and made the following changes based on Revision 6:
     We deleted proposed AD paragraph (f), which referenced 
full sets of fan blades modified using RR Service Bulletin No. RB.211-
72-C946, Revision 2, dated September 26, 2002, as the reference is 
unnecessary. As a result we recodified paragraphs (f) through (n).
     We clarified that the ultrasonic inspection is performed 
on the fan blade roots.
     Proposed AD paragraph (g) is changed from ``On RB211-535E4 
engines, operated to Flight Profile A, ultrasonically inspect, and if 
required,

[[Page 65512]]

relubricate using the following Table 2'' to the following:
    ``(f) On RB211-535E4 engines, operated to Flight Profile A:
    (1) Ultrasonically inspect the fan blade root, and if required, 
relubricate using one of the methods in Table 2 of this AD.
    (2) If the initial inspection is complete prior to 18,600 cycles-
since-new (CSN), then the next inspection may be postponed until 20,000 
CSN.''
     Proposed AD paragraph (h) is changed from ``On RB211-535E4 
engines, operated to Flight Profile B, ultrasonically inspect, and if 
required, relubricate using the following Table 3:'' to the following:
    ``(g) On RB211-535E4 engines, operated to Flight Profile B:
    (1) Ultrasonically inspect the fan blade root, and if required, 
relubricate using one of the methods in Table 3 of this AD.
    (2) If the initial inspection is complete prior to 14,150 CSN, then 
the next inspection may be postponed until 15,000 CSN.''
     Proposed AD paragraph (i) is changed from ``On RB211-535E4 
engines, operated to Flight Profile A and B, ultrasonically inspect, 
and if required, relubricate using the following Table 4:'' to the 
following:
    ``(i) For fan blades operated to any combination of RB211-535E4 
Flight Profile A, -535E4 Flight Profile B, -535E4-B, -535E4-B and -
535E4-C engines:
    (1) Calculate an equivalent CSN as defined in the Time Limits 
Manual. See References Section 1.G.(3), of MSB RB.211-72-C879, Revision 
6, dated December 14, 2007.
    (2) For fan blades that are currently flying in Profile A, inspect 
using paragraph (f) and Table 2 of this AD using equivalent CSN.
    (3) For fan blades that are currently flying in Profile B, inspect 
using paragraph (g) and Table 3 of this AD using equivalent CSN.
    (4) For fan blades that are currently flying in an RB211-535E4-B 
engine, inspect using paragraph (h) and Table 4 of this AD using 
equivalent CSN.''
     We deleted proposed AD Table 4 because the information in 
it was redundant. We recodified proposed AD Table 5 to Table 4.
     We clarified in three of the proposed AD tables that 
relubrication is to be done at shop visit if blade life is more than 
19,650 cycles, 14,650 cycles, and 19,650 respectively.
     Proposed AD paragraph (j) is changed from ``For RB211-
535E4 engines that are currently flying in Profile A, if the initial 
inspection is completed before X minus 1,400 cycles then the next 
inspection may be delayed to X, where X is 65% of the revised life 
limit'' to ``(i)(2) For fan blades that are currently flying in Profile 
A, inspect using paragraph (f) and Table 2 of this AD using equivalent 
CSN''.
     Proposed AD paragraph (k) is changed from ``For RB211-
535E4 engines that are currently flying in Profile B, if the initial 
inspection is completed before X minus 850 cycles then the next 
inspection may be delayed to X, where X is 65% of the revised life 
limit'' to ``(i)(3) For fan blades that are currently flying in Profile 
B, inspect using paragraph (g) and Table 3 of this AD using equivalent 
CSN''.
     Proposed AD paragraph (l) is deleted and incorporated into 
paragraph (i).
     Proposed AD paragraph (m) is changed from ``On RB211-
535E4-B engines, ultrasonically inspect, and if required, relubricate 
using the following Table 5:'' to the following:
    ``(h) On RB211-535E4-B engines:
    (1) Ultrasonically inspect the fan blade root, and if required, 
relubricate using one of the methods in Table 4 of this AD.
    (2) If the initial inspection is complete prior to 18,800 CSN, then 
the next inspection may be postponed until 20,000 CSN.''
    In addition, we updated our estimate of the total cost of the AD to 
U.S. operators to $441,280. The proposed AD estimated the total cost of 
the AD to U.S. operators to be $358,540. The estimate in the proposed 
AD was based on an estimated average labor rate of $65 per work-hour. 
The latest estimated average labor rate is $80 per work-hour.

Conclusion

    We have carefully reviewed the available data, including the 
comment received, and determined that air safety and the public 
interest require adopting the AD with the change described previously. 
We have determined that these changes will neither increase the 
economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

    We estimate that this AD will affect 788 engines installed on 
airplanes of U.S. registry. We also estimate that it will take about 7 
work-hours per engine to perform the actions, and that the average 
labor rate is $80 per work-hour. Based on these figures, we estimate 
the total cost of the AD to U.S. operators to be $441,280.

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 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); 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 summary of the costs to comply with this AD and 
placed it in the AD Docket. You may get a copy of this summary at the 
address listed under ADDRESSES.

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 Federal Aviation Administration amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

[[Page 65513]]

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

Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by removing Amendment 39-13950 (70 FR 
3863, January 27, 2005), and by adding a new airworthiness directive, 
Amendment 39-15721, to read as follows:

2008-22-24 Rolls-Royce plc: Amendment 39-15721. Docket No. FAA-2007-
29343; Directorate Identifier 2000-NE-13-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective December 
9, 2008.

Affected ADs

    (b) This AD supersedes AD 2005-02-05, Amendment 39-13950.

Applicability

    (c) This AD applies to Rolls-Royce plc (RR) RB211-535E4-37, 
RB211-535E4-B-37, and RB211-535E4-B-75 series turbofan engines with 
low pressure compressor (LPC) fan blades with the part numbers (P/
Ns) listed in Table 1 of this AD. These engines are installed on, 
but not limited to, Boeing 757 and Tupolev Tu204 series airplanes. 
Table 1 follows:

                                     Table 1--Applicable LPC Fan Blade P/Ns
----------------------------------------------------------------------------------------------------------------

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            UL16135                UL16171                UL16182                UL19643               UL20044
            UL20132                UL20616                UL21345                UL22286               UL23122
            UL24525                UL24528                UL24530                UL24532               UL24534
            UL27992                UL28601                UL28602                UL29511               UL29556
            UL30817                UL30819                UL30933                UL30935               UL33707
            UL33709                UL36992                UL37090                UL37272               UL37274
            UL37276                UL37278                UL38029                UL38032
----------------------------------------------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from RR issuing Mandatory Service Bulletin 
(MSB) No. RB.211-72-C879, Revision 5 and Revision 6, that introduced 
a relaxed repetitive compliance schedule for fan blades operating 
within RB211-535E4 flight profiles A and B, if certain requirements 
are met, and introduced a relaxed initial compliance threshold. We 
are issuing this AD to detect cracks in low pressure compressor 
(LPC) fan blade roots, which if not detected, could lead to 
uncontained multiple fan blade failure, 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.
    (f) On RB211-535E4 engines, operated to Flight Profile A:
    (1) Ultrasonically inspect the fan blade root, and if required, 
relubricate using one of the methods in Table 2 of this AD.
    (2) If the initial inspection is complete prior to 18,600 
cycles-since-new (CSN), then the next inspection may be postponed 
until 20,000 CSN.

                                      Table 2--RB211-535E4 Flight Profile A
----------------------------------------------------------------------------------------------------------------
                                                                                                      Repeat
                                                                                                    inspection
                                        Initial                              In accordance with   within  cycles
          Engine location             inspection         Type action         mandatory service      since last
                                     within  (CSN)                             bulletin (MSB)       inspection
                                                                                                      (CSLI)
----------------------------------------------------------------------------------------------------------------
(1) On-wing.......................          20,000  (i) Root Probe         RB.211-72-C879                  1,400
                                                     inspect, OR.           Revision 6, 3.A.(1)
                                                                            through 3.A.(7),
                                                                            dated December 14,
                                                                            2007.
                                                    (ii) Wave Probe        RB.211-72-C879                  1,150
                                                     inspect.               Revision 6, 3.B.(1)
                                                                            through 3.B.(7),
                                                                            dated December 14,
                                                                            2007.
(2) In shop.......................          20,000  Root Probe inspect.    RB.211-72-C879                  1,400
                                                     Relubricate if blade   Revision 6, 3.C.(1)
                                                     life is more than      through 3.C.(4),
                                                     19,650 cycles.         dated December 14,
                                                                            2007.
----------------------------------------------------------------------------------------------------------------

    (g) On RB211-535E4 engines, operated to Flight Profile B:
    (1) Ultrasonically inspect the fan blade root, and if required, 
relubricate using one of the methods in Table 3 of this AD.
    (2) If the initial inspection is complete prior to 14,150 CSN, 
then the next inspection may be postponed until 15,000 CSN.

                                      Table 3--RB211-535E4 Flight Profile B
----------------------------------------------------------------------------------------------------------------
                                        Initial                                                       Repeat
          Engine location             inspection         Type action         In accordance with     inspection
                                     within  (CSN)                                  MSB             within CSLI
----------------------------------------------------------------------------------------------------------------
(1) On-wing.......................          15,000  (i) Root Probe         RB.211-72-C879                    850
                                                     inspect, OR.           Revision 6, 3.A.(1)
                                                                            through 3.A.(7),
                                                                            dated December 14,
                                                                            2007.
                                                    (ii) Wave Probe        RB.211-72-C879                    700
                                                     inspect.               Revision 6, 3.B.(1)
                                                                            through 3.B.(7),
                                                                            dated December 14,
                                                                            2007.
(2) In shop.......................          15,000  Root Probe, inspect.   RB.211-72-C879                    850
                                                     Relubricate if blade   Revision 6, 3.C.(1)
                                                     life is more than      through 3.C.(4),
                                                     14,650 cycles.         dated December 14,
                                                                            2007.
----------------------------------------------------------------------------------------------------------------

[[Page 65514]]

    (h) On RB211-535E4-B engines:
    (1) Ultrasonically inspect the fan blade root, and if required, 
relubricate using one of the methods in Table 4 of this AD.
    (2) If the initial inspection is complete prior to 18,800 CSN, 
then the next inspection may be postponed until 20,000 CSN.

                                             Table 4--RB211-535E4-B
----------------------------------------------------------------------------------------------------------------
                                        Initial                                                       Repeat
          Engine location             inspection         Type action         In accordance with     inspection
                                     within  (CSN)                                  MSB            within (CSLI)
----------------------------------------------------------------------------------------------------------------
(i) On-wing.......................          20,000  (A) Root Probe         RB.211-72-C879                  1,200
                                                     inspect, OR.           Revision 6, 3.A.(1)
                                                                            through 3.A.(7),
                                                                            dated December 14,
                                                                            2007.
                                                    (B) Wave Probe         RB.211-72-C879                  1,000
                                                     inspect.               Revision 6, 3.B.(1)
                                                                            through 3.B.(7),
                                                                            dated December 14,
                                                                            2007.
(ii) In shop......................          20,000  Root Probe inspect.    RB.211-72-C879                  1,200
                                                     Relubricate if blade   Revision 6, 3.C.(1)
                                                     life is more than      through 3.C.(4),
                                                     19,650 cycles.         dated December 14,
                                                                            2007.
----------------------------------------------------------------------------------------------------------------

    (i) For fan blades operated to any combination of RB211-535E4 
Flight Profile A, -535E4 Flight Profile B, -535E4-B, -535E4-B and -
535E4-C engines:
    (1) Calculate an equivalent CSN as defined in the Time Limits 
Manual. See References Section 1.G.(3), of MSB RB.211-72-C879, 
Revision 6, dated December 14, 2007.
    (2) For fan blades that are currently flying in Profile A, 
inspect using paragraph (f) and Table 2 of this AD using equivalent 
CSN.
    (3) For fan blades that are currently flying in Profile B, 
inspect using paragraph (g) and Table 3 of this AD using equivalent 
CSN.
    (4) For fan blades that are currently flying in an RB211-535E4-B 
engine, inspect using paragraph (h) and Table 4 of this AD using 
equivalent CSN.

Optional Terminating Action

    (j) Application of Metco 58 blade root coating using RR SB No. 
RB.211-72-C946, Revision 2, dated September 26, 2002, constitutes 
terminating action to the repetitive inspection requirements 
specified in paragraphs (f), (g), (h), and (i) of this AD.

Alternative Methods of Compliance

    (k) The Manager, Engine Certification Office, has the authority 
to approve alternative methods of compliance for this AD if 
requested using the procedures found in 14 CFR 39.19.

Previous Credit

    (l) Inspections and relubrication done before the effective date 
of this AD that use AD 2003-12-15 (Amendment 39-13200, 68 FR 37735, 
June 25, 2003), RR MSB No. RB.211-72-C879, Revision 3, dated October 
9, 2002, MSB No. RB.211-72-C879, Revision 4, dated April 2, 2004, or 
MSB No. RB.211-72-C879, Revision 5, dated March 8, 2007, comply with 
the requirements specified in this AD.

Related Information

    (m) United Kingdom Civil Aviation Authority airworthiness 
directive AD 002-01-2000, dated October 9, 2002, also addresses the 
subject of this AD.
    (n) 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.

Material Incorporated by Reference

    (o) You must use Rolls-Royce plc Mandatory Service Bulletin No. 
RB.211-72-C879, Revision 6, dated December 14, 2007 to perform the 
inspections and relubrication required by this AD. The Director of 
the Federal Register approved the incorporation by reference of this 
service bulletin in accordance with 5 U.S.C. 552(a) and 1 CFR part 
51. Contact Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; 
telephone: 011-44-1332-242424; fax: 011-44-1332-249936, for a copy 
of this service information. 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.

    Issued in Burlington, Massachusetts, on October 23, 2008.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E8-25891 Filed 11-3-08; 8:45 am]

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