Document ID: FAA-2007-29343-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan Engines
Posted Date: 2007-10-25T04:00Z

[Federal Register: October 25, 2007 (Volume 72, Number 206)]
[Proposed Rules]               
[Page 60606-60609]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr25oc07-28]                         

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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]
RIN 2120-AA64

 
Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan 
Engines

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

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to supersede 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 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. That AD also 
introduces an alternative technique to ultrasonically inspect installed 
fan blades on-wing using a surface wave ultrasonic probe. Also, that AD 
introduces application of Metco 58 blade root coating as an optional 
terminating action. This proposed AD would require the same actions but 
would 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. This proposed AD 
results from RR issuing Mandatory Service Bulletin (MSB) No. RB.211-72-
C879, Revision 5. That MSB introduces a relaxed repetitive compliance 
schedule for RB211-535E4 engines operating in flight profiles A and B, 
if certain requirements are met. We are proposing 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: We must receive any comments on this proposed AD by December 24, 
2007.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     Government-wide rulemaking Web site: Go to http://www.regulations.gov
 and follow the instructions for sending your 

comments electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue, SE., 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, PO Box 31, Derby, England, DE248BJ; 
telephone: 011-44-1332-242-424; fax: 011-44-1332-249-936 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 01803-5299; e-mail: 
ian.dargin@faa.gov; telephone: (781) 238-7178; fax: (781) 238-7199.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2007-29343; 
Directorate Identifier 2000-NE-13-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.

[[Page 60607]]

    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 January 18, 2005, we issued AD 2005-02-05, Amendment 39-13950 
(70 FR 3863, January 27, 2005). That AD requires initial and repetitive 
ultrasonic inspections of installed LPC fan blade roots on-wing and 
during overhaul using a surface wave ultrasonic probe, and 
relubrication according to accumulated life cycles. That AD also adds 
the application of Metco 58 blade root coating as an optional 
terminating action. That AD results from RR issuing MSB No. RB.211-72-
C879, Revision 4, which contains revised Accomplishment Instructions 
and consumable materials list.

Actions Since We Issued AD 2005-02-05

    Since we issued AD 2005-02-05, Rolls-Royce plc updated MSB No. 
RB.211-72-C879, Revision 4, dated April 2, 2004, to Revision 5, dated 
March 8, 2007, for RR RB211 series turbofan engines. Revision 5 relaxes 
the compliance for repetitive inspections for RB211-535E4 engines 
operating in flight profiles A and B, if certain requirements are met.

Clarification Changes

    Also, as clarification, we changed the Table 4 initial compliance 
from ``65% hard life'' to ``within 350 cycles after achieving 65% hard 
life''. These changes better reflect the proposed AD wording, with the 
latest MSB.

Relevant Service Information

    We have reviewed and approved the technical contents of Rolls-Royce 
plc MSB No. RB.211-72-C879, Revision 5, dated March 8, 2007. That MSB 
describes procedures for ultrasonic inspection of high cyclic life 
blades on-wing with either the LPC fan blades in place or removed from 
the LPC. The Civil Aviation Authority (CAA), which is the airworthiness 
authority for the United Kingdom (UK), classified the original issue of 
the service bulletin as mandatory and issued AD 002-01-2000 to ensure 
the airworthiness of these RR engines in the UK.

Bilateral Agreement Information

    This engine model is manufactured in UK 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 UK 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 ultrasonic inspection of installed LPC fan blade 
roots on-wing and during overhaul using a surface wave ultrasonic 
probe, and relubrication according to accumulated life cycles. This 
proposed AD would also maintain the application of Metco 58 blade root 
coating as an optional terminating action. 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 788 engines 
installed on airplanes of U.S. registry. We also estimate that it would 
take about 7 work-hours per engine to perform the proposed actions, and 
that the average labor rate is $80 per work-hour. Based on these 
figures, we estimate the total cost of the proposed AD to U.S. 
operators to be $358,540.

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

[[Page 60608]]

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 39-13950 (70 FR 
3863, January 27, 2005) and by adding a new airworthiness directive, to 
read as follows:

Rolls-Royce plc: Docket No. FAA-2007-29343; Directorate Identifier 
2000-NE-13-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by December 24, 
2007.

Affected ADs

    (b) This AD revises 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
----------------------------------------------------------------------------------------------------------------

----------------------------------------------------------------------------------------------------------------
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, that introduces a relaxed 
repetitive compliance schedule for RB211-535E4 engines operating in 
flight profiles A and B, if certain requirements are met. 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) If you have a full set of fan blades, modified using RR 
Service Bulletin No. RB.211-72-C946, Revision 2, dated September 26, 
2002, that can be identified by a blue triangle etched on the blade 
airfoil suction surface close to the leading edge tip of each blade, 
no further action is required.
    (g) On RB211-535E4 engines, operated to Flight Profile A, 
ultrasonically inspect, and if required, relubricate using the 
following Table 2:

                                     Table 2.--RB211-535E4 Flight Profile A
----------------------------------------------------------------------------------------------------------------
                        Initial inspection                            In accordance with
    Engine location       within cycles-          Type action          mandatory service      Repeat inspection
                         since-new  (CSN)                               bulletin  (MSB)         within  (CSN)
----------------------------------------------------------------------------------------------------------------
(1) On-wing...........              17,350  (i) Root Probe,         RB.211-72-C879                         1,400
                                             inspect and             Revision 5, 3.A.(1)
                                             relubricate, OR         through 3.A.(7),
                                                                     dated March 8, 2007.
                        ..................  (ii) Wave Probe.......  RB.211-72-C879                         1,150
                                                                     Revision 5, 3.B.(1)
                                                                     through 3.B.(7),
                                                                     dated March 8, 2007.
(2) In Shop...........              17,350  Root Probe, inspect     RB.211-72-C879                         1,400
                                             and relubricate.        Revision 5, 3.C.(1)
                                                                     through 3.C.(4),
                                                                     dated March 8, 2007.
----------------------------------------------------------------------------------------------------------------

    (h) On RB211-535E4 engines, operated to Flight Profile B, 
ultrasonically inspect, and if required, relubricate using the 
following Table 3:

                                     Table 3.--RB211-535E4 Flight Profile B
----------------------------------------------------------------------------------------------------------------
                         Initial inspection                                                    Repeat inspection
    Engine location         within  (CSN)          Type action        In accordance with MSB     within  (CSN)
----------------------------------------------------------------------------------------------------------------
(1) On-wing............              12,350  (i) Root Probe, inspect  RB.211-72-C879                         850
                                              and relubricate, OR      Revision 5, 3.A.(1)
                                                                       through 3.A.(7),
                                                                       dated March 8, 2007.
                         ..................  (ii) Wave Probe........  RB.211-72-C879                         700
                                                                       Revision 5, 3.B.(1)
                                                                       through 3.B.(7),
                                                                       dated March 8, 2007.
(2) In Shop............              12,350  Root Probe, inspect and  RB.211-72-C879                         850
                                              relubricate.             Revision 5, 3.C.(1)
                                                                       through 3.C.(4),
                                                                       dated March 8, 2007.
----------------------------------------------------------------------------------------------------------------

[[Page 60609]]

    (i) On RB211-535E4 engines, operated to combined Flight Profile 
A and B, ultrasonically inspect, and if required, relubricate using 
the following Table 4:

                                  Table 4.--RB211-535E4 Flight Profile A and B
----------------------------------------------------------------------------------------------------------------
                            Initial inspection                          In accordance with    Repeat inspection
     Engine location           within  (CSN)          Type action               MSB             within  (CSN)
----------------------------------------------------------------------------------------------------------------
(1) On-wing..............  350 cycles after      (i) Root Probe,       RB.211-72-C879        As current flight
                            achieving 65% hard    inspect and           Revision 5, 3.A.(1)   profile. See
                            life (To calculate,   relubricate, OR       through 3.A.(7),      paragraphs (j) and
                            see MSB Compliance                          dated March 8, 2007.  (k) of this AD.
                            Section 1.C.(4)).
                                                 (ii) Wave Probe.....  RB.211-72-C879        As current flight
                                                                        Revision 5, 3.B.(1)   profile. See
                                                                        through 3.B.(7),      paragraphs (j) and
                                                                        dated March 8, 2007.  (k) of this AD.
(2) In Shop..............  350 cycles after      Root Probe, inspect   RB.211-72-C879        As current flight
                            achieving 65% hard    and relubricate.      Revision 5, 3.C.(1)   profile. See
                            life (To calculate,                         through 3.C.(4),      paragraphs (j) and
                            see MSB Compliance                          dated March 8, 2007.  (k) of this AD.
                            Section 1.C.(4)).
----------------------------------------------------------------------------------------------------------------

    (j) For RB.211-535E4 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.
    (k) For RB.211-535E4 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.
    (l) Fan blades that have been operated within RB.211-535E4 
Flight Profile A and B will have final life as defined in the Time 
Limits Manual. See References Section 1.G.(3), of MSB RB.211-72-
C879, Revision 5, dated March 8, 2007.
    (m) On RB.211-535E4-B engines, ultrasonically inspect, and if 
required, relubricate using the following Table 5:

                                             Table 5.--RB211-535E4-B
----------------------------------------------------------------------------------------------------------------
                         Initial inspection                                                    Repeat inspection
    Engine location         within  (CSN)          Type action        In accordance with MSB     within  (CSN)
----------------------------------------------------------------------------------------------------------------
(1) On-wing............              17,000  (i) Root Probe, inspect  RB.211-72-C879                       1,200
                                              and relubricate, OR      Revision 5, 3.A.(1)
                                                                       through 3.A.(7),
                                                                       dated March 8, 2007.
                                             (ii) Wave Probe........  RB.211-72-C879                       1,000
                                                                       Revision 5, 3.B.(1)
                                                                       through 3.B.(7),
                                                                       dated March 8, 2007.
(2) In Shop............              17,000  Root Probe, inspect and  RB.211-72-C879                       1,200
                                              relubricate.             Revision 5, 3.C.(1)
                                                                       through 3.C.(4),
                                                                       dated March 8, 2007.
----------------------------------------------------------------------------------------------------------------

Optional Terminating Action

    (n) 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 (g), (h), (i), and (k) of this AD.

Alternative Methods of Compliance

    (o) 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

    (p) Previous credit is allowed for initial and repetitive 
inspections performed using 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, and RR MSB No. RB.211-72-C879, Revision 4, dated 
April 2, 2004.

Related Information

    (q) CAA airworthiness directive AD 002-01-2000, dated October 9, 
2002, also addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on October 18, 2007.
Francis A. Favara,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
 [FR Doc. E7-20999 Filed 10-24-07; 8:45 am]

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