Document ID: FAA-2009-1369-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives:  Rolls-Royce plc RB211 Trent 800 Series Turbofan Engines,
Posted Date: 2009-04-27T04:00Z

[Federal Register Volume 74, Number 79 (Monday, April 27, 2009)]
[Proposed Rules]
[Pages 19025-19027]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: E9-9479]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-1369; Directorate Identifier 2003-NE-03-AD]
RIN 2120-AA64

Airworthiness Directives; Rolls-Royce plc RB211 Trent 800 Series 
Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), 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 RB211 Trent 875-17, Trent 877-17, 
Trent 884-17, Trent 892-17, Trent 892B-17, and Trent 895-17 turbofan 
engines with high pressure (HP) compressor rotor rear stage 5 and 6 
discs and cone shafts, part numbers (P/Ns) FK25230 and FK27899 
installed. This proposed AD would require removing these parts at new 
reduced cycle limits. This proposed AD results from Rolls-Royce plc 
reducing the lives of these parts and changing the life calculating 
method to use ``Standard Duty Cycles'' with ``Multiple Flight Profile 
Monitoring'' and ``Flight Cycles'' with ``Heavy Flight Profile 
Monitoring''. We are proposing this AD to prevent stage 5 and 6 disc 
crack initiation and propagation that might lead to uncontained disc 
failure and damage to the airplane.

DATES: We must receive any comments on this proposed AD by June 26, 
2009.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     Federal eRulemaking Portal: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 1200 New Jersey Avenue SE., West Building Ground Floor, 
Room W12-140, 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.

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: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposed AD. Send your comments to an address 
listed under the ADDRESSES section. Include ``Docket No. FAA-2009-1369; 
Directorate Identifier 2003-NE-03-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this proposed AD. We 
will consider all comments received by the closing date and may amend 
this proposed AD based on 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 
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 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 July 23, 2003, we issued AD 2003-15-06, Amendment 39-13249 (68 
FR 44610, July 30, 2003). That AD requires removal from service of HP 
compressor rotor rear stage 5 and 6 discs and cone shafts, P/Ns FK25230 
and FK27899, before reaching newly reduced life limits. The Civil 
Aviation Authority (CAA), which is the airworthiness authority for the 
United Kingdom (U.K.), had notified the FAA that an unsafe condition 
may exist on Rolls-Royce plc RB211 Trent 875, Trent 877, Trent 884, 
Trent 892, Trent 892B, and Trent 895 turbofan engines. The CAA advised 
that three HP compressor rotor rear stage 5 and 6 discs and cone 
shafts, P/Ns FK25230 and FK27899, were found with crack indications in 
the stage 5 and 6 blade loading slots, during overhaul inspection. The 
manufacturer's analysis had not yet been able to identify the root 
cause of these cracks, or to fully explain the crack propagation rate. 
As a result of the analysis, a new lower life limit of 7,500 cycles-
since-new had been assigned by the manufacturer to these HP compressor 
rotor rear stage 5 and 6 discs and cone shafts. This condition, if not 
corrected,

[[Page 19026]]

could result in stage 5 and 6 disc crack initiation and propagation 
that might lead to uncontained disc failure and damage to the airplane.

Actions Since AD 2003-15-06 Was Issued

    Since AD 2003-15-06 was issued, Rolls-Royce plc has further reduced 
the lives of HP compressor rotor rear stage 5 and 6 discs and cone 
shafts, P/Ns FK25230 and FK27899, and changed the life calculating 
method to use ``Standard Duty Cycles'' with ``Multiple Flight Profile 
Monitoring'' and ``Flight Cycles'' with ``Heavy Flight Profile 
Monitoring''.

Bilateral Agreement Information

    This engine model is manufactured in the United Kingdom 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 European Aviation Safety Agency (EASA) 
kept us informed of the situation described above. We have examined the 
findings of EASA, 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 
changing the life calculating method to use ``Standard Duty Cycles'' 
with ``Multiple Flight Profile Monitoring'' and ``Flight Cycles'' with 
``Heavy Flight Profile Monitoring'', and reducing the lives of the 
affected parts to 5,000 ``Standard Duty Cycles'' or 5,000 Flight 
cycles'', respectively.

Costs of Compliance

    We estimate that this proposed AD would affect 94 Rolls-Royce plc 
RB211 Trent 875-17, Trent 877-17, Trent 884-17, Trent 892-17, Trent 
892B-17, and Trent 895-17 turbofan engines installed on airplanes of 
U.S. registry. Removal of these HP compressor rotor rear stage 5 and 6 
discs and cone shafts would not impose any additional labor costs if 
performed at the time of scheduled engine overhaul. The prorated life 
loss is about $225,000 per engine. Based on these figures, we estimate 
the cost of this proposed AD on U.S. operators to be $21,150,000.

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 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 39-13249 (68 FR 
44610, July 30, 2003) and by adding a new airworthiness directive, to 
read as follows:

Rolls-Royce plc: Docket No. FAA-2009-1369; Directorate Identifier 
2003-NE-03-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by June 26, 
2009.

Affected ADs

    (b) This AD supersedes AD 2003-15-06, Amendment 39-13249.

Applicability

    (c) This AD applies to Rolls-Royce plc RB211 Trent 875-17, Trent 
877-17, Trent 884-17, Trent 892-17, Trent 892B-17, and Trent 895-17 
turbofan engines with high pressure (HP) compressor rotor rear stage 
5 and 6 discs and cone shafts, part numbers (P/Ns) FK25230 and 
FK27899 installed. These engines are installed on, but not limited 
to, Boeing 777 series airplanes.

Unsafe Condition

    (d) This AD results from Rolls-Royce plc reducing the lives of 
these parts and changing the life calculating method to use 
``Standard Duty Cycles'' with ``Multiple Flight Profile 
Monitoring'', and ``Flight Cycles'' with ``Heavy Flight Profile 
Monitoring''. We are issuing this AD to prevent stage 5 and 6 disc 
crack initiation and propagation that might lead to uncontained disc 
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) For operators using ``Multiple Flight Profile Monitoring'' 
(Flight Profiles ``A'' through ``F''), remove HP compressor rotor 
rear stage 5 and 6 discs and cone shafts from service at or before 
accumulating 5,000 ``Standard Duty Cycles''. Information on 
``Multiple Flight Profile Monitoring'' can be found in the Aircraft 
Maintenance Manual, Chapter 70-01-10.
    (g) For operators using ``Heavy Flight Profile Monitoring'', 
remove HP compressor rotor rear stage 5 and 6 discs and cone shafts 
from service at or before accumulating 5,000 ``Flight Cycles''. 
Information on ``Heavy Flight Profile Monitoring'' can be found in 
the Aircraft Maintenance Manual, Chapter 70-01-10.

Alternative Methods of Compliance

    (h) 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.

[[Page 19027]]

Related Information

    (i) 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.
    (j) European Aviation Safety Agency AD 2007-0004, dated January 
8, 2007, also addresses the subject of this AD.
    (k) Rolls-Royce plc Alert Service Bulletin No. RB.211-72-AE082, 
Revision 7, dated June 18, 2008, pertains to the subject of this AD. 
Contact Rolls-Royce plc, P.O. Box 31, Derby, DE24 8BJ, UK, telephone 
44 (0) 1332 242424; fax 44 (0) 1332 249936, for a copy of this 
service information.
    (l) Contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, 
Washington 98124-2207, for a copy of the Aircraft Maintenance Manual 
referenced in this AD.

    Issued in Burlington, Massachusetts, on April 17, 2009.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E9-9479 Filed 4-24-09; 8:45 am]
BILLING CODE 4910-13-P