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/ October
/ Monday, October 27, 2003
[Federal Register: October 27, 2003 (Volume 68, Number 207)]
[Proposed Rules]
[Page 61158-61161]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr27oc03-21]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2002-NE-40-AD]
RIN 2120-AA64
Airworthiness Directives; Rolls-Royce plc RB211-524 Series
Turbofan Engines
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD)
for Rolls-Royce plc (RR) RB211-524 series turbofan engines, with
certain part number (P/N) intermediate pressure (IP) compressor stage 5
discs installed. This proposed AD would establish new reduced IP
compressor stage 5 disc cyclic limits. This action would also require
removing from service, affected discs that already exceed the new
reduced cyclic limit, and removing other affected discs before
exceeding their cyclic limits, using a drawdown schedule. This action
would also allow optional inspections at each shop visit or a one-time
on-wing eddy current inspection (ECI) to extend the disc life beyond
the lives specified. This proposed AD is prompted by the discovery of
cracks in the cooling air hole areas of the disc front spacer arm. We
are proposing this AD to prevent IP compressor stage 5 disc failure,
which could result in uncontained engine failure and possible damage to
the airplane.
DATES: We must receive any comments on this proposed AD by December 26,
2003.
ADDRESSES: Use one of the following addresses to submit comments on
this proposed AD:
[sbull] By mail: Federal Aviation Administration (FAA), New England
Region, Office of the Regional Counsel, Attention: Rules Docket No.
2002-NE-40-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
[sbull] By fax: (781) 238-7055. [sbull] By e-mail: 9-ane-adcomment@faa.gov.
You can get the service information identified in this proposed AD
from Rolls-Royce plc, P.O. Box 31 Derby, DE248BJ, United Kingdom;
telephone 011-44-1332-242424; fax 011-44-1332-249936.
You may examine the AD docket at the FAA, New England Region,
Office of the Regional Counsel, 12 New England Executive Park,
Burlington, MA.
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; telephone (781) 238-
7178; fax (781) 238-7199.
SUPPLEMENTARY INFORMATION:
Comments Invited
We invite you to submit any written relevant data, views, or
arguments regarding this proposal. Send your comments to an address
listed under ADDRESSES. Include ``AD Docket No. 2002-NE-40-AD'' in the
subject line of your comments. If you want us to acknowledge receipt of
your mailed comments, send us a self-addressed, stamped postcard with
the docket number written on it; we will date-stamp your postcard and
mail it back to you. We specifically invite comments on the overall
regulatory, economic, environmental, and energy aspects of the proposed
AD. If a person contacts us verbally, and that contact relates to a
substantive part of this proposed AD, we will summarize the contact and
place the summary in the docket. We will consider all comments received
by the closing date and may amend the proposed AD in light of those
comments.
We are reviewing the writing style we currently use in regulatory
documents. We are interested in your comments on whether the style of
this document is clear, and your suggestions to improve the clarity of
our communications that affect you. You may get more information about
plain language at http://www.faa.gov/language and http://www
.plainlanguage.gov.
Examining the AD Docket
You may examine the AD Docket (including any comments and service
information), by appointment, between 8 a.m. and 4:30 p.m., Monday
through Friday, except Federal holidays. See ADDRESSES for the
location.
Discussion
The Civil Aviation Authority (CAA), which is the airworthiness
authority for the United Kingdom (U.K.), recently notified the FAA that
an unsafe condition may exist on certain RR model RB211-524 series
turbofan engines. The CAA reports that cracks were found, during
overhaul, in the cooling air hole areas of the disc front spacer arm.
The engine manufacturer has performed a reassessment of the safe cyclic
limits of certain IP compressor stage 5 discs. The cyclic limits of
these discs are reduced based on that reassessment. This condition, if
not corrected, could result in uncontained engine failure and possible
damage to the airplane.
Relevant Service Information
We have reviewed and approved the technical contents of mandatory
service bulletin (MSB) RB.211-72-D428, Revision 3, dated June 30, 2003,
that specifies a drawdown schedule for removing from service affected
IP compressor stage 5 discs, using new Time Limits Manual (TLM) cyclic
limits. The MSB also describes procedures for optional inspections at
each shop visit to extend the disc life beyond the lives specified. The
CAA has classified this service bulletin as mandatory and issued AD
006-04-2002 in order to ensure the airworthiness of these RR plc
turbofan engines in the U.K. We have also reviewed and approved the
technical contents of Service Bulletin (SB) RB.211-72-E148, dated March
13, 2003 and SB RB.211-72-E150, dated April 17, 2003 that provide an
optional on-wing ECI of the affected discs, to extend the disc life
beyond the lives specified.
Differences Between This Proposed AD and the Manufacturer's Service
Information
The compliance time is added, to remove or inspect discs not later
than 30 days after the effective date of this AD.
[[Page 61159]]
FAA's Determination and Requirements of the Proposed AD
These engine models, manufactured in the U.K., are 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 CAA has kept us informed of the situation
described above. We have examined the CAA's findings, 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. Therefore, we are proposing this AD, which would
require:
[sbull] Establishing new reduced IP compressor stage 5 disc cyclic
limits.
[sbull] Removing from service affected discs that already exceed the
new reduced cyclic limit.
[sbull] Removing other affected discs before exceeding their cyclic
limits, using a drawdown schedule.
[sbull] Allowing optional inspections at each shop visit or a one-time
on-wing ECI to extend the disc life beyond the specified life.
The proposed AD would require you to use the service information
described previously to perform these actions.
Changes to 14 CFR Part 39--Effect on the Proposed AD
On July 10, 2002, we published a new version of 14 CFR part 39 (67
FR 47997, July 22, 2002), which governs the FAA's AD system. This
regulation now includes material that relates to altered products,
special flight permits, and alternative methods of compliance. This
material previously was included in each individual AD. Since this
material is included in 14 CFR part 39, we will not include it in
future AD actions.
Costs of Compliance
There are about 939 RR RB211-524 series turbofan engines of the
affected design in the worldwide fleet. We estimate that 35 engines
installed on airplanes of U.S. registry would be affected by this
proposed AD. We also estimate that it would take about 8 work hours per
engine to perform an inspection, and 300 work hours per engine to
replace an IP compressor stage 5 disc. The average labor rate is $65
per work hour. Required parts would cost about $49,000 per engine.
Based on these figures, we estimate the total cost of the proposed AD
to U.S. operators to be $2,397,500.
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
regulation:
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 summary of the costs to comply with this proposal and
placed it in the AD Docket. You may get a copy of this summary by
sending a request to us at the address listed under ADDRESSES. Include
``AD Docket No. 2002-NE-40-AD'' in your request.
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 adding the following new
airworthiness directive:
Rolls-Royce plc: Docket No. 2002-NE-40-AD.
Comments Due Date
(a) The FAA must receive comments on this airworthiness
directive (AD) action by December 26, 2003.
Affected ADs
(b) None.
Applicability
(c) This AD applies to the Rolls-Royce plc RB211-524 series
turbofan engines listed in the following Table 1, with intermediate
pressure (IP) compressor stage 5 disc part numbers (P/Ns) listed in
Table 2 of this AD, installed.
Table 1.--Engine Models Affected
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-524B-02 -524B-B-02 -524B3-02 -524B4-02 -524B4-D-02
-524B2-19 -524B2-B-19 -524C2-19 -524C2-B-19 -524D4-19
-524D4-B-19 -524D4X-19 524D4X-B-19 -524D4-39 -524D4-B-39
-524G2-19 -524G2-T-19 -524G3-19 -524G3-T-19 -524H2-19
-524H2-T-19 -524H-36 -524H-T-36
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These engines are installed on, but not limited to, Boeing 747,
767, and Lockheed L-1011 airplanes.
Table 2.--IP Compressor Stage 5 Disc P/Ns Affected
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LK60130 LK65932 LK69021 LK81269 LK83282
LK83283 UL12290 UL15743 UL15744 UL15745
UL19132 UL20785 UL20832 UL23291 UL25011
UL36821 UL36977 UL36978 UL36979 UL36980
UL36981 UL36982 UL36983 UL37078 UL37079
UL37080 UL37081 UL37082 UL37083 UL37084
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[[Page 61160]]
Unsafe Condition
(d) This AD is prompted by the discovery of cracks in the
cooling air hole areas of the IP compressor stage 5 disc front
spacer arm. We are issuing this AD to prevent IP compressor stage 5
disc failure, which could result in uncontained engine failure and
possible 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.
Cycle Limits
(f) Change the service cyclic limits for the IP compressor stage
5 discs installed in the engine models listed in the following Table
3, within 30 days after the effective date of this AD.
Table 3.--Cyclic Life Limits Without Qualifying Magnetic Particle Inspection (MPI) or Eddy Current Inspection
(ECI)
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Engine models
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-524G2, G2-T,
Date of reduced life limit G3, G3-T, H2, H2- -524D4, D4-B, D4- -524B2, B2-B, -524B-02, B-B-
T, H-36,H-T-36 B-39, D4X, D4X- C2, C2-B 02, B3-02, B4-
B, D4-39 02, B4-D-02
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November 30, 2002....................... \1\ 13,500 CIS 16,150 CIS 16,000 CIS 16,200 CIS
April 1, 2003........................... 13,500 CIS 13,500 CIS 13,500 CIS 14,000 CIS
December 1, 2003........................ 12,000 CIS 13,500 CIS 13,500 CIS 14,000 CIS
December 1, 2004........................ 11,000 CIS 13,500 CIS 12,000 CIS 12,000 CIS
December 1, 2005........................ 11,000 CIS 12,000 CIS 12,000 CIS 12,000 CIS
December 1, 2008........................ 7,830 CIS 8,700 CIS 12,000 CIS 12,000 CIS
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\1\ Cycles-in-service.
Optional Inspections
(g) Before December 1, 2008, optional inspections are allowed at
each shop visit or a one-time on-wing ECI is allowed to extend the
disc life. Guidance for these inspections is provided in paragraphs
(h) or (i) of this AD.
Optional Inspections at Shop Visit
(h) Perform optional inspections at shop visit, as follows:
(1) Remove corrosion protection from IP stage 5 disc.
Information on corrosion protection removal can be found in the
Engine Manual.
(2) Visual-inspect and binocular-inspect the IP stage 5 disc for
corrosion pitting at the cooling air holes and defender holes in the
disc front spacer arm. Follow paragraph 3.C. of the Accomplishment
Instructions of RR MSB No. RB.211-72-D428, Revision 3, dated June
30, 2003.
(3) Discs with corrosion pitting in excess of limits must be
removed from service. Information on disc corrosion pitting limits
can be found in the Engine Manual.
(4) If the disc is free from corrosion pitting, MPI entire disc.
Inspection on MPI can be found in the Engine Manual.
(5) If the disc has corrosion pitting within limits, ECI all
disc cooling air holes, defender holes, and inner and outer faces.
Follow paragraph 3.D. of the Accomplishment Instructions of RR MSB
No. RB.211-72-D428, Revision 3, dated June 30, 2003. Information on
corrosion pitting limits can be found in the Engine Manual.
(6) If the disc passes ECI and no cracks are found, MPI entire
disc. Information on MPI can be found in the Engine Manual.
(7) If the disc passes MPI and no cracks are found, re-apply
corrosion protection to disc, and return the disc to service in
accordance with the cyclic limits allowed by paragraph (l) of this
AD. Information on MPI limits can be found in the Engine Manual.
Information on re-applying corrosion protection can be found in RR
Repair FRS5900.
Optional One-Time On-Wing EC Inspection
(i) For RB211-524B2/C2 and RB211-524B4/D4 engine models, a one-
time on-wing ECI of the IP compressor stage 5 disc may be performed
in lieu of a shop visit inspection. Follow RR paragraph 3.A. through
3.F. of Accomplishment Instructions of SB No. RB.211-72-E148, and RR
SB No. RB.211-72-E150, respectively, to do the ECI. If the disc
passes the ECI and no cracks are found, an extension is allowed as
specified in paragraph (l) of this AD.
Definition of Shop Visit
(k) For the purposes of this AD, a shop visit is defined as the
separation of an engine major case flange. This definition excludes
shop visits when only field maintenance type activities are
performed in lieu of performing them on-wing. (i.e., for purposes
such as to perform an on-wing inspection of a tail engine
installation on an L1011 airplane).
Cyclic Life Extension
(l) Discs that pass an optional inspection may remain in service
after that inspection for the additional cycles listed in the
following Table 4, or until the next inspection, or until the
December 1, 2008 life limit in Table 3 is reached, whichever occurs
first.
Note 1: Discs may remain in service for additional periods if
repeat optional inspections are conducted and associated AD criteria
are met.
Table 4.--Cyclic Life Extension
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Engine models
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-524G2, G2-T, G3, G3-T, H2, -524D4, D4-B, D4-B-39, D4X, -524B-02, B-B-02, B3-02, B4-
H2-T, H-36, H-T-36 D4X-B, D4-39 -524B2, B2-B, C2, C2-B 0-2, B4-D-02
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Extension after passing MPI.... 1,600 cycles................. 2,000 cycles................ 2,000 cycles................ 2,000 cycles.
Extension after passing In-Shop 3,800 cycles................. 4,500 cycles................ 4,500 cycles................ 4,500 cycles.
ECI.
Extension after passing On-Wing 1,000 cycles................. 1,200 cycles................ 1,200 cycles................ 1,200 cycles.
ECI.
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[[Page 61161]]
Discs That Have Been Intermixed Between Engine Models
(m) Information on intermixing discs between engine models can
be found in the RR Time Limits Manual, 05-00-01.
Alternative Methods of Compliance
(n) 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.
Material Incorporated by Reference
(o) You must use the service information specified in the
following Table 5 to perform the inspections and drawdown required
by this AD. Approval of incorporation by reference from the Office
of the Federal Register is pending.
Table 5.--Incorporation by Reference
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Service bulletin No. Page Revision Date
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Mandatory Service Bulletin No. All....................... 3........................ June 30, 2003.
RB.211-72-D428.
Total Pages: 27
Service Bulletin No. RB.211-72- All....................... Original................. March 13, 2003.
E148.
Total Pages: 83
Service Bulletin No. RB.211-72- All....................... 1........................ June 4, 2003.
E150.
Total pages: 72
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Related Information
(p) CAA airworthiness directive 006-04-2002, dated April 2002,
also addresses the subject of this AD.
Issued in Burlington, Massachusetts, on October 21, 2003.
Robert J. Ganley,
Acting Manager, Engine and Propeller Directorate, Aircraft
Certification Service.
[FR Doc. 03-26980 Filed 10-24-03; 8:45 am]
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