AD 2000-11-10

[Federal Register Volume 65, Number 109 (Tuesday, June 6, 2000)]
[Rules and Regulations]
[Pages 35814-35817]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 00-13566]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 94-ANE-16-AD; Amendment 39-11758; AD 2000-11-10]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan 
Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD) applicable to certain Rolls-Royce plc (R-R) RB211 series turbofan 
engines. That AD currently requires the removal from service of 
intermediate pressure (IP) compressor stage 6-7 rotor shafts that 
exceed reduced cyclic life limits. This amendment requires further 
reduction of cyclic life limits and introduction of new reduced cyclic 
bands for rework. This action is prompted by additional stress analysis 
conducted following failure of an IP compressor stage 6 disk. The 
actions specified by this AD are intended to prevent an uncontained 
engine failure due to rupture of an IP compressor stage 6-7 rotor 
shaft.

DATES: Effective August 7, 2000. The incorporation by reference of 
certain publications listed in the rule is approved by the Director of 
the Federal Register as of August 7, 2000.

ADDRESSES: The service information referenced in this AD may be 
obtained from Rolls-Royce plc, Technical Publications Department, P.O. 
Box 31, Derby, DE24 8BJ, UK, telephone 011-44-1332-242424. This 
information may be examined at the Federal Aviation Administration 
(FAA), New England Region, Office of the Regional Counsel, 12 New 
England Executive Park, Burlington, MA, or at the Office of the Federal 
Register, 800 North Capitol Street, NW., suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Jason Yang, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803-5299; telephone (781) 238-
7747, fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) by superseding AD 94-18-03, 
Amendment 39-9016 (59 FR 46536), applicable to R-R RB211-22B and -524 
series turbofan engines, was published in the Federal Register on 
August 31, 1999 (64 FR 47447). That action proposed to require the 
removal from service of IP compressor stage 6-7 rotor shafts that 
exceed reduced cyclic life limits.

Conclusion

    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. No comments were received on the 
proposal or the FAA's determination of the cost to the public. The FAA 
has determined that air safety and the public interest require the 
adoption of the rule as proposed.

[[Page 35815]]

Economic Analysis

    There are approximately 1,300 engines of the affected design in the 
worldwide fleet. The manufacturer has advised the FAA that there are 
228 engines installed on aircraft of U.S. registry that will be 
affected by this AD. It will take approximately 24 work hours or $1,440 
per engine to accomplish the proposed rework actions, if rework of the 
rotor shafts is selected. Otherwise, to maintain the record of the 
cyclic life of IP compressor stage 6-7 rotor shafts has minimum 
economic impact on U.S operators. Based on these figures, the total 
cost impact of the AD on U.S. operators is estimated to be less than 
$330,000.

Regulatory Impact

    This final rule does not have federalism implications, as defined 
in Executive Order 13132, because it does 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. Accordingly, 
the FAA has not consulted with state authorities prior to publication 
of this final rule.
    For the reasons discussed above, I certify that this action: (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. A final evaluation has been prepared for this action 
and is contained in the Rules Docket. A copy of it may be obtained from 
the Rules Docket at the location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (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. Section 39.13 is amended by removing amendment 39-9016 (59 FR 
46536, September 9, 1994) and by adding a new airworthiness directive 
to read as follows:

2000-11-10  Rolls-Royce plc: Amendment 39-11758. Docket No. 94-ANE-
16-AD. Supersedes AD 94-18-03, Amendment 39-9016.

Applicability

    Rolls-Royce plc (R-R) Model RB211-22B and -524 series turbofan 
engines, not incorporating new intermediate pressure (IP) compressor 
stage 6-7 rotor shafts assemblies with redesigned stage 6 disks in 
accordance with R-R Service Bulletin (SB) No. RB.211-72-9993, dated 
August 26, 1994. These engines are installed on but not limited to 
Boeing 747 series and 767 series, and Lockheed L-1011 series 
aircraft.

    Note 1: This airworthiness directive (AD) applies to each engine 
identified in the preceding applicability provision, regardless of 
whether it has been modified, altered, or repaired in the area 
subject to the requirements of this AD. For engines that have been 
modified, altered, or repaired so that the performance of the 
requirements of this AD is affected, the owner/operator must request 
approval for an alternative method of compliance in accordance with 
paragraph (e) of this AD. The request should include an assessment 
of the effect of the modification, alteration, or repair on the 
unsafe condition addressed by this AD; and, if the unsafe condition 
has not been eliminated, the request should include specific 
proposed actions to address it.

Compliance

    Required as indicated, unless previously accomplished.
    To prevent an uncontained engine failure due to rupture of an IP 
compressor stage 6-7 rotor shaft, accomplish the following:

Corrective Action

    (a) For IP compressor stage 6-7 rotor shafts that have not been 
reworked in accordance with SB RB.211-72-9594, Revision 8, dated 
January 14, 1999, Revision 7, dated September 16, 1994, Revision 6, 
dated August 12, 1994, or Revision 5, dated February 12, 1993, 
remove the rotor shafts prior to exceeding the life limits 
established in Table 1 of this AD under sub-title ``Pre SB72-9594'' 
and replace with serviceable parts.

                                                                                             Table 1
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                                                                         Pre SB72-9594                      Rework bands                     Post SB72-9594                Post SB72-9618
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                                                                   Life      Life      Life       Rework                                Life      Life      Life      Life      Life      Life
                  Engine mark and mod standard                    limits    limits    limits      bands        Rework       Rework     limits    limits    limits    limits    limits    limits
                                                                  through    after     after   through  12/ bands after  bands after   through    after     after    through    after     after
                                                                 12/31/00  12/31/00  12/31/01     31/00       12/31/00     12/31/01   12/31/00  12/31/00  12/31/01  12/31/00  12/31/00  12/31/01
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RB.211-22B-02 Pre SB72-5787 and Pre SB72-8700..................     11000     10000      9000   8000-11000   7500-10000    7500-9000     18000     17600     16600       N/A       N/A       N/A
RB.211-22B-02 Pre SB72-5787 and Post SB72-8700.................     11000     10000     10000   8000-11000   7500-10000   7500-10000     17310     16960     15960       N/A       N/A       N/A
RB.211-22B-02 Post SB72-5787 and Pre SB72-8700.................     11000     11000     11000   8000-11000   8000-11000   8000-11000     18000     18000     18000       N/A       N/A       N/A
RB.211-22B-02 Post SB72-5787 and Post SB72-8700................     11000     11000     11000   8000-11000   8000-11000   8000-11000     17310     17310     17310       N/A       N/A       N/A
RB.211-524B-02 RB.211-524B3-02 RB.211-524B4-02 Pre SB72-5787...      7500      7250      6250    6000-7500    4750-7250    4750-6250     13500     13500     12750     17500     17500     17500
RB.211-524B-02 RB.211-524B3-02 RB.211-524B4-02 Post SB72-5787..      8500      8200      7200    6500-8500    5700-8200    5700-7200     15000     14700     13700     19000     19000     18000

[[Page 35816]]

 
RB.211-524B-B-02 RB.211-524B4-D-02 Pre SB72-5787...............      7500      7500      7400    6000-7500    6000-7500    5500-7400     13500     13500     13500     17500     17500     17500
RB.211-524B-B-02 RB.211-524B4-D-02 Post SB72-5787..............      8500      8200      7200    6500-8500    5700-8200    5700-7200     15000     14700     13700     19000     19000     18000
RB211-524B2 RB211-524C2 RB211-524D4 RB211-524D4X Pre SB72-5787.      7500      7500      7300    6000-7500    6000-7500    5800-7300     13500     13500     13500     17500     17500     17500
RB.211-524B2 RB.211-524C2 RB.211-524D4 RB.211-524D4X Post SB72-      8500      8250      7250    6500-8500    5800-8250    5800-7250     15000     14500     13500     19000     18750     17750
 5787..........................................................
RB.211-524B2-B RB.211-524C2-B Pre SB72-5787....................      7500      7500      7300    6000-7500    6000-7500    5800-7300     13500     13500     13500     17500     17500     17500
RB.211-524B2-B RB.211-524C2-B Post SB72-5787...................      8500      8200      7250    6500-8500    5800-8200    5800-7250     15000     14500     13500     19000     18650     17650
RB.211-524D4-B RB.211-524D4X-B Post SB72-5787..................      8500      8500      7750    6500-8500    6500-8500    5750-7750     15000     15000     15000     19000     19000     19000
RB.211-524G RB.211-524G-T RB.211-524H RB.211-524H-T Post SB72-       8500      8150      7150    6500-8500    5750-8150    5750-7150     13950     13950     13950       N/A       N/A       N/A
 5787..........................................................
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    (b) Remove from service IP stage 6-7 rotor shafts that have been 
reworked in accordance with R-R SB RB.211-72-9594, Revision 8, dated 
January 14, 1999, Revision 7, dated September 16, 1994, Revision 6, 
dated August 12, 1994, or Revision 5, dated February 12, 1993, prior 
to exceeding the new, reduced cyclic life listed in Table 1 of this 
AD under the sub-title ``Post SB72-9594'' and replace with 
serviceable parts.
    (c) Remove from service IP compressor stage 6-7 rotor shafts 
that have been reworked in accordance with R-R SB RB.211-72-9618, 
dated August 7, 1992, prior to exceeding the new, reduced cyclic 
life limits listed in Table 1 of this AD under the sub-title ``Post 
SB72-9618'' and replace with serviceable parts.
    (d) IP compressor stage 6-7 rotor shaft rework in accordance 
with R-R SB RB.211-72-9594 can only be accomplished when the cyclic 
life of the part falls within the rework bands established in Table 
1 of this AD. To accomplish rework of IP compressor stage 6-7 rotor 
shafts prior to reaching the lower limit of the rework bands 
specified in Table 1 of this AD, the part must be artificially aged 
to the cyclic life which defines the lower limit of the applicable 
rework bands in Table 1 of this AD.

    Note 2: For example, if the lower limit of the rework band is 
8,000 cycles, and the part is reworked at 7,000 cycles, the part 
must be artificially aged by adding 1,000 cycles to the cycles since 
new recorded on the part; i.e., on return to service the cycles 
since new on this part would be 8,000 cycles.

Alternative Method of Compliance

    (e) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Engine Certification Office. 
Operators shall submit their request through an appropriate FAA 
Principal Maintenance Inspector, who may add comments and then send 
it to the Manager, Engine Certification Office.

    Note 3: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the Engine Certification Office.

Ferry Flights

    (f) Special flight permits may be issued in accordance with 
Sec. Sec. 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the aircraft to a location where 
the requirements of this AD can be accomplished.

Incorporation By Reference

    (g) The actions of this AD shall be done in accordance with the 
following R-R Service Bulletins:

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           Document No.                     Pages                Revision                      Date
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RB.211-72-9993....................  1-6..................  Original............  August 26, 1994.
Supplement........................  1 of 1...............  Original............  August 26, 1994.
Modification Acceptance...........  .....................  Original............  August 26, 1994.
Total pages: 8
RB.211-72-9594....................  1-4..................  8...................  January 14, 1999.
                                    4A...................  8...................  January 14, 1999.
                                    5-6..................  8...................  January 14, 1999.
                                    6A...................  2...................  May 8, 1992.
                                    7....................  6...................  August 12, 1994.
                                    8-8A.................  8...................  January 14, 1999.
                                    9....................  2...................  May 8, 1992.
                                    10-11................  6...................  August 12, 1994.

[[Page 35817]]

 
                                    12-12A...............  8...................  January 14, 1999.
                                    13-15................  7...................  September 16, 1994.
                                    16-18................  Original............  February 5, 1992.
                                    19-20................  4...................  November 13, 1992.
                                    21-26................  6...................  August 12, 1994.
                                    27...................  7...................  September 16, 1994.
Appendix..........................  1-4..................  5...................  February 12, 1993.
                                    5....................  Original............  February 5, 1992.
Supplement........................  1-2..................  1...................  August 12, 1994.
Total pages: 38
RB.211-72-9618....................  1-6..................  2...................  January 14, 1999.
Total pages: 6
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    This incorporation by reference was approved by the Director of 
the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR 
part 51. Copies may be obtained from Rolls-Royce plc, P.O. Box 31, 
Derby, DE24 8BJ, UK, telephone 011-44-1332-242424. Copies may be 
inspected at the FAA, New England Region, Office of the Regional 
Counsel, 12 New England Executive Park, Burlington, MA; or at the 
Office of the Federal Register, 800 North Capitol Street, NW., suite 
700, Washington, DC.

Effective Date

    (h) This amendment becomes effective on August 7, 2000.

    Issued in Burlington, Massachusetts, on May 23, 2000.
Thomas A. Boudreau,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 00-13566 Filed 6-5-00; 8:45 am]
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