AD 2002-11-08

[Federal Register Volume 67, Number 109 (Thursday, June 6, 2002)]
[Rules and Regulations]
[Pages 38852-38855]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 02-13885]



[[Page 38852]]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2001-NE-17-AD; Amendment 39-12769; AD 2002-11-08]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc. RB211 Trent 875, 877, 
884, 892, 892B, and 895 Series Turbofan Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that 
is applicable to Rolls-Royce plc (RR) RB211 Trent 875, 877, 884, 892, 
892B, and 895 series turbofan engines with certain part number (P/N) 
low pressure compressor (LPC) fan blades installed. This action 
requires initial and repetitive ultrasonic inspection of the fan blade 
dovetail roots. This amendment is prompted by the loss of an LPC fan 
blade during takeoff. The actions specified in this AD are intended to 
prevent multiple LPC fan blade failures due to cracks, which could 
result in uncontained engine failure and possible damage to the 
airplane.

DATES: Effective June 21, 2002. The incorporation by reference of 
certain publications listed in the rule is approved by the Director of 
the Federal Register as of June 21, 2002.
    Comments for inclusion in the Rules Docket must be received on or 
before August 5, 2002.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
Counsel, Attention: Rules Docket No. 2001-NE-17-AD, 12 New England 
Executive Park, Burlington, MA 01803-5299. Comments may also be sent 
via the Internet using the following address: <a href="/cdn-cgi/l/email-protection#d9e0f4b8b7bcf4b8bdbab6b4b4bcb7ad99bfb8b8f7beb6af"><span class="__cf_email__" data-cfemail="152c38747b70387471767a7878707b61557374743b727a63">[email&#160;protected]</span></a>. 
Comments sent via the Internet must contain the docket number in the 
subject line. The service information referenced in this AD may be 
obtained from Rolls-Royce plc, P.O. Box 31, Derby DE24 6BJ, UK; 
Telephone 44 (0) 1332 242424; fax 44 (0) 1332 249936. This information 
may be examined, by appointment, 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.

FOR FURTHER INFORMATION CONTACT: Keith Mead, Aerospace Engineer, Engine 
Certification Office, FAA, Engine and Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803-5299; telephone (781) 238-
7744; fax (781) 238-7199.

SUPPLEMENTARY INFORMATION: The Civil Aviation Authority (CAA), which is 
the airworthiness authority for the United Kingdom (UK), recently 
notified the FAA that an unsafe condition may exist on RR RB211 Trent 
875, 877, 884, 892, 892B, and 895 series turbofan engines with certain 
P/N LPC fan blades installed. The CAA advises there has been an 
incident involving the loss of an LPC fan blade during takeoff. The 
release of the blade occurred as the result of the initiation and 
propagation of a crack in the LPC fan blade root, convex side, located 
on either side of the shear key slot. A subsequent ``around the fleet 
inspection'' revealed a similar condition in four additional LPC fan 
blades. The effects of dry film lubrication and improved blade root 
lubrication (Metco 58) were determined to be critical in preventing the 
initiation of cracking in the root of the LPC fan blade. In addition, 
blade root configurations, airplane type, and engine ratings were found 
to affect initial and repetitive inspection requirements.

Manufacturer's Service Information

    RR has issued service bulletin (SB) RB.211-72-D344, Revision 4, 
dated March 15, 2002, that provides procedures to ultrasonic-inspect 
the blade root on LPC fan blades. The CAA classified this service 
bulletin as mandatory and issued AD 001-02-2001, dated February 2, 
2000, in order to assure the airworthiness of these RR engines in the 
UK.

Bilateral Airworthiness Agreement

    This engine model is manufactured in the UK and is type 
certificated for operation in the United States under the provisions of 
Sec. 21.29 of the Federal Aviation Regulations (14 CFR 21.29) and the 
applicable bilateral airworthiness agreement. Pursuant to this 
bilateral airworthiness agreement, the CAA has kept the FAA informed of 
the situation described above. The FAA has 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 of an Unsafe Condition and Required Actions

    Since an unsafe condition has been identified that is likely to 
exist or develop on other RR RB211 Trent 875, 877, 884, 892, 892B, and 
895 series turbofan engines of the same type design, this AD is being 
issued to prevent multiple LPC fan blade failures due to cracks, which 
could result in uncontained engine failure and possible damage to the 
airplane. This AD requires ultrasonic inspection of the dovetail roots 
of LPC fan blades P/N's FK30838, FK30840, FK30842, FW12960, FW12961, 
FW12962, and FW13175. The actions must be done in accordance with the 
service bulletin described previously.

Immediate Adoption of This AD

    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications should identify the Rules Docket number and be submitted 
in triplicate to the address specified under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments

[[Page 38853]]

submitted in response to this action must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2001-NE-17-AD.'' The postcard will be date stamped and 
returned to the commenter.

Regulatory Analysis

    This final rule does not have federalism implications, as defined 
in Executive Order 13132, because it 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. Accordingly, 
the FAA has not consulted with state authorities prior to publication 
of this final rule.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and is not a ``significant regulatory action'' 
under Executive Order 12866. It has been determined further that this 
action involves an emergency regulation under DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979). If it is determined 
that this emergency regulation otherwise would be significant under DOT 
Regulatory Policies and Procedures, a final regulatory evaluation will 
be prepared and placed in the Rules Docket. A copy of it, if filed, 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 adding the following new 
airworthiness directive:

2002-11-08  Rolls-Royce plc: Amendment 39-12769. Docket No. 2001-NE-
17-AD.

Applicability

    This airworthiness directive (AD) is applicable to Rolls-Royce 
plc. (RR) RB211 Trent 875, 877, 884, 892, 892B, and 895 series 
turbofan engines with low pressure compressor (LPC) fan blades, part 
numbers (P/N's) FK30838, FK30840, FK30842, FW12960, FW12961, 
FW12962, and FW13175, installed. These engines are installed on, but 
not limited to, Boeing Company 777 series airplanes.

    Note 1: This 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 (h) 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

    Compliance with this AD is required as indicated, unless already 
done.
    To prevent multiple LPC fan blade failures due to cracks, which 
could result in uncontained engine failure and possible damage to 
the airplane, do the following:
    (a) Ultrasonic-inspect and disposition the dovetail roots of LPC 
fan blades, P/N's FK30838, FK30840, FK30842, FW12960, FW12961, 
FW12962, and FW13175, that are removed from the engine, in 
accordance with 3.A.(1) through 3.A.(5) or, for blades that are not 
removed from the engine, in accordance with 3.B.(1) through 3.B.(5) 
of the Accomplishment Instructions of RR service bulletin (SB) 
RB.211-72-D344, Revision 4, dated March 15, 2002.
    (b) For blades P/N's FK30838, FK30840, and FK30842, that have 
not been relubricated using either RR SB RB.211-72-D344 or RB.211-
72-D347, during any interval exceeding 600 cycles-since-new (CSN) or 
cycles-since-rework (CSR), inspect in accordance with paragraph (a) 
of this AD and within the compliance times specified in the 
following Table 1:

                                                     Table 1
----------------------------------------------------------------------------------------------------------------
                                                                                                    Repetitive
                                                                                                    inspection
                                           Boeing 777     Airplane maximum gross      Initial     (cycles-since-
             Engine series                series (IGW)      weight (times 1000      inspection         last-
                                                                 pounds)               (CSN)        inspection
                                                                                                      (CSLI)
----------------------------------------------------------------------------------------------------------------
(1) -892...............................            -300        (i) 660 and 632.5             600              80
                                                                        (ii) 580           2,000             600
----------------------------------------------------------------------------------------------------------------
(2) -884, -892, -892B, and -895........   -200 with IGW        (i) 632.5 and 648           1,200             100
                                                                        (ii) 656             600              80
                                                                       (iii) 555           2,000             600
----------------------------------------------------------------------------------------------------------------
(3) -875...............................            -200                      535           2,000             600
----------------------------------------------------------------------------------------------------------------
(4) -877...............................            -200                      545           2,000             600
----------------------------------------------------------------------------------------------------------------

    (c) For blades P/N's FK30838, FK30840, and FK30842, that have 
been relubricated at intervals not exceeding 600 CSN or CSR using 
either RR SB RB.211-72-D344 or SB RB.211-72-D347, inspect in 
accordance with paragraph (a) of this AD and within the compliance 
times specified in the following Table 2:

[[Page 38854]]



                                                     Table 2
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                                                                                                    Repetitive
                                                                                                    inspection
                                           Boeing 777     Airplane maximum gross      Initial     (cycles-since-
             Engine series                series (IGW)      weight (times 1000      inspection         last-
                                                                 pounds)               (CSN)        inspection
                                                                                                      (CSLI)
----------------------------------------------------------------------------------------------------------------
(1) -892...............................            -300        (i) 660 and 632.5             600              80
                                                                        (ii) 580           2,400             600
----------------------------------------------------------------------------------------------------------------
(2) -884, -892, -892B, and -895........   -200 with IGW        (i) 632.5 and 648           2,400             100
                                                                        (ii) 656             600              80
                                                                       (iii) 555           2,400             600
----------------------------------------------------------------------------------------------------------------
(3) -875...............................            -200                      535           2,400             600
----------------------------------------------------------------------------------------------------------------
(4) -877...............................            -200                      545           2,400             600
----------------------------------------------------------------------------------------------------------------

    (d) For blades P/N's FW12960, FW12961, FW12962, and FW13175, 
either new or reworked to that configuration at greater than 600 CSN 
or since previous rework, or that have not been relubricated during 
any interval exceeding 600 CSN or CSR using either RR SB RB.211-72-
D344 or RB.211-72-D347 requirements, inspect in accordance with 
paragraph (a) of this AD and within the compliance times specified 
in the following Table 3:

                                                     Table 3
----------------------------------------------------------------------------------------------------------------
                                                          Airplane maximum gross      Initial       Repetitive
             Engine series                 Boeing 777       weight (times 1000      inspection      inspection
                                          series (IGW)           pounds)               (CSN)          (CSLI)
----------------------------------------------------------------------------------------------------------------
(1) -892...............................            -300        (i) 660 and 632.5             600             100
                                                                        (ii) 580           2,000             600
----------------------------------------------------------------------------------------------------------------
(2) -884, -892, -892B, and -895........   -200 with IGW        (i) 632.5 and 648           1,200             125
                                                                        (ii) 656             600             100
                                                                       (iii) 555           2,000             600
----------------------------------------------------------------------------------------------------------------
(3) -875...............................            -200                      535           2,000             600
----------------------------------------------------------------------------------------------------------------
(4) -877...............................            -200                      545           2,000             600
----------------------------------------------------------------------------------------------------------------

    (e) For blades P/N's FW12960, FW12961, FW12962, and FW13175, 
either new or reworked to that configuration at fewer than 600 CSN 
or since previous rework, and that have been relubricated using 
either RR SB RB.211-72-D344 or SB RB.211-72-D347 at intervals not 
exceeding 600 CSN or repetitive lubrication, inspect in accordance 
with paragraph (a) of this AD and within the compliance times 
specified in the following Table 4:

                                                     Table 4
----------------------------------------------------------------------------------------------------------------
                                                          Airplane maximum gross      Initial       Repetitive
             Engine series                 Boeing 777       weight (times 1000      inspection      inspection
                                          series (IGW)           pounds)               (CSN)          (CSLI)
----------------------------------------------------------------------------------------------------------------
(1) -892...............................            -300        (i) 660 and 632.5             600             100
                                                                        (ii) 580           2,400           1,200
----------------------------------------------------------------------------------------------------------------
(2) -884, -892, -892B, and -895........   -200 with IGW        (i) 632.5 and 648           2,400             125
                                                                        (ii) 656             600             100
                                                                       (iii) 555           2,400           1,200
(3) -875...............................            -200                      535           2,400           1,200
----------------------------------------------------------------------------------------------------------------
(4) -877...............................            -200                      545           2,400           1,200
----------------------------------------------------------------------------------------------------------------

    (f) When engines containing blades P/N's FK30838, FK30840, 
FK30842, FW12960, FW12961, FW12962, and FW13175 are moved from one 
gross weight category to another, the inspection schedule that is 
applicable to the higher gross weight category must be used.

Optional Terminating Action

    (g) Replacement of LPC fan blades P/N's FK30838, FK30840, 
FK30842, FW12960, FW12961, FW12962, and FW13175 with a complete set 
of LPC fan blades that have a P/N that is not listed in this AD 
constitutes terminating action for the repetitive inspection 
requirements of paragraphs (a) through (e) of this AD.

Alternative Methods of Compliance

    (h) 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 (ECO). 
Operators must submit their requests through an appropriate FAA 
Principal Maintenance Inspector, who may add comments and then send 
it to the Manager, ECO.


[[Page 38855]]


    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the ECO.

Special Flight Permits

    (i) Special flight permits may be issued in accordance with 
Secs. 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 
21.197 and 21.199) to operate the airplane to a location where the 
requirements of this AD can be done.

Documents That Have Been Incorporated By Reference

    (j) The inspection must be done in accordance with Rolls-Royce 
plc. (RR) service bulletin RB.211-72-D344, Revision 4, dated March 
15, 2002. 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 6BJ, UK; Telephone 44 (0) 1332 242424; fax 44 (0) 
1332 249936. Copies may be inspected, by appointment, 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.


    Note 3: The subject of this AD is addressed in CAA airworthiness 
directive 001-02-2001, dated February 2, 2000.


Effective Date

    (k) This amendment becomes effective on June 21, 2002.


    Issued in Burlington, Massachusetts, on May 27, 2002.
Mark C. Fulmer,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 02-13885 Filed 6-5-02; 8:45 am]
BILLING CODE 4910-13-P