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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

CFR Citation: 14 CFR Part 39

Docket ID: [Docket No. 2002-NE-16-AD; Amendment 39-13290; AD 2003-17-15]

RIN ID: RIN 2120-AA64

NOTICE: RULES

ACTION: Airworthiness directives:

DOCUMENT ACTION: Final rule.

SUBJECT CATEGORY: Airworthiness Directives; Rolls-Royce plc. RB211-535 Turbofan Engines

DATES: Effective October 2, 2003. The incorporation by reference of certain publications listed in the regulations is approved by the Director of the Federal Register as of October 2, 2003.

DOCUMENT SUMMARY: This amendment supersedes an existing airworthiness directive (AD)
[[Page 51683]]
that applies to RollsRoyce plc. (RR) models RB211535E437, RB211 535E4B37, and RB211535E4B75 turbofan engines, with certain part number (P/N) low pressure (LP) turbine stage 2 discs installed. That AD currently requires establishing new reduced LP turbine stage 2 disc cyclic limits. That AD also requires removing from service affected discs that already exceed the new reduced cyclic limits, and removing other affected discs before exceeding their cyclic limits, using a drawdown schedule. This amendment requires changing certain cyclic limits, changing the effective date of certain disc cyclic lives, and would allow intermix of Flight Plan A and Flight Plan B intermix calculations. This amendment is prompted by a reassessment of the thermal and stress data from recent operational experience and comments received from operators on the current AD. We are issuing this AD to prevent LP turbine stage 2 disc failure, which could result in uncontained engine failure and possible loss of the airplane.

SUMMARY: Rolls-Royce plc,

SUPPLEMENTAL INFORMATION

A proposal to amend part 39 of the Federal Aviation Regulations (14 CFR part 39) by superseding AD 20022308, Amendment 3912952 (67 FR 71094, November 29, 2002), which applies to RR models RB211535E437, RB211535E4B37, and RB211535E4B75
turbofan engines, with certain P/N low pressure LP turbine stage 2 discs installed was published in the Federal Register on March 25, 2003 (68 FR 14355). That action proposed to require establishing new reduced LP turbine stage 2 disc cyclic limits. That AD also requires removing from service affected discs that already exceed the new reduced cyclic limits, and removing other affected discs before exceeding their cyclic limits, using a drawdown schedule in accordance with mandatory service bulletin (MSB) RB.21172D181, Revision 3, dated August 16, 2002. Comments

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.

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.

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 the 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 it is contained in the Rules Docket. A copy of it may be obtained by contacting 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 39AIRWORTHINESS 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 3912952 (67 FR 71094, November 29, 2002) and by adding a new airworthiness directive, Amendment 3913290, to read as follows:
20031715 RollsRoyce plc: Amendment 3913290. Docket No. 2002NE 16AD. Supersedes AD 20022308, Amendment 3912952.

Applicability: This airworthiness directive (AD) is applicable to RollsRoyce plc. (RR) models RB211535E437, RB211535E4B37, and RB211535E4B75 turbofan engines, with low pressure (LP) turbine stage 2 discs part numbers (P/Ns) UL11508, UL17141, UL18947, UL29029, and UL37352 installed. These engines are installed on, but not limited to, Boeing 757 and Tupolev Tu204 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: You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done.

To prevent LP turbine stage 2 disc failure, which could result in an uncontained engine failure and possible loss of the airplane, do the following:
Cycle Limits
(a) Change the RR Time Limits Manual cyclic limits for LP turbine stage 2 discs as specified in the following Table 1: [[Page 51684]]
Table 1.Time Limits Manual (TLM) Cyclic Limits
Life limits for
RB211535E4 engines Life limits for operating in flight RB211535E4 engines Date of reduced life limit plan A, and RB211 operating in flight 535E4B engines plan B (1) December 31, 2001....... 23,200 cyclessince 19,700 CSN. new (CSN).
(2) December 31, 2002....... 22,500 CSN.......... 19,000 CSN. (3) December 31, 2003....... 21,500 CSN.......... 18,000 CSN. (4) December 31, 2004....... 20,000 CSN.......... 16,500 CSN. (5) December 31, 2005....... 18,100 CSN.......... 14,600 CSN. RB211535E4 Engines Operating to Flight Plan A, and RB211535E4B Engines
(b) For RB211535E4 engines operating to flight plan A, and RB211535E4B engines, remove the LP turbine stage 2 disc from service using the CSN and Action times listed in the following Table 2.

Table 2.Drawdown Schedule for RB211535E4 Engines Operating to Flight Plan A, and RB211535E4B Engines Replace disc Disc CSN Action Without eddy current With eddy current inspection inspection (1) 20,001 CSN or greater on December Remove disc from Within 21 days after Within 3,000 cyclesin 31, 2000. service or perform the effective date of service (CIS) after optional onwing eddy this AD. the inspection, but do current disc not exceed the new inspection within 21 reduced life limit days after the specified in Table 1 effective date of this of this AD AD.
(2) 18,100 to 20,000 CSN on December Remove disc from Before accumulating Within 3,000 CIS after 31, 2000. service or perform 21,000 CSN or within the inspection, but do optional onwing eddy 21 days after the not exceed the new current disc effective date of this reduced life limit inspection. AD, whichever occurs specified in Table 1 first. of this AD. (3) Fewer than 18,100 CSN on December Remove disc from Before accumulating Within 3,000 CIS after 31, 2000 and greater than 20,000 CSN service or perform 20,500 CSN or by the inspection, but do on December 31, 2004. optional onwing eddy December 31, 2004, not exceed the new current disc whichever occurs first. reduced life limit inspection. specified in Table 1 of this AD. (4) Fewer than 18,100 CSN on December Remove disc from Before accumulating Within 3,000 CIS after 31, 2000 and greater than 18,100 CSN service or perform on 20,000 CSN or by the inspection, but do on December 31, 2005. wing eddy current disc December 31, 2005, not exceed the new inspection. whichever occurs first. reduced life limit specified in Table 1 of this AD. (5) Fewer than 18,100 CSN on December No action required..... N/A.................... N/A. 31, 2000 and fewer than 18,100 CSN
on December 31, 2005.
(c) Information regarding disc removal may be found in 3.A. of the Accomplishment Instructions of Mandatory Service Bulletin (MSB) RB.21172D181, Revision 3, dated August 16, 2002.
(d) The optional onwing eddy current disc inspection noted in Table 2 of this AD must be performed in accordance with 3.C.(1) through 3.C.(6) of the Accomplishment Instructions of MSB RB.21172 D181, Revision 3, dated August 16, 2002.
RB211535E4 Engines Operating to Flight Plan B
(e) For RB211535E4 engines operating to flight plan B, remove the LP turbine stage 2 disc from service using the CSN and Action times listed in the following Table 3.
Table 3.Drawdown Schedule for RB211535E4 Engines Operating to Flight Plan B Replace disc Disc CSN Action Without eddy current With eddy current inspection inspection (1) 16,501 CSN or greater on December Remove disc from Within 21 days after Within 3,000 CIS after 31, 2000. service or perform the effective date of the inspection, but do optional onwing eddy this AD. not exceed the new current disc reduced life limit inspection within 21 specified in Table 1 days after the of this AD. effective date of this AD.
(2) Greater than 14,600 CSN on Remove disc from Before accumulating Within 3,000 CIS after December 31, 2000. service or perform 17,500 CSN or within the inspection, but do optional onwing eddy 21 days after the not exceed the new current disc effective date of this reduced life limit inspection. AD, whichever occurs specified in Table 1 first. of this AD. [[Page 51685]]
(3) Fewer than 14,600 CSN on December Remove disc from Before accumulating Within 3,000 CIS after 31, 2000 and greater than 16,500 CSN service or perform 17,000 CSN or by the inspection, but do on December 31, 2004. optional onwing eddy December 31, 2004, not exceed the new current disc whichever occurs first. reduced life limit inspection. specified in Table 1 this AD. (4) Fewer than 14,600 CSN on December Remove disc from Before accumulating Within 3,000 CIS after 31, 2000 and greater than 14,600 CSN service or perform on 16,500 CSN or by the inspection, but do on December 31, 2005. wing eddy current disc December 31, 2005, not exceed the new inspection. whichever occurs first. reduced life limit specified in this AD. (5) Fewer than 14,600 CSN on December No action required..... N/A.................... N/A. 31, 2000 and fewer than 14,600 CSN
on December 31, 2005.
(f) Information regarding disc removal may be found in 3.A. of the Accomplishment Instructions of MSB RB.21172D181, Revision 3, dated August 16, 2002.
(g) The optional onwing eddy current disc inspection must be performed in accordance with 3.C.(1) through 3.C.(6) of the Accomplishment Instructions of MSB RB.21172D181, Revision 3, dated August 16, 2002.

Note 2: For engines moving from Flight Plans A to B or B to A, the intermix calculations found in MSB RB.21172D181, Revision 3, dated August 16, 2002, may be applied to the life limits.
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 request through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, ECO.

Note 3: 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 Sec. Sec. 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 actions must be done in accordance with RollsRoyce plc mandatory service bulletin RB.21172D181, Revision 3, dated August 16, 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 RollsRoyce plc, P.O. Box 31 Derby, DE24 8BJ, United Kingdom; telephone 011441332 242424; fax 011441332249936. 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.

Note 4: The subject of this AD is addressed in CAA airworthiness directive 006052001, dated August 3, 2001.
Effective Date
(k) This amendment becomes effective on October 2, 2003.

Issued in Burlington, Massachusetts, on August 20, 2003. Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft Certification Service.
[FR Doc. 0321740 Filed 82703; 8:45 am]
BILLING CODE 491013P

FOR FURTHER INFORMATION CONTACT Ian Dargin, Aerospace Engineer, Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive Park, Burlington, MA 018035299; telephone (781) 238 7178; fax (781) 2387199.