2002-23-08: Low Pressure (LP) Turbine Stage 2 Discs

2002-23-08 Rolls-Royce plc.: Amendment 39-12952. Docket No. 2002-NE-16-AD. Applicability: This airworthiness directive (AD) is applicable to Rolls-Royce plc. (RR) models RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 turbofan engines, with low pressure (LP) turbine stage 2 discs part numbers (P/N's) 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 (d) 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 LP turbine stage 2 disc failure, which could result in an uncontained engine failure and possible loss of the airplane, do the following: Cyclic Limits (a) Change the RR Time Limits Manual cyclic limits for LP turbine stage 2 discs as specified in the following Table 1: TABLE 1.-TIME LIMITS MANUAL (TLM) CYCLIC LIMITS Date of reduced life limit Life limits for RB211-535E4 engines operating in flight plan A, and RB211-535E4-B engines Life limits for RB211-535E4 engines operating in flight plan B (1) December 31, 2001 22,500 cycles-since-new (CSN) 19,700 CSN. (2) December 31, 2002 22,500 cycles-since-new (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. RB211-535E4 Engines Operating to Flight Plan A, and RB211-535E4-B Engines (b)(1) For RB211-535E4 engines operating to flight plan A, and RB211-535E4-B 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 RB211-535E4 ENGINES OPERATING TO FLIGHT PLAN A, AND RB211-535E4-B ENGINES Replace Disc Disc CSN on the effective date of this AD Action Without Eddy current inspection With Eddy current inspection (i) 20,001 CSN or greater Remove disc from service or perform optional on-wing eddy current disc inspection within 21 days after the effective date of this AD. Within 21 days after the effective date of this AD. Within 3,000 cycles-in-service (CIS) after the inspection, but do not exceed the new reduced life limit specified in Table 1 of this AD. (ii) 18,100 to 20,000 CSN Remove disc from service or perform optional on-wing eddy current disc inspection. Before accumulating 21,000 CSN or by December 31, 2002, whichever occurs first. Within 3,000 cycles-in-service (CIS) after the inspection, but do not exceed the new reduced life limit specified in Table 1 of this AD. (iii) Fewer than 18,100 CSN Remove disc from service or perform optional on-wing eddy current disc inspection. Before accumulating 20,500 CSN or by December 31, 2004, whichever occurs first. Within 3,000 cycles-in-service (CIS) after the inspection, but do not exceed the new reduced life limit specified in Table 1 of this AD. (2) Information regarding disc removal may be found in 3.A. of the Accomplishment Instructions of Mandatory Service Bulletin (MSB) RB.211-72-D181, Revision 3, dated August 16, 2002. (3) The optional on-wing 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.211-72-D181, Revision 3, dated August 16, 2002. RB211-535E4 Engines Operating to Flight Plan B (c)(1) For RB211-535E4 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 RB211-535E4 Engines Operating to Flight Plan B Replace Disc Disc CSN on the effective date of this AD Action Without Eddy current inspection With Eddy current inspection (i) 16,501 CSN or greater Remove disc from service or perform optional on-wing eddy current disc inspection within 21 days after the effective date of this AD. Within 21 days after the effective date of this AD. Within 3,000 cycles-in-service (CIS) after the inspection, but do not exceed the new reduced life limit specified in Table 1 of this AD. (ii) 14,600 to 16,500 CSN Remove disc from service or perform optional on-wing eddy current disc inspection. Before accumulating 17,500 CSN or by December 31, 2002, whichever occurs first. Within 3,000 cycles-in-service (CIS) after the inspection, but do not exceed the new reduced life limit specified in Table 1 of this AD. (iii) Fewer than 14,600 CSN Remove disc from service or perform optional on-wing eddy current disc inspection. Before accumulating 17,000 CSN or by December 31, 2004, whichever occurs first. Within 3,000 cycles-in-service (CIS) after the inspection, but do not exceed the new reduced life limit specified in Table 1 of this AD. (2) Information regarding disc removal may be found in 3.A. of the Accomplishment Instructions of MSB RB.211-72-D181, Revision 3, dated August 16, 2002. (3) The optional on-wing eddy current disc inspection must be performed in accordance with 3.C.(1) through 3.C.(6) of the Accomplishment Instructions of MSB RB.211-72-D181, Revision 3, dated August 16, 2002. Alternative Methods of Compliance (d) An alternative method of compliance or adjustmentof 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. 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 (e) Special flight permits may be issued in accordance with 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 (f) The disc removals and inspections must be done in accordance with Roll-Royce MSB RB.211-72-D181, Revision 3, dated August 16, 2002. This incorporation by reference was approved by the Director of the FederalRegister in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from Rolls-Royce plc, PO Box 31, Derby, England; telephone: 011-44-1332-249428; fax 011-44-1332-249223. 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 3: The subject of this AD is addressed in CAA airworthiness directive 006-05-2001. Effective Date (g) This amendment becomes effective on December 16, 2002.