2004-19-04: Critical Life-Limited Rotating Engine Parts

2004-19-04 Rolls-Royce plc: Amendment 39-13798; Docket No. 2003-NE-57-AD. Effective Date (a) This AD becomes effective October 27, 2004. Affected ADs (b) None. Applicability (c) This AD applies to Rolls-Royce plc (RR) RB211-22B, RB211-524, and RB211-535 series turbofan engines. These engines are installed on, but not limited to, Boeing 747, 757, 767, Lockheed L-1011, and Tupolev Tu204 airplanes. Unsafe Condition (d) This AD results from the need to require enhanced inspection of selected critical life-limited parts of RB211-22B, RB211-524, and RB211-535 series turbofan engines. The actions specified in this AD are intended to prevent failure of critical life-limited rotating engine parts, which could result in an uncontained engine failure and 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. (f) Within the next 40 days after the effective date of this AD, revise the Time Limits Manual (TLM), and for air carrier operations revise the approved continuous airworthiness maintenance program, by adding the following text and the applicable table determined by engine model number: "GROUP A PARTS MANDATORY INSPECTION (1) Inspections referred to as 'Focus Inspect' in the applicable Engine Manual inspection Task are mandatory inspections for the components given below, when the conditions that follow are satisfied: (i) When the component has been completely disassembled to piece-part level as given in the applicable disassembly procedures contained in the Engine Manual; and (ii) The part has more than 100 recorded flight cycles in operation since the last piece-part inspection; or (iii) The component removal was for damage or a cause directly related to its removal; or (iv) Where serviceable used components, for which the inspection history is not fully known, are to be used again. (2) The list of Group A Parts for RB211-22B engines is specified below: Part nomenclature (RB211-22B series engines) Part number Inspected per overhaul manual task Low Pressure Compressor Rotor Disc All 72-31-12-200-006 Low Pressure Compressor Rotor Shaft All 72-31-20-200-000 Intermediate Pressure Compressor Rotor Shaft Stages 1 to 5 All 72-32-31-200-000 Intermediate Pressure Compressor Rotor Shaft Stages 6 to 7 All 72-32-31-200-001 Intermediate Pressure Compressor Rotor Rear Stubshaft All 72-33-31-200-000 High Pressure Compressor Rotor Stage 1 to 2 Disc Shaft All 72-41-31-200-000 High Pressure Compressor Rotor Stage 3 Disc All 72-41-31-200-001 High Pressure Compressor Rear Rotor Shaft Assembly All 72-41-31-200-002 Compressor/Turbine Joint Flange Support Disc All 72-41-31-200-003 High Pressure Turbine Disc All 72-41-51-200-000 Intermediate Pressure Turbine Disc All 72-51-31-200-000 Intermediate Pressure TurbineShaft All 72-51-33-200-000 Low Pressure Turbine Stage 1 Disc All 72-51-61-200-000 Low Pressure Turbine Stage 2 Disc All 72-51-61-200-001 Low Pressure Turbine Stage 3 Disc All 72-51-61-200-002 Low Pressure Turbine Shaft All 72-51-63-200-000 (3) The list of Group A Parts for RB211-535 series engines is specified below: Part nomenclature (RB211-535 series engines) Part number Inspected per overhaul manual task Low Pressure Compressor Rotor Disc All 72-31-12-200-000 Low Pressure Compressor Rotor Shaft All 72-31-20-200-000 Intermediate Pressure Compressor Rotor Shaft All 72-32-31-200-001 Intermediate Pressure Compressor Rotor Rear Stubshaft All 72-33-21-200-000 High Pressure Compressor Rotor Stage 1 & 2 Disc All 72-41-31-200-000 High Pressure Compressor Rotor Stage 3 Disc All 72-41-31-200-001 High Pressure Compressor Rear Rotor Shaft Assembly All 72-41-31-200-002 Compressor/Turbine Joint Flange Support Disc (applicable to -535C only) All 72-41-31-200-003 High Pressure Turbine Disc All 72-41-51-200-000 Intermediate Pressure Turbine Rotor Disc All 72-51-31-200-000 Intermediate Pressure Turbine Shaft All 72-51-33-200-000 Low Pressure Turbine Stage 1 Disc All 72-51-61-200-000 Low Pressure Turbine Stage 2 Disc All 72-51-61-200-001 Low Pressure Turbine Stage 3 Disc All 72-51-61-200-002 Low Pressure Turbine Shaft All 72-51-63-200-000 (4) The list of Group A Parts for RB211-524B, -524B3, and -524B4 series engines is specified below: Part nomenclature (RB211-524B, -524B3, and -524B4 series engines) Part number Inspected per overhaul manual task Low Pressure Compressor Rotor Disc All 1 72-31-12-200-05 2 72-31-12-200-013 Low Pressure Compressor Rotor Shaft All 72-31-20-200-000 Intermediate Pressure Compressor Stage 1 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 2 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 3 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 4 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 5 Disc All 72-32-31-200-001 Intermediate Pressure Compressor Rotor Shaft Stages 6 to 7 All 72-32-31-200-001 Intermediate Pressure Compressor Front Stubshaft Drive Cone All 72-32-31-200-008 Intermediate Pressure Compressor Rotor Rear Stubshaft All 72-33-21-200-010 High Pressure Compressor Rotor Stage 1 to 2 Disc All 72-41-31-200-000 High Pressure Compressor Rotor Stage 3 Disc All 72-41-31-200-001 High Pressure Compressor Rear Rotor Shaft Assembly All 72-41-31-200-002 High Pressure Compressor/Turbine Joint Flange Support Disc All 72-41-31-200-006 High Pressure Turbine Bearing Inner Race Support Panel All 72-41-51-200-005 High Pressure Turbine Disc All 72-41-51-200-019 High Pressure Turbine Conical Shaft All 72-41-51-200-021 Intermediate Pressure Turbine Disc All 72-51-31-200-003 Intermediate Pressure Turbine Shaft All 72-51-33-200-005 Low Pressure Turbine Stage 1 Disc All 1 72-51-61-200-000 2 72-51-61-200-007 Low Pressure Turbine Stage 2 Disc All 1 72-51-61-200-001 2 72-51-61-200-008 Low Pressure Turbine Stage 3 Disc All 1 72-51-61-200-002 2 72-51-61-200-009 Low Pressure Turbine Shaft All 1 72-51-63-200-000 2 72-51-63-200-003 1 (Configuration 1). 2 (Configuration 2). (5) The list of Group A Parts for RB211-524B2, -524C2, and -524D4 series engines is specified below: Part nomenclature (RB211-524B2, -524C2, and -524D4 series engines) Part number Inspected per overhaul manual task Low Pressure Compressor Rotor Disc All 72-31-12-200-013 Low Pressure Compressor Rotor Shaft All 72-31-20-200-000 Intermediate Pressure Compressor Stage 1 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 2 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 3 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 4 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 5 Disc All 72-32-31-200-001 Intermediate Pressure Compressor Rotor Shaft Stages 6 to 7 All 72-32-31-200-001 Intermediate Pressure Compressor Front Stubshaft Drive Cone All 72-32-31-200-008 Intermediate Pressure Compressor Rotor Rear Stubshaft All 72-33-21-200-010 High Pressure Compressor Rotor Stage 1 to 2 Disc All 72-41-31-200-000 High Pressure Compressor Rotor Stage 3 Disc All 72-41-31-200-001 High Pressure Compressor Rear Rotor Shaft Assembly All 72-41-31-200-002 High Pressure Compressor/Turbine Joint Flange Support Disc All 72-41-31-200-006 High Pressure Turbine Bearing Inner Race Support Panel All 72-41-51-200-005 High Pressure Turbine Disc All 72-41-51-200-019 High Pressure Turbine Conical Shaft All 72-41-51-200-021 Intermediate Pressure Turbine Rotor Disc All 72-51-31-200-003 Intermediate Pressure Turbine Shaft All 72-51-33-200-005 Low Pressure Turbine Stage 1 Disc All 72-51-61-200-007 Low Pressure Turbine Stage 2 Disc All 72-51-61-200-008 Low Pressure Turbine Stage 3 Disc All 72-51-61-200-009 Low Pressure Turbine Shaft All 72-51-63-200-003 (6) The list of Group A Parts for RB211-524G and -524H series engines is specified below: Part nomenclature (RB211-524G and -524H series engines) Part number Inspected per overhaul manual task Low Pressure Compressor Rotor Disc All 72-31-12-200-000 Low Pressure Compressor Rotor Shaft All 72-31-20-200-000 Intermediate Pressure Compressor Stage 1 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 2 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 3 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 4 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Stage 5 Disc All 72-32-31-200-000 Intermediate Pressure Compressor Rotor Shaft Stages 6 to 7 All 72-32-31-200-001 Intermediate Pressure Compressor Front Stubshaft Drive Cone All 72-32-31-200-008 Intermediate Pressure Compressor Rotor Rear Stubshaft All 72-33-21-200-010 High Pressure Compressor Rotor Stage 1 to 2 Disc All 1 72-41-31-200-000 High Pressure Compressor Rotor Stage 3 Disc All 1 72-41-31-200-001 High Pressure Compressor Rear Rotor Shaft Assembly All 1 72-41-31-200-002 Compressor/Turbine Joint Flange Support Disc All 1 72-41-31-200-003 High Pressure Compressor Rotor Shaft Assembly All 2 72-41-31-200-014 High Pressure Turbine Disc All 1 72-41-51-200-010 2 72-41-51-200-024 Intermediate Pressure Turbine Disc All 72-51-31-200-003 Intermediate Pressure Turbine Shaft All 72-51-33-200-005 Low Pressure Turbine Stage 1 Disc All 72-51-61-200-007 Low Pressure Turbine Stage 2 Disc All 72-51-61-200-008 Low Pressure Turbine Stage 3 Disc All 72-51-61-200-009 Low Pressure Turbine Shaft All 72-51-63-200-003" 1 (Configuration 1). 2 (Configuration 2). Alternative Methods of Compliance (g) You must perform these mandatory inspections using the TLM and the applicable Engine Manual unless you receive approval to use an alternative method of compliance under paragraph (h) of this AD. Section 43.16 of the Federal Aviation Regulations (14 CFR 43.16) may not be used to approve alternative methods of compliance or adjustments to the times in which these inspections must be performed. (h) 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. Maintaining Records of the Mandatory Inspections (i) You have met the requirements of this AD by using a TLM changed as specified in paragraph (f) of this AD, and, for air carriers operating under part 121 of the Federal Aviation Regulations (14 CFR part 121), by modifying your continuous airworthiness maintenance plan to reflect those changes. You must maintain records of the mandatory inspections that result from those changes to the TLM according to the regulations governing your operation. You do not need to record each piece-part inspection as compliance to this AD. For air carriers operating under part 121, you may use either the system established to comply with section 121.369 or use an alternative system that your principal inspector has accepted if that alternative system: (1) Includes a method for preserving and retrieving the records of the inspections resulting from this AD; and (2) Meets the requirements of Sec. 121.369(c); and (3) Maintains the records either indefinitely or until the work is repeated. (j) These record keeping requirements apply only to the records used to document the mandatory inspections required as a result of revising the Time Limits Manual as specified in paragraph (f) of this AD, and do not alter or amend the record keeping requirements for any other AD or regulatory requirement. Material Incorporated by Reference (k) None. Related Information (l) Civil Aviation Authority (CAA) airworthiness directives No. G-2003-0006, dated September 18, 2003, No. G-2003-0009, dated September 19, 2003, and No. G-2003-0007, dated September 18, 2003 also address the subject of this AD.