2004-26-03: High pressure (HP) turbine discs

2004-26-03 Rolls-Royce plc: Amendment 39-13915. Docket No. 2000-NE- 62-AD. Supersedes AD 2001-23-02, Amendment 39-12499. Effective Date (a) This airworthiness directive (AD) becomes effective January 13, 2005. Affected ADs (b) This AD supersedes AD 2001-23-02, Amendment 39-12499. Applicability (c) This AD applies to Rolls-Royce plc (RR) models RB211-535E4- 37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4- C, and RB211-22B-02 turbofan engines with turbine discs having part numbers and serial numbers listed in the following Tables 1, 3, and 5 of this AD. These turbofan engines are installed on, but not limited to, Boeing 757, Tupolev Tu204, and Lockheed L-1011 series airplanes. Unsafe Condition (d) This AD results from a report of cracks, in an RB211 HP turbine disc, that had propagated further than expected. We are issuing this AD to prevent possible disc failure, 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. Eddy Current Inspection for All Except Model RB211-22B-02 (f) For all except model RB211-22B-02 engines, do the following: (1) Perform an eddy current inspection of the high pressure (HP) turbine discs listed in Table 1 of this AD, for cracks in the rim cooling air holes. Use paragraph 3. of the Accomplishment Instructions of RR Alert SB No. RB.211-72-AE651, dated November 22, 2004, to perform the eddy current inspection. Table 1--Affected HP Turbine Discs Using Compliance Schedule in Table 2 Part No. Serial No. Part No. Serial No. LK80623 CQDY6397 UL27681 LDRCZ12893 LK80623 CQDY6504 UL27681 LDRCZ12985 UL27680 CQDY6451 UL27681 LDRCZ13044 UL27680 CQDY6452 UL27681 LDRCZ13047 UL27680 CQDY6466 UL27681 LQDY6803 UL27680 CQDY6468 UL27681 LQDY6814 UL27680 CQDY6471 UL27681 LQDY6847 UL27680 CQDY6496 UL27681 LQDY6868 UL27680 CQDY6505 UL27681 LQDY6875 UL27680 CQDY6653 UL27681 LQDY6892 UL27680 CQDY6656 UL27681 LQDY6898 UL27680 CQDY6657 UL27681 LQDY6904 UL27680 CQDY6684 UL27681 LQDY6909 UL27680 CQDY6883 UL27681 LQDY6910 UL27681 CQDY6465 UL27681 LQDY9133 UL27681 LAQDY6002 UL27681 LQDY9574 UL27681 LAQDY6083 UL27681 LQDY9579 UL27681 LAQDY6087 UL27681 LQDY9672 UL27681 LDRCZ10247 UL27681 LQDY9770 UL27681 LDRCZ10277 UL27681 LQDY9783 UL27681 LDRCZ10318 UL27681 LQDY9786 UL27681 LDRCZ10335 UL27681 LQDY9900 UL27681 LDRCZ10430 UL27681 LQDY9902 UL27681 LDRCZ10531 UL27681 LQDY9929 UL27681 LDRCZ10750 UL27681 LQDY9957 UL27681 LDRCZ10899 UL27681 LQDY9982 UL27681 LDRCZ11616 UL27681 LQDY9992 UL27681 LDRCZ11720 UL27681 WGQDY90005 UL27681 LDRCZ11893(2) Use the compliance schedule in Table 2 of this AD. Table 2.--Compliance Schedule for HP Turbine Discs Listed in Table 1 If disc cycles-since-new (CSN) on October 8, 2004 are: Then eddy current inspect: (1) 12,750 CSN or more Within 250 cycles-in-service (CIS) from October 8, 2004 or within 14,500 CSN, whichever occurs first. (2) Fewer than 12,750 CSN but 10,500 CSN or more Within 500 CIS from October 8, 2004. (3) Fewer than 10,500 CSN Before 11,000 CSN or at next shop visit after the effective date of this AD, whichever occurs first. (3) On discs that pass inspection, use paragraph 3. of the Accomplishment Instructions of RR Alert SB No. RB.211-72-AE651, dated November 22, 2004, to permanently etch NMSB 72-AE651 onto the disc, adjacent to the part number. (4) Perform an eddy current inspection of the HP turbine discs listed in Table 3 of this AD, for cracks in the rim cooling air holes. Use paragraph 3. of the Accomplishment Instructions of RR Alert SB No. RB.211-72-AE651, dated November 22, 2004, to perform the eddy current inspection. Table 3.--Affected HP Turbine Discs Using Compliance Schedule in Table 4 Part No. Serial No. UL10323 CQDY6070 and higher. UL27680 All. UL27681 All. LK80622 LQDY6316 and higher. LK80623 CQDY5945 and higher. UL28267 All. (5) Use the compliance schedule in Table 4 of this AD. Table 4.--Compliance Schedule for HP Turbine Discs Listed in Table 3 If disc cycles-since-new (CSN) on January 29, 2001 are: Then eddy current inspect: (1) Fewer than 13,700 CSN Before reaching 14,500 CSN, or at the next shop visit after the effective date of this AD, whichever occurs first. (2) 13,700 CSN or more Before reaching one of the following, whichever occurs first after the effective date of this AD: (i) 15,300 CSN. (ii) Within 800 CIS since January 29, 2001. (iii) At next shop visit. (6) For discs that pass inspection, use paragraph 3. of the Accomplishment Instructions of RR Alert SB No. RB.211-72-AE651, dated November 22, 2004, to permanently etch NMSB 72-AE651 onto the disc, adjacent to the part number. Eddy Current Inspection for Model RB211-22B-02 (g) For model RB211-22B-02 engines, do the following: (1) Perform an eddy current inspection of the HP turbine discs listed in Table 5 of this AD, for cracks in the rim cooling air holes. Use paragraph 3. of the Accomplishment Instructions of RR SB No. RB.211-72-C877, Revision 1, dated March 7, 2001, to perform the eddy current inspection. Table 5.--Affected HP Turbine Discs in RR Model RB211-02 Series Turbofan Engines Part No. Serial No. LK80622 LQDY6316 and higher. LK80623 CQDY5945 and higher. UL28267 All. (2) Use the compliance schedule in Table 6 of this AD. Table 6.--Compliance Schedule for HP Turbine Discs Listed in Table 5 If disc cycles-since-new (CSN) on December 24, 2001 are: Then eddycurrent inspect: (1) 11,000 CSN or fewer Before exceeding 11,000 CSN, or at the next shop visit after the effective date of this AD, whichever occurs first. (2) More than 11,000 CSN Within 300 CIS after December 24, 2001. (3) For discs that pass inspection, use paragraph 3. of the Accomplishment Instructions of RR SB No. RB.211-72-C877, Revision 1, dated March 7, 2001, to permanently etch NMSB 72-C877 onto the disc, adjacent to the part number. Other Conditions for All Engines (h) Do not perform the actions of this AD to a disc until that disc has reached at least 1,500 CSN. (i) Engines with an affected HP turbine disc at shop visit on the effective date of this AD and with the HPT rotor still removed from the combustor outer case, must have the disc eddy current inspected before assembling the engine. (j) Engines with an affected HP turbine disc at shop visit on the effective date of this AD with the HPT rotor reinstalled in the combustor case need not have the disc eddy current inspected at this time. (k) HP turbine discs previously eddy current inspected at fewer than 1,500 CSN must be inspected again using this AD. (l) Replace cracked HP turbine discs with a serviceable disc. Definition (m) For the purpose of this AD, next shop visit is defined as the first shop visit opportunity when the HPT rotor is removed from the combustion case. (n) For the purpose of this AD, a serviceable part is one with cyclic life remaining and either not listed in any of the preceding tables or one listed in a preceding table, but previously eddy current inspected and permanently etch marked with the Service Bulletin (SB) number NMSB 72-AE651 or NMSB 72-C877 on the disc. Previous Credit (o) Previous credit is allowed for the actions in this AD for HP turbine discs with 1,500 CSN or more that were eddy current inspected using applicable RR SB No. RB.211-72-C817, Revision 2, dated March 7, 2001, RR TSD 594-J, Overhaul Processes Manual, Task 70-00-00-200-223, or RR SB No. RB.211-72-C877, Revision 1, dated March 7, 2001. Reporting Requirements (p) For all except model RB211-22B-02 engines, report findings of the inspection using paragraph 3.E. of the Accomplishment Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004. The Office of Management and Budget (OMB) has approved the reporting requirements specified in paragraph 3.E. of the Accomplishment Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004, and assigned OMB control number 2120-0056. (q) For model RB211-22B-02 engines, report findings of the inspection using paragraph 3.E. of the Accomplishment Instructions of RR SB RB.211-72-C877, Revision 1, dated March 7, 2001. The Office of Management and Budget (OMB) has approved the reporting requirements specified in paragraph 3.E. of the Accomplishment Instructions of RR SB RB.211-72-C877, Revision 1, dated March 7, 2001, and assigned OMB control number 2120-0056. Alternative Methods of Compliance (r) 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. Material Incorporated by Reference (s) You must use the service information specified in Table 7 of this AD to perform the inspections required by this AD. The Director of the Federal Register approved the incorporation by reference of RR Alert SB No. RB.211-72-AE651, dated November 22, 2004, listed in Table 7 of this AD in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. The incorporation by reference of RR MSB No. RB.211-72-C877, Revision 1, dated March 7, 2001, was approved previously by the Director of the Federal Register as of December 24, 2001 (66 FR 57859, November 19, 2001). You can get a copy from Rolls-Royce plc, PO Box 31, Derby, England; telephone: 011 44 1332-249428, fax: 011 44 1332-249223, for a copy of this service information. You may review copies at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA; or the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. Table 7 follows: Table 7.--Incorporation by Reference Service bulletin Page numbers Revision Date RB.211-72-AE651 Total Pages-7 All Original November 22, 2004. RB.211-72-C877 Total Pages-5 All 1 March 7, 2001. Related Information (t) CAA airworthiness directive G-2004-0027, dated November 19, 2004, also addresses the subject of this AD.