2005-02-05: Low Pressure Compressor (LPC) Fan Blade Roots

2005-02-05 Rolls-Royce plc: Amendment 39-13950. Docket No. 2000-NE-13-AD. Supersedes AD 2003-12-15, Amendment 39-13200. Effective Date (a) This airworthiness directive (AD) becomes effective February 11, 2005. Affected ADs (b) This AD supersedes AD 2003-12-15, Amendment 39-13200. Applicability (c) This AD applies to Rolls-Royce (RR) plc RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 series turbofan engines with low pressure compressor (LPC) fan blades with the part numbers (P/Ns) listed in Table 1 of this AD. These engines are installed on, but not limited to, Boeing 757 and Tupolev Tu204 series airplanes. Table 1 follows: Table 1.-Applicable LPC Fan Blade P/Ns UL16135 UL28602 UL16171 UL29511 UL16182 UL29556 UL19643 UL30817 UL20044 UL30819 UL20132 UL30933 UL20616 UL30935 UL21345 UL33707 UL22286 UL33709 UL23122 UL36992 UL24525 UL37090 UL24528 UL37272 UL24530 UL37274 UL24532 UL37276 UL24534 UL37278 UL27992 UL38029 UL28601 UL38032 Unsafe Condition (d) This AD results from RR issuing Mandatory Service Bulletin (MSB) No. RB.211-72-C879, Revision 4, which contains revised Accomplishment Instructions and consumable materials list. We are issuing this AD to detect cracks in low pressure compressor (LPC) fan blade roots, which if not detected, could lead to uncontained multiple fan blade 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) If you have a full set of fan blades, modified using RR Service Bulletin No. RB.211-72-C946, Revision 2, dated September 26, 2002, that can be identified by a blue triangle etched on the blade airfoil suction surface close to the leading edge tip of each blade, no further action is required. (g) On RB211-535E4 engines, operated to Flight Profile A, ultrasonically inspect, and if required, relubricate using the following Table 2: Table 2.-RB211-535E4 Flight Profile A Engine location Initial inspection within cycles-since-new (CSN) Type action In accordance with Repeat inspection within (CSN) (i) Root Probe, inspect and relubricate, OR RB.211-72-C879 Revision 4, 3.A.(1) through 3.A.(7), dated April 2, 2004. 1,400 (1) On-wing 17,350 (ii) Wave Probe RB.211-72-C879 Revision 4, 3.B.(1) through 3.B.(7), dated April 2, 2004. 1,150 (2) In Shop 17,350 Root Probe, inspect and relubricate. RB.211-72-C879 Revision 4, 3.C.(1) through 3.C.(4), dated April 2, 2004. 1,400 (h) On RB211-535E4 engines, operated to Flight Profile B, ultrasonically inspect, and if required, relubricate using the following Table 3: Table 3.-RB211-535E4 Flight Profile B Engine location Initial inspection within (CSN) Type action In accordance with Repeat inspection within (CSN) (i) Root Probe, inspect and relubricate, OR RB.211-72-C879 Revision 4, 3.A.(1) through 3.A.(7), dated April 2, 2004. 850 (1) On-wing 12,350 (ii) Wave Probe RB.211-72-C879 Revision 4, 3.B.(1) through 3.B.(7), dated April 2, 2004. 700 (2) In Shop 12,350 Root Probe, inspect and relubricate. RB.211-72-C879 Revision 4, 3.C.(1) through 3.C.(4), dated April 2, 2004. 850 (i) On RB211-535E4 engines, operated to combined Flight Profile A and B, ultrasonically inspect, and if required, relubricate using the following Table 4: Table 4.-RB211-535E4 Flight Profile A and B Engine location Initial inspection within (CSN) Type action In accordance with Repeat inspection within (CSN) (i) Root Probe, inspect and relubricate, OR RB.211-72-C879 Revision 4, 3.A.(1) through 3.A.(7), dated April 2, 2004. As current flight profile. (1) On-wing 65% hard life (To calculate, see Compliance Section 1.C(4)). (ii) Wave Probe RB.211-72-C879 Revision 4, 3.B.(1) through 3.B.(7), dated April 2, 2004. As current flight profile. (2) In Shop65% hard life (To calculate, see Compliance Section 1.C.(4)). Root Probe, inspect and relubricate. RB.211-72-C879 Revision 4, 3.C.(1) through 3.C.(4), dated April 2, 2004. As current flight profile. (j) Fan blades that have been operated within RB211-535E4 Flight Profile A and B will have final life as defined in the Time Limits Manual. See References Section 1.G.(3), of MSB RB.211-72-C879, Revision 4, dated April 2, 2004. (k) On RB211-535E4-B engines, ultrasonically inspect, and if required, relubricate using the following Table 5: Table 5.-RB211-535E4-B Engine location Initial inspection within (CSN) Type action In accordance with Repeat inspection within (CSN) (i) Root Probe, inspect and relubricate, OR RB.211-72-C879 Revision 4, 3.A.(1) through 3.A.(7), dated April 2, 2004. 1,200 (1) On-wing 17,000 (ii) Wave Probe. RB.211-72-C879 Revision 4, 3.B.(1) through 3.B.(7), dated April 2, 2004. 1,000 (2) In Shop 17,000 Root Probe, inspect and relubricate.. RB.211-72-C879 Revision 4, 3.C.(1) through 3.C.(4), dated April 2, 2004. 1,200 Optional Terminating Action (l) Application of Metco 58 blade root coating using RR SB No. RB.211-72-C946, Revision 2, dated September 26, 2002, constitutes terminating action to the repetitive inspection requirements specified in paragraphs (g), (h), (i), and (k) of this AD. Alternative Methods of Compliance (m) 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. Previous Credit (n) Previous credit is allowed for initial and repetitive inspections performed using AD 2003-12-15 (Amendment 39-13200, 68 FR 37735, June 25, 2003) and RR MSB No. RB.211-72-C879, Revision 3, dated October 9, 2002. Material Incorporated by Reference (o) You must use Rolls-Royce Mandatory Service Bulletin No. RB.211-72-C879, Revision 4, dated April 2, 2004, to perform the inspections and relubrication required by this AD. The Director of the Federal Register approved the incorporation by reference of this service bulletin in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. You can get a copy from Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; telephone: 011-44-1332-242-424; fax: 011-44-1332-249-936. You may review copies at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA; or on the Internet at http://dms.dot.gov; or at 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. Related Information (p) CAA airworthiness directive AD 002-01-2000, dated October 9, 2002, also addresses the subject of this AD.