2006-11-05: High pressure compressor (HPC) stage 3 disc assemblies

2006-11-05 Rolls-Royce plc: Amendment 39-14609. Docket No. 2003-NE- 12-AD. Effective Date (a) This AD becomes effective June 27, 2006. Affected ADs (b) This AD supersedes AD 2004-01-20. Applicability (c) This AD applies to Rolls-Royce plc (RR) RB211-22B series, RB211-524B, -524C2, -524D4, -524G2, -524G3, and -524H series, and RB211-535C and -535E series turbofan engines with high pressure compressor (HPC) stage 3 disc assemblies, part numbers (P/Ns) LK46210, LK58278, LK67634, LK76036, UL11706, UL15358, UL22577, UL22578, and UL24738 installed. These engines are installed on, but not limited to, Boeing 747, Boeing 757, Boeing 767, Lockheed L-1011, and Tupolev Tu204 series airplanes. Unsafe Condition (d) This AD results from the manufacturer's reassessment of the corrosion risk on HPC stage 3 disc assemblies that have not yet been modified with sufficient application of anticorrosion protection. The actions specified in this AD are intended to preventcorrosion- induced uncontained disc failure, resulting in 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. Removal of HPC Stage 3 Discs (f) Remove from service affected HPC stage 3 disc assemblies identified in the following Table 1, using one of the following criteria: Table 1.--Affected HPC Stage 3 Disc Assemblies Engine model Rework band for cyclic life accumulated on disc assemblies P/Ns LK46210 and LK58278 (pre RR service bulletin (SB) No. RB.211 72 5420) Rework band for cyclic life accumulated on disc assembly P/N LK67634 (pre RR SB No. RB.211 72 5420) Rework band for cyclic life accumulated on P/Ns LK76036, UL11706, UL15358, UL22577, UL22578, and UL24738 disc assemblies (pre RR SB No. RB.211 72 9434) 22B series 4,000 6,200 7,000 10,000 11,500 14,000 535E4 series N/A N/A 9,000 15,000 -524B-02, B-B-02, B3-02, and B4 series, Pre and Post accomplishment of SB No. 72-7730 4,000 6,000 7,000 9,000 11,500 14,000 524B2 and C2 series, Pre SB No. 72 7730 4,000 6,000 7,000 9,000 11,500 14,000 524B2 B 19 and C2 B 19, SB No. 72 7730 4,000 6,000 7,000 9,000 8,500 11,000 524D4 series, Pre SB No. 72 7730 4,000 6,000 7,000 9,000 11,500 14,000 524D4 B series, SB No. 72 7730 4,000 6,000 7,000 9,000 8,500 11,000 524G2, G3, H, and H2 series 4,000 6,000 7,000 9,000 8,500 11,000 (1) For discs that entered into service before 1990, remove disc and rework as specified in paragraph (g)(2) of this AD, on or before January 4, 2007, but not to exceed the upper cyclic limit in Table 1 of this AD before rework. Discs reworked may not exceed the manufacturer's published cyclic limit in the time limits section of the manual. (2) For discs that entered into service in 1990 or later, remove disc within the cyclic life rework bands in Table 1 of this AD, or within 17 years after the date of the disc assembly entering into service, whichever is sooner, but not to exceed the upper cyclic limit of Table 1 of this AD before rework. Discs reworked may not exceed the manufacturer's published cyclic limit in the time limits section of the manual. (3) For disc assemblies that when new, were modified with an application of anticorrosion protection and re-marked to P/N LK76036 (not previously machined) as specified by Part 1 of the original issue of RR service bulletin (SB) No. RB.211-72-5420, dated April 20, 1979, remove RB211-22B disc assemblies before accumulating 10,000 cycles-in-service (CIS), and remove RB211-524 disc assemblies before accumulating 9,000 CIS. (4) If the disc assembly date of entry into service cannot be determined, the date of disc manufacture may be obtained from RR and used instead. (5) Discs in RB211-535C operation are unaffected by the interim rework cyclic band limits in Table 1 of this AD, but must meet the calendar life requirements of either paragraph (f)(1) or (f)(2) of this AD, as applicable. Optional Rework of HPC Stage 3 Discs (g) Rework HPC stage 3 disc assemblies that were removed in paragraph (f) of this AD as follows: (1) For disc assemblies that when new, were modified with an application of anticorrosion protection and re-marked to P/N LK76036 (not previously machined) as specified by Part 1 of the original issue of RR SB RB.211-72-5420, dated April 20, 1979, rework disc assemblies and re-mark to either LK76034 or LK78814 using paragraph 2.B. of the Accomplishment Instructions of RR SB No. RB.211-72-5420, Revision 4, dated February 29, 1980. This rework constitutes terminating action to the removal requirements in paragraph (f) of this AD. (2) For all other disc assemblies, rework using Paragraph 3.B. of the Accomplishment Instructions of RR SB No. RB.211-72-9434, Revision 4, dated January 12, 2000. This rework constitutes terminating action to the removal requirements in paragraph (f) of this AD. Note 1: If rework is done on disc assemblies that are removed before the disc assembly reaches the lower life of the cyclic life rework band in Table 1 of this AD, artificial aging of the disc to the lower life of the rework band, at time of rework, is required. Alternative Methods of Compliance (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. Related Information (i) Civil Aviation Authority airworthiness directive 004-01-94, dated January 4, 2002, and RR Mandatory Service Bulletin No. RB.211- 72-9661, Revision 4, dated January 4, 2002, pertain to the subject of this AD. Material Incorporated by Reference (j) You must use Rolls-Royce plc Service Bulletin No. RB.211-72- 5420, Revision 4, dated February 29, 1980, and Rolls-Royce plc Service Bulletin No. RB.211-72-9434, Revision 4, dated January 12, 2000, to perform the rework required by this AD. The Director of the Federal Register previously approved the incorporation by reference of these service bulletins in accordance with 5 U.S.C. 552(a) and 1 CFR part 51, as of February 24, 2004 (69 FR 2661, January 20, 2004). You can get copies from Rolls-Royce plc, PO Box 31, Derby, England, DE248BJ; telephone: 011-44-1332-242424; fax: 011-44-1332-245-418. You can review copies at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA; 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/cfr/ibr-locations.html .