2007-26-19: Low pressure (LP) compressor case

2007-26-19 Rolls-Royce Deutschland Ltd & Co KG (Formerly Rolls-Royce plc): Amendment 39-15321. Docket No. FAA-2007-27811; Directorate Identifier 2004-NE-11-AD. Effective Date (a) This airworthiness directive (AD) becomes effective February 11, 2008. Affected ADs (b) This AD supersedes AD 2004-26-10, Amendment 39-13922. Applicability (c) This AD applies to: (1) Rolls-Royce Deutschland Ltd & Co KG (RRD) Tay 611-8, Tay 620-15, Tay 650-15, and Tay 651-54 turbofan engines that have one or more ice-impact panels installed in the low pressure (LP) compressor case that conform to the (RRD) Service Bulletin (SB) No. TAY-72-1326 standard. (2) RRD Tay 611-8C turbofan engines with serial numbers (SN) below SN 85078. (3) The turbofan engines listed in paragraph (c) of this AD are installed on, but not limited to, Fokker F.28 Mk.0070 and Mk.0100 series airplanes, Gulfstream Aerospace G-IV and G-IV-X series airplanes, and Boeing Company 727-100 series airplanes modified in accordance with Supplemental Type Certificate SA8472SW (727-QF). Unsafe Condition (d) This AD results from RRD introducing new LP compressor case ice-impact panels with additional retention features, to these Tay turbofan engines. We are issuing this AD to prevent release of ice- impact panels due to improper bonding that can result in loss of thrust in both engines. 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. Inspecting Ice-Impact Panels in Tay 620-15, Tay 650-15, and Tay 651-54 Engines (f) For airplanes that have any Tay 620-15, Tay 650-15, or Tay 651-54 engines with ice-impact panels incorporated by the RR SB No. TAY-72-1326 standard, and not all panels were repaired using polysulfide bonding material by RR repair scheme TV5451R, HRS3491, HRS3615, HRS3648, or HRS3649, do the following: (1) Before further flight,rework all six ice-impact panels using repair scheme HRS3648 or HRS3649 on at least one of the affected engines. (2) Before further flight, inspect the ice-impact panels and the surrounding fillers on the engine not reworked. Use paragraphs 3.C. through 3.E. of the Accomplishment Instructions of RRD SB No. TAY- 72-1638, Revision 2, dated September 21, 2004, or SB No. TAY-72- 1638, Revision 3, dated February 25, 2005, and the inspection disposition criteria in Table 1 of this AD. Table 1.--Inspection Disposition Criteria If: Then: (i) Any movement or rocking motion of LP compressor ice-impact panel, or any movement of the front edge of ice-impact panel. Before further flight, replace all panels using repair scheme HRS3648 or HRS3649. (ii) Reappearing signs of moisture on the ice-impact panel or the surrounding filler. Before further flight, replace all panels using repair scheme HRS3648 or HRS3649. (iii) Any dents or impact damage on the ice-impact panel that is greater than 3.1 square inch in total. Before further flight, replace the damaged panel using repair scheme HRS3648 or HRS3649. (iv) Any dents or impact damage on the ice-impact panel that is between 1.55 square inch and 3.1 square inch in total. Within 5 flight cycles or 5 flight hours, whichever occurs first, replace the damaged panel using repair scheme HRS3648 or HRS3649. (v) Any dents or impact damage on the ice-impact panel that is less than 1.55 square inch in total. Within 50 flight cycles or 50 flight hours, whichever occurs first, replace the damaged panel using repair scheme HRS3648 or HRS3649. (vi) Any crack appears on the ice-impact panel and there is visible distortion of the airwashed surface. Within 50 flight cycles or 50 flight hours, whichever occurs first, replace the damaged panel using repair scheme HRS3648 or HRS 3649. (vii) Any crack appears on the ice-impact panel and there is no visible distortion of the airwashed surface. Within 150 flight cycles or 150 flight hours, whichever occurs first, replace the damaged panel using repair scheme HRS3648 or HRS3649. (viii) Delamination or peeling of the compound layers of the airwashed surface and the penetrated area is greater than 3.1 square inch in total. Before further flight, replace the damaged panel using repair scheme HRS3648 or HRS3649. (iv) Delamination or peeling of the compound layers of the airwashed surface and the penetrated area is between 1.55 square inch and 3.1 square inch in total. Within 5 flight cycles or 5 flight hours, whichever occurs first, replace the damaged panel using repair scheme HRS3648 or HRS3649. (x) Delamination or peeling of the compound layers of the airwashed surface and the penetrated area is less than 1.55 square inch in total. Within 50 flight cycles or 50 flight hours, whichever occurs first, replace the damaged panel using repair scheme HRS3648 or HRS3649. (xi) Delamination or peeling of the compound layers but the airwashed surface is not penetrated. Within 150 flight cycles or 150 flight hours, whichever occurs first, repair the damaged panel using repair scheme HRS3630. (xii) Missing filler surrounding the LP compressor case. Before further flight, repair the damaged filler using repair scheme HRS3630. (xiii) Damage to the filler surrounding the LP compressor case such as chipped, cracked, or missing material. Within 25 flight cycles or 25 flight hours, whichever occurs first, repair damaged filler using repair scheme HRS 3630. (3) Re-inspect all ice-impact panels within every 500 cycles- since-last-inspection (CSLI) or two months since-last-inspection, whichever occurs first. Use paragraphs 3.C. through 3.E. of the Accomplishment Instructions of RRD SB No. TAY-72-1638, Revision 2, dated September 21, 2004, or SB No. TAY-72-1638, Revision 3, dated February 25, 2005, and the inspection disposition criteria in Table 1 of this AD. Repetitive Inspections for Tay 620-15, Tay 650-15, and Tay 651-54 Engines With All Ice-Impact Panels Repaired by Polysulfide Bonding Material (g) For Tay 620-15, Tay 650-15, and Tay 651-54 engines with ice- impact panels incorporated by the RRD SB No. TAY-72-1326 standard, and all panels were repaired using polysulfide bonding material by RR repair scheme TV5451R, HRS3491, HRS3615, HRS3648 or HRS3649, do the following: (1) Re-inspect within every 1,500 CSLI, for the condition of the ice-impact panels and the surrounding fillers. (2) Use paragraphs 3.C. through 3.E. of the Accomplishment Instructions of RRD SB No. TAY-72-1638, Revision 2, dated September 21, 2004 or SB No. TAY-72-1638, Revision 3, dated February 25, 2005, and the inspection disposition criteria in Table 1 of this AD. Inspecting Ice-Impact Panels in Tay 611-8 Engines (h) For airplanes that have any Tay 611-8 engines with ice- impact panels incorporated by the RR SB No. TAY-72-1326 standard, and RR repair scheme HRS3491 or HRS3615 was done with two pack epoxy (Omat 8/52) on oneor more of the six ice-impact panels, do the following: (1) Before further flight, rework all six ice-impact panels using repair scheme HRS3648 or HRS3649 on at least one of the affected engines. (2) Before further flight, inspect the ice-impact panels and the surrounding fillers on the engine not reworked. Use paragraphs 3.C. through 3.E. of the Accomplishment Instructions of RRD SB No. TAY- 72-1639, Revision 2, dated September 21, 2004 and the inspection disposition criteria in Table 1 of this AD. (3) Re-inspect the ice-impact panels within every 1,000 operating hours or six months since-last-inspection, whichever occurs first. Use paragraphs 3.C. through 3.E. of the Accomplishment Instructions of RRD SB No. TAY-72-1639, Revision 2, dated September 21, 2004, and the inspection disposition criteria in Table 1 of this AD. Repetitive Inspections for Tay 611-8 Engines With All Ice-Impact Panels Repaired by Polysulfide Bonding Material or Introduced Since New Production (i) For Tay 611-8 engines with ice-impact panels incorporated by the RRD SB No. TAY-72-1326 standard and all panels were repaired using polysulfide bonding material by RR repair scheme TV5451R, HRS3491, HRS3615, HRS3648 or HRS3649, or panels were introduced since new production, do the following: (1) Re-inspect within every 3,000 hours-since-last-inspection, for the condition of the ice-impact panels and the surrounding fillers. (2) Use paragraphs 3.C. through 3.E. of the Accomplishment Instructions of RRD SB No. TAY-72-1639, Revision 2, dated September 21, 2004, and the inspection disposition criteria in Table 1 of this AD. Installing Tay 620-15, Tay 650-15, or Tay 651-54 Engines That Are Not Inspected (j) After the effective date of this AD, do not install any Tay 620-15, Tay 650-15, or Tay 651-54 engines with ice-impact panels if: (1) Those ice-impact panels incorporate the RR SB No. TAY-72- 1326 standard; and (2) Ice-impact panels were repaired using RR repair scheme TV5451R, HRS3491, or HRS3615 and bonding material other than polysulfide; unless (3) The panels and the surrounding fillers are inspected for condition using 3.B. through 3.D.(3) (in-service) or 3.K.(1) through 3.(M)(3) (at overhaul or shop visit) of the Accomplishment Instructions of RRD SB No. TAY-72-1638, Revision 2, dated September 21, 2004, or SB No. TAY-72-1638, Revision 3, dated February 25, 2005. (k) Perform repetitive inspections as specified in paragraph (g) of this AD. Installing Tay 611-8 Engines That Are Not Inspected (l) After the effective date of this AD, do not install any Tay 611-8 engine with ice-impact panels if: (1) Those ice-impact panels incorporate the RR SB No. TAY-72- 1326 standard; and (2) Ice-impact panels were repaired using RR repair scheme TV5451R, HRS3491, or HRS3615 and bonding material other than polysulfide, unless (3) The panels and the surrounding fillers are inspected for condition using 3.B. through 3.D.(2) (in-service) or 3.K.(1) through 3.M.(3) (at overhaul or shop visit) of the Accomplishment Instructions of RRD SB No. TAY-72-1639, Revision 2, dated September 21, 2004. (m) Perform repetitive inspections as specified in paragraph (i) of this AD. Mandatory Terminating Action (n) No later than December 31, 2011, as mandatory terminating action to the repetitive visual inspections or rework required by paragraphs (f), (g), (h), (i), (j), (k), (l), and (m) of this AD, do the following: (1) Rework the LP compressor case and install new LP compressor case ice-impact panels with additional retention features, at the next shop visit requiring the removal of any module, except when the work scope requires only the removal of the high speed gearbox module. (2) For Tay 620-15, Tay 650-15, and Tay 651-54 turbofan engines, do the rework and installation using the Accomplishment Instructions of RRD Alert SB No. TAY-72-A1643, Revision 1, dated November 2, 2005.(3) For Tay 611-8 turbofan engines, do the rework and installation using the Accomplishment Instructions of RRD Alert SB No. TAY-72-A1650, dated November 2, 2005. Tay 611-8C Turbofan Engines (o) For Tay 611-8C turbofan engines, no later than December 31, 2011, do the following: (1) Rework the LP compressor case and install new LP compressor case ice-impact panels with additional retention features, at the next shop visit after the effective date of this AD, requiring the removal of any module, except when the work scope requires only the removal of the high speed gearbox module. (2) Do the rework and installation using the Accomplishment Instructions of RRD Alert SB No. TAY-72-A1650, dated November 2, 2005. Alternative Methods of Compliance (p) 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 (q) German AD D2004-313R5, dated November 15, 2005, also addresses the subject of this AD. (r) Contact Jason Yang, Aerospace Engineer, Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; e-mail: Jason.yang@faa.gov; telephone (781) 238-7747; fax (781) 238-7199, for more information about this AD. Material Incorporated by Reference (s) You must use the service information specified in Table 2 of this AD to perform the inspections and rework required by this AD. Except for Service Bulletin No. TAY-72-1638, Revision 3, Alert Service Bulletin No. TAY-72-A1643, Revision 1, and Alert Service Bulletin No. TAY-72-A1650, the Director of the Federal Register previously approved the incorporation by reference of the Rolls- Royce Deutschland Ltd & Co KG service information listed in Table 2 of this AD as of January 21, 2005 (70 FR 1172, January 6, 2005). The Director of the Federal Register approved the incorporation by reference of Service Bulletin No. TAY-72-1638, Revision 3, dated February 25, 2005, Alert Service Bulletin No. TAY-72-A1643, Revision 1, dated November 2, 2005, and Alert Service Bulletin No. TAY-72- A1650, dated November 2, 2005, in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Contact Rolls-Royce Deutschland Ltd & Co KG, Eschenweg 11, D-15827 Dahlewitz, Germany; telephone 49 (0) 33-7086- 1768; fax 49 (0) 33-7086-3356 for a copy of this service information. You may review copies at the FAA, New England Region, 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. Table 2.--Incorporation by Reference Service Information No. Page Revision Date SB No. TAY-72-1638 Total Pages: 35 ALL 2 September 21, 2004 SB No. TAY-72-1638 Total Pages: 35 ALL 3 February 25, 2005 SBNo. TAY-72-1639 Total Pages: 28 ALL 2 September 21, 2004 Alert SB No. TAY-72-A1643 Total Pages: 13 ALL 1 November 2, 2005 Alert SB No. TAY-72-A1643 Appendix 1 Total Pages: 43 ALL 1 November 2, 2005 Alert SB No. TAY-72-A1650 Total Pages: 11 ALL Original November 2, 2005 Alert SB No. TAY-72-A1650 Appendix 1 Total Pages: 45 ALL Original November 2, 2005 Repair Scheme No. HRS3648 Front Sheet Total Pages: 1 ALL 2 January 28, 2004 Repair Scheme No. HRS3648 History Sheet Total Pages: 3 ALL 2 January 28, 2004 Repair Scheme No. HRS3648 Total Pages: 30 ALL 2 January 27, 2004 Repair Scheme No. HRS3649 Front Sheet Total Pages: 1 ALL 2 September 1, 2004 Repair Scheme No. HRS3649 History Sheet Total Pages: 3 ALL 2 September 7, 2004 Repair Scheme No. HRS3649 Total Pages: 24 ALL 2 June 17, 2004