AD 2003-22-04 Airworthiness Directives; Rolls-Royce plc RB211-524 Series Turbofan Engines

This AD applies to Rolls-Royce plc (RR) RB211-524G2-19,-524G2-T-19, -524G3-19, -524G3-T-19, -524H2-19, -524H2-T-19, -524H-36, and “524-H-T-36 turbofan engines with low pressure (LP) compressor fan blades part numbers (PNs) and serial numbers (SNs) as listed in Table 1 of RR Mandatory Service Bulletin (MSB) No. RB.211-72-D184, Revision 3, dated December 20, 2002, installed. These engines are installed on, but not limited to, Boeing 747 and 767 series airplanes.

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. Reworked LP Compressor Fan Blades Not Affected (f) LP compressor fan blades listed in Table 1 of RR MSB No. RB.211-72-D184, Revision 3, dated December 20, 2002, that have been reworked using Service Bulletin (SB) No. RB.211-72-D051, dated August 23, 2000, or SB No. RB.211-72-D020, dated April 19, 2000, are considered to have had all damage addressed during rework and are not affected by this AD. Removal and Inspection of LP Compressor Fan Blades (g) Using the compliance thresholds in Table 1 of this AD, remove LP compressor fan blades and inspect the blade roots of all LP compressor fan blades listed by PN and SN in Table 1 of RR MSB No. RB.211-72-D184, Revision 3, dated December 20, 2002. Follow the inspection criteria in paragraph 3.B. of the Accomplishment Instructions of RR MSB No. RB.211-72-D184, Revision 3, dated December 20, 2002. Table 1.—LP Compressor Fan Blade Inspection Compliance Thresholds Engine models Compliance thresholds (1) RB211-524G2-19, -524G2-T-19, -524G3-19, -524G3-T-19, -524H-36, -524H-T-36 (i) For blades exceeding 2,000 cycles-since-incorporation of RR Repair Scheme FRS5712, subtask 72-31-11-380-119, before further flight.   (ii) For blades with fewer than 2,000 cycles-since-incorporation of RR Repair Scheme FRS5712, subtask 72-31-11-380-119, before accumulating 2,000 cycles-since-incorporation of the Repair Scheme. (2) RB211-524H-36 and RB211-524-H-T-36 Engines on Short Haul Operation Airplanes Before further flight. (3) RB211-524H2-19 and -524H2-T-19 Before accumulating 800 cycles-since-incorporation of RR Repair Scheme FRS5712, subtask 72-31-11-380-119, or before December 2005, whichever occurs sooner. (4) RB211-524H-36 and RB211-524-H-T-36 Engines On Long Haul Operation Airplanes Before accumulating 870 cycles-since-incorporation of RR Repair Scheme FRS5712, subtask 72-31-11-380-119, or before December 2005, whichever occurs sooner. Removal From Service or Repair of LP Compressor Fan Blades That Do Not Pass Inspection (h) Remove from service LP compressor fan blades that do not pass the inspection criteria in paragraph 3.B. of the Accomplishment Instructions of RR MSB No. RB.211-72-D184, Revision 3, dated December 20, 2002, or repair blades. Follow paragraph 3.B.(3)(b) of the Accomplishment Instructions of RR MSB No. RB.211-72-D184, Revision 3, dated December 20, 2002 to repair blades. Prohibition of LP Compressor Fan Blades Not Inspected or Repaired (i) After the effective date of this AD, do not install any blade that was removed as specified in paragraph (g) of this AD, unless the blade has passed inspection or has been repaired using paragraph 3.B. of the Accomplishment Instructions of RR MSB No. RB.211-72-D184, Revision 3, dated December 20, 2002. Definition (j) For the purpose of this AD, a Long Haul Operation is defined as an operation with an average stage length of more than five hours. Alternative Methods of

This AD was prompted by the discovery of damaged LP compressor blade roots resulting from entrapment of ceramic polishing media between the blade roots and the masking boot during blade root repair. We are issuing this AD to prevent possible uncontained multiple LP compressor fan blade release, and damage to the airplane.