AD 2005-15-13 Airworthiness Directives; Rolls-Royce plc RB211-524 Series Turbofan Engines

This AD applies to the Rolls-Royce plc (RR) RB211-524 series turbofan engines listed in the following Table 1, with intermediate pressure (IP) compressor stage 5 disk part numbers (P/Ns) listed in Table 2 of this AD, installed. Table 1.—Engine Models Affected           −524B-02 −524B-B-02 −524B3-02 −524B4-02 −524B4-D-02 −524B2-19 −524B2-B-19 −524C2-19 −524C2-B-19 −524D4-19 −524D4-B-19 −524D4X-19 −524D4X-B-19 −524D4-39 −524D4-B-39 −524G2-19 −524G2-T-19 −524G3-19 −524G3-T-19 −524H2-19 −524H2-T-19 −524H-36 −524H-T-36 These engines are installed on, but not limited to, Boeing 747, 767, and Lockheed L-1011 airplanes. Table 2.—IP Compressor Stage 5 Disk P/Ns Affected           LK60130 LK65932 LK69021 LK81269 LK83282 LK83283 UL12290 UL15743 UL15744 UL15745 UL19132 UL20785 UL20832 UL23291 UL25011 UL36821 UL36977 UL36978 UL36979 UL36980 UL36981 UL36982 UL36983 UL37078 UL37079 UL37080 UL37081 UL37082 UL37083 UL37084

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. Cycle Limits (f) Change the service cyclic limits contained in the Time Limits Manual, 05-10-01, for the IP compressor stage 5 discs installed in the engine models listed in the following Table 3, within 30 days after the effective date of this AD. Table 3.—Cyclic Life Limits Without Qualifying Magnetic Particle Inspection (MPI) or Eddy Current Inspection (ECI) Date of reduced life limit Engine models -524G2, G2-T, G3, G3-T, H2, H2-T, H-36, H-T-36 -524D4, D4-B, D4-B-39, D4X, D4X-B, D4-39 CIS -524B2, B2-B, C2, C2-B CIS -524B-02, B-B-02, B3-02, B4-02, B4-D-02 CIS November 30, 2002 13,500 cycles-in-service (CIS) 16,150 16,000 16,200 April 1, 2003 13,500 CIS 13,500 13,500 14,000 December 1, 2003 12,000 CIS 13,500 13,500 14,000 December 1, 2004 11,000 CIS 13,500 12,000 12,000 December 1, 2005 11,000 CIS 12,000 12,000 12,000 December 1, 2008 7,830 CIS 8,700 8,900 9,000 Optional Inspections (g) Before December 1, 2008, optional inspections are allowed at each shop visit or on-wing to extend the disk life. Guidance for these inspections is provided in paragraphs (h) or (i) of this AD. Optional Inspections at Shop Visit (h) Perform optional inspections at shop visit, as follows: (1) Remove corrosion protection from IP stage 5 disk. Information on corrosion protection removal can be found in the Engine Manual. (2) Visual-inspect and binocular-inspect the IP stage 5 disk for corrosion pitting at the cooling air holes and defender holes in the disk front spacer arm. Follow paragraph 3.C. of the Accomplishment Instructions of RR MSB No. RB.211-72-D428, Revision 3, dated June 30, 2003. Information on disk corrosion pitting limits can be found in the Engine Manual. (i) If the disk has corrosion pitting in excess of limits, remove the disk from service. (ii) If the disk is free from corrosion pitting, MPI the entire disk. Information on MPI can be found in the Engine Manual. If the disk passes MPI and no cracks are found, complete all other inspections, re-apply corrosion protection to disk, and return the disk to service in accordance with the cyclic limits allowed by paragraph (k) of this AD. Information on MPI limits can be found in the Engine Manual. Information on re-applying corrosion protection can be found in RR Repair FRS5900. (iii) If the disk has corrosion pitting within limits, ECI all disk cooling air holes, defender holes, and inner and outer faces. Follow paragraph 3.D. of the Accomplishment Instructions of RR MSB No. RB.211-72-D428, Revision 3, dated June 30, 2003. Information on corrosion pitting limits can be found in the Engine Manual. If the disk passes ECI and no cracks are found, MPI the entire disk. Information on MPI can be found in the Engine Manual. If the disk passes MPI and no cracks are found, re-apply corrosion protection to disk, and return the disk to service in accordance with the cyclic limits allowed by paragraph (k) of this AD. Optional On-Wing EC Inspections (i) For RB211-524B2/C2 and RB211-524B4/D4 engine models, an on-wing ECI of the IP compressor stage 5 disk may be performed only once between shop visit inspections. Follow paragraphs 3.A. through 3.F. of the Accomplishment Instructions of RR SB No. RB.211-72-E148, dated March 13, 2003, and RR SB No. RB.211-72-E150, Revision 1, dated June 4, 2003, respectively, to do the ECI. If the disk passes the ECI and no cracks are found, an extension is allowed as specified in paragraph (k) of this AD. Definition of Shop Visit (j) For the purposes of this AD, a shop visit is defined as the separation of an engine major case flange. This definition excludes shop visits when only field maintenance type activities are performed in lieu of performing them on-wing. ( i.e. , for purposes such as to perform an on-wing inspection of a tail engine installation on a Lockheed L-1011 airplane). Cyclic Life Extension (k) Disks that pass an optional inspection may remain in service after that inspection for the additional cycles listed in the following Table 4, until the next inspection, or December 1, 2008, or until the cyclic life limit published in the Time Limits Manual is reached, whichever occurs first. Table 4.—Cyclic Life Extension Engine models -524G2, G2-T, G3, G3-T, H2, H2-T, H-36, H-T-36 (cycles) -524D4, D4-B, D4-B-39, D4X, D4X-B, D4-39 (cycles) -524B2, B2-B, C2, C2-B (cycles) -524B-02, B-B-02, B3-02, B4-02, B4-D-02 (cycles) Extension After Passing MPI 1,600 2,000 2,000 2,000 Extension After Passin In-Shop ECI 3,800 4,500 4,500 4,500 Extension After Passing On-Wing ECI 1,000 1,200 1,200 1,200 Disks That Have Been Intermixed Between Engine Models (l) Information on intermixing disks between engine models can be found in the RR Time Limits Manual, 05-00-01. Alternative Methods of

This AD results from discovery of cracks in the cooling air hole areas of the disk front spacer arm. The actions specified in this AD are intended to prevent IP compressor stage 5 disk failure, which could result in uncontained engine failure and possible damage to the airplane.