AD 2006-11-05R2 Airworthiness Directives; Rolls-Royce plc RB211 Series Turbofan Engines

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.

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 Disc Assemblies (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 disc assemblies P/Ns LK76036, UL11706, UL15358, UL22577, UL22578, and UL24738 (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 series, 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 disc assemblies that entered into service before 1990, remove disc assembly 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. Disc assemblies reworked may not exceed the manufacturer's published cyclic limit in the time limits section of the manual. (2) For disc assemblies that entered into service in 1990 or later, remove disc assembly 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. Disc assemblies 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 SB No. RB.211-72-5420, dated April 20, 1979, remove RB211-22B series disc assemblies before accumulating 10,000 cycles-in-service (CIS), and remove RB211-524 series disc assemblies before accumulating 9,000 CIS. (4) If the disc assembly date of entry into service cannot be determined, the date of disc assembly manufacture may be obtained from RR and used instead. (5) Disc assemblies in RB211-535C series 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 Disc Assemblies (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 P/N LK76034 or P/N 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. (3) 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 assembly to the lower life of the rework band, at time of rework, is required. (4) Disc assemblies that have a record of detailed inspection, regardless of the date of entry into service, are allowed to remain in service for 17 years from last overhaul inspection date but not to exceed the manufacturer's published cyclic limit in the time limits section of the manual. Alternative Methods of

This AD results from the FAA allowing certain affected disc assemblies that have a record of a detailed inspection, to remain in service for a longer period than the previous AD allowed. We are issuing this AD to relax the compliance time for disc assemblies manufactured both “ before and after 1990” by providing an option to track the disc life based on a record of a detailed inspection rather than by its entry into service date, while continuing to prevent corrosion-induced uncontained disc assembly failure, resulting in damage to the airplane.