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Airworthiness directives › 2008-22-24

AD 2008-22-24 Airworthiness Directives; Rolls-Royce plc RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 Series Turbofan Engines

Superseded. This directive was replaced by AD 2020-08-03. Work to the current one.
2008-12-09
2008-11-04
39-15721
FAA-2007-29343
Engine
2020-08-03

Applicability*9

This AD applies to Rolls-Royce plc (RR) RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 series turbofan engines with low pressure compressor (LPC) fan blades with the part numbers (P/Ns) listed in Table 1 of this AD. These engines are installed on, but not limited to, Boeing 757 and Tupolev Tu204 series airplanes. Table 1 follows: Table 1—Applicable LPC Fan Blade P/Ns           UL16135 UL16171 UL16182 UL19643 UL20044 UL20132 UL20616 UL21345 UL22286 UL23122 UL24525 UL24528 UL24530 UL24532 UL24534 UL27992 UL28601 UL28602 UL29511 UL29556 UL30817 UL30819 UL30933 UL30935 UL33707 UL33709 UL36992 UL37090 UL37272 UL37274 UL37276 UL37278 UL38029 UL38032

Compliance

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. (f) On RB211-535E4 engines, operated to Flight Profile A: (1) Ultrasonically inspect the fan blade root, and if required, relubricate using one of the methods in Table 2 of this AD. (2) If the initial inspection is complete prior to 18,600 cycles-since-new (CSN), then the next inspection may be postponed until 20,000 CSN. Table 2—RB211-535E4 Flight Profile A Engine location Initial inspection within (CSN) Type action In accordance with mandatory service bulletin (MSB) Repeat inspection within cycles since last inspection (CSLI) (1) On-wing 20,000 (i) Root Probe inspect, OR RB.211-72-C879 Revision 6, 3.A.(1) through 3.A.(7), dated December 14, 2007 1,400   (ii) Wave Probe inspect RB.211-72-C879 Revision 6, 3.B.(1) through 3.B.(7), dated December 14, 2007 1,150 (2) In shop 20,000 Root Probe inspect. Relubricate if blade life is more than 19,650 cycles RB.211-72-C879 Revision 6, 3.C.(1) through 3.C.(4), dated December 14, 2007 1,400 (g) On RB211-535E4 engines, operated to Flight Profile B: (1) Ultrasonically inspect the fan blade root, and if required, relubricate using one of the methods in Table 3 of this AD. (2) If the initial inspection is complete prior to 14,150 CSN, then the next inspection may be postponed until 15,000 CSN. Table 3—RB211-535E4 Flight Profile B Engine location Initial inspection within (CSN) Type action In accordance with MSB Repeat inspection within CSLI (1) On-wing 15,000 (i) Root Probe inspect, OR RB.211-72-C879 Revision 6, 3.A.(1) through 3.A.(7), dated December 14, 2007 850   (ii) Wave Probe inspect RB.211-72-C879 Revision 6, 3.B.(1) through 3.B.(7), dated December 14, 2007 700 (2) In shop 15,000 Root Probe, inspect. Relubricate if blade life is more than 14,650 cycles RB.211-72-C879 Revision 6, 3.C.(1) through 3.C.(4), dated December 14, 2007 850 (h) On RB211-535E4-B engines: (1) Ultrasonically inspect the fan blade root, and if required, relubricate using one of the methods in Table 4 of this AD. (2) If the initial inspection is complete prior to 18,800 CSN, then the next inspection may be postponed until 20,000 CSN. Table 4—RB211-535E4-B Engine location Initial inspection within (CSN) Type action In accordance with MSB Repeat inspection within (CSLI) (i) On-wing 20,000 (A) Root Probe inspect, OR RB.211-72-C879 Revision 6, 3.A.(1) through 3.A.(7), dated December 14, 2007 1,200   (B) Wave Probe inspect RB.211-72-C879 Revision 6, 3.B.(1) through 3.B.(7), dated December 14, 2007 1,000 (ii) In shop 20,000 Root Probe inspect. Relubricate if blade life is more than 19,650 cycles RB.211-72-C879 Revision 6, 3.C.(1) through 3.C.(4), dated December 14, 2007 1,200 (i) For fan blades operated to any combination of RB211-535E4 Flight Profile A, -535E4 Flight Profile B, -535E4-B, -535E4-B and -535E4-C engines: (1) Calculate an equivalent CSN as defined in the Time Limits Manual. See References Section 1.G.(3), of MSB RB.211-72-C879, Revision 6, dated December 14, 2007. (2) For fan blades that are currently flying in Profile A, inspect using paragraph (f) and Table 2 of this AD using equivalent CSN. (3) For fan blades that are currently flying in Profile B, inspect using paragraph (g) and Table 3 of this AD using equivalent CSN. (4) For fan blades that are currently flying in an RB211-535E4-B engine, inspect using paragraph (h) and Table 4 of this AD using equivalent CSN. Optional Terminating Action (j) Application of Metco 58 blade root coating using RR SB No. RB.211-72-C946, Revision 2, dated September 26, 2002, constitutes terminating action to the repetitive inspection requirements specified in paragraphs (f), (g), (h), and (i) of this AD. Alternative Methods of

Unsafe condition

This AD results from RR issuing Mandatory Service Bulletin (MSB) No. RB.211-72-C879, Revision 5 and Revision 6, that introduced a relaxed repetitive compliance schedule for fan blades operating within RB211-535E4 flight profiles A and B, if certain requirements are met, and introduced a relaxed initial compliance threshold. We are issuing this AD to detect cracks in low pressure compressor (LPC) fan blade roots, which if not detected, could lead to uncontained multiple fan blade failure, and damage to the airplane.

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