AD 2010-16-07 Airworthiness Directives; Rolls-Royce plc (RR) RB211-Trent 900 Series Turbofan Engines

This AD applies to RR model RB211-Trent 970-84, 970B-84, 972-84, 972B-84, 977-84, 977B-84, and 980-84 turbofan engines. These engines are installed on, but not limited to, Airbus A380 series airplanes. Reason (d) European Aviation Safety Agency (EASA) AD No. 2010-0008, dated January 15, 2010, states: Wear, beyond Engine Manual limits, has been identified on the abutment faces of the splines on the Trent 900 Intermediate Pressure (IP) shaft rigid coupling on several engines during strip. The shaft to coupling spline interface provides the means of controlling the turbine axial setting and wear through of the splines would permit the IP turbine to move rearwards. Rearward movement of the IP turbine would enable contact with static turbine components and would result in loss of engine performance with potential for in-flight shut down, oil migration and oil fire below the LP turbine discs prior to sufficient indication resulting in loss of LP turbine disc integrity. We are issuing this AD to detect rearward movement of the IP turbine, which could result in loss of disc integrity, an uncontained failure of the engine, and damage to the airplane.

Unless already done, do the following actions. On-Wing Borescope Inspection (1) Inspect the IP shaft coupling splines using section 3.A of RR RB211 Trent 900 Series Propulsion Systems Alert Non-Modification Service Bulletin (NMSB) RB.211-72-AG329, Revision 1, dated January 13, 2010, before accumulating 400 cycles-since-new or within 150 cycles-in-service (CIS) after the effective date of this AD, whichever occurs later. (2) If the coupling, P/N FW33264, was replaced with a new coupling, P/N FW33264, during any shop visit, then you may use the life since that shop visit in place of engine time since new to establish the inspection threshold. (3) Use the inspection results and actions compliance times or specified in Table 1 of this AD to disposition the engine or to determine the interval for the repetitive inspections. Table 1—On-Wing Borescope Inspection—Further Action and Repetitive Inspection Intervals Condition measured spline crest in accordance with section 3.A of Rolls-Royce alert NMSB RB.211-72-AG329, Revision 1, dated January 13, 2010, is: Action Compliance time/repetitive interval (not to exceed) flight cycles since last inspection (i) Less than 0.5 mm with no material remaining Remove the engine Before next flight. (ii) Less than 0.5 mm with some material remaining Remove the engine Within 10 flight cycles. (iii) Equal to or more than 0.5 mm but less than 1 mm Repeat inspection Within 50 flight cycles. (iv) Equal to or more than 1 mm but less than 1.5 mm Repeat inspection Within 100 flight cycles. (v) Equal to or more than 1.5 mm but less than 2 mm Repeat inspection Within 200 flight cycles. (vi) Equal to or more than 2 mm but less than 2.4 mm Repeat inspection Within 300 flight cycles. (vii) Equal to or more than 2.4 mm Repeat inspection Within 400 flight cycles. Note 1: The nominal unworn dimension of the spline crest is 2.65 mm. In-Shop Replacement and Inspection (4) At the next shop visit after the effective date of this AD perform the following: (i) Replace any IP shaft coupling that was previously borescope inspected in accordance with paragraph (e)(1) of this AD and put on a reduced re-inspection interval in accordance with paragraphs (e)(3)(i) through (e)(3)(vii) of this AD. (ii) Inspect all other IP shaft coupling splines using paragraphs 3.B.(2) or 3.B.(3) of RR RB211 Trent 900 Series Propulsion Systems Alert NMSB RB.211-72-AG329, Revision 1, dated January 13, 2010. Definitions (5) For the purposes of this AD, a shop visit is the induction of an engine into the shop for maintenance involving the separation of pairs of major mating engine flanges, except that the separation of engine flanges solely for the purposes of transportation without subsequent engine maintenance does not constitute an engine shop visit. FAA AD Differences (f) None. Other FAA AD Provisions (g) Alternative Methods of Compliance (AMOCs): The Manager, Engine Certification Office, FAA, has the authority to approve AMOCs for this AD, if requested using the procedures found in 14 CFR 39.19. Related Information (h) Refer to MCAI EASA Airworthiness Directive 2010-0008, dated January 15, 2010, for related information. (i) Contact Ian Dargin, Aerospace Engineer, Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; e-mail: ian.dargin@faa.gov ; telephone (781) 238-7178; fax (781) 238-7199, for more information about this AD. Material Incorporated by Reference (j) You must use Rolls-Royce RB211 Trent 900 Series Propulsion Systems Alert Non-Modification Service Bulletin RB.211-72-AG329 Revision 1, dated January 13, 2010 to do the actions required by this AD, unless the AD specifies otherwise. (1) The Director of the Federal Register approved the incorporation by reference of this service information under 5 U.S.C. 552(a) and 1 CFR part 51. (2) For service information identified in this AD, contact Rolls-Royce plc, P.O. Box 31, Derby, DE24 8BJ, United Kingdom; telephone 044 1332 242424; fax 044 1332 249936. (3) 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. Issued in Burlington, Massachusetts, on July 26, 2010. Peter A. White, Assistant Manager, Engine and Propeller Directorate, Aircraft Certification Service. [FR Doc. 2010-18730 Filed 8-12-10; 8:45 am] BILLING CODE 4910-13-P

Unless already done, do the following actions. On-Wing Borescope Inspection (1) Inspect the IP shaft coupling splines using section 3.A of RR RB211 Trent 900 Series Propulsion Systems Alert Non-Modification Service Bulletin (NMSB) RB.211-72-AG329, Revision 1, dated January 13, 2010, before accumulating 400 cycles-since-new or within 150 cycles-in-service (CIS) after the effective date of this AD, whichever occurs later. (2) If the coupling, P/N FW33264, was replaced with a new coupling, P/N FW33264, during any shop visit, then you may use the life since that shop visit in place of engine time since new to establish the inspection threshold. (3) Use the inspection results and actions compliance times or specified in Table 1 of this AD to disposition the engine or to determine the interval for the repetitive inspections. Table 1—On-Wing Borescope Inspection—Further Action and Repetitive Inspection Intervals Condition measured spline crest in accordance with section 3.A of Rolls-Royce alert NMSB RB.211-72-AG329, Revision 1, dated January 13, 2010, is: Action Compliance time/repetitive interval (not to exceed) flight cycles since last inspection (i) Less than 0.5 mm with no material remaining Remove the engine Before next flight. (ii) Less than 0.5 mm with some material remaining Remove the engine Within 10 flight cycles. (iii) Equal to or more than 0.5 mm but less than 1 mm Repeat inspection Within 50 flight cycles. (iv) Equal to or more than 1 mm but less than 1.5 mm Repeat inspection Within 100 flight cycles. (v) Equal to or more than 1.5 mm but less than 2 mm Repeat inspection Within 200 flight cycles. (vi) Equal to or more than 2 mm but less than 2.4 mm Repeat inspection Within 300 flight cycles. (vii) Equal to or more than 2.4 mm Repeat inspection Within 400 flight cycles. Note 1: The nominal unworn dimension of the spline crest is 2.65 mm. In-Shop Replacement and Inspection (4) At the next shop visit after the effective date of this AD perform the following: (i) Replace any IP shaft coupling that was previously borescope inspected in accordance with paragraph (e)(1) of this AD and put on a reduced re-inspection interval in accordance with paragraphs (e)(3)(i) through (e)(3)(vii) of this AD. (ii) Inspect all other IP shaft coupling splines using paragraphs 3.B.(2) or 3.B.(3) of RR RB211 Trent 900 Series Propulsion Systems Alert NMSB RB.211-72-AG329, Revision 1, dated January 13, 2010. Definitions (5) For the purposes of this AD, a shop visit is the induction of an engine into the shop for maintenance involving the separation of pairs of major mating engine flanges, except that the separation of engine flanges solely for the purposes of transportation without subsequent engine maintenance does not constitute an engine shop visit. FAA AD Differences (f) None. Other FAA AD Provisions (g) Alternative Methods of Compliance (AMOCs): The Manager, Engine Certification Office, FAA, has the authority to approve AMOCs for this AD, if requested using the procedures found in 14 CFR 39.19. Related Information (h) Refer to MCAI EASA Airworthiness Directive 2010-0008, dated January 15, 2010, for related information. (i) Contact Ian Dargin, Aerospace Engineer, Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; e-mail: ian.dargin@faa.gov ; telephone (781) 238-7178; fax (781) 238-7199, for more information about this AD. Material Incorporated by Reference (j) You must use Rolls-Royce RB211 Trent 900 Series Propulsion Systems Alert Non-Modification Service Bulletin RB.211-72-AG329 Revision 1, dated January 13, 2010 to do the actions required by this AD, unless the AD specifies otherwise. (1) The Director of the Federal Register approved the incorporation by reference of this service information under 5 U.S.C. 552(a) and 1 CFR part 51. (2) For service information identified in this AD, contact Rolls-Royce plc, P.O. Box 31, Derby, DE24 8BJ, United Kingdom; telephone 044 1332 242424; fax 044 1332 249936. (3) 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. Issued in Burlington, Massachusetts, on July 26, 2010. Peter A. White, Assistant Manager, Engine and Propeller Directorate, Aircraft Certification Service. [FR Doc. 2010-18730 Filed 8-12-10; 8:45 am] BILLING CODE 4910-13-P