Airworthiness Directive · Amendment 39-14733 · Rolls-Royce plc RB211 Series Turbofan Engines
Rolls-Royce plc RB211 Series Turbofan Engines
This AD applies to Rolls-Royce plc (RR) models RB211-535E4-37, RB211-535E4-B-37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4-C, and RB211-22B-02 turbofan engines with turbine discs having part numbers and serial numbers listed in the following Tables 1, 3, and 5 of this AD. These turbofan engines are installed on, but not limited to, Boeing 757, Tupolev Tu204, and Lockheed L-1011 series airplanes.
This amendment supersedes an existing airworthiness directive (AD), that is applicable to Rolls-Royce plc (RR) models RB211-535E4-37, RB211-535E4--37, RB211-535C-37, RB211-535E4-B-75, RB211-535E4-C, and RB211-22B-02 turbofan engines. That AD currently requires inspecting certain high pressure (HP) turbine discs, manufactured between 1989 and 1999, for cracks in the rim cooling air holes, and, if necessary, replacing the discs with serviceable parts. The manufacturer identified reaming-induced machining anomalies (RIMA) as the cause for the cracking. This amendment requires the same inspections, and reduces the compliance times for eddy current inspection (ECI) for the RR RB211- 22B-02 engines. This amendment results from the manufacturer reducing their recommended compliance times for inspections on RB211-22B-02 engines. We are issuing this AD to prevent possible disc failure, which could result in an uncontained engine failure and damage to the airplane.
You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done.
For all except model RB211-22B-02 engines, do the following:
(1) Perform an eddy current inspection of the high pressure (HP) turbine discs listed in Table 1 of this AD, for cracks in the rim cooling air holes. Use paragraph 3. of the Accomplishment Instructions of RR Alert Service Bulletin (ASB) No. RB.211-72-AE651, dated November 22, 2004, to perform the eddy current inspection.
| Part No. | Serial No. | Part No. | Serial No. |
|---|---|---|---|
| LK80623 | CQDY6397 | UL27681 | LDRCZ12893 |
| LK80623 | CQDY6504 | UL27681 | LDRCZ12985 |
| UL27680 | CQDY6451 | UL27681 | LDRCZ13044 |
| UL27680 | CQDY6452 | UL27681 | LDRCZ13047 |
| UL27680 | CQDY6466 | UL27681 | LQDY6803 |
| UL27680 | CQDY6468 | UL27681 | LQDY6814 |
| UL27680 | CQDY6471 | UL27681 | LQDY6847 |
| UL27680 | CQDY6496 | UL27681 | LQDY6868 |
| UL27680 | CQDY6505 | UL27681 | LQDY6875 |
| UL27680 | CQDY6653 | UL27681 | LQDY6892 |
| UL27680 | CQDY6656 | UL27681 | LQDY6898 |
| UL27680 | CQDY6657 | UL27681 | LQDY6904 |
| UL27680 | CQDY6684 | UL27681 | LQDY6909 |
| UL27680 | CQDY6883 | UL27681 | LQDY6910 |
| UL27681 | CQDY6465 | UL27681 | LQDY9133 |
| UL27681 | LAQDY6002 | UL27681 | LQDY9574 |
| UL27681 | LAQDY6083 | UL27681 | LQDY9579 |
| UL27681 | LAQDY6087 | UL27681 | LQDY9672 |
| UL27681 | LDRCZ10247 | UL27681 | LQDY9770 |
| UL27681 | LDRCZ10277 | UL27681 | LQDY9783 |
| UL27681 | LDRCZ10318 | UL27681 | LQDY9786 |
| UL27681 | LDRCZ10335 | UL27681 | LQDY9900 |
| UL27681 | LDRCZ10430 | UL27681 | LQDY9902 |
| UL27681 | LDRCZ10531 | UL27681 | LQDY9929 |
| UL27681 | LDRCZ10750 | UL27681 | LQDY9957 |
| UL27681 | LDRCZ10899 | UL27681 | LQDY9982 |
| UL27681 | LDRCZ11616 | UL27681 | LQDY9992 |
| UL27681 | LDRCZ11720 | UL27681 | WGQDY90005 |
| UL27681 | LDRCZ11893 |
(2) Use the compliance schedule in Table 2 of this AD.
| If disc Cycles-Since-New (CSN) on October 8, 2004 are: | Then eddy current inspect: |
|---|---|
| (i) 12,750 CSN or more | Within 250 cycles-in-service (CIS) from October 8, 2004 or within 14,500 CSN, whichever occurs first. |
| (ii) Fewer than 12,750 CSN but 10,500 CSN or more | Within 500 CIS from October 8, 2004. |
| (iii) Fewer than 10,500 CSN | Before 11,000 CSN or at next shop visit after the effective date of this AD, whichever occurs first. |
(3) On discs that pass inspection, use paragraph 3. of the Accomplishment Instructions of RR ASB No. RB.211-72-AE651, dated November 22, 2004, to permanently etch NMSB 72-AE651 onto the disc, adjacent to the part number.
(4) Perform an eddy current inspection of the HP turbine discs listed in Table 3 of this AD, for cracks in the rim cooling air holes. Use paragraph 3. of the Accomplishment Instructions of RR ASB No. RB.211-72-AE651, dated November 22, 2004, to perform the eddy current inspection.
| Part No. | Serial No. |
|---|---|
| UL10323 | CQDY6070 and higher. |
| UL27680 | All. |
| UL27681 | All. |
| LK80622 | LQDY6316 and higher. |
| LK80623 | CQDY5945 and higher. |
| UL28267 | All. |
(5) Use the compliance schedule in Table 4 of this AD.
| If disc CSN on January 29, 2001 are: | Then eddy current inspect: |
|---|---|
| (i) Fewer than 13,700 CSN | Before reaching 14,500 CSN, or at the next shop visit after the effective date of this AD, whichever occurs first. |
| (ii) 13,700 CSN or more | Before reaching one of the following, whichever occurs first after the effective date of this AD: |
| (A) 15,300 CSN. | |
| (B) Within 800 CIS since January 29, 2001. | |
| (C) At next shop visit. |
(6) For discs that pass inspection, use paragraph 3. of the Accomplishment Instructions of RR ASB No. RB.211-72-AE651, dated November 22, 2004, to permanently etch NMSB 72-AE651 onto the disc, adjacent to the part number.
For model RB211-22B-02 engines, do the following:
(1) Perform an eddy current inspection of the HP turbine discs listed in Table 5 of this AD, for cracks in the rim cooling air holes. Use paragraph 3. of the Accomplishment Instructions of RR ASB No. RB.211-72-AE717, dated January 21, 2005, to perform the eddy current inspection.
| Part No. | Serial No. |
|---|---|
| LK80622 | LQDY6316 and higher. |
| LK80623 | CQDY5945 and higher. |
| UL28267 | All. |
(2) Use the compliance schedule in Table 6 of this AD.
| If disc CSN on January 1, 2005 are: | Then eddy current inspect: |
|---|---|
| (i) More than 9,000 CSN | Within 500 CIS after January 1, 2005, but before 11,000 CSN, whichever is sooner. |
| (ii) More than 1,500, but fewer than 9,001 CSN | Before exceeding 9,500 CSN, or at the next shop visit after the effective date of this AD, whichever occurs first. |
(3) For discs that pass inspection, use paragraph 3. of the Accomplishment Instructions of RR ASB No. RB.211-72-AE717, dated January 21, 2005, to permanently etch NMSB 72-AE717 onto the disc, adjacent to the part number.
Do not perform the actions of this AD to a disc until that disc has reached at least 1,500 CSN.
(i) Engines with an affected HP turbine disc at shop visit on the effective date of this AD and without the HP turbine rotor installed in the combustor outer case, must have the disc eddy current inspected before assembling the engine.
(j) Engines with an affected HP turbine disc at shop visit on the effective date of this AD with the HPT rotor installed in the combustor case need not have the disc eddy current inspected at this time.
(k) HP turbine discs previously eddy current inspected at fewer than 1,500 CSN must be inspected again using this AD.
(l) Replace cracked HP turbine discs with a serviceable disc.
For the purpose of this AD, next shop visit is defined as the first shop visit opportunity when the HPT rotor is removed from the combustion case.
(n) For the purpose of this AD, a serviceable part is one with cyclic life remaining and either not listed in any of the preceding tables or one listed in a preceding table, but previously eddy current inspected and permanently etch marked with the Service Bulletin (SB) number NMSB 72-AE651 or NMSB 72-C877 on the disc.
Previous credit is allowed for the actions in this AD for HP turbine discs with 1,500 CSN or more that were eddy current inspected using applicable RR SB No. RB.211-72-C817, Revision 2, dated March 7, 2001, RR TSD 594-J, Overhaul Processes Manual, Task 70-00-00-200-223, or RR SB No. RB.211-72-C877, Revision 1, dated March 7, 2001.
For all except model RB211-22B-02 engines, report findings of the inspection using paragraph 3.E. of the Accomplishment Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004. The Office of Management and Budget (OMB) has approved the reporting requirements specified in paragraph 3.E. of the Accomplishment Instructions of RR ASB RB.211-72-AE651, dated November 22, 2004, and assigned OMB control number 2120-0056.
(q) For model RB211-22B-02 engines, report findings of the inspection using paragraph 3.E. of the Accomplishment Instructions of RR ASB RB.211-72-AE717, dated January 21, 2005. The OMB has approved the reporting requirements specified in paragraph 3.E. of the Accomplishment Instructions of RR ASB RB.211-72-AE717, dated January 21, 2005, and assigned OMB control number 2120-0056.
The aircraft, engines and makers this AD names, by the model designations in its text. A model listed here may still be outside the AD's serial ranges.
Engines
