Airworthiness Directive · Amendment 39-14991 · Rolls-Royce plc RB211-524 Series Turbofan Engines
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 compressor (IPC) stage 5 disk part numbers (P/Ns) listed in Table 2 of this AD, installed.
| -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 series airplanes.
| 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 |
The FAA is superseding an existing airworthiness directive (AD) for Rolls Royce plc (RR) RB211-524 series turbofan engines with certain part number (P/N) intermediate pressure compressor (IPC) stage 5 disks installed. That AD currently requires new reduced IPC stage 5 disk cyclic limits. This AD requires the same reduced IPC stage 5 disk cyclic limits, requires removal from service of affected disks that already exceed the new reduced cyclic limit, and, removal from service of other affected disks before exceeding their cyclic limits using a drawdown schedule. This AD also exempts disks reworked to RR Service Bulletin (SB) No. RB.211-72-E182, Revision 1, dated July 30, 2004, and allows an on-wing eddy current inspection (ECI) on RB211-524G and RB211-524H series engines. This AD results from the manufacturer issuing a revised Alert Service Bulletin (ASB) to remove certain disks from applicability, and to allow an on-wing ECI on RB211-524G and RB211-524H series engines. We are issuing this AD to prevent failure of the IPC stage 5 disk, which could result in uncontained engine failure and possible 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 engines with an IPC stage 5 disk P/N listed in Table 2 of this AD, reworked to RR SB No. RB.211-72-E182, Revision 1, dated July 30, 2004, no further action is necessary.
Comply with the reduced cyclic life limits in Table 3 of this AD within 30 days after the effective date of this AD, or conduct optional qualifying nondestructive test (NDT) inspections before December 1, 2008 to extend the IPC stage 5 disk life, as specified in paragraph (i) of this AD.
| 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 | -524B2, B2-B, C2, C2-B | -524B-02, B-B-02, B3-02, B4-02, B4-D-02 |
|---|---|---|---|---|
| November 30, 2002 | 13,500 cycles-in-service (CIS) | 16,150 CIS | 16,000 CIS | 16,200 CIS. |
| April 1, 2003 | 13,500 CIS | 13,500 CIS | 13,500 CIS | 14,000 CIS. |
| December 1, 2003 | 12,000 CIS | 13,500 CIS | 13,500 CIS | 14,000 CIS. |
| December 1, 2004 | 11,000 CIS | 13,500 CIS | 12,000 CIS | 12,000 CIS. |
| December 1, 2005 | 11,000 CIS | 12,000 CIS | 12,000 CIS | 12,000 CIS. |
(h) On December 1, 2008, the revised cyclic life limits specified in Table 4 of this AD become effective. Incorporate the revised cyclic life limits specified in Table 4 of this AD into the RR Time Limits Manual, 05-10-01.
| 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 | -524B2, B2-B, C2, C2-B | -524B-02, B-B-02, B3-02, B4-02, B4-D-02 |
|---|---|---|---|---|
| December 1, 2008 | 7,830 CIS | 8,700 CIS | 8,900 CIS | 9,000 CIS. |
(i) Before December 1, 2008, you may perform an optional NDT inspection on-wing or at each shop visit to extend the disk life. Guidance for these inspections is provided in paragraphs (j) or (k) of this AD.
Perform optional inspections at shop visit, as follows:
(1) Remove corrosion protection from IPC stage 5 disk. Information on corrosion protection removal can be found in the Engine Maintenance Manual.
(2) Perform a visual inspection and a binocular inspection of the IPC 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 ASB No. RB.211-72-AD428, Revision 5, dated March 18, 2005. The RR Engine Maintenance Manual, Inspection Check-00 (ATA 72-32-31-200-000), contains limits for corrosion pitting of the IPC stage 5 disk.
(3) If the disk has corrosion pitting in excess of limits, remove the disk from service.
(4) If the disk is free from corrosion pitting, perform a magnetic penetrant inspection (MPI) of the entire disk as follows:
(i) For RB211-524G2-T, RB211-524G3-T, and RB211-524H-T series engines, the RR Engine Maintenance Manual, Inspection Check 08 (ATA 72-32-31-200-008), contains limits for corrosion pitting of the IPC stage 5 disk.
(ii) For RB211-524G2, RB211-524G3, and RB211-524H series engines, the RR Engine Maintenance Manual, Inspection Check 09 (ATA 72-32-31-200-009), contains limits for corrosion pitting of the IPC stage 5 disk.
(iii) If the disk passes the MPI and you find no cracks, complete all other inspections, re-apply corrosion protection to the disk, and return the disk to service using the cyclic limits allowed by paragraph (m) of this AD. RR Repair FRS5900 contains information on re-applying corrosion protection.
(5) If the disk has corrosion pitting that is within limits, do the following:
(i) Perform an ECI on all disk cooling air holes, defender holes, and inner and outer faces. Use paragraph 3.D. of the Accomplishment Instructions of RR ASB No. RB.211-72-AD428, Revision 5, dated March 18, 2005. The RR Engine Maintenance Manual, Inspection Check-00 (ATA 72-32-31-200-000), contains limits for corrosion pitting of the IPC stage 5 disk.
(ii) If the disk passes the ECI and you find no cracks, perform an MPI on the entire disk.
(iii) If the disk passes the MPI and you find no cracks, re-apply corrosion protection to the disk, and return the disk to service using the cyclic limits allowed by paragraph (m) of this AD.
You may perform an optional on-wing ECI of the IPC stage 5 disk only once between shop visit inspections as follows:
(1) For RB211-524B2/C2, RB211-524B/B3, and RB211-524B4/D4 series engines, use 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.
(2) For RB211-524G2, RB211-524G2-T, RB211-524G3, RB211-524G3-T, RB211-524H, RB211-524H-T, RB211-524H2, and RB211-524H2-T series engines, use paragraphs 3.A. through 3.M. of the Accomplishment Instructions of RR SB No. RB.211-72-E171, Revision 1, dated February 8, 2005.
(3) If the disk passes the ECI and you find no cracks, you may extend the cycle life as specified in paragraph (m) of this AD.
The manufacturer defines a shop visit 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 (such as to perform an on-wing inspection of a tail engine installation on a Lockheed L-1011 series airplane).
Disks that pass an optional inspection may remain in service after that inspection for the additional cycles listed in the following Table 5, until the next inspection, until the cyclic life limit published in the RR Time Limits Manual, 05-10-01, is reached, or December 1, 2008, whichever occurs first.
| 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 Passing 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 |
The RR Time Limits Manual, 05-00-01, contains information on intermixing disks between engine models.
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
