Airworthiness Directive · Amendment 39-15721 · Rolls-Royce plc RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 Series Turbofan Engines
Rolls-Royce plc RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 Series Turbofan Engines
Superseded. A later AD replaced this one: AD 2020-08-03. Comply with the one in force.
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:
| 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 |
The FAA is superseding an existing airworthiness directive (AD) for Rolls-Royce plc (RR) RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-B-75 series turbofan engines. That AD currently requires initial and repetitive ultrasonic inspections of installed low pressure compressor (LPC) fan blade roots on-wing and during overhaul, and relubrication according to accumulated life cycles. Also, that AD introduces application of Metco 58 blade root coating as an optional terminating action. This AD requires the same actions but adds compliance paragraphs to relax the compliance schedule for repetitive inspections for fan blades operating within RB211-535E4 flight profiles A and B, if certain requirements are met. This AD also relaxes the initial compliance threshold by extending the cycles at which an initial inspection is required. 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 LPC fan blade roots, which if not detected, could lead to uncontained multiple fan blade 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.
(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.
| 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.
| 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.
| 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.
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.
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
