[Federal Register Volume 69, Number 43 (Thursday, March 4, 2004)]
[Proposed Rules]
[Pages 10179-10181]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-4799]
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Proposed Rules
Federal Register
________________________________________________________________________
This section of the FEDERAL REGISTER contains notices to the public of
the proposed issuance of rules and regulations. The purpose of these
notices is to give interested persons an opportunity to participate in
the rule making prior to the adoption of the final rules.
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Federal Register / Vol. 69, No. 43 / Thursday, March 4, 2004 /
Proposed Rules
[[Page 10179]]
DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2003-NE-54-AD]
RIN 2120-AA64
Airworthiness Directives; Rolls-Royce plc RB211 Trent 800 Series
Turbofan Engines
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD)
for Rolls-Royce plc (RR) RB211-Trent 800 series turbofan engines. This
proposal would require revising the Time Limits Manual for RR RB211-
Trent 800 series turbofan engines. These revisions would include
required enhanced inspection of selected critical life-limited parts at
each piece-part exposure. This proposal results from the need to
require enhanced inspection of selected critical life-limited parts of
RB211-Trent 800 series turbofan engines. We are proposing this AD to
prevent failure of critical life-limited rotating engine parts, which
could result in an uncontained engine failure and damage to the
airplane.
DATES: We must receive any comments on this proposed AD by May 3, 2004.
ADDRESSES: Use one of the following addresses to submit comments on
this proposed AD:
[sbull] By mail: Federal Aviation Administration (FAA), New England
Region, Office of the Regional Counsel, Attention: Rules Docket No.
2003-NE-54-AD, 12 New England Executive Park, Burlington, MA 01803-
5299.
[sbull] By fax: (781) 238-7055.
[sbull] By e-mail: [email protected].
You may examine the AD docket, by appointment, at the FAA, New
England Region, Office of the Regional Counsel, 12 New England
Executive Park, Burlington, MA.
FOR FURTHER INFORMATION CONTACT: Christopher Spinney, Aerospace
Engineer, Engine Certification Office, FAA, Engine and Propeller
Directorate, 12 New England Executive Park, Burlington, MA 01803-5299;
telephone (781) 238-7175, fax (781) 238-7199.
SUPPLEMENTARY INFORMATION:
Comments Invited
We invite you to submit any written relevant data, views, or
arguments regarding this proposal. Send your comments to an address
listed under ADDRESSES. Include ``AD Docket No. 2003-NE-54-AD'' in the
subject line of your comments. If you want us to acknowledge receipt of
your mailed comments, send us a self-addressed, stamped postcard with
the docket number written on it; we will date-stamp your postcard and
mail it back to you. We specifically invite comments on the overall
regulatory, economic, environmental, and energy aspects of the proposed
AD. If a person contacts us verbally, and that contact relates to a
substantive part of this proposed AD, we will summarize the contact and
place the summary in the docket. We will consider all comments received
by the closing date and may amend the proposed AD in light of those
comments.
We are reviewing the writing style we currently use in regulatory
documents. We are interested in your comments on whether the style of
this document is clear, and your suggestions to improve the clarity of
our communications that affect you. You may get more information about
plain language at http://www.faa.gov/language and http://www.plainlanguage.gov.
Examining the AD Docket
You may examine the AD Docket (including any comments and service
information), by appointment, between 8 a.m. and 4:30 p.m., Monday
through Friday, except Federal holidays. See ADDRESSES for the
location.
Discussion
A recent FAA study analyzing 15 years of accident data for
transport category airplanes identified several root causes for a
failure mode that can result in serious safety hazards to transport
category airplanes. This study identified uncontained failure of
critical life-limited rotating engine parts as the leading engine-
related safety hazard to airplanes. Uncontained engine failures have
resulted from undetected cracks in rotating parts that started and grew
to failure. Cracks can start from causes such as unintended excessive
stress from the original design, or they may start from stresses
induced from material flaws, handling, or damage from machining
operations. The failure of a rotating part can present a significant
safety hazard to the airplane by release of high-energy fragments that
could injure passengers or crew by penetration of the cabin, damage
flight control surfaces, sever flammable fluid lines, or otherwise
compromise the airworthiness of the airplane.
Based on these findings, the FAA, with the concurrence of the Civil
Aviation Authority (CAA), which is the Airworthiness Authority for the
United Kingdom (U.K.), has developed an intervention strategy to
significantly reduce uncontained engine failures. This intervention
strategy was developed after consultation with industry and will be
used as a model for future initiatives. The intervention strategy is to
conduct enhanced, nondestructive inspections of rotating parts, which
could most likely result in a safety hazard to the airplane in the
event of a part fracture. We are considering the need for additional
rulemaking. We might issue future ADs to introduce additional
intervention strategies to further reduce or eliminate uncontained
engine failures.
Properly focused enhanced inspections require identification of the
parts whose failure presents the highest safety hazard to the airplane,
identifying the most critical features to inspect on these parts, and
utilizing inspection procedures and techniques that improve crack
detection. The CAA, with close cooperation of RR, has completed a
detailed analysis that identifies the most safety significant parts and
features, and the most appropriate inspection methods.
Critical life-limited high-energy rotating parts are currently
subject to some form of recommended crack inspection when exposed
during engine maintenance or disassembly. The inspections currently
recommended by the manufacturer would become mandatory for those parts
listed in the
[[Page 10180]]
compliance section as a result of this proposed AD. Furthermore, we
intend that additional mandatory enhanced inspections resulting from
this AD would serve as an adjunct to the existing inspections. We have
determined that the enhanced inspections will significantly improve the
probability of crack detection on disassembled parts during
maintenance. All mandatory inspections must be conducted in accordance
with detailed inspection procedures prescribed in the manufacturer's
Engine Manual.
Additionally, this proposed AD would:
[sbull] Allow air carriers that operate under the provisions of 14
CFR part 121 with an FAA-approved continuous airworthiness maintenance
program, and maintenance facilities to verify completion of the
enhanced inspections.
[sbull] Allow the air carrier or maintenance facility to retain the
maintenance records that include the inspections resulting from this
proposed AD, if the records include the date and signature of the
person who performed the maintenance action.
[sbull] Require retaining the records with the maintenance records
of the part, engine module, or engine until the task is repeated.
[sbull] Establish a method of record preservation and retrieval
typically used in existing continuous airworthiness maintenance
programs.
[sbull] Require adding instructions in an air carrier's maintenance
manual on how to implement and integrate this record preservation and
retrieval system into the air carrier's record keeping system.
For engines or engine modules that are approved for return to
service by an authorized FAA-certificated entity, and that are acquired
by an operator after the effective date of the proposed AD, you would
not need to perform the mandatory enhanced inspections until the next
piece-part opportunity. For example, you would not have to disassemble
to piece-part level, an engine or module returned to service by an FAA-
certificated facility simply because that engine or module was
previously operated by an entity not required to comply with this
proposed AD. Furthermore, we intend that operators perform the enhanced
inspections of these parts at the next piece-part opportunity after the
initial acquisition, installation, and removal of the part after the
effective date of this proposed AD. For piece parts not approved for
return to service before the effective date of this AD, the proposed AD
would require that you perform the mandatory enhanced inspections
before approval of those parts for return to service. The proposed AD
would allow installation of piece parts approved for return to service
before the effective date of this AD. However, the proposed AD would
require an enhanced inspection at the next piece-part opportunity.
This proposal would require, within the next 40 days after the
effective date of this proposed AD, revisions to the Time Limits
Manual.
FAA's Determination and Requirements of the Proposed AD
Since an unsafe condition has been identified that is likely to
exist or develop on other Rolls-Royce plc RR RB211 Trent 800 series
turbofan engines of the same type design that are used on Boeing 777
airplanes registered in the United States, the proposed AD would
require revisions to the Time Limits Manual for RR RB211-Trent 800
series turbofan engines to include required enhanced inspection of
selected critical parts at each piece-part exposure.
Changes to 14 CFR Part 39--Effect on the Proposed AD
On July 10, 2002, we issued a new version of 14 CFR part 39 (67 FR
47998, July 22, 2002), which governs the FAA's AD system. This
regulation now includes material that relates to altered products,
special flight permits, and alternative methods of compliance. This
material previously was included in each individual AD. Since this
material is included in 14 CFR part 39, we will not include it in
future AD actions.
Costs of Compliance
There are about 350 engines of the affected design in the worldwide
fleet. We estimate that 90 engines installed on airplanes of U.S.
registry would be affected by this proposed AD. We also estimate that
it would take about 75 work hours per engine to perform the proposed
inspections, and that the average labor rate is $65 per work hour.
Since this is an added inspection requirement, included as part of the
normal maintenance cycle, no additional part costs are involved. Based
on these figures, the total cost impact of the proposed AD on U.S.
operators is estimated to be $438,750.
Regulatory Findings
We have determined that this proposed AD would not have federalism
implications under Executive Order 13132. This proposed AD would not
have a substantial direct effect on the States, on the relationship
between the national Government and the States, or on the distribution
of power and responsibilities among the various levels of government.
For the reasons discussed above, I certify that the proposed
regulation:
1. Is not a ``significant regulatory action'' under Executive Order
12866;
2. Is not a ``significant rule'' under the DOT Regulatory Policies
and Procedures (44 FR 11034, February 26, 1979); and
3. Would not have a significant economic impact, positive or
negative, on a substantial number of small entities under the criteria
of the Regulatory Flexibility Act.
We prepared a summary of the costs to comply with this proposal and
placed it in the AD Docket. You may get a copy of this summary by
sending a request to us at the address listed under ADDRESSES. Include
``AD Docket No. 2003-NE-54-AD'' in your request.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Safety.
The Proposed Amendment
Accordingly, under the authority delegated to me by the
Administrator, the Federal Aviation Administration proposes to amend 14
CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
Sec. 39.13 [Amended]
2. The FAA amends Sec. 39.13 by adding the following new
airworthiness directive:
Rolls-Royce plc: Docket No. 2003-NE-54-AD.
Comments Due Date
(a) The Federal Aviation Administration (FAA) must receive
comments on this airworthiness directive (AD) action by May 3, 2004.
Affected ADs
(b) None.
Applicability
(c) This AD applies to Rolls-Royce plc (RR) RB211-Trent 800
series turbofan engines. These engines are installed on, but not
limited to, Boeing 777 airplanes.
Unsafe Condition
(d) This AD results from the need to require enhanced inspection
of selected critical life-limited parts of RB211-Trent 800 series
turbofan engines. We are issuing this AD to prevent critical life-
limited rotating engine part failure, which could result in an
uncontained engine failure and damage to the airplane.
[[Page 10181]]
Compliance
(e) 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) Within the next 40 days after the effective date of this AD,
revise the Time Limits Manual (TLM), and for air carrier operations
revise the approved continuous airworthiness maintenance program, by
adding the following: GROUP A PARTS MANDATORY INSPECTION.
(1) Inspections referred to as `Focus Inspect' in the applicable
Engine Manual inspection Task are mandatory inspections for the
components given below, when the conditions that follow are
satisfied:
(i) When the component has been completely disassembled to
piece-part level as given in the applicable disassembly procedures
contained in the Engine Manual; and
(ii) The part has more than 100 recorded flight cycles in
operation since the last piece-part inspection; or
(iii) The component removal was for damage or a cause directly
related to its removal; or
(iv) Where serviceable used components, for which the inspection
history is not fully known, are to be used again.
(2) The list of Group A Parts is specified below:
------------------------------------------------------------------------
Inspected per overhaul
Part nomenclature Part number manual task
------------------------------------------------------------------------
Low Pressure Compressor Rotor All............. 72-31-16-200-801
Disc.
Low Pressure Compressor Rotor All............. 72-31-20-200-801
Shaft.
Intermediate Pressure All............. 72-32-31-200-801
Compressor Rotor Shaft.
Intermediate Pressure Rear All............. 72-33-21-200-801
Shaft.
High Pressure Compressor All............. 72-41-31-200-801
Stage 1 to 4 Rotor Discs
Shaft.
High Pressure Compressor All............. 72-41-31-200-802
Stage 5 & 6 Discs and Cone.
High Pressure Turbine Rotor All............. 72-41-51-200-801
Disc.
Intermediate Pressure Turbine All............. 72-51-31-200-801
Rotor Disc.
Intermediate Pressure Turbine All............. 72-51-33-200-801
Rotor Shaft.
Low Pressure Turbine Stage 1 All............. 72-52-31-200-801
Rotor Disc.
Low Pressure Turbine Stage 2 All............. 72-52-31-200-802
Rotor Disc.
Low Pressure Turbine Stage 3 All............. 72-52-31-200-803
Rotor Disc.
Low Pressure Turbine Stage 4 All............. 72-52-31-200-804
Rotor Disc.
Low Pressure Turbine Stage 5 All............. 72-52-31-200-805
Rotor Disc.
Low Pressure Turbine Rotor All............. 72-52-33-200-801
Shaft.
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Alternative Methods of Compliance
(g) You must perform these mandatory inspections using the TLM
and the applicable Engine Manual unless you receive approval to use
an alternative method of compliance under paragraph (h) of this AD.
Section 43.16 of the Federal Aviation Regulations (14 CFR 43.16) may
not be used to approve alternative methods of compliance or
adjustments to the times in which these inspections must be
performed.
(h) The Manager, Engine Certification Office, has the authority
to approve alternative methods of compliance for this AD if
requested using the procedures found in 14 CFR 39.19.
Maintaining Records of the Mandatory Inspections
(i) You have met the requirements of this AD by using a TLM
changed as specified in paragraph (f) of this AD, and, for air
carriers operating under part 121 of the Federal Aviation
Regulations (14 CFR part 121), by modifying your continuous
airworthiness maintenance plan to reflect those changes. You must
maintain records of the mandatory inspections that result from those
changes to the TLM according to the regulations governing your
operation. You do not need to record each piece-part inspection as
compliance to this AD. For air carriers operating under part 121,
you may use either the system established to comply with section
121.369 or use an alternative system that your principal maintenance
inspector has accepted if that alternative system:
(1) Includes a method for preserving and retrieving the records
of the inspections resulting from this AD; and
(2) Meets the requirements of section 121.369(c); and
(3) Maintains the records either indefinitely or until the work
is repeated.
(j) These record keeping requirements apply only to the records
used to document the mandatory inspections required as a result of
revising the Time Limits Manual as specified in paragraph (f) of
this AD, and do not alter or amend the record keeping requirements
for any other AD or regulatory requirement.
Related Information
(k) CAA airworthiness directive No. G-2003-0003, dated November
25, 2003, also addresses the subject of this AD.
Issued in Burlington, Massachusetts, on February 25, 2004.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification
Service.
[FR Doc. 04-4799 Filed 3-3-04; 8:45 am]
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