[Federal Register Volume 85, Number 84 (Thursday, April 30, 2020)]
[Proposed Rules]
[Pages 23925-23929]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2020-09009]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2020-0009; Project Identifier MCAI-2019-00111-E]
RIN 2120-AA64
Airworthiness Directives; Rolls-Royce Deutschland Ltd & Co KG
(Type Certificate Previously Held by Rolls-Royce plc) Turbofan Engines
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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[[Page 23926]]
SUMMARY: The FAA proposes to supersede airworthiness directive (AD)
2018-08-02 which applies to all Rolls-Royce Deutschland Ltd & Co KG
(RRD) Trent 1000-A2, Trent 1000-AE2, Trent 1000-C2, Trent 1000-CE2,
Trent 1000-D2, Trent 1000-E2, Trent 1000-G2, Trent 1000-H2, Trent 1000-
J2, Trent 1000-K2, and Trent 1000-L2 model turbofan engines. AD 2018-
08-02 requires initial and repetitive ultrasonic or visual inspections
of the intermediate-pressure compressor (IPC) stage 1 rotor blades, IPC
stage 2 rotor blades, and IPC shaft stage 2 dovetail posts, and removal
of any cracked parts from service. Since the FAA issued AD 2018-08-02,
the manufacturer identified cracking of parts in-service resulting in
the need to require new inspections using new inspection thresholds and
intervals. This proposed AD would require new inspections based on
updated inspection thresholds and intervals for these IPC parts. This
AD would also add an optional terminating action, amend the asymmetric
power condition for engine inspection, and require an inspection after
a cabin depressurization event. The FAA is proposing this AD to address
the unsafe condition on these products.
DATES: The FAA must receive comments on this proposed AD by June 15,
2020.
ADDRESSES: You may send comments, using the procedures found in 14 CFR
11.43 and 11.45, by any of the following methods:
Federal eRulemaking Portal: Go to https://www.regulations.gov. Follow the instructions for submitting comments.
Fax: 202-493-2251.
Mail: U.S. Department of Transportation, Docket
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New
Jersey Avenue SE, Washington, DC 20590.
Hand Delivery: Deliver to Mail address above between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
For service information identified in this NPRM, contact Rolls-
Royce Deutschland Ltd & Co KG, Eschenweg 11, 15827 Blankenfelde-Mahlow,
Germany; phone: +49 (0) 33 708 6 0; email: https://www.rolls-royce.com/contact-us.aspx. You may view this service information at the FAA,
Airworthiness Products Section, Operational Safety Branch, 1200
District Avenue, Burlington, MA 01803. For information on the
availability of this material at the FAA, call 781-238-7759.
Examining the AD Docket
You may examine the AD docket on the internet at https://www.regulations.gov by searching for and locating Docket No. FAA-2020-
0009; or in person at Docket Operations between 9 a.m. and 5 p.m.,
Monday through Friday, except Federal holidays. The AD docket contains
this NPRM, the mandatory continuing airworthiness information (MCAI),
any comments received, and other information. The street address for
Docket Operations is listed above. Comments will be available in the AD
docket shortly after receipt.
FOR FURTHER INFORMATION CONTACT: Stephen Elwin, Aerospace Engineer, ECO
Branch, FAA, 1200 District Avenue, Burlington, MA 01803; phone: 781-
238-7236; fax: 781-238-7199; email: [email protected].
SUPPLEMENTARY INFORMATION:
Comments Invited
The FAA invites you to send any written relevant data, views, or
arguments about this proposed AD. Send your comments to an address
listed under the ADDRESSES section. Include ``Docket No. FAA-2020-0009;
Project Identifier MCAI-2019-00111-E'' at the beginning of your
comments. The FAA specifically invites comments on the overall
regulatory, economic, environmental, and energy aspects of this NPRM.
The FAA will consider all comments received by the closing date and may
amend this NPRM because of those comments.
Except for Confidential Business Information as described in the
following paragraph, and other information as described in 14 CFR
11.35, the FAA will post all comments received, without change, to
https://www.regulations.gov, including any personal information you
provide. The FAA will also post a report summarizing each substantive
verbal contact received about this NPRM.
Confidential Business Information
Confidential Business Information (CBI) is commercial or financial
information that is both customarily and actually treated as private by
its owner. Under the Freedom of Information Act (FOIA) (5 U.S.C. 552),
CBI is exempt from public disclosure. If your comments responsive to
this NPRM contain commercial or financial information that is
customarily treated as private, that you actually treat as private, and
that is relevant or responsive to this NPRM, it is important that you
clearly designate the submitted comments as CBI. Please mark each page
of your submission containing CBI as ``PROPIN.'' The FAA will treat
such marked submissions as confidential under the FOIA, and they will
not be placed in the public docket of this NPRM. Submissions containing
CBI should be sent to Stephen Elwin, Aerospace Engineer, ECO Branch,
FAA, 1200 District Avenue, Burlington, MA 01803. Any commentary that
the FAA receives which is not specifically designated as CBI will be
placed in the public docket for this rulemaking
Discussion
The FAA issued AD 2018-08-02, Amendment 39-19255 (83 FR 17746,
April 24, 2018), (``AD 2018-08-02''), for all RRD Trent 1000-A2, Trent
1000-AE2, Trent 1000-C2, Trent 1000-CE2, Trent 1000-D2, Trent 1000-E2,
Trent 1000-G2, Trent 1000-H2, Trent 1000-J2, Trent 1000-K2, and Trent
1000-L2 model turbofan engines. AD 2018-08-02 requires initial and
repetitive ultrasonic and visual inspections of the IPC stage 1 rotor
blades, IPC stage 2 rotor blades, and IPC shaft stage 2 dovetail posts,
and removal of any cracked parts from service. AD 2018-08-02 resulted
from IPC blade separations resulting in engine failures. The FAA issued
AD 2018-08-02 to prevent failure of the IPC.
Actions Since AD 2018-08-02 Was Issued
Since the FAA issued AD 2018-08-02, The European Union Aviation
Safety Agency (EASA), which is the Technical Agent for the Member
States of the European Community, has issued EASA AD 2019-0250, dated
October 9, 2019 (referred to after this as ``the MCAI''), to address
the unsafe condition on these products. The MCAI states:
Occurrences were reported on Rolls-Royce Trent 1000 `Pack C'
engines, where some IPC Rotor 1 and Rotor 2 blades were found
cracked.
This condition, if not detected and corrected, could lead to in-
flight blade release, possibly resulting in reduced control of the
aeroplane.
To address this potential unsafe condition, Rolls-Royce
initially issued Alert NMSB TRENT 1000 72-AJ814 and 72-AJ819 to
provide inspection instructions for IPC Rotor 1 blades, and IPC
Rotor 2 blades and IPC shaft Stage 2 dovetail posts, respectively.
Rolls-Royce also issued NMSB TRENT 1000 72-J871 to provide rework
instructions for the affected parts, and Alert NMSB TRENT 1000 72-
AJ869 to inspect those post-rework parts. Consequently, EASA issued
AD 2017-0248 to require repetitive inspections of the affected IPC
Rotor blades and IPC shaft Stage 2 dovetail posts and, depending on
findings, removal from service of the engine for corrective action.
After that [EASA] AD was issued, Rolls-Royce issued Alert NMSB
TRENT 1000 72-AK058 to provide instructions for a one-time on-wing
inspection. Consequently, EASA
[[Page 23927]]
issued AD 2018-0073, retaining the requirements of EASA AD 2017-
0248, which was superseded, to require an additional borescope
inspection of certain engines and, depending on findings, removal
from service of the engine for corrective action.
After that [EASA] AD was issued, it was determined that
repetitive borescope inspections are necessary on all engines to
ensure fleet-wide continued safe operation. Consequently, Rolls-
Royce revised Alert NMSB TRENT 1000 72-AJ869, Alert NMSB TRENT 1000
72-AJ814, Alert NMSB TRENT 1000 72-AJ819 and NMSB TRENT 1000 72-
J871, and issued NMSB TRENT 1000 72-AK060 to consolidate all
inspection instructions. Consequently, EASA issued AD 2018-0084
(later revised), retaining the requirements of EASA AD 2018-0073,
which was superseded, and requiring repetitive on-wing borescope
inspections of the affected Rotor 1 parts and affected Rotor 2 parts
and, depending on findings, removal from service of the engine for
corrective action. That [EASA] AD also introduced specific
requirements for engines installed on aeroplanes involved in ETOPS,
and inspection following operation in asymmetric power conditions.
Rolls-Royce then introduced NMSB Trent 1000 72-AK092 to provide
inspections for the rear face of the Rotor 2 blades and NMSB TRENT
1000 72-AK060 was revised (R1) accordingly. Later, Rolls-Royce
developed mod 72-J941, installing improved IPC Stage 1 and Stage 2
rotor blades, and issued the modification SB, providing the
necessary instructions for in-service application. EASA issued AD
2018-0084R2 to exclude post-mod 72-J941 engines from the
Applicability and introducing the modification SB as terminating
action for the repetitive inspections as required by that [EASA] AD.
Since that [EASA] AD was issued, Rolls-Royce issued the NMSB and
revised Alert NMSB TRENT 1000 72-AJ814, 72-AJ819 and 72-AK092 to
introduce new inspections, new thresholds and new intervals,
depending on engine configuration. These inspections are now
applicable for all operations, ETOPS and non-ETOPS. The latest
revision of the NMSB also amended the asymmetric power conditions
for engine inspection and introduced cabin depressurisation as an
event to trigger engine inspection(s).
For the reason described above, this [EASA] AD requires
introduction of the new inspections, replacing those previously
imposed by EASA AD 2018-0084R2 (through NMSB TRENT 1000 72-AK060),
and removes the references to Engine Health Monitoring messages and
ETOPS-related requirements.
You may obtain further information by examining the MCAI in the AD
docket on the internet at https://www.regulations.gov by searching for
and locating Docket No. FAA-2020-0009.
Related Service Information Under 1 CFR Part 51
The FAA reviewed Rolls-Royce plc (RR) Alert Non-Modification
Service Bulletin (NMSB) Trent 1000 72-AK313, Revision 1, dated August
22, 2019; and RR Service Bulletin (SB) Trent 1000 72-J941, Revision 1,
dated February 6, 2019, and Initial Issue, dated December 6, 2018. RR
Alert NMSB Trent 1000 72-AK313 defines the initial inspection threshold
and repeat inspection intervals for Trent 1000 IPC stage 1 blade, stage
2 blade, and IPC shaft stage 2 dovetail posts. RR SB Trent 1000 72-J941
describes procedures for modifying the engine by installing the
redesigned IPC stage 1 and stage 2 rotor blades. This service
information is reasonably available because the interested parties have
access to it through their normal course of business or by the means
identified in the ADDRESSES section.
Other Related Service Information
The FAA reviewed RR Alert NMSB Trent 1000 72-AJ819, Revision 4,
dated May 3, 2019; RR Alert NMSB Trent 1000 72-AJ814, Revision 5, dated
May 3, 2019; and RR Alert NMSB Trent 1000 72-AK092, Revision 4, dated
May 3, 2019. RR Alert NMSB Trent 1000 72-AJ819 describes procedures for
performing a visual borescope inspection of the IPC stage 2 rotor
blades and IPC shaft stage 2 dovetail posts. RR Alert NMSB Trent 1000
72-AJ814 describes procedures for performing an ultrasonic inspection
(USI) of the IPC stage 1 rotor blades. RR Alert NMSB Trent 1000 72-
AK092 describes procedures for performing a USI of the IPC stage 2
rotor blades.
FAA's Determination
The FAA is proposing this AD because we evaluated all the relevant
information and determined the unsafe condition described previously is
likely to exist or develop in other products of the same type design.
Proposed AD Requirements
This proposed AD would retain certain requirements of AD 2018-08-
02. This proposed AD would require initial and repetitive ultrasonic or
visual inspections, of the IPC stage 1 blade root (front face), IPC
stage 2 blade root (front and rear face), and IPC shaft stage 2
dovetail post (front face), and removal of any cracked parts from
service. This AD would also require an inspection after asymmetric
power and cabin depressurization events.
Costs of Compliance
The FAA estimates that this AD affects 7 engines installed on
airplanes of U.S. registry.
The FAA estimates the following costs to comply with this proposed
AD:
Estimated Costs
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Cost per Cost on U.S.
Action Labor cost Parts cost product operators
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Inspect the IPC stage 1 blade root 20 work-hours x $85 per $0 $1,700 $11,900
(Front Face). hour = $1,700.
Inspect the IPC stage 2 blade root 6 work-hours x $85 per 0 510 3,570
(Front Face) and IPC shaft stage 2 hour = $510.
dovetail post (Front Face).
Inspect the IPC stage 2 blade root 10 work-hours x $85 per 0 850 5,950
(Rear Face). hour = $850.
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The FAA estimates the following costs to do any necessary
replacements that would be required based on the results of the
proposed inspection. The FAA has no way of determining the number of
engines that might need these replacements.
On-Condition Costs
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Cost per
Action Labor cost Parts cost product
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Replace all 34 R1 Blades...................... 280 work-hours x $85 per hour = $52,360 $76,160
$23,800.
[[Page 23928]]
Replace all 49 R2 Blades...................... 280 work-hours x $85 per hour = 48,755 72,555
$23,800.
Replace IPC Drum.............................. 144 work-hours x $85 per hour = 1,370,000 1,382,240
$12,240.
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Authority for This Rulemaking
Title 49 of the United States Code specifies the FAA's authority to
issue rules on aviation safety. Subtitle I, Section 106, describes the
authority of the FAA Administrator. Subtitle VII, Aviation Programs,
describes in more detail the scope of the Agency's authority.
The FAA is issuing this rulemaking under the authority described in
Subtitle VII, Part A, Subpart III, Section 44701, ``General
requirements.'' Under that section, Congress charges the FAA with
promoting safe flight of civil aircraft in air commerce by prescribing
regulations for practices, methods, and procedures the Administrator
finds necessary for safety in air commerce. This regulation is within
the scope of that authority because it addresses an unsafe condition
that is likely to exist or develop on products identified in this
rulemaking action.
Regulatory Findings
The FAA has 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) Will not affect intrastate aviation in Alaska, and
(3) Will not have a significant economic impact, positive or
negative, on a substantial number of small entities under the criteria
of the Regulatory Flexibility Act.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
The Proposed Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA proposes to amend 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
0
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]
0
2. The FAA amends Sec. 39.13 by removing airworthiness directive (AD)
2018-08-02, Amendment 39-19255 (83 FR 17746, April 24, 2018), and
adding the following new AD:
Rolls-Royce Deutschland Ltd & Co KG (Type Certificate previously
held by Rolls-Royce plc): Docket No. FAA-2020-0009; Project
Identifier MCAI-2019-00111-E.
(a) Comments Due Date
The FAA must receive comments on this AD action by June 15,
2020.
(b) Affected ADs
This AD replaces AD 2018-08-02, Amendment 39-19255 (83 FR 17746,
April 24, 2018).
(c) Applicability
This AD applies to Rolls-Royce Deutschland Ltd & Co KG (Type
Certificate previously held by Rolls-Royce plc) Trent 1000-A2, Trent
1000-AE2, Trent 1000-C2, Trent 1000-CE2, Trent 1000-D2, Trent 1000-
E2, Trent 1000-G2, Trent 1000-H2, Trent 1000-J2, Trent 1000-K2, and
Trent 1000-L2 model turbofan engines, except those that have the
redesigned intermediate-pressure compressor (IPC) stage 1 and stage
2 rotor blades introduced by Rolls-Royce plc (RR) Service Bulletin
(SB) Trent 1000 72-J941, Revision 1, dated February 6, 2019.
(d) Subject
Joint Aircraft System Component (JASC) Code 7230, Turbine Engine
Compressor Section.
(e) Unsafe Condition
This AD was prompted by IPC blade separations resulting in
engine failures. Subsequently, the manufacturer identified cracking
of parts in-service resulting in the need to require new inspections
using new inspection thresholds and intervals. The manufacturer also
determined the need to add an optional terminating action, amend the
asymmetric power condition for engine inspection, and require an
inspection after a cabin depressurization event. The FAA is issuing
this AD to prevent failure of the IPC. The unsafe condition, if not
addressed, could result in failure of one or more engines, loss of
thrust control, and loss of the airplane.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Required Actions
(1) After the effective date of this AD, before exceeding the
initial inspection thresholds and repeat inspection intervals
specified in Table 1 of RR Alert Non-Modification Service Bulletin
(NMSB) Trent 1000 72-AK313, Revision 1, dated August 22, 2019 (``RR
NMSB Trent 1000 72-AK313, R1''):
(i) Perform initial ultrasonic inspections (USIs) of the IPC
stage 1 blade root (front face).
(ii) Thereafter, perform repetitive USIs of the IPC stage 1
blade root (front face).
(iii) Use the Accomplishment Instructions, paragraph 3.A.(1)(a)
(on-wing) or 3.A.(2)(a) and (b) (in-shop) of RR NMSB Trent 1000 72-
AK313, R1 to perform the inspections.
(2) After the effective date of this AD, before exceeding the
initial inspection thresholds and repeat inspection intervals
specified in Table 2 of RR NMSB Trent 1000 72-AK313, R1:
(i) Perform initial visual inspections of the IPC stage 2 blade
root (front face) and IPC shaft stage 2 dovetail post (front face).
(ii) Thereafter, perform repetitive visual inspections of the
IPC stage 2 blade root (front face) and IPC shaft stage 2 dovetail
post (front face).
(iii) Use the Accomplishment Instructions, paragraph 3.B.(1)(a)
(on-wing) or 3.B.(2)(b) (in-shop) of RR NMSB Trent 1000 72-AK313, R1
to perform the inspections.
(3) After the effective date of this AD, before exceeding the
initial inspection threshold and repeat inspection intervals
specified in Table 2 of RR NMSB Trent 1000 72-AK313, R1:
(i) Perform initial USIs of IPC stage 2 blade root (rear face).
(ii) Thereafter, perform repetitive USIs of IPC stage 2 blade
root (rear face).
(iii) Use the Accomplishment Instructions, paragraph 3.C.(1)(a)
(on-wing) or 3.C.(2)(a) (in-shop) of RR NMSB Trent 1000 72-AK313, R1
to perform the inspections.
(4) After the effective date of this AD, within 5 engine flight
cycles (FCs) after each occurrence in which any engine operates in
asymmetric power conditions at an altitude of less than 28,000 feet,
perform the following inspections on the engine not affected by the
power reduction or in-flight shutdown (IFSD):
(i) Perform initial USIs and visual inspections required by
paragraphs (g)(1), (2), and (3) of this AD.
(ii) Thereafter, perform the repetitive USIs and visual
inspections required by paragraphs (g)(1), (2), and (3) of this AD.
[[Page 23929]]
(iii) Use the service information and repetitive inspection
thresholds required by paragraphs (g)(1)(iii), (2)(iii), and
(3)(iii) to perform the inspections, as applicable.
(5) After the effective date of this AD, within 5 engine FCs
following a cabin depressurization event, perform the following
inspections on both engines installed on the airplane:
(i) Perform initial USIs and visual inspections required by
paragraphs (g)(1), (2), and (3) of this AD.
(ii) Thereafter, perform the repetitive USIs and visual
inspections required by paragraphs (g)(1), (2), and (3) of this AD.
(iii) Use the service information and repetitive inspection
thresholds required by paragraphs (g)(1)(iii), (2)(iii), and
(3)(iii) to perform the inspections, as applicable.
(6) If any IPC stage 1 blade root (front face), IPC stage 2
blade root (front face), IPC shaft stage 2 dovetail post (front
face), or IPC stage 2 blade root (rear face) is found cracked during
any inspection required by this AD, replace the part with a part
eligible for installation before further flight.
(h) Terminating Action (Optional)
Modification of an engine by installing the redesigned IPC stage
1 and stage 2 rotor blades, using RR SB Trent 1000 72-J941, Revision
1, dated February 6, 2019, or Initial Issue, dated December 6, 2018,
is the terminating action for the initial and repetitive ultrasonic
or visual inspection requirements, as applicable, of paragraph
(g)(1) through (5) of this AD for that engine.
(i) Definition
For the purpose of this AD, an ``asymmetric power condition'' is
the operation of the airplane at an altitude of less than 28,000
feet, experiencing either single engine take-off, engine fault
(reduced power on one engine), or single engine IFSD, which includes
execution of any non-normal checklist procedure.
(j) Credit for Previous Actions
You may take credit for the initial inspections required by
paragraphs (g)(1) through (5) of this AD if you performed these
inspections before the effective date of this AD using any of the
following.
(1) RR Alert NMSB Trent 1000 72-AJ819, Revision 3, dated April
13, 2018, or earlier revisions;
(2) RR NMSB Trent 1000 72-AJ814, Revision 4, dated September 28,
2018, or earlier revisions;
(3) RR Alert NMSB Trent 1000 72-AK313, Initial Issue, dated May
2, 2019; or
(4) RR Alert NMSB Trent 1000 72-AK092, Revision 3, dated
February 28, 2019 or earlier revisions.
(k) Special Flight Permit
Special flight permits, as described in Section 21.197 and
Section 21.199 of the Federal Aviation Regulations (14 CFR 21.197
and 21.199), are subject to the requirements of paragraph (k)(1) of
this AD.
(1) Operators who are prohibited from further flight due to a
crack finding as a result of paragraph (g) of this AD, may perform a
one-time non-revenue ferry flight to a location where the engine can
be removed from service. This ferry flight must be performed without
passengers, involve non-ETOPS operation, and consume no more than
three FCs.
(2) [Reserved]
(l) Alternative Methods of Compliance (AMOCs)
(1) The Manager, ECO Branch, FAA, has the authority to approve
AMOCs for this AD, if requested using the procedures found in 14 CFR
39.19. In accordance with 14 CFR 39.19, send your request to your
principal inspector or local Flight Standards District Office, as
appropriate. If sending information directly to the manager of the
certification office, send it to the attention of the person
identified in paragraph (m)(1) of this AD. You may email your
request to: [email protected].
(2) Before using any approved AMOC, notify your appropriate
principal inspector, or lacking a principal inspector, the manager
of the local flight standards district office/certificate holding
district office.
(m) Related Information
(1) For more information about this AD, contact Stephen Elwin,
Aerospace Engineer, ECO Branch, FAA, 1200 District Avenue,
Burlington, MA 01803; phone: 781-238-7236; fax: 781-238-7199; email:
[email protected].
(2) Refer to European Union Aviation Safety Agency (EASA) AD
2019-0250, dated October 9, 2019, for more information. You may
examine the EASA AD in the AD docket on the internet at https://www.regulations.gov by searching for and locating it in Docket No.
FAA-2020-0009.
(3) For service information identified in this AD, contact
Rolls-Royce Deutschland Ltd. & Co KG, Eschenweg 11, 15827
Blankenfelde-Mahlow, Germany; phone: +49 (0) 33 708 6 0; email:
https://www.rolls-royce.com/contact-us.aspx. You may view this
referenced service information at the FAA, Airworthiness Products
Section, Operational Safety Branch, 1200 District Avenue,
Burlington, MA, 01803. For information on the availability of this
material at the FAA, call 781-238-7759.
Issued on April 23, 2020.
Gaetano A. Sciortino,
Deputy Director for Strategic Initiatives, Compliance & Airworthiness
Division, Aircraft Certification Service.
[FR Doc. 2020-09009 Filed 4-29-20; 8:45 am]
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