83 FR 17746 - Airworthiness Directives; Rolls-Royce plc Turbofan Engines

DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration

Federal Register Volume 83, Issue 79 (April 24, 2018)

We are adopting a new airworthiness directive (AD) for all Rolls-Royce plc (RR) 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 turbofan engines. This AD requires initial and repetitive inspections of the intermediate-pressure compressor (IPC) stage 1 rotor blades, IPC stage 2 rotor blades, and IPC shaft stage 2 dovetail posts, and removing any cracked parts from service. This AD was prompted by IPC blade separations resulting in engine failures. We are issuing this AD to address the unsafe condition on these products.

[Federal Register Volume 83, Number 79 (Tuesday, April 24, 2018)]
[Rules and Regulations]
[Pages 17746-17749]
From the Federal Register Online  [www.thefederalregister.org]
[FR Doc No: 2018-08602]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2018-0314; Product Identifier 2018-NE-11-AD; Amendment 
39-19255; AD 2018-08-02]
RIN 2120-AA64


Airworthiness Directives; Rolls-Royce plc Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: We are adopting a new airworthiness directive (AD) for all 
Rolls-Royce plc (RR) 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 turbofan 
engines. This AD requires initial and repetitive inspections of the 
intermediate-pressure compressor (IPC) stage 1 rotor blades, IPC stage 
2 rotor blades, and IPC shaft stage 2 dovetail posts, and removing any 
cracked parts from service. This AD was prompted by IPC blade 
separations resulting in engine failures. We are issuing this AD to 
address the unsafe condition on these products.

DATES: This AD is effective April 24, 2018.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in this AD as of April 24, 
2018.
    We must receive comments on this AD by June 8, 2018.

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 http://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: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE, Washington, DC 20590, between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays.
    For service information identified in this final rule, contact 
Rolls-Royce plc, Corporate Communications, P.O. Box 31, Derby, England, 
DE24 8BJ; phone: 011-44-1332-242424; fax: 011-44-1332-249936; email: 
royce.com">corporate.care@rolls-royce.com. Internet: https://customers.rolls-royce.com/public/rollsroycecare. You may view this service information 
at the FAA, Engine & Propeller Standards Branch, 1200 District Avenue, 
Burlington, MA 01803. For information on the availability of this 
material at the FAA, call 781-238-7759. It is also available on the 
internet at http://www.regulations.gov by searching for and locating 
Docket No. FAA-2018-0314.

Examining the AD Docket

    You may examine the AD docket on the internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2018-
0314; 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 final rule, the mandatory continuing airworthiness information 
(MCAI), the regulatory evaluation, any comments received, and other 
information. The street address for Docket Operations (phone: 800-647-
5527) is listed above. Comments will be available in the AD docket 
shortly after receipt.

FOR FURTHER INFORMATION CONTACT: Kevin M. Clark, Aerospace Engineer, 
ECO Branch, FAA, 1200 District Avenue, Burlington, MA 01803; phone: 
781-238-7088; fax: 781-238-7199; email: [email protected].

[[Page 17747]]


SUPPLEMENTARY INFORMATION:

Discussion

    The European Aviation Safety Agency (EASA), which is the Technical 
Agent for the Member States of the European Community, has issued EASA 
AD 2018-0084, dated April 13, 2018 (referred to after this as the 
MCAI), to address an unsafe condition for the specified products. The 
MCAI states:

    Occurrences were reported on RR 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, RR 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. RR 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, prompted by further analysis, 
it was determined that, for certain engines, the front face of IPC 
Rotor 2 Blades and the dovetail posts of the IPC Shaft Stage 2 Rotor 
assembly needed to be inspected earlier. RR issued Alert NMSB TRENT 
1000 72-AK058 to provide instructions for a one-time on-wing 
inspection. Consequently, EASA 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.
    Since 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, RR 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 the NMSB to consolidate all inspection instructions.
    For the reason described above, this [EASA] AD retains the 
requirements of EASA AD 2018-0073, which is superseded, and requires 
repetitive on-wing borescope inspections of the affected Rotor 1 and 
Rotor 2 parts and, depending on findings, removal from service of 
the engine for corrective action. This [EASA] AD also introduces 
specific requirements for engines installed on aeroplanes involved 
in ETOPS, and inspection following operation in asymmetric power 
conditions.

    You may obtain further information by examining the MCAI in the AD 
docket on the internet at http://www.regulations.gov by searching for 
and locating Docket No. FAA-2018-0314.

Related Service Information Under 1 CFR Part 51

    We reviewed RR Alert Non-Modification Service Bulletin (NMSB) Trent 
1000 72-AJ819, Revision 2, dated April 12, 2018, and RR Alert NMSB 
Trent 1000 72-AK060, dated April 13, 2018. 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 NMSB Trent 1000 72-AK060 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. 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.

FAA's Determination

    This product has been approved by EASA and is approved for 
operation in the United States. Pursuant to our bilateral agreement 
with the European Community, EASA has notified us of the unsafe 
condition described in the MCAI and service information referenced 
above. We are issuing this AD because we evaluated all the relevant 
information provided by EASA and determined the unsafe condition 
described previously is likely to exist or develop in other products of 
the same type design.

AD Requirements

    This AD requires initial and repetitive inspections of the IPC 
stage 1 rotor blades, IPC stage 2 rotor blades, and IPC stage 2 shaft 
dovetail posts, and removing any cracked parts from service.

Interim Action

    We consider this AD interim action. RR is developing a modification 
which is expected to be terminating action for the repetitive 
inspections required by this AD.

FAA's Justification and Determination of the Effective Date

    An unsafe condition exists that requires the immediate adoption of 
this AD without providing an opportunity for public comments prior to 
adoption. The FAA has found that the risk to the flying public 
justifies waiving notice and comment prior to adoption of this rule 
because the compliance time for the action is less than the time 
required for public comment. The FAA has reviewed and agrees with 
EASA's determination that certain affected IPC rotor blades and 
dovetail posts must be inspected and, if needed, replaced with a part 
eligible for installation prior to further flight. Failure to inspect 
and replace these parts within the required compliance times could lead 
to failure of the IPC, failure of one or more engines, loss of thrust 
control, and loss of the airplane. Therefore, we find good cause that 
notice and opportunity for prior public comment are impracticable. In 
addition, for the reason stated above, we find that good cause exists 
for making this amendment effective in less than 30 days.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment. However, we invite you to send any written data, views, or 
arguments about this final rule. Send your comments to an address 
listed under the ADDRESSES section. Include the docket number FAA-2018-
0314 and Product Identifier 2018-NE-11-AD at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this final rule. We will 
consider all comments received by the closing date and may amend this 
final rule because of those comments.
    We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact we 
receive about this final rule.

Costs of Compliance

    We estimate that this AD affects 28 engines installed on airplanes 
of U.S. registry.
    We estimate the following costs to comply with this AD:

[[Page 17748]]



                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
Inspect IPC blade and dovetail post...  6 work-hours x $85 per                $0            $510         $14,280
                                         hour = $510.
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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.
    We are 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.
    This AD is issued in accordance with authority delegated by the 
Executive Director, Aircraft Certification Service, as authorized by 
FAA Order 8000.51C. In accordance with that order, issuance of ADs is 
normally a function of the Compliance and Airworthiness Division, but 
during this transition period, the Executive Director has delegated the 
authority to issue ADs applicable to engines, propellers, and 
associated appliances to the Manager, Engine and Propeller Standards 
Branch, Policy and Innovation Division.

Regulatory Findings

    This AD will not have federalism implications under Executive Order 
13132. This AD will 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 this AD:
    (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),
    (3) Will not affect intrastate aviation in Alaska, and
    (4) 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.

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 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 adding the following new airworthiness 
directive (AD):

2018-08-02 Rolls-Royce plc: Amendment 39-19255; Docket No. FAA-2018-
0314; Product Identifier 2018-NE-11-AD.

(a) Effective Date

    This AD is effective April 24, 2018.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to all Rolls-Royce plc (RR) 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 turbofan engines.

(d) Subject

    Joint Aircraft System Component (JASC) Code 7230, Turbine Engine 
Compressor Section.

(e) Unsafe Condition

    This AD was prompted by reports of intermediate-pressure 
compressor (IPC) rotor blade separations resulting in engine 
failures. We are 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) Inspect the IPC stage 1 rotor blades before exceeding the 
applicable initial inspection thresholds specified in Table 1 of RR 
Alert Non-Modification Service Bulletin (NMSB) Trent 1000 72-AK060, 
dated April 13, 2018, or within 80 flight cycles (FCs) after the 
effective date of this AD, whichever occurs later. If Direct 
Accumulation Count cycles, as specified in Table 1 of RR Alert NMSB 
Trent 1000 72-AK060, are not available, then use FCs, regardless of 
Engine Health Monitoring alerts. Thereafter at intervals not to 
exceed 200 FCs, repeat the inspection of the IPC stage 1 rotor 
blades. Use the Accomplishment Instructions, paragraph 3.A., of RR 
Alert NMSB Trent 1000 72-AK060, dated April 13, 2018 to perform the 
inspections.
    (2) Perform an initial inspection of the IPC stage 2 rotor 
blades and IPC shaft stage 2 dovetail posts, using the 
Accomplishment Instructions, paragraph 3.B., of RR Alert NMSB Trent 
1000 72-AK060, dated April 13, 2018. Perform the initial inspection 
based on engine operations as specified in the following paragraphs 
and within the following compliance times:
    (i) For engines with less than 300 FCs since new on the 
effective date of this AD:
    (A) For engines that are not operated on ETOPS (extended 
operations) flights, prior to exceeding 300 FCs or within 50 days 
after the effective date of this AD, whichever occurs later.
    (B) For engines that are operated on ETOPS flights, before 
exceeding 300 FCs or before the next ETOPS flight, whichever occurs 
later.
    (ii) For engines with 300 or more FCs since new on the effective 
date of this AD:
    (A) For engines that are not operated on ETOPS flights, prior to 
exceeding 50 days after the effective date of this AD or within 80 
FCs since the last inspection performed in accordance with RR Alert 
NMSB Trent 1000 72-AJ819, whichever occurs later. This inspection is 
not to exceed 200 FCs since the previous inspection.
    (B) For engines that are operated on ETOPS flights, before the 
next ETOPS flight, or within 80 FCs since the last inspection 
performed in accordance with RR Alert NMSB Trent 1000 72-AJ819, 
whichever occurs later.
    (3) Thereafter, at intervals not to exceed 80 FCs, repeat the 
inspections of the IPC stage 2 rotor blades and IPC shaft stage 2 
dovetail posts required by paragraph (g)(2) of this AD. Use the 
Accomplishment Instructions, paragraph 3.B., of RR Alert Trent 1000 
72-AK060, dated April 13, 2018, to perform these inspections.
    (4) For engines involved in ETOPS operations, inspect the rear 
face of IPC stage 2 rotor blades, part number KH25730, at each 
inspection interval defined in paragraph

[[Page 17749]]

(g)(3) of this AD in accordance with the Accomplishment 
Instructions, paragraph 3.C., of RR Alert Trent 1000 72-AK060, dated 
April 13, 2018.
    (5) As of the effective date of this AD, before the next flight 
after each occurrence where engine operation in asymmetric power 
conditions was sustained for more than 30 minutes at less than 
25,000 feet, either resulting from engine power reduction, or from 
engine in-flight shut-down (IFSD), perform an on-wing borescope 
inspection of the IPC stage 2 rotor blades and IPC shaft stage 2 
dovetail posts on the unaffected engine (no power reduction, no 
IFSD) installed on the airplane. Use the Accomplishment 
Instructions, either paragraph 3.B. for engines not involved in 
ETOPS operations, or paragraphs 3.B. and 3.C. for engines involved 
in ETOPS operations, of RR Alert NMSB Trent 1000 72-AK060, dated 
April 13, 2018, to perform this inspection.
    (6) If any IPC stage 1 rotor blade, IPC stage 2 rotor blade, or 
an IPC shaft stage 2 dovetail post is found cracked during any 
inspection required by this AD, replace the part with a part 
eligible for installation before further flight.

(h) Definitions

    For the purpose of this AD, flight cycles indicated in paragraph 
(g)(1) of this AD are those accumulated by the engine. FCs indicated 
in paragraph (g)(2) of this AD are those accumulated by each 
affected IPC stage 2 rotor blade since first installation on an 
engine. If FCs accumulated by an affected IPC stage 2 rotor blade 
are unknown, then engine FCs since new apply.

(i) Credit for Previous Actions

    (1) If you performed the initial inspections required by 
paragraph (g) of this AD before the effective date of this AD, using 
any of the following you met the initial inspection requirements of 
paragraph (g) of this AD; however, all of the repetitive actions 
still apply:
    (i) RR Alert NMSB Trent 1000 72-AJ814, Initial Issue, dated 
August 17, 2017, or Revision 1, dated September 26, 2017; or
    (ii) RR Alert NMSB Trent 1000 72-AK058, Initial Issue, dated 
March 30, 2018;
    (iii) RR NMSB Trent 1000 72-AJ819, Revision 1, October 9, 2017, 
or Initial Issue, dated August 17, 2017.
    (2) Reserved.

(j) Special Flight Permits

    (1) 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 (j)(1)(i) 
of this AD.
    (i) Operators who are prohibited from further flight due to an 
IPC stage 1 rotor blade, IPC stage 2 rotor blade, or an IPC shaft 
stage 2 dovetail post being found cracked, 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.
    (ii) Reserved.
    (2) Reserved.

(k) 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 (l)(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.

(l) Related Information

    (1) For more information about this AD, contact Kevin M. Clark, 
Aerospace Engineer, ECO Branch, FAA, 1200 District Avenue, 
Burlington, MA 01803; phone: 781-238-7088; fax: 781-238-7199; email: 
[email protected].
    (2) Refer to European Aviation Safety Agency (EASA) AD 2018-
0084, dated April 13, 2018, for more information. You may examine 
the EASA AD in the AD docket on the internet at http://www.regulations.gov by searching for and locating it in Docket No. 
FAA-2018-0314.

(m) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Rolls-Royce plc (RR) Alert Non-Modification Service Bulletin 
(NMSB) Trent 1000 72-AJ819, Revision 2, dated April 12, 2018.
    (ii) RR Alert NMSB Trent 1000 72-AK060, Initial Issue, dated 
April 13, 2018.
    (3) For RR service information identified in this AD, contact 
Rolls-Royce plc, Corporate Communications, P.O. Box 31, Derby, 
England, DE24 8BJ; phone: 011-44-1332-242424; fax: 011-44-1332-
249936; email: royce.com">corporate.care@rolls-royce.com; internet: https://customers.rolls-royce.com/public/rollsroycecare.
    (4) You may view this service information at FAA, Engine & 
Propeller Standards Branch, 1200 District Avenue, Burlington, MA. 
For information on the availability of this material at the FAA, 
call 781-238-7759.
    (5) You may view this service information that is incorporated 
by reference at the National Archives and Records Administration 
(NARA). For information on the availability of this material at 
NARA, call 202-741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued in Burlington, Massachusetts, on April 19, 2018.
Karen M. Grant,
Acting Manager, Engine and Propeller Standards Branch, Aircraft 
Certification Service.
[FR Doc. 2018-08602 Filed 4-20-18; 11:15 am]
BILLING CODE 4910-13-P