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This document transmits Revision 3 to Service Bulletin TRENTXWB-72-AK188 Document History Service Bulletin Revision Status Supplement Revision Status Initial Issue Aug.13/19 Revision 1 Sep.20/19 Revision 2 Dec.17/19 Bulletin Revision 3 Remove Incorporate Reason for change All pages of the Service Bulletin Pages 1 to 23 of the Service Bulletin To update 1.C. Description,
2. Material Information and
3.B. Accomplishment Instructions All pages of Appendix 1 Page 1 and 2 of Appendix 1 To update 1.C. Description,
2. Material Information and
3.B. Accomplishment Instructions All pages of Appendix 2 Page 1 of Appendix 2 To update 1.C. Description,
2. Material Information and
3.B. Accomplishment Instructions Printed in Great Britain May. 9/22
TRENT XWB SERIES PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN ALERT TRENT XWB 72−AK188 Transmittal - Page 1 of 2 Date ALERT
LIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin following incorporation of Revision 3 are as follows:
Page Revision Number Revision Date Bulletin R 1 3 May 9/22 R 2 3 May 9/22 R 3 3 May 9/22 R 4 3 May 9/22 R 5 3 May 9/22 R 6 3 May 9/22 R 7 3 May 9/22 R 8 3 May 9/22 R 9 3 May 9/22 R 10 3 May 9/22 R 11 3 May 9/22 R 12 3 May 9/22 R 13 3 May 9/22 R 14 3 May 9/22 R 15 3 May 9/22 R 16 3 May 9/22 R 17 3 May 9/22 R 18 3 May 9/22 R 19 3 May 9/22 R 20 3 May 9/22 R 21 3 May 9/22 R 22 3 May 9/22 R 23 3 May 9/22 Appendix 1 R 1 3 May 9/22 R 2 3 May 9/22 Appendix 2 R 1 3 May 9/22 Printed in Great Britain TRENT XWB 72−AK188 Transmittal - Page 2
1. Planning Information A. Effectivity Airbus A350-900 All Trent XWB-75 Engines All Trent XWB-79 Engines All Trent XWB-79B Engines All Trent XWB-84 Engines B. Reason
(1) Problem The purpose of the engine mount is to position the engine relative to the aircraft pylon and to transfer all loads and rotational moments between engine and aircraft pylon.
The front Engine Mount Support Structure (EMSS) comprises of the LP Compressor Outlet Guide Vane (OGV) assembly and OGV Outer Mount Ring Assembly (CSN 72354601150).
Revised analysis of these parts when the Front Mount Catcher Lug is engaged in the failsafe condition has now been undertaken using more advanced modelling techniques. This gives a more comprehensive understanding of the loading and therefore stresses in the structure. This analysis predicts that once the Front Engine Mount is in the failsafe condition, the most highly stressed LP Compressor OGV (CSN 72354601500) has a life that could be substantially lower than one shop visit.
This Non-Modification Service Bulletin (NMSB) introduces an inspection to protect against the front engine mount entering the failsafe condition via a failure of the OGV Outer Mount Ring Assembly outer rail lug fillet.
(2) Safety Intent The safety intent of this Non-Modification Service Bulletin (NMSB) is to confirm that the OGV Outer Mount Ring Assembly lug fillet area is not cracked, to prevent any potential progression to failsafe operation when the life of the EMSS is predicted to be low and failure of the EMSS could occur.
ENGINE - RING, ASSY OGV OUTER MOUNT - FLUORESCENT PENETRANT INSPECTION OF THE MOUNT RING OUTER RAIL LUG FILLETS - NON-MODIFICATION SERVICE BULLETIN - MOD.72-AK188 Printed in Great Britain TRENT XWB 72−AK188 Page 1 of 23 Aug 13/19 May. 9/22R
TRENT XWB SERIES
SERVICE BULLETIN
C. Description This NMSB instructs the repeat inspection of the OGV Outer Mount Ring Assembly using a fluorescent penetrant technique (FPI).
Accomplishment of this NMSB 72-AK188R is to be recorded in accordance with local Service Bulletin tracking system procedures and a completed copy of Appendix 1 (or similar form) returned to your Rolls-Royce Representative upon completion of the inspection.
Revision 1 of this NMSB was issued to correct a cleaning procedure reference in
3.B In-Shop Accomplishment Instructions.
Revision 2 of this NMSB wasR issued to clarify the limits for redeposited material/blackspots in 3.A. and 3.B. Accomplishment Instructions and to clarify labelling of the fillets in Appendix 1.
Revision 3 of this NMSB is issued to increase the required inspection interval to align with an engine refurbishment shop visit (Level 3 or 4 on the HP system module) and remove the on-wing compliance.
R R R D. Compliance
(1) On-Wing Not applicableR
(2) In-Shop ALERT This Non-Modification Service Bulletin is subject to the incorporation requirements of an EASA Airworthiness Directive.
R R Carry out the inspection in accordance with 3. Accomplishment Instructions at every engine refurbishment shop visit (Level 3 or 4 on the HP system module).
R R R E. Approval The technical content of this Non-Modification Service Bulletin was approved under the authority of Design Organisation Approval EASA.21J.065 on Aug.12/19 and was re-approved Dec.17/19.
NMSB 72-AK188 was approved by Rolls-Royce on May. 5/22. The technical content of this document is approved under the authority of the DOA ref. EASA.21J.065.
R R Printed in Great Britain TRENT XWB 72−AK188 Page 2 Aug 13/19 May. 9/22R
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F. Manpower
(1) On-wing Not applicable.R
(2) In-shop
(a) Time to inspectR 2 hours (1 perso n * 2 hours) - EstimatedR The Fluorescent Penetrant Inspection (FPI) defined in this NMSB shall only be performed by personnel qualified to FPI level 2 or higher and in possession of up-to-date eyesight record in accordance with EN4179/NAS410 or alternative standards/guidelines accepted by the applicable National Aviation Authority.
R R R R R NOTE: The parts affected by this NMSB are accessible in-shop when carrying out a Level 1 or above workscope.
R R G. Material Price and Availability For Material price and availability contact your assigned Rolls-Royce Representative.
H. Tooling Price and Availability Part Description Quantity Fan case access ladders RRT081482 (or equivalent) 1 Dark Non-Reflective cover to darken the area for inspection No specific As necessary Battery powered Ultraviolet Light Source capable of providing a minimum UV radiation intensity of 1200 microwatts per square centimetre at the inspection surface.
No specific 1 Printed in Great Britain TRENT XWB 72−AK188 Page 3 Aug 13/19 May. 9/22R
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Battery powered White light source, capable of providing a minimum of 1000 Lux at the inspection surface No specific 1 Temporary stand/tripod for positioning inspection lights No specific 1 Calibrated light radiometer, containing both UV and visible sensor No specific 1 I. References
(1) Overhaul Process Manual (TSD594J):
(a) TASK 70-00-00-100-101 - Overhaul Process 101 - Non-Aqueous Vapour and Liquid Degreasing.
(b) TASK 70-00-00-200-210 - Overhaul Process 210 - Fluorescent Penetrant Inspection.
Printed in Great Britain TRENT XWB 72−AK188 Page 4 Aug 13/19 May. 9/22R
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2. Material Information A. Consumables, materials and expendables Name Quantity Remarks AMS2644 Type 1, Method D, Level 2 (1D2) compliant aerosol penetrant (Fluorescent, Post Emulsified, Medium Sensitivity) As necessary OMat 650 AMS2644 Type 1, Method D, Level 4 (1D4) compliant aerosol penetrant (Fluorescent, Post Emulsified, Ultra-high Sensitivity) As necessary OMat 652 AMS2644 Type 1, Method A, Level 3 (1A3) compliant aerosol penetrant (Fluorescent, water washable, High Sensitivity) As necessary OMat 632 AMS2644 Form D - Non-Aqueous Wet Developer
- Aerosol As necessary OMat 617 Acetone based solvent degreaser As necessary OMat 150 Solvent penetrant removerR As necessaryR OMat 616R Penetrant 1D2 test panel (TAM Panel) As necessary OMat 677 Penetrant 1D4 test panel (TAM Panel) As necessary OMat 677 Penetrant 1A3 test panel (TAM Panel) As necessary OMat 677 Absorbent Cloths, Lint Free As necessary OMat 2-101 Printed in Great Britain TRENT XWB 72−AK188 Page 5 Aug 13/19 May. 9/22R
TRENT XWB SERIES
SERVICE BULLETIN
Scotch-brite As necessary OMat 582 Scotch-brite As necessary OMat 583 Sponge type cotton buds As necessary No specific Disposable plastic nitrile gloves As necessary No specific Waterproof, Silicon Carbide As necessary OMat 5/36 Waterproof, Silicon Carbide As necessary OMat 5/32 Emery, Polishing Paper As necessary OMat 5/60 Emery, Polishing Paper As necessary OMat 5/54 Printed in Great Britain TRENT XWB 72−AK188 Page 6 Aug 13/19 May. 9/22R
TRENT XWB SERIES
SERVICE BULLETIN
3. Accomplishment Instructions A. On-wing Not applicable.R B. In-shop WARNING: BE CAREFUL WHEN YOU DO THIS PROCEDURE. OBEY THE EQUIPMENT MANUFACTURER'S HEALTH AND SAFETY INSTRUCTIONS AND YOUR LOCAL REGULATIONS. INJURY CAN OCCUR IF YOU DO NOT OBEY THESE INSTRUCTIONS.
WARNING: DO NOT OPERATE AN ULTRAVIOLET SOURCE IF IT DOES NOT HAVE A FILTER OR THE FILTER DOES NOT HAVE THE CORRECT FIT OR THE FILTER HAS A CRACK.
ULTRAVIOLET RADIATION THAT IS NOT FILTERED CAN CAUSE INJURY TO YOUR EYES AND SKIN.
WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER INSTRUCTIONS AND YOUR LOCAL REGULATIONS.
CAUTION: THE FLUORESCENT PENETRANT SHOULD BE ONLY APPLIED ON THE INSPECTION SURFACE. DO NOT LET THE FLUORESCENT PENETRANT GO INTO ANY LOCATION OTHER THAN THE INSPECTION SURFACE. IF THE FLUORESCENT PENETRANT GOES INTO ANY
LOCATION OTHER THAN THE INSPECTION SURFACE, STOP THE PROCEDURE AND CONTACT ROLLS-ROYCE FOR FURTHER INSTRUCTIONS.
CAUTION: THE USE OF HAND HELD AIR AND ELECTRICAL POWER TOOLS IS NOT PERMITTED.
CAUTION: MAKE SURE THAT ONLY PERSONS WHO ARE APPROVED BY THE APPLICABLE AUTHORITY DO THESE PROCEDURES. PERSONS WHO ARE NOT APPROVED CAN POSSIBLY GET AN INCORRECT RESULT, WHICH CAN SUBSEQUENTLY CAUSE COMPONENT FAILURE.
CAUTION: USE ONLY THE CONSUMABLE MATERIALS GIVEN IN THIS TASK. IF YOU DO NOT OBEY THIS INSTRUCTION, YOU CAN GET AN UNSATISFACTORY RESULT.
CAUTION: DO NOT LET THE FLUORESCENT PENETRANT REMOVER STAY ON THE SURFACE FOR MORE THAN THE SPECIFIED TIME. IF THE REMOVER STAYS ON THE SURFACE FOR MORE THAN THE SPECIFIED TIME, YOU CAN GET AN INCORRECT RESULT. THIS CAN SUBSEQUENTLY CAUSE COMPONENT FAILURE.
CAUTION: DO NOT USE A TEST PANEL TAM (PSM-5) THAT WAS USED WITH A FLUORESCENT PENETRANT WITH A DIFFERENT OMAT NUMBER. IF YOU DO, YOU CAN GET AN
INCORRECT RESULT AND THIS CAN SUBSEQUENTLY CAUSE COMPONENT FAILURE
(1) For the following Fluorescent Penetrant Inspection (FPI), use OMat 652 Penetrant where Penetrant is referred to and use OMat 677 Penetrant 1D4 test panel (TAM panel) where an OMat 677 Penetrant test panel is referred to unless otherwise instructed.
Printed in Great Britain TRENT XWB 72−AK188 Page 7 Aug 13/19 May. 9/22R
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(2) Prepare the Ring, Assy OGV Outer Mount outer rail fillets (72-35-46, 01-150), see Figures 1 to 5 for inspection area, for Fluorescent Penetrant Inspection in accordance with the following steps.
(a) Clean the inspection areas prior to FPI in accordance with the following steps, refer to TSD594J OP 101 Section 9. (Subtask 70-00-00-110-101-A03).
WARNING: IT IS THE RESPONSIBILITY OF THE OPERATOR TO OBTAIN AND
OBSERVE THE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS. THIS WILL CONTAIN INFORMATION SUCH AS,
HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS,
FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS
FOR SAFE HANDLING, USE, CONTROL MEASURES, ENVIRONMENTAL EFFECTS. IT IS ALSO THE OPERATOR'S RESPONSIBILITY TO TAKE LOCAL REGULATIONS INTO CONSIDERATION.
CAUTION: TO MAINTAIN THE CLEANLINESS OF THE WIPING SOLVENT, YOU MUST POUR THE SOLVENT ONTO THE WIPING CLOTH. THE CLOTH MUST NOT BE DIPPED INTO THE SOLVENT CONTAINER. IF YOU DO NOT OBEY
THIS INSTRUCTION, YOU CAN CAUSE CONTAMINATION OF THE SOLVENT IN THE CONTAINER.
NOTE: The inspection surface must be clean, dry and free from soils, oil, grease, paint, coatings, corrosion products, scale, smeared metal, welding flux, chemical residues or any other material that could prevent penetrant from entering a discontinuity and affect the process performance or produce unacceptable background.
(i) Apply OMat 150 Acetone based solvent degreaser to a clean OMat 2-101 Absorbent cloth, lint free.
(ii) Clean the inspection surfaces as shown in Figures 2-5 with a clean and moist OMat 2-101 Absorbent cloth, lint free.
(iii) Ensure that all contaminants have been removed. If necessary repeat the swabbing using fresh lint free cloth and solvent until the area is clean and free of soil and grease.
(iv) Allow 10 minutes for the area to be completely dry prior to penetrant application.
NOTE: You can use a clean lint free cloth to remove the unwanted solvent.
(v) Safely discard the used materials.
Printed in Great Britain TRENT XWB 72−AK188 Page 8 Aug 13/19 May. 9/22R
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(3) Visually examine the 4-off outer rail lug fillets on the Ring, Assy OGV Outer Mount in accordance with the following limits, refer to Figures 1-5.
DamageR LimitR ActionR CorrosionR R No permitted limitR R Reject the OGV outer mount ring assembly R R R DentsR One dent not more than
4.5 mm (0.177 in.) in diameter R R R R Repair, FRS3253 SPM TASK 70-42-11-300-001.
Dress diameter to depth aspect ratio 10:1 R R R R R Two or more dents not more than 4.5 mm (0.177 in.) in diameter and minimum distance between dents is more than 10.0 mm (0.394 in.)
R R R R R R R R Repair, FRS3253 SPM TASK 70-42-11-300-001.
Dress diameter to depth aspect ratio 10:1 R R R R R More than above permitted limits R R R Reject the OGV outer mount ring assembly R R R Nicks/scratchesR One nick/scratch not more than 0.6 mm (0.024 in.) in depth and not more than 9.0 mm (0.354 in.) in length R R R R R R Repair, FRS3253 SPM TASK 70-42-11-300-001.
Dress length and width to depth aspect ratio 10:1 R R R R R R Two or more nicks/scratches and not more than 0.6 mm (0.024 in.) in depth and not more than 9.0 mm (0.354 in.) in length, minimum distance between nicks/scratches is more than 10.0 mm (0.394 in.)
R R R R R R R R R R R Repair, FRS3253 SPM TASK 70-42-11-300-001.
Dress length and width to depth aspect ratio 10:1 R R R R R R More than above permitted limits R R R Reject the OGV outer mount ring assembly R R R Printed in Great Britain TRENT XWB 72−AK188 Page 9 Aug 13/19 May. 9/22R
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Fretting/gallingR One area of fretting/galling not more than 0.6 mm (0.024 in.) in depth and area not more than 6.5 mm
(0.256 in.) in width by
6.5 mm (0.256 in.) in length R R R R R R R R Repair, FRS3253 SPM TASK 70-42-11-300-001 R R Two or more areas of fretting/galling not more than 0.6 mm (0.024 in.) in depth and area not more than 6.5 mm
(0.256 in.) in width by
6.5 mm (0.256 in.) in length, minimum distance between fretting/galling is more than 10.0 mm
(0.394 in.)
R R R R R R R R R R R R R Repair, FRS3253 SPM TASK 70-42-11-300-001 R R R More than above permitted limits R R R Reject the OGV outer mount ring assembly R R R Table.1 Damage acceptance limitsR
(4) The local penetrant processing for this component must be performed in accordance with the following steps, refer to TSD 594J OP210 (TASK 70-00-00-200-210) - Fluorescent Penetrant Inspection.
(a) Cover the region of the engine with a dark non-reflective cover in order to reduce the white light levels.
(b) Prepare the portable Ultraviolet (UV) light source:
(i) Examine the portable UV light source to make sure that it is serviceable, then set the lamp to the ON position.
(ii) Let the lamp become warm for approximately 10 minutes so that it is in a stabilized condition.
NOTE: For LED UV lamps the stabilising time is declared by the manufacturer and it may not be necessary to wait 10 minutes R R Printed in Great Britain TRENT XWB 72−AK188 Page 10 Aug 13/19 May. 9/22R