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This document transmits Revision 1 to Service Bulletin TRENT1000-72-AK451 Document History Service Bulletin Revision Status Supplement Revision Status Initial Issue Nov.14/19 Bulletin Revision 1 Remove Incorporate Reason for change Pages 1 to 21 of the Service Bulletin Pages 1 to 22 of the Service Bulletin To update 1.A. Effectivity,
1.C. Description, 1.D.
Compliance, 1.E. Approval,
1.H. Tooling Price and Availability, 1.I.
References, 3.
Accomplishment Instructions and Appendix 2.
All pages of Appendix 1 Page 1 and 2 of Appendix 1 To update 1.A. Effectivity,
1.C. Description, 1.D.
Compliance, 1.E. Approval,
1.H. Tooling Price and Availability, 1.I.
References, 3.
Accomplishment Instructions and Appendix 2.
Printed in Great Britain Jul.15/21 TRENT 1000 SERIES PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN ALERT TRENT 1000 72−AK451 Transmittal - Page 1 of 3 Date ALERT
CHECK THAT ALL PREVIOUS TRANSMITTALS HAVE BEEN INCORPORATED If any have not been received please advise Customer Data Services, Rolls-Royce plc, Derby, England ©Rolls-Royce plc (date as above) Printed in Great Britain
All pages of Appendix 2 Page 1 of Appendix 2 To update 1.A. Effectivity,
1.C. Description, 1.D.
Compliance, 1.E. Approval,
1.H. Tooling Price and Availability, 1.I.
References, 3.
Accomplishment Instructions and Appendix 2.
Printed in Great Britain TRENT 1000 72−AK451 Transmittal - Page 2
LIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin following incorporation of Revision 1 are as follows:
Page Revision Number Revision Date Bulletin R 1 1 Jul.15/21 R 2 1 Jul.15/21 R 3 1 Jul.15/21 R 4 1 Jul.15/21 R 5 1 Jul.15/21 R 6 1 Jul.15/21 R 7 1 Jul.15/21 R 8 1 Jul.15/21 R 9 1 Jul.15/21 R 10 1 Jul.15/21 R 11 1 Jul.15/21 R 12 1 Jul.15/21 R 13 1 Jul.15/21 R 14 1 Jul.15/21 R 15 1 Jul.15/21 R 16 1 Jul.15/21 R 17 1 Jul.15/21 R 18 1 Jul.15/21 R 19 1 Jul.15/21 R 20 1 Jul.15/21 R 21 1 Jul.15/21 R 22 1 Jul.15/21 Appendix 1 R 1 1 Jul.15/21 R 2 1 Jul.15/21 Appendix 2 R 1 1 Jul.15/21 Printed in Great Britain TRENT 1000 72−AK451 Transmittal - Page 3
1. Planning Information A. Effectivity
(1) BOEING 787 AllR TRENT 1000-AE3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-CE3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-D3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-G3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-H3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-J3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-K3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-L3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-M3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-N3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-P3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-Q3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R AllR TRENT 1000-R3 Engines not incorporating Rolls-Royce Service Bulletin 72-K571.
R R
ENGINE - IP COMPRESSOR (IPC) SHAFT - BORESCOPE INSPECTION OF THE FRONT AIR SEAL - NON-MODIFICATION SERVICE BULLETIN - MOD.72-AK451 Printed in Great Britain TRENT 1000 72−AK451 Page 1 of 22 Nov 14/19 Jul.15/21R TRENT 1000 SERIES
SERVICE BULLETIN
(2) AIRBUS A330 AllR TRENT 7000-72 Engines not incorporating Rolls-Royce Service Bulletin 72-K570.
R R AllR TRENT 7000-72C Engines not incorporating Rolls-Royce Service Bulletin 72-K570.
R R B. Reason
(1) Problem Cracking of the front air seal on IP Compressor (IPC) shaft assembly (72-32-31, 01-450, Part Number KH18436) has been identified during strip of a flight test vehicle. Subsequent inspections have identified two further examples of cracked front air seal on in-service engines. These cracks could propagate and have the potential to lead to in-flight events.
(2) Safety Intent The safety intent of this Non-Modification Service Bulletin (NMSB) is to identify and remove cracked components from service which, if not accomplished, could lead to high energy debris release and a potentially hazardous condition.
C. Description This NMSB instructs the procedures for the initial inspection and repeats of an in-situ borescope inspection of the IP Compressor shaft assembly (72-32-31, 01-450, Part Number KH18436) at a specific area between the fourth (rearmost) seal fin of the IP Compressor Shaft Assembly front air seal and the IP Compressor Stage 1 disc. This inspection procedure uses a standard 4mm borescope accessing the IP Compressor Stage 1 area through the Engine Section Stator (ESS) vanes. This inspection can be performed in shop and on-wing. Where intervals allow, this inspection can be performed on-wing concurrently with:
BOEING 787 aircraft: AMM Task DMC-B787-A-R72-00-00-46A-280C-A, IP Compressor Stag e 1 - Front Surface of the Blade Root Dovetail and Rotor Disc Post (With a Borescope).
AIRBUS A330 aircraft: AMM TASK 72-00-00-290-848-A,R Special Detailed Inspection of the Intermediate Pressure Compressor Stag e 1 - Front Surface of the Blade Root Dovetail and Rotor Disc Post (with a Borescope).
In both cases, access can alternatively be gained using the method described in the applicable AMM Task.
Accomplishment of this NMSB should be recorded in accordance with local NMSB tracking system procedures. A copy of the completed Appendix 1 or a similar form should be used to capture results along with photographic/video recording.
Printed in Great Britain TRENT 1000 72−AK451 Page 2 Nov 14/19 Jul.15/21R TRENT 1000 SERIES
SERVICE BULLETIN
Revision 1 of this NMSB introduces an additional method of in-shop compliance, various typographical improvements and amends the effectivity to Trent 1000 engines not incorporating SB 72-K571 and Trent 7000 engines not incorporating SB 72-K570.
R R R R D. Compliance This Non-Modification Service Bulletin is anticipated to be the subject of an EASA Airworthiness Directive.
This Non-Modification Service Bulletin is the subject of EASA Airworthiness Directive 2019-0282 and FAA Airworthiness Directive 2020-20-07. It is anticipated that these will be up-issued following this revision.
R R R
(1) IN-SHOP ALERT
(a) Inspect the IP Compressor Shaft Assembly in accordance with Section
3.A Accomplishment Instructions at engine shop visit, including those engines currently in-shop at time of issue of this NMSB.
NOTE : A shop visit is defined as the time from engine removal from wing for the purpose of a visit to a Maintenance, Repair & Overhaul (MRO) facility until the time of dispatch of the engine(s) from the MRO facility to the operator. Any engine that is in such condition at the date of issue of this NMSB is considered to be In-shop.
(b) A previous accomplishment of Service Bulletin 72-K452, Service Bulletin 72-K618 R R or Technical Variance TV207889 may be considered as an acceptable means of compliance for the inspection set by Section
1.D.(1)(a).
(2) ON-WING ALERT
(a) Inspect the IP Compressor Shaft Assembly in accordance with Section
3.B Accomplishment Instructions as per the following schedule:
(i) Initial inspection to be completed before 500 cycles (IP Compressor Shaft Assembly cycles since new) or within 100 cycles of initialR issue date of this NMSB, whichever is later.
(ii) Repeat inspections to be completed at intervals not exceeding 200 cycles.
Printed in Great Britain TRENT 1000 72−AK451 Page 3 Nov 14/19 Jul.15/21R TRENT 1000 SERIES
SERVICE BULLETIN
(b) For IP Compressor Shaft Assemblies of greater than 700 cycles (IP Compressor Shaft Assembly cycles since new) at time of initialR issue of this NMSB, inspect the IP Compressor Shaft Assembly in accordance with Section 3.B Accomplishment Instructions as follows:
(i) Initial inspection to be completed within 50 cycles from initialR issue of this NMSB.
(ii) Repeat inspection to be completed at intervals not exceeding 200 cycles.
(c) For IP Compressor Shaft Assemblies of greater than 1000 cycles (IP Compressor Shaft Assembly cycles since new) at time of initialR issue of this NMSB, inspect the IP Compressor Shaft Assembly in accordance with Section 3.B Accomplishment Instructions as follows:
(i) Initial inspection to be completed within 25 cycles from initialR issue of this NMSB or before 1st December 2019, whichever is sooner.
(ii) Repeat inspection to be completed at intervals not exceeding 200 cycles.
(d) A previous accomplishment of Service Bulletin 72-K452, Service Bulletin 72-K618 R R or Technical Variance TV207889 In-shop or On-wing may be considered as an acceptable means of compliance for the initial inspection set by paragraphs (a)(i), (b)(i) or (c)(i) of Section
1.D.(2).
(e) Accomplishment of this NMSB In-shop (Section 1.D.(1)) may be considered as an acceptable means of compliance for the initial or repeat inspection set by paragraphs (a)(i)/(ii), (b)(i)/(ii) or
(c)(i)/(ii) of Section 1.D.(2).
NOTE : Accomplishment of this NMSB In-shop before 300 cycles (IP Compressor Shaft Assembly cycles since new) may be taken as an additional one-time inspection. An additional initial inspection as per Section 1.D.(2).(a) is required to initiate the repeat inspection regime.
E. Approval NMSB 72-AK451 was approved by Rolls-Royce on Jul. 2/21.R The technical content of this documentR is approved under the authority of the DOA ref. EASA.21J.065.
Printed in Great Britain TRENT 1000 72−AK451 Page 4 Nov 14/19 Jul.15/21R TRENT 1000 SERIES
SERVICE BULLETIN
F. Manpower
(1) In-Shop
(a) Time to gain access 30 minutes (2 persons) - Estimated
(b) Time to inspect 45 minutes (2 persons) - Estimated
(c) Time to restore to serviceable condition 30 minutes (2 persons) - Estimated
(2) On-Wing
(a) Time to gain access 30 minutes (2 persons) - Estimated
(b) Time to inspect 45 minutes (2 persons) - Estimated
(c) Time to restore to serviceable condition 30 minutes (2 persons) - Estimated G. Material Price and Availability Not applicable.
H. Tooling Price and Availability
(1) Flexible video-capable borescope, with a forward-view 0.157in (4 mm) diameter lens (STD-7028)
(2) Immobiliser - LP Compressor (HU44525-1/SPL-8907)
(3) Inlet Protective Mat (HU55142-1/SPL-9039)
(4) Engine Fan Cover (98K1010H005-000/SPL-8837)
(5) Engine Exhaust Cover (98K1010H006-000/SPL-8836)
(6) Rotor 1 Borescope Guide Tube (RRT108139/SPL-16443) or locally sourced borescope guide tube - OPTIONAL
(7) OMat 150 (Acetone) or OMat 1/40 (Isopropyl Alcohol) - OPTIONAL Printed in Great Britain TRENT 1000 72−AK451 Page 5 Nov 14/19 Jul.15/21R TRENT 1000 SERIES
SERVICE BULLETIN
(8) OMat 582 (Ultrafine Scotch Brite) - OPTIONAL
(9) Delivery tube for OMat 150 (Acetone) or OMat 1/40 (Isopropyl Alcohol) -
OPTIONAL
(10) Adhesive tape (OMat 283 or OMat 256) - OPTIONAL
(11) IP Turning Tool - (Trent 1000 - SPL-7771/RRT042712 or Trent 7000 - RRT095945) R R
(12) Syringe (locally sourced) - OPTIONALR I. References
(1) Aircraft Maintenance Manual (AMM):
(a) BOEING 787
(i) DMC-B787-A-R72-00-00-46A-280C-A, Intermediate Pressure Compressor Stag e 1 - Front Surface of the Blade Root Dovetail and Rotor Disc Post (with a Borescope) - Special Detailed Inspection
(ii) DMC-B787-A-R72-00-00-01A-950A-A, Turn the Intermediate Pressure System - Standard Practices
(b) AIRBUS A330
(i) AMM TASK 72-00-00-290-848-A,R Special Detailed Inspection of the Intermediate Pressure Compressor Stag e 1 - Front Surface of the Blade Root Dovetail and Rotor Disc Post (with a Borescope)
(ii) AMM TASK 72-00-00-910-801-A, Turn the Intermediate Pressure System - Standard Practices
(2) Rolls-Royce Non-Modification Service Bulletins:R
(a) 72-K452
(i) ENGINE - IP COMPRESSOR (IPC) SHAFT BORESCOPE INSPECTION OF THE
FRONT AIR SEAL - NON-MODIFICATION SERVICE BULLETIN R R
(b) 72-K618R
(i) ENGINE - INTERMEDIATE PRESSURE COMPRESSOR SHAFT FRONT SEAL -
FLUORESCENT PENETRANT INSPECTION - NON-MODIFICATION SERVICE
BULLETIN R R R Printed in Great Britain TRENT 1000 72−AK451 Page 6 Nov 14/19 Jul.15/21R TRENT 1000 SERIES
SERVICE BULLETIN
(3) Technical Variance (TV):R
(a) TV207889R
(i) INSPECTION OF IPC DRUM FRONT SEAL AND IPC DISC STAGE 1 FOR
POTENTIAL CRACKING R R
(4) Airworthiness Directives:R
(a) European Union Aviation Safety Agency (EASA)R
(i) 2019-0282, ATA 72 - Engine - Intermediate Pressure Compressor Shaft Assembly - Inspection R R
(b) Federal Aviation Authority (FAA)R
(i) 2020-20-07, Rolls-Royce Deutschland Ltd and Co KG (Type Certificate previously held by Rolls-Royce plc): Amendment 39-21263; Docket No. FAA-2020-0293; Project Identifier MCAI-2019-00122-E.
R R R R
(5) Rolls-Royce Service Bulletins:R
(a) 72-K570R
ENGINE - IP COMPRESSOR SHAFT - INTRODUCTION OF AN IP COMPRESSOR STAGES 1 TO 8 ROTOR SHAFT ASSEMBLY FEATURING REVISED FRONT SEAL GEOMETRY R R
(b) 72-K571R
ENGINE - IP COMPRESSOR SHAFT - INTRODUCTION OF AN IP COMPRESSOR STAGES 1 TO 8 ROTOR SHAFT ASSEMBLY FEATURING REVISED FRONT SEAL GEOMETRY R R Printed in Great Britain TRENT 1000 72−AK451 Page 7 Nov 14/19 Jul.15/21R TRENT 1000 SERIES
SERVICE BULLETIN
2. Material Information None Printed in Great Britain TRENT 1000 72−AK451 Page 8 Nov 14/19 Jul.15/21R TRENT 1000 SERIES
SERVICE BULLETIN
3. Accomplishment Instructions A. In-Shop
(1) Use the borescope equipment to do a visual inspection of the front air seal of the IP Compressor Shaft Assembly (72-32-31, 01-450).
(a) Assemble the applicable flexible video-capable borescope.
(b) If using a borescope guide tube:
(i) Carefully put the guide tube between the LP Compressor blades, through the ESS vanes and stop just before the cavity in front of the IP Compressor Stage 1 blades. Refer to Fig.1.
It is recommended that access is gained at Top Dead Centre (TDC) to facilitate the borescope positioning into the engine.
The Variable Inlet Guide Vanes (VIGV) can prevent access from the front of the engine. If the VIGV do prevent access, manually actuate the VIGV mechanism until a clear path to the IP Compressor Stage 1 blades is seen from the front of the engine.
(ii) Attach the borescope guide tube to the engine with adhesive tape (OMat 283 or OMat 256).R
(iii) Carefully put the borescope through the borescope guide tube, until the borescope tip is into the cavity in front of the IP Compressor Stage 1 blades. Refer to Fig.1.
(c) If not using a borescope guide tube:
(i) Carefully put the borescope between the LP Compressor blades, through the ESS vanes and into the cavity in front of the IP Compressor Stage 1 blades. Refer to Fig.1.
It is recommended that access is gained at Top Dead Centre (TDC) to facilitate the borescope positioning into the engine.
The Variable Inlet Guide Vanes (VIGV) can prevent access from the front of the engine. If the VIGV do prevent access, manually actuate the VIGV mechanism until a clear path to the IP Compressor Stage 1 blades is seen from the front of the engine.
Printed in Great Britain TRENT 1000 72−AK451 Page 9 Nov 14/19 Jul.15/21R TRENT 1000 SERIES