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This document transmits the Initial Issue of Service Bulletin TRENT1000-72-K132 Bulletin Initial Issue Remove Incorporate Reason for change Pages 1 to 40 of the Service Bulletin Initial Issue Page 1 and 2 of Appendix 1 Initial Issue Page 1 and 2 of Appendix 2 Initial Issue Page 1 and 2 of Appendix 3 Initial Issue Page 1 and 2 of Appendix 4 Initial Issue Printed in Great Britain Jun.29/18 TRENT 1000 SERIES PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN TRENT 1000 72−K132 Transmittal - Page 1 of 3 Date
LIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin are as follows:
Page Revision Number Revision Date Bulletin 1 Jun.29/18 2 Jun.29/18 3 Jun.29/18 4 Jun.29/18 5 Jun.29/18 6 Jun.29/18 7 Jun.29/18 8 Jun.29/18 9 Jun.29/18 10 Jun.29/18 11 Jun.29/18 12 Jun.29/18 13 Jun.29/18 14 Jun.29/18 15 Jun.29/18 16 Jun.29/18 17 Jun.29/18 18 Jun.29/18 19 Jun.29/18 20 Jun.29/18 21 Jun.29/18 22 Jun.29/18 23 Jun.29/18 24 Jun.29/18 25 Jun.29/18 26 Jun.29/18 27 Jun.29/18 28 Jun.29/18 29 Jun.29/18 30 Jun.29/18 31 Jun.29/18 32 Jun.29/18 33 Jun.29/18 34 Jun.29/18 35 Jun.29/18 36 Jun.29/18 37 Jun.29/18 38 Jun.29/18 39 Jun.29/18 40 Jun.29/18 Appendix 1 1 Jun.29/18 2 Jun.29/18 Printed in Great Britain TRENT 1000 72−K132 Transmittal - Page 2
Appendix 2 1 Jun.29/18 2 Jun.29/18 Appendix 3 1 Jun.29/18 2 Jun.29/18 Appendix 4 1 Jun.29/18 2 Jun.29/18 Printed in Great Britain TRENT 1000 72−K132 Transmittal - Page 3
1. Planning Information A. Effectivity Boeing 787 TRENT1000-A/01 All Engines TRENT1000-A/01A All Engines TRENT1000-AE All Engines TRENT1000-AE/01A All Engines TRENT1000-C/01 All Engines TRENT1000-C/01A All Engines TRENT1000-CE All Engines TRENT1000-CE/01A All Engines TRENT1000-D/01 All Engines TRENT1000-D/01A All Engines TRENT1000-E/01 All Engines TRENT1000-E/01A All Engines TRENT1000-G/01 All Engines TRENT1000-G/01A All Engines TRENT1000-H/01 All Engines TRENT1000-H/01A All Engines Trent1000 IP Compressor Modules B. Reason It has been identified that there is a requirement to replace Intermediate Pressure (IP) compressor stage 1 rotor blades (FW61601 or KH16052) and/or stage 2 rotor blades (FW61602 or KH16053) and/or the IP compressor drum (FW75680) on the Trent 1000 Package B engines using a cost-effective method.
ENGINE COMPONENT - REPLACEMENT OF THE IP COMPRESSOR ROTOR STAGE 1 BLADES AND/OR STAGE 2 BLADES AND/OR IPC ROTOR - NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-K132 Printed in Great Britain TRENT 1000 72−K132 Page 1 of 40 Jun.29/18 Jun.29/18 TRENT 1000 SERIES
SERVICE BULLETIN
C. Description This Non-Modification Service Bulletin (NMSB) instructs the restoration to a serviceable condition of engines or modules which require IP compressor stage 1 rotor and/or IP compressor stage 2 rotor blades to be replaced. Engines/IPC modules embodied with NMSB 72-K132 will be subjected to inspection requirements as detailed in NMSB 72-AK130.
The Initial Issue of this NMSB will only cover the accomplishment of 2 workscope options:
Part B - The replacement of up to a maximum of 6 IP compressor stage 1 rotor blades and/or up to 6 IP compressor stage 2 rotor blades with new or serviceable used material (SUM) with the 02 module removed from the core engine.
Part C - To replace all IP compressor stage 1 rotor blades and all IP compressor stage 2 rotor blades with new.
Subsequent revisions to this NMSB will include additional blade replacement workscopes including replacing the IP Compressor Rotor Shaft.
D. Compliance The on-wing inspection requirements as detailed in NMSB 72-AK130 is anticipated to be the subject of an Airworthiness Directive. Therefore, when recording compliance to NMSB 72-K132 in the engine/module log book the Revision Number of this NMSB must be recorded along with which Part of this NMSB was accomplished.
(1) ON-WING Not Applicable
(2) IN-SHOP
OPTIONAL
(a) To replace up to a maximum of 6 IP compressor stage 1 rotor blades and/or up to 6 IP compressor stage 2 rotor blades with new or SUM with the 02 module removed from the core engine, carry out accomplishment instructions in accordance with 3.B. Accomplishment Instructions.
(b) To replace all IP compressor stage 1 rotor blades and all IP compressor stage 2 rotor blades with new, carry out accomplishment instructions in accordance with 3.C. Accomplishment Instructions.
E. Approval The technical content of this Non-Modification Service Bulletin was approved under the authority of Design Organisation Approval EASA.21J.035 on Jun.28/18.
Printed in Great Britain TRENT 1000 72−K132 Page 2 Jun.29/18 Jun.29/18 TRENT 1000 SERIES
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F. Manpower
(1) On-wing Not applicable
(2) In-shop Accomplishment Instructions
(a) 3.A. Accomplishment Instructions - Reserved for Future Use
(b) 3.B Accomplishment Instructions
(i) Time to gain access:
5 Days (4 persons)
(ii) Time to inspect and refurbish parts:
8 Days (2 persons)
(iii) Time to restore to a serviceable condition:
5 Days (4 persons)
(c) 3.C Accomplishment Instructions
(i) Time to gain access:
5 Days (4 persons)
(ii) Time to inspect and refurbish parts:
5 Days (2 persons)
(iii) Time to restore to a serviceable condition:
10 Days (4 persons)
(d) 3.D Accomplishment Instructions - Reserved for future use.
(e) 3.E Accomplishment Instructions - Reserved for future use.
(f) 3.F Accomplishment Instructions - Reserved for future use.
NOTE: The parts affected by this Non-Modification Service Bulletin are accessible in-shop only.
Printed in Great Britain TRENT 1000 72−K132 Page 3 Jun.29/18 Jun.29/18 TRENT 1000 SERIES
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G. Material Price and Availability Prices are available on request.
H. Tooling Price and Availability Special tools are not required I. References
(1) Repeat Technical Variances
(a) RTV180888 - ADVANCE ISSUE OF RMR128586
(b) RTV183155 - Install the IP Compressor Module (Gantry Method TTL Tooling Series)
(c) RTV183187 - Install the LP Compressor Module and LP Compressor Retention Shaft (Gantry Method TTL Tooling Series).
(2) Engine Manual (EM):
(a) EM Task, 72-32-00-020-802, Remove the Air/Oil Seal Tube from the IP Compressor Module
(b) EM Task, 72-32-00-030-801, Disassemble the IP Compressor Module
(c) EM Task, 72-32-00-420-801, Install the Air and Oil Guide Tubes in the IP Compressor Module
(d) EM Task, 72-32-20-030-801, Case and Rotor Disassembly
(e) EM Task, 72-32-30-040-801, Disassemble the IP Compressor Rotor Assembly
(f) EM Task, 72-32-30-440-801, Assemble the IP Compressor Rotor Assembly
(g) EM Task, 75-31-11-050-801, Remove the VSV Actuators from the IP Compressor Module
(3) Source Controlled Repairs:
(a) Clean, Inspection and Repair Manual, 72-32-32-300-032, Intermediate Pressure (IP) Compressor Stage 1 Blades - Re-Shot Peen the Blade Root (FRSB775).
(b) Engine Manual, 72-32-32-300-033, Intermediate Pressure (IP) Compressor Stage 2 Blades - Re-Shot Peen the Blade Root (FRSB776).
(c) Check and Rectify Manual, 72-32-00-300-003, Intermediate Pressure (IP) Compressor Stage 1 and Stage 2 Blades - Machine the Blades (FRSB777).
Printed in Great Britain TRENT 1000 72−K132 Page 4 Jun.29/18 Jun.29/18 TRENT 1000 SERIES
SERVICE BULLETIN
(4) Non-Source Controlled Repairs:
(a) Clean, Inspection and Repair Manual, 72-32-32-300-001, Intermediate Pressure (IP) Compressor Blades Stages 1 to 6 - Re-apply the Dry Film Lubricant (FRSB368).
(5) Clean, Inspection and Repair (CIR) Manual:
(a) CIR Task, 72-32-32, Clean, Inspect and Repair the Compressor Blades.
(b) CIR Task, 72-32-32-100-801, Clean the Stage 1 Rotor Blade
(c) CIR Task, 72-32-32-100-802, Clean the Stage 2 thru Stage 6 Rotor Blades
(d) CIR Task, 72-32-32-200-801, Examine the Stage 1 Rotor Blade
(e) CIR Task, 72-32-32-200-802, Examine the Stage 2 to Stage 6 Rotor Blades
(6) Check and Rectify Manual (CRM):
(a) CRM Task, 72-32-00-200-801, Examine the IP Compressor Cases, Rotor Assembly and Front Bearing Housing
(7) Overhaul Process Manual TSD594-J:
(a) Task, 70-00-00-100-108, Overhaul Process 108 - Stripping of Silicone Rubbers
(b) Task, 70-00-00-100-148, Overhaul Process 148 - Swab Etch
(c) Task, 70-00-00-200-210, Overhaul Process 210 - Fluorescent Penetrant Inspection
(d) Task, 70-00-00-200-224, Overhaul Process 224 - Assessment of Surface Features using Rubber Replica Material
(e) Task, 70-00-00-300-363, Overhaul Process 363 - Marking Methods
(8) Standard Practices Manual (SPM):
(a) Task, 70-31-00-200-000, Inspection of Parts
(9) TSD7019, Authorised Repair Vendor Directory
(10) Rolls-Royce Non Modification Service Bulletin (NMSB):
(a) NMSB 72-AK130 - IP Compressor Stage 1 Blades, Stage 2 Blades and IPC Shaft Stage 2 Dovetailposts - Inspection Interval Definition Printed in Great Britain TRENT 1000 72−K132 Page 5 Jun.29/18 Jun.29/18 TRENT 1000 SERIES
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(b) NMSB 72-J871 - Replacement of the IP Compressor Rotor Stage 1 Blades and/or Stage 2 Blades and/or IPC Rotor.
Printed in Great Britain TRENT 1000 72−K132 Page 6 Jun.29/18 Jun.29/18 TRENT 1000 SERIES
SERVICE BULLETIN
2. Material Information A. The parts required to accomplish this Non-Modification Service Bulletin:
Consumable Materials OMat PART NO. DESCRIPTION OMat 1/286 Remover - Cured Polysulphide and Silicone Rubber OMat 261 Temporary Marker OMat 262 Temporary marker felt/fibre tip OMat 283 Masking tape OMat 606 Developer, Powder OMat 652 Fluorescent penetrant Ultra high sensitivity post-emulsified Printed in Great Britain TRENT 1000 72−K132 Page 7 Jun.29/18 Jun.29/18 TRENT 1000 SERIES
SERVICE BULLETIN
3. Accomplishment Instructions Only carry out a visual check on modules, mini modules, sub-assemblies and parts that are removed solely to gain access to parts that require repair or modification, do not carry out any additional disassembly for the purpose of visual inspection. Refer to SPM TASK 70-31-00-200-000 Inspection of Parts and report any findings to Rolls-Royce.
NOTE: A visual inspection is the examination of a part for obvious damage, only inspect exposed areas. This evaluation is to be carried out with white light, without magnification, and does not require dimensional measurements.
Unless the engine requires an in-shop engine test, or if required for access to complete the defined workscope, any covers or blanks that are installed on the engine are not to be removed.
A. Part A - Reserved for Future Use B. Part B - To replace no more than 6 Intermediate Pressure (IP) Compressor Stage 1 rotor blades and/or up to 6 IP Compressor Stage 2 rotor blades only with new or SUM with the 02 module removed from the core engine.
If more than 6 blades from either stage 1 or 2 require replacing, do Part C. of the Accomplishment Instructions, instead.
NOTE: The following Accomplishment Instructions define how blades from both stage 1 and 2 should be removed, inspected, and installed.
NOTE: The following is to be accomplished at an Overhaul Facility with the IP compressor module removed and partially disassembled. This is to reduce the workscope to a minimum.
(1) Use currently published EM procedures to gain access to the IP compressor blades.
(a) When removing the LP and IP Compressor Modules there are 4 alternative procedures published in the EM Vertical Build, Engine Build Stand, Gantry Method ROT and Gantry Method TTL Tooling series.
If stripping the engine using the Gantry Method TTL Tooling Series, Refer to RTV180888 until Dec.31/18.
Printed in Great Britain TRENT 1000 72−K132 Page 8 Jun.29/18 Jun.29/18 TRENT 1000 SERIES
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(b) Prior to removing the IP Compressor Module, temporarily mark one of the 4-off location pins (72-33-21, 01-325) on the IP compressor rear stub shaft (72-33-21, 01-250) and the correlating location pin hole on the IP compressor rotor curvic cone (72-32-31, 01-125). Use OMat 261 or OMat 262.
NOTE: The temporary mark created on the IP compressor rear stub shaft location pin and IP compressor rotor curvic cone is important for avoiding an increase in vibration when the IP compressor module is reinstalled to the intermediate casing module.
(c) Remove the air/oil seal tube from the IP compressor module in accordance with current overhaul procedures (EM Task 72-32-00-020-802, Remove the Air/Oil Seal Tube from the IP Compressor Module).
(d) Disassemble the IP Compressor Module in accordance with current overhaul procedures (EM TASK 72-32-00-030-801, Disassemble the IP Compressor Module and EM TASK 72-32-20-030-801 IP Compressor Case and Rotor Group Assembly).
When disassembling the IP Compressor Module:
(i) Do not perform SUBTASK 72-32-00-030-028, Remove the Two Variable Stator Vane (VSV) Actuators.
(ii) Do not perform SUBTASK 72-32-00-030-029, Remove the IP Compressor Variable Inlet Guide Vanes (VIGV) and VSV Actuating Mechanism unless there are obvious visible signs of damage.
(iii) Do not perform SUBTASK 72-32-00-030-030, Disassemble the Actuating Mechanism Control Rods, unless there are obvious visible signs of damage.
(iv) If there are no obvious visible signs of damage, remove the VSV and VIGV Actuation Mechanism Assembly. Do steps 1.to 7. below:
(1) Refer to Engine Manual TASK 72-32-00-030-801 - Fig.72-32-00-990-322-001, Fig.72-32-00-990-322-002, Fig.72-32-00-990-322-003, Fig.72-32-00-990-323-001, Fig.72-32-00-990-323-002, Fig.72-32-00-990-323-003, Fig.72-32-00-990-324, and Fig. 1 from this NMSB. Refer to Engine Manual TASK 75-31-11-050-801, Fig. 75-31-11-990-011 and Fig. 75-31-11-990-014.
(2) For the removal of the Left VIGV Control Rod, remove the Cotter Split Pin (72-32-42, 02-175), release the Nuts (72-32-42, 02-180), Washer (72-32-42, 02-190) and the Bolts (72-32-12, 01-150). Release the VIGV Control Rod (72-32-42, 02-200) from the Bridge Plate (72-32-12, 01-510). Repeat for the Right VIGV control rod.
Printed in Great Britain TRENT 1000 72−K132 Page 9 Jun.29/18 Jun.29/18 TRENT 1000 SERIES