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This document transmits the Initial Issue of Service Bulletin TRENT1000-72-K571 and the Initial Issue of the Supplement Bulletin Initial Issue Remove Incorporate Reason for change Pages 1 to 58 of the Service Bulletin Initial Issue Supplement Initial Issue Remove Incorporate Reason for change Page 1 Initial Issue Printed in Great Britain Jun.15/21 TRENT 1000 SERIES PROPULSION SYSTEMS SERVICE BULLETIN TRENT 1000 72−K571 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.15/21 2 Jun.15/21 3 Jun.15/21 4 Jun.15/21 5 Jun.15/21 6 Jun.15/21 7 Jun.15/21 8 Jun.15/21 9 Jun.15/21 10 Jun.15/21 11 Jun.15/21 12 Jun.15/21 13 Jun.15/21 14 Jun.15/21 15 Jun.15/21 16 Jun.15/21 17 Jun.15/21 18 Jun.15/21 19 Jun.15/21 20 Jun.15/21 21 Jun.15/21 22 Jun.15/21 23 Jun.15/21 24 Jun.15/21 25 Jun.15/21 26 Jun.15/21 27 Jun.15/21 28 Jun.15/21 29 Jun.15/21 30 Jun.15/21 31 Jun.15/21 32 Jun.15/21 33 Jun.15/21 34 Jun.15/21 35 Jun.15/21 36 Jun.15/21 37 Jun.15/21 38 Jun.15/21 39 Jun.15/21 40 Jun.15/21 41 Jun.15/21 42 Jun.15/21 43 Jun.15/21 44 Jun.15/21 45 Jun.15/21 Printed in Great Britain TRENT 1000 72−K571 Transmittal - Page 2
46 Jun.15/21 47 Jun.15/21 48 Jun.15/21 49 Jun.15/21 50 Jun.15/21 51 Jun.15/21 52 Jun.15/21 53 Jun.15/21 54 Jun.15/21 55 Jun.15/21 56 Jun.15/21 57 Jun.15/21 58 Jun.15/21 Supplement 1 Jun.15/21 Printed in Great Britain TRENT 1000 72−K571 Transmittal - Page 3
1. Planning Information A. Effectivity Boeing 787 TRENT1000-AE3 Engines prior to Serial No.11466.
TRENT1000-CE3 Engines prior to Serial No.11466.
TRENT1000-D3 Engines prior to Serial No.11466.
TRENT1000-G3 Engines prior to Serial No.11466.
TRENT1000-H3 Engines prior to Serial No.11466.
TRENT1000-J3 Engines prior to Serial No.11466.
TRENT1000-K3 Engines prior to Serial No.11466.
TRENT1000-L3 Engines prior to Serial No.11466.
TRENT1000-M3 Engines prior to Serial No.11466.
TRENT1000-N3 Engines prior to Serial No.11466.
TRENT1000-P3 Engines prior to Serial No.11466.
TRENT1000-Q3 Engines prior to Serial No.11466.
TRENT1000-R3 Engines prior to Serial No.11466.
TRENT1000, M32100836, M32101261, M32 Modules.
B. Concurrent Requirements None.
C. Reason
(1) Problem The current standard of Intermediate Pressure (IP) compressor stages 1 to 8 rotor shaft assembly is susceptible to high cycle fatigue cracking travelling axially rearwards from the front edge of the front seal. This cracking may result in reduced stage 1 disc integrity.
ENGINE - IP COMPRESSOR SHAFT - INTRODUCTION OF AN IP COMPRESSOR STAGES 1 TO 8 ROTOR SHAFT ASSEMBLY FEATURING REVISED FRONT SEAL GEOMETRY - MOD.72-K571 Printed in Great Britain TRENT 1000 72−K571 Page 1 of 58 Jun.15/21 Jun.15/21 TRENT 1000 SERIES
SERVICE BULLETIN
The problem is attributed to:
(a) Frequency alignment with the acoustic resonance of the cavity downstream of the IP Compressor front seal.
(b) Seal instability as a result of an acoustic bite from the interaction with the acoustic resonance of the cavity downstream of the IP Compressor front seal.
(c) A feedback mechanism between the IP Compressor front seal and buffer seal involving the buffer seal exciting an inner cavity acoustic mode, which successively excites the front seal.
(2) Evidence The problem has been identified on in-service and development programme engines with maximum crack lengths ranging between 5,4 mm (0.21 in.) and 6,3 mm (0.25 in.).
In addition, the problem has been observed in the flight test development programme of one other Rolls-Royce Trent series engine with a similar design of IP Compressor stages 1 to 8 rotor shaft assembly, with a maximum crack length of 8,34 mm (0.33 in.).
(3) Substantiation The changes introduced by this Service Bulletin have been the subject of satisfactory engineering evaluation, including stress, vibration and thermals analysis.
(4) Objective Incorporation of this Service Bulletin (Modification) is designed to maintain reliability.
(5) Effect of Bulletin on:
(a) Operation Not affected.
(b) Maintenance Not affected.
(c) Overhaul Affected (see 1.L. Other Publications Affected).
Printed in Great Britain TRENT 1000 72−K571 Page 2 Jun.15/21 Jun.15/21 TRENT 1000 SERIES
SERVICE BULLETIN
(d) Repair Schemes Affected (affected Repair Schemes will be revised to include the part(s) introduced by this Service Bulletin).
(e) Interchangeability Affected (see 1.M. Interchangeability of Parts).
D. Description
(1) The changes are:
(a) A revised IP compressor stages 1 to 8 rotor shaft assembly is introduced similar to the existing item except for:
(i) The number of seal fins on the front seal is reduced from 4 to 3 resulting in the axial length of the seal arm to be reduced by 9,05 mm (0.36 in.).
(ii) A chamfer is introduced on upper and lower front edges of the front seal.
(2) Existing IP compressor stages 1 to 8 rotor shaft assemblies may be reworked. The rework standard features identical changes as the new production standard except for a radius feature on the upper front edge that is a result of machining the part, and a machining tolerance of Plus/Minus 0.3 mm (0.01 in.) is applied. Additionally, the upper and lower front edges of the machined part are deburred.
(3) This Service Bulletin is in two parts as follows:
(a) Part 1 New production and in-service applications.
(b) Part 2 The application of a reworked standard of IP Compressor stages 1 to 8 rotor shaft assembly.
(4) For effect on declared life see Time Limits Manual 05-10-01.
E. Compliance
(1) ON-WING Not applicable.
Printed in Great Britain TRENT 1000 72−K571 Page 3 Jun.15/21 Jun.15/21 TRENT 1000 SERIES
SERVICE BULLETIN
(2) IN-SHOP
RECOMMENDED It is recommended that this Service Bulletin be accomplished on engines/powerplants at Module 32 Level 2 (Check and Repair and Hospital Shop Visits) provided that the module is disassembled sufficiently to expose the front face of the IP Compressor rotor assembly or Level 3 (Engine Refurbishment) or Level 4 (Engine Overhaul).
F. Approval The technical content of Modification 72-K571 was approved by a representative of the European Union Aviation Safety Agency (EASA) on May.21/21, EASA certificate No. EASA.C.10076524.
G. Manpower
(1) On-wing Not applicable.
(2) In-shop 12 man-hours - (Estimated) NOTE: The parts affected by this Service Bulletin are accessible In-shop.
H. Material Price and Availability Modification kit not required; parts supplied as single line items.
For prices and availability of future spares see supplement to this bulletin.
I. Tooling, Price and Availability Special tools are required.
J. Weight and Balance
(1) Weight Change Minus 0,36 kg (0.8 lb).
(2) Moment Arm 150 mm (5.9 in.) forwards.
(3) Datum Power Plant Station (PPS) 3000 mm (118.11 in.).
Printed in Great Britain TRENT 1000 72−K571 Page 4 Jun.15/21 Jun.15/21 TRENT 1000 SERIES
SERVICE BULLETIN
K. References Engine Manual, 72-32-30, Disassembly and Assembly.
L. Other Publications Affected
(1) For effect on Illustrated Parts Catalogue (IPC) see 2. Material Information.
(2) Cleaning/Inspection and Repair Manual, 72-32-31, Inspection/Check.
(3) Time Limits Manual, 05-10-01 and 05-20-01.
M. Interchangeability of Parts Affected (see 2.D.(1) Instruction disposition codes).
Printed in Great Britain TRENT 1000 72−K571 Page 5 Jun.15/21 Jun.15/21 TRENT 1000 SERIES
SERVICE BULLETIN
2. Material Information A. The kit required consists of the following parts:
None.
B. Parts to be reworked:
All Engines and Modules P a r t2o fS B 72-32-31 FIG ITEM NO.
NEW PART NO. QTY PART TITLE OLD PART NO.
INSTR DISP 01 450 LV18447 1 SHAFT, ASSY-ROTOR, STAGES 1T O8-I P COMP KH18436 (1) C. New production parts:
The following parts will be made available as future spares in addition to those listed under B:
All Engines and Modules P a r t1o fS B 72-32-31 FIG ITEM NO.
NEW PART NO. QTY PART TITLE OLD PART NO.
INSTR DISP 01 450 LV19601 1 SHAFT, ASSY-ROTOR, STAGES 1T O8-I P COMP KH18436 (1) D. Instruction disposition codes:
(1) One-Way Interchangeable. The old part may be replaced by the old or new part in isolation, but the new part must not be replaced by the old part in isolation.
Printed in Great Britain TRENT 1000 72−K571 Page 6 Jun.15/21 Jun.15/21 TRENT 1000 SERIES
SERVICE BULLETIN
3. Accomplishment Instructions A. The revised IP compressor stage 1 to 8 rotor shaft assembly introduced by this Service Bulletin is one-way interchangeable (see 1.M. Interchangeability of Parts). Remove the existing and install the new or reworked IP compressor stage 1 to 8 rotor shaft assembly in accordance with current overhaul procedures (Engine Manual, 72-32-30, Disassembly and Assembly).
B. Rework the existing Intermediate Pressure (IP) Compressor Rotor Shaft Assembly (KH18436) (IPC ATA 72-32-31, Fig/Item 01-450).
GENERAL DATA CAUTION: THE IP COMPRESSOR ROTOR SHAFT MUST STAY CLEAN AND MUST HAVE NO CONTAMINATION AT ALL TIMES. PUT ON CLEAN COTTON GLOVES BEFORE YOU TOUCH THE SHAFT. WHEN THE PROCEDURE IS STOPPED OR COMPLETED, A COVER MUST BE PUT ON THE SHAFT.
WARNING: MAKE SURE NECESSARY MASKING IS APPLIED, ELSE INJURY CAN OCCUR.
This TASK gives the procedure to modify the Intermediate Pressure (IP) Compressor Rotor Shaft Assembly by machining the front seal arm.
Source demonstration is necessary for this rework. Only those companies who hold letters of approval for this rework from Rolls-Royce plc are authorised to do this rework. Vendors who hold this approval are listed in TSD 7019 (Authorised Repair Vendor Directory). This source controlled rework and associated repair vendor shop documentation are classified as fixed process documents and must be controlled as specified in RRES90000.
Protect the part during Rework in between operations and after Rework in accordance with OP TASK 70-00-00-300-340.
Overhaul Processes (OP) referenced in the text by TASK/SUBTASK number are detailed in the Engine Overhaul Processes Manual (TSD594-J).
TASKS identified by SPM TASK are in the Standard Practices Manual.
This rework can be done by one of the below three parts:
Part 1: Rework with the Stages 1 and 2 blades removed, Stages 3 to 8 blades, IP Compressor Front Stubshaft (KH36286) and Curvic (KH26324) installed.
Part 2: Rework in the piece part level.
Part 3: Rework with the Stages 1 to 8 blades, IP Compressor Front Stubshaft (KH36286) and Curvic (KH26324) installed.
Printed in Great Britain TRENT 1000 72−K571 Page 7 Jun.15/21 Jun.15/21 TRENT 1000 SERIES
SERVICE BULLETIN
This Service Bulletin requires the use of the RRT119749 lifter and RRT119747 shaft centraliser that can be used to machine the Trent 1000-TEN application only. When using the RRT119747 shaft centraliser, there is no requirement to remove the dampening ring.
This Service Bulletin permits the use of an alternative RRT119750 lifter and RRT119748 shaft centraliser. This specific tooling can also be used for the Trent 7000 application. Use of the RRT119750 lifter and RRT119748 shaft centraliser requires the removal of the RRT119756 dampening ring assembly before the lifter is installed and re-installation of the dampening ring before the machining is done. An RRT119754 lifting collar must be installed on the RRT119750 lifter before the lifter is installed on a Trent 1000-TEN IP Compressor Front Stubshaft (KH36286).
Equivalent locally manufactured tooling can be used. Agreement with Rolls-Royce is necessary for the use of locally manufactured tooling.
Part 1 and Part 3 of this instruction require that no coolant is permitted to ingress into the masked areas of the assembly. The vendor is to use an applicable method to confirm that there is no ingress of coolant. The recommended method is to apply litmus paper to the inside of the masked areas of the assembly.
With the agreement of Rolls-Royce, it is acceptable to change the build order of the masking to apply shrink wrap before the polymer moulding tools and to apply additional OMat 2/247 polyethylene tape or equivalent to get an improved seal, if necessary.
Material of Component Description RR Symbol Material Intermediate Pressure (IP) Compressor Rotor Shaft Assembly TJK Titanium Alloy These rework instructions are controlled by RPR61138.
C. EQUIPMENT AND MATERIAL
(1) Standard Equipment degreasing equipment hand tools heat gun inspection equipment locally made tooling machining equipment penetrant crack test equipment swab etch equipment suction equipment vibration peen equipment Printed in Great Britain TRENT 1000 72−K571 Page 8 Jun.15/21 Jun.15/21 TRENT 1000 SERIES
SERVICE BULLETIN
x3 to x7 magnification equipment
(2) Consumable Materials OMat 2/101 lint free cloth OMat 2/247 polyethylene tape OMat 5/28 waterproof silicon carbide OMat 652 fluorescent penetrant ultra-high sensitivity, post-emulsified OMat 1099 coolant, heavy duty concentrate OMat 1284 polyethylene shrink wrap NOTE: 1. To identify consumable materials, refer to the Overhaul Materials Manual (OMat).
2. Additional consumable materials are included in the Overhaul Processes referenced within this rework.
(3) Expendable Parts
FIG/ITEM PART NO PART IDENT QTY None.
(4) Rework Parts
FIG/ITEM PART NO PART IDENT QTY None.
(5) Special Tools
TOOL NUMBER TOOL DESCRIPTION QTY RRT026842 dummy shaft RRT081238 polymer stage 2-3 seal fin protector RRT081239 polymer stage 1-2 seal fin protector RRT081240 polymer stage 3-4 seal fin protector RRT081241 polymer stage 4-5 seal fin protector RRT081243 polymer stage 6-7 seal fin protector RRT091632 polymer stage 5-6 seal fin protector RRT091633 polymer stage 7-8 seal fin protector RRT119749 lifter RRT119750 lifter RRT119751 lifting eye tool RRT119752 top hat clamp RRT119753 polymer top hat cover RRT119755 polymer trough RRT119757 polymer front seal arm seal fin protector RRT119758 polymer stage 1 dovetail protector RRT119759 polymer stage 1 blade protector Printed in Great Britain TRENT 1000 72−K571 Page 9 Jun.15/21 Jun.15/21 TRENT 1000 SERIES