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P.O. Box 31, DERBY DE24 8BJ, UK Rolls-Royce Telephone: 44 (0) 1332 242424 Fax: 44 (0) 1332 249936 ROYCE
PUBLICATION TRANSMITTAL The technical information contained in this document has been approved under the authority of - See Planning Information, Approval.
Date Mar. 31/16 RB211 TRENT 800 SERIES PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN Printed in Great Britain This document transmits the Initial Issue of Service Bulletin RB211-72-AJ165 ALERT Bulletin Initial Issue Remove Incorporate Reason for change Pages 1 to 12 of the Initial Issue Service Bulletin ALERT RB.211-72-AJ165 Transmittal - Page 1 of 2
CHECK THAT ALL PREVIOUS TRANSMITTALS HAVE BEEN INCORPORATED If any have not been received please advise Customer Data Services, Rolls-Royce pic, Derby, England © Rolls-Royce p/c (date as above) Printed in Great Britain
The effective pages to this Service Bulletin are as follows:
Revision Number Revision Date Bulletin 1 Mar. 31/16 Printed in Great Britain Mar. 31/16 Mar. 31/16 Mar. 31/16 Mar. 31/16 6 Mar. 31/16 Mar. 31/16 Mar. 31/16 Mar.31/16 10 Mar. 31/16 Mar. 31/16 Mar.31/16 RB.211-72-AJ165 Transmittal - Page 2
RB211 PROPULSION SYSTEM
SERVICE
BULLETIN
POWERPLANT - UPPER BIFURCATION FAIRING SEAL FACE INSPECTION - NON-MODIFICATION SERVICE BULLETIN - MOD.72-AJ165
1. Planning Information Printed in Great Britain A. Effectivity Boeing 777 RB211 TRENT 875-17 Engines RB211 TRENT 877-17 Engines RB211 TRENT 884-17 Engines RB211 TRENT 884B-17 Engines RB211 TRENT 892-17 Engines RB211 TRENT 892B-17 Engines RB211 TRENT 895-17 Engines B. Reason
(1) Problem A number of upper bifurcation fairings (EIPC 72-03-14, 07-250) (AIPC 72-03-14, 01-110) were found with titanium cracks located on the lower part of the upper bifurcation fairing right seal face. These cracks were found both in service and in overhaul shops. In some cases the cracks had extended further and led to material release.
It is understood that the cracks initially propagate under low cycle fatigue until vibration stresses become high enough to propagate under
(2) The safety intent of this Non-Modification Service Bulletin (NMSB) is to prevent material loss of the fairing seal face and avoid a breach of the fire wall.
C. Description This NMSB instructs the repeat inspection of a specific zone of the upper bifurcation fairing assembly. The inspection requires the use of a Non Destructive Testing (NDT) method known as Fluorescent Penetrant Inspection (FPI) to identify potential cracks in the lower part of the upper bifurcation fairing right seal face.
Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 1 of 12 © Rolls-Royce p/c
•B211 SYSTEN PROPULSION
SERVICE
BULLETIN The inspection is to be carried out both on-wing and in-shop. If the on-wing inspection fails, on-wing repair FRSJ739 can in some cases, be carried out to avoid an upper bifurcation fairing replacement. The in-shop inspection can be performed in an assembled condition if the fairing is not removed from the Any rejected upper bifurcation fairings in-shop can be repaired to a Printed in Great Britain serviceable condition in accordance with Engine Manual TASK, 72-03-14, Examine the upper bifurcation fairing (72-03-14, 07-250) and related parts.
If a fairing is found to have released titanium material, inform the local Rolls-Royce Service representative.
D. Compliance
(1) ALERT Part 1 - Initial Inspection on-wing and in-shop
(a) Carry out NSB initial inspection when the earliest of these following conditions occur.
(i) Inspect on-wing in accordance with Accomplishment Instruction
3.A prior to achieving 7,500 engine flight hours since the upper bifurcation fairing was last inspected on-wing or in-shop. If the time since last inspection exceeds 7,500 flight hours at the issue date of this NMSB, inspect within the next 150 cycles from the issue date of this NMSB.
NOTE: The last inspection could have been carried out in-shop in accordance with Engine Manual TASK 72-03-14, Examine the upper bifurcation fairing (72-03-14, 07-250) and related parts. This Engine Manual inspection task is part of the generic Engine Management Plan (EMP) for all engines going through engine level refurbishment and overhaul shop visits. The last inspection could also have been carried out On-wing in accordance with Maintenance Planning Data (MPD) document, inspection item number 72-390-01 (for left engine) or 72-390-02 (for right engine).
(ii) Inspect on-wing in accordance with Accomplishment Instruction
3.A when the engine maintenance schedule requires AMM TASK 72-03-14, upper bifurcation fairing inspection to be carried out.
(iii) Inspect in-shop in accordance with Accomplishment Instruction
3.B at next engine level check and repair, refurbishment or overhaul (level 2, 3 or 4) shop visit. For those engines currently in the shop, carry out inspection where the affected part is exposed and substantial rebuild has not yet started.
Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 2 © Rolls-Royce p/c
RB211 SYS PULSION SYSTEM
SERVICE
BULLETIN
(2) ALERT Part 2 - Repeat Inspections
(a) On-wing Printed in Great Britain (ї) Repeat at intervals not exceeding 7,500 engine flight hours since last on-wing or in-shop inspection.
(b) In-shop (ї) Inspect at each engine level check and repair, refurbishment and overhaul (level 2,3 and 4) shop visits.
(3) This Non-Modification Service Bulletin is anticipated to be the subject of an EASA Airworthiness Directive.
E. Approval The technical content of this Non-Modification Service Bulletin was approved under the authority of Design Organisation Approval EASA.21J.035 on 24th March 2016.
F. Manpower
(1) On-wing
(a) Time to gain access - 15 mins (1 person).
(b) Time to inspect - 3 hours (1 person) - Personnel with NDT level 2 training are required to carry out FPI inspection.
(c) Time to repair if required - 8 hours (2 persons)
(d) Time to replace fairing if required - 30 hours (2 persons)
(2) In-shop
(a) Time to gain access - Not Applicable.
(b) Time to inspect - 2 hours (1 person) - Personnel with NDT level 2 training are required to carry out FPI inspection.
(c) Time to repair if required - Various depending on Engine Manual repair carried out.
NOTE: The parts affected by this Non-Modification Service Bulletin are accessible On-wing and In-shop.
Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 3 © Rolls-Royce pic
RB211 PASTEM SION SYSTEM
SERVICE
BULLETIN G. Material Price and Availability Material price and availability is on request via your assigned Rolls-Royce airline support team or Rolls-Royce overhaul support team.
H. Tooling Price and Availability None. Printed in Great Britain
1. References
(1) Engine Manual
(a) TASK, 72-03-00, Remove the Upper Bifurcation Fairing.
(b) TASK, 72-03-00, Install the Upper Bifurcation Fairing.
(c) TASK, 72-03-14, Examine the Upper Bifurcation Fairing.
(d) TASK, 72-00-00, Overhaul Process 210 - Fluorescent Penetrant Inspection.
(2) Aircraft Maintenance Manual
(a) TASK, 27-81-00, Retract the Leading Edge Slats.
(b) TASK, 27-81-00, Leading Edge Slat Deactivation.
(c) TASK, 27-81-00, Leading Edge Slat Reactivation.
(d) TASK, 78-31-00, Thrust Reverser Deactivation for Ground Maintenance.
(e) TASK, 78-31-00, Thrust Reverser Activation after Ground Maintenance.
(f) TASK, 71-11-04, Open the Fan Cowl Panel (Selection).
(g) TASK, 71-11-04, Close the Fan Cowl Panel (Selection).
(h) TASK, 78-31-00, Open the Thrust Reverser (Selection).
(i) TASK, 78-31-00, Close the Thrust reverser (Selection).
(j) TASK, 72-03-14, Upper Bifurcation Fairing Removal.
(k) TASK, 72-03-14, Upper Bifurcation Fairing Installation.
(L) TASK, 72-03-14, Upper Bifurcation Fairing Inspection.
(m) TASK, 70-20-02, Water - Washable Fluorescent Penetrant Inspection (Maintenance Process 213).
Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 4 © Rolls-Royce pic
RB211 PROPULSION SYSTEM
SERVICE
OYCE BULLETIN
2. Material Information A. Consumable materials required for the On-wing FPI inspection Printed in Great Britain Reference Description Specification B00668 (OMat 101) Kerosene OMat 101 G00034 Cotton Wiper - Process BMS15-5, Class A Cleaning Absorbent Wiper (Cheesecloth, Gauze) G02383 (OMat 2/101) Cloth - Absorbent, Lint OMat 2/101 free G02384 (OMat 606A) Developer - Powder - OMat 606A Ardrox : 9D4A G02385 (OMat 616) Remover - Solvent 919 7ewo Penetrant G02386 (OMat 621A) Remover - Fluorescent Penetrant (Hydrophilic)
- Ardrox 9PR12 G02397 (OMat 617) Developer - Non-Aqueous 219 7eWo Aerosol G02401 (OMat 653) Penetrant - ESO FeWO Fluorescent, Medium Sensitivity Water Washable G02400 (OMat 632) Penetrant - OMat 632 Fluorescsent, High Sensitivity water Washable If the repair FRSJ739 is to be carried out, the part below is required.
Part Number Description Qty KH67157 Bracket 1 Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 5 © Rolls-Royce p/c
RB211 SYSTEM PROPULSION
SERVICE
BULLETIN
3. Accomplishment Instructions A. On-wing For this procedure the upper bifurcation fairing will be referred to as the fairing. You must open the thrust reversers to get access to the fairing.
WARNING: YOU MUST BE CAREFUL WHEN YOU WORK ON THE ENGINE AFTER THE ENGINE IS Printed in Great Britain SHUTDOWN. THE ENGINE CAN STAY HOT FOR ALMOST ONE HOUR.
WARNING: YOU MUST NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT PARTS CAN CAUSE INJURY. IF YOU GET AN INJURY, PUT IT IN COLD WATER FOR 10 MINUTES. THEN GET MEDICAL AID.
CAUTION: IN ORDER TO REDUCE THE POTENTIAL FOR MULTIPLE-ENGINE IN-FLIGHT SHUTDOWN,
POWER LOSS, OR OTHER ANOMALY DUE TO MAINTENANCE ERROR, ROLLS-ROYCE
RECOMMENDS THAT OPERATORS AVOID PERFORMING MAINTENANCE ON MULTIPLE ENGINES INSTALLED ON THE SAME AIRCRAFT AT THE SAME TIME. IF IT IS NOT
POSSIBLE TO AVOID MAINTENANCE ON MORE THAN ONE ENGINE AT THE SAME TIME,
ROLLS-ROYCE RECOMMENDS THAT ADDITIONAL CONTROLS ARE APPLIED IN ORDER TO MAKE SURE THAT MAINTENANCE TASKS HAVE BEEN COMPLETED AS DEFINED.
MAINTENANCE GUIDELINES SHOULD BE REVISED, WHERE POSSIBLE, TO PROMOTE
THIS RECOMMENDATION
(1) Gain access.
(a) Do these tasks in sequence to safely open the left and right thrust reversers on the applicable engine:
(i) Do this AMM TASK: Retract the Leading Edge Slats, TASK 27-81-00.
(ii) Do this AMM TASK: Leading Edge Slat Deactivation, TASK 27-81-00.
(iii) Do this AMM TASK: Thrust Reverser Deactivation for Ground Maintenance, TASK 78-31-00.
(iv) For the left and right fan cowl panels, do this AMM TASK: Open the Fan Cowl Panel (Selection), 71-11-04.
Number Name/Location 413AL Left Fan Cowl Panel, Left Engine 414AR Right Fan Cowl Panel, Left Engine 423AL Left Fan Cowl Panel, Right Engine 424AR Right Fan Cowl Panel, Right Engine Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 6 © Rolls-Royce pic
RB211 PASPEL SION SYSTEM
SERVICE
BULLETIN
(v) For the left and right thrust reversers, do this AMM TASK: Open the Thrust reverser (Selection), TASK 78-31-00.
Number Name/Location Printed in Great Britain 416AR Right Thrust Reverser, Left Engine 415AL Left Thrust Reverser, Left Engine 425AL Left Thrust Reverser, Right Engine 426AR Right Thrust Reverser, Right Engine
(b) Install the protective mat, SPL-13999 into the LP compressor rear case. Make sure that the red warning flag can be seen from the ground.
(2) Examine the fairing. Refer to Fig.1 and Fig.2.
(a) Visually examine the fairing for any titanium cracks or material loss on the right hand side fairing seal face 22 and the right hand side seal support 23. Pay particular attention towards the lower part of the fairing and especially in Zone A.
(ї) If the titanium seal face 22 is found to have released material, replace the fairing in accordance with AMM TASK 72-03-14, Upper Bifurcation Fairing Removal/Installation.
(ii) If more than one crack is found, replace the fairing within 15 engine flight cycles in accordance with AMM TASK 72-03-14, Upper Bifurcation Fairing Removal/Installation.
(iii) If material loss or one crack is found on the seal support 23, replace the fairing within 15 flight cycles in accordance with AMM TASK 72-03-14, Upper Bifurcation Fairing Removal/Installation.
(iv) If there is a single crack on the lower right hand side of the fairing seal face 22, do the following:
(1) If the crack is shorter than 6mm, repair (refer to FRSJ739) or replace the fairing (refer to AMM TASK 72-03-14, Upper Bifurcation Fairing Removal/Installation) within 100 engine flight cycles.
(2) If the crack is longer than 6mm, repair (refer to FRSJ739) or replace the fairing (refer to AMM TASK 72-03-14, Upper Bifurcation Fairing Removal/Installation) within 15 engine flight cycles.
Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 7 © Rolls-Royce p/c
RB211 SYSTEM PROPULSION
SERVICE
BULLETIN
(b) If the visual inspection does not detect any crack, carry out a crack test in zone A (refer to Fig.1). Refer to AMM TASK 70-20-02, Water Washable Fluorescent Penetrant Inspection (Maintenance Process 213).
NOTE: NDT Level 3 personnel can approve a change to the penetrant OMat 632. classification of the penetrant to the high sensitivity Printed in Great Britain (і) If a crack shorter than 6mm is detected during the crack test inspection, repair (refer to FRSJ739) or replace the fairing (refer to AMM TASK 72-03-14, Upper Bifurcation Fairing Removal/Installation) within 100 engine flight cycles.
(ii) If a crack longer than 6mm is detected during the crack test inspection, repair (refer to FRSJ739) or replace the fairing (refer to AMM TASK 72-03-14, Upper Bifurcation Fairing Removal/Installation) within 15 engine flight cycles.
(3) Close up
(a) Return the engine to a serviceable condition.
CAUTION: MAKE SURE THAT YOU REMOVE ALL TOOLS, LOOSE PARTS AND
UNWANTED MATERIAL FROM THE AREA WHEN YOU COMPLETE MAINTENANCE. DAMAGE TO EQUIPMENT COULD OCCUR.
(і) Remove the protective mat, SPL-13999 from the rear compressor case.
WARNING: DO ALL OF THE SPECIFIED TASKS IN THE CORRECT SEQUENCE TO CLOSE THE THRUST REVERSERS. IF YOU DO NOT OBEY THIS
INSTRUCTION, INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT
CAN OCCUR (ії) Do these tasks in sequence to safely close the left and right thrust reversers on the applicable engine:
(1) Do this AMM TASK: Close the Thrust Reverser (Selection), TASK 78-31-00.
Number Name/Location 415AL Left Thrust Reverser, Left Engine 416AR Right Thrust Reverser, Left Engine 425AL Left Thrust Reverser, Right Engine 426AR Right Thrust Reverser, Right Engine Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 8 © Rolls-Royce pic
RB211 PRSTEMSION SYSTEM
SERVICE
BULLETIN Do this AMM TASK: Close the Fan Cowl Panel (Selection), TASK 71-11-04.
Number Name/Location Printed in Great Britain 413AL Left Fan Cowl Panel, Left Engine 414AR Right Fan Cowl Panel, Left Engine 423AL Left Fan Cowl Panel, Right Engine 424AR Right Fan Cowl Panel, Right Engine
(3) Do this AMM task: Thrust Reverser Activation after Ground Maintenance, TASK 78-31-00.
(4) Do this AMM task: Leading Edge Slat Reactivation, TASK 27-81-00.
(4) Record of accomplishment of this Non-Modification Service Bulletin is required in accordance with local Service Bulletin tracking system procedures.
B. In-Shop
(1) Examine the fairing. Refer to Fig.1 and Fig.3.
NOTE: Inspection can be done in the assembled condition if the fairing was not removed from the engine. If it is required to remove the fairing from the engine for repair purposes, refer to EM TASK 72-03-00, Remove the upper bifurcation fairing.
(a) Visually examine for any titanium cracks or material loss on the right hand side fairing seal face 22 and the right hand side seal support
23. Pay particular attention towards the lower part of the fairing and especially in zone A.
(і) If the titanium seal face 22 or seal support 23 is found to have released material, repair or replace the fairing.
(її) If the titanium seal face 22 or seal support 23 is found with a crack, repair or replace the fairing.
(b) If the visual inspection does not detect any crack, do a local penetrant crack test in zone A, refer to EM 70-00-00, Overhaul Process 210 - Fluorescent Penetrant Inspection.
(ї) If any crack is found, repair or replace the fairing.
Record of accomplishment of this Non-Modification Service Bulletin is required in the engine log book.
Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 9 © Rolls-Royce pic
ROLLS RB211 PYSPEMSION
R SERVICE SYSTEM
ROYCE BULLETIN 22 UPPER Printed in Great Britain
BIFURCATION 21 UPPER - FAIRING
BIFURCATION SEAL FACES
OUTER SKIN 23 SEAL
• SUPPORT
1.57 in
(40.0 mm)
0.79 in
(20.0 mm) LEGEND:
ZONE A def0017666 Upper Bifurcation Fairing - Inspection location Fig.1.
Mar. 31/16 RB.211-72-AJ165 Mar. 31/16 Page 10 © Rolls-Royce plc