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P.O. Box 31, DERBY DE24 8BJ, UK Telephone: 44 (0) 1332 242424 Rolls-Royce Fax: 44(0) 1332 249936
PUBLICATION TRANSMITTAL The technical information contained in this document has been approved under the authority of - See Planning Information, Approval.
Date May. 5/16 RB211 TRENT 900 SERIES PROPULSION SYSTEMS NON-MODIFICATION SERVICE BULLETIN ALERT Printed in Great Britain This document transmits Revision 2 to Service Bulletin RB211-72-AG971 Document History Service Bulletin Revision Status Supplement Revision Status Initial Issue Sep. 20/12 Revision 1 Sep. 27/13 Bulletin Revision 2 Remove Incorporate Reason for change Pages 1 to 5 and 7 Pages 1 to 5 and 7 To introduce an alternative method of inspection.
to 19 of the Service to 31 of the Service Bulletin Bulletin All pages of Page 1 of Appendix 1 To introduce an alternative Appendix 1 method of inspection.
ALERT RB.211-72-AG971 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 plc (date as above) Printed in Great Britain
LIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin following incorporation of Revision 2 are as follows:
Page Revision Number Revision Date Bulletin R 1 2 May 5/16 R 2 2 May 5/16 R 3 2 May 5/16 R 4 2 May 5/16 R 5 2 May 5/16 6 1 Sep.27/13 R 7 2 May 5/16 R 8 2 May 5/16 R 9 2 May 5/16 R 10 2 May 5/16 R 11 2 May 5/16 R 12 2 May 5/16 R 13 2 May 5/16 R 14 2 May 5/16 R 15 2 May 5/16 R 16 2 May 5/16 R 17 2 May 5/16 R 18 2 May 5/16 R 19 2 May 5/16 R 20 2 May 5/16 R 21 2 May 5/16 R 22 2 May 5/16 R 23 2 May 5/16 R 24 2 May 5/16 R 25 2 May 5/16 R 26 2 May 5/16 R 27 2 May 5/16 R 28 2 May 5/16 R 29 2 May 5/16 R 30 2 May 5/16 R 31 2 May 5/16 Appendix 1 R 1 2 May 5/16 Printed in Great Britain RB.211−72−AG971 Transmittal - Page 2
1. Planning Information A. Effectivity Airbus A380 All RB211 TRENT 900 Engines with part numbers FW27718, FW35923, FW51434, KH46678, KH45090 or KH46677 only.
R R B. Reason Problem Re-analysis of Tail Bearing Housing (TBH) structural features identified a potential limitation to R R the TBH capability in the fail safe condition. To confirm intact capability, an on-wing and in-shop inspection regime wasR defined for the Trent 900 TBH. The structural features to be inspected are the TBH mount lug run-outs and Top Core Vanes (TCV). In addition, the life of the TBH wasR limited to 17200 cycles to make sure it did not enter in fail safe mode.
Additionally, historical inspections of the TBH to initial issue of Non-Modification Service Bulletin (NMSB) 72-AG971 identified issues which required additional inspection criteria as part of a revised containment strategy. This has been addressed independently through NMSB 72-AH154.
Revision 1 of this NMSB wasR issued to provide additional clarity for some of the materials, tooling and cleaning tasks associated with inspections. It also revisedR the acceptance criteria for the on-wing inspections (section 3.A.(2)) and introducedR the inspection of the fail safe catcher in-shop to inform root cause understanding for the issues addressed in NMSB 72-AH154.
Revision 2 of this NMSB is issued to introduce eddy current inspection method as an alternative to the existing FP inspection of the mount lug run out region. It also removes the life limitation for the component following a re-assessment of the TBH that has demonstrated full limit load capability of the structure. The on-wing inspections of the mount lug run-outs are to be maintained until a pin check is introduced into the Maintenance Planning Document (MPD) every 3800 flight cycles. Finally, it also clarifies that the Central Male Catcher Run-Out is also addressed as part of the full FP inspection of the TBH in the shop.
R R R R R R R R R C. Description This Non-Modification Service Bulletin (NMSB) instructs the following:
TRENT 900 LP TURBINE EXHAUST CASE AND SUPPORT ASSEMBLY (TAIL BEARING HOUSING) MOUNT
LUG RUN-OUT AND TOP CORE VANE INSPECTIONS - NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-AG971 Printed in Great Britain RB.211−72−AG971 Page 1 of 31 Sep 20/12 May. 5/16R
(1) On-wing or in-shop TBH mount lug run-out inspections which are required onR Trent 900 Tail Bearing Housings with part numbers FW27718, FW35923, FW51434, KH46678, KH45090 or KH46677 R R every 2200 cycles.
(2) The in-shop inspection of TBH top core vanes and central male catcher runout R R which are required on Trent 900 Tail Bearing Housings with part numbers FW27718, FW35923, FW51434, KH46678, KH45090 or KH46677 R R every 3800 cycles.
On-wing a specified area on the mount lug run-outs is to be crack tested using a Fluorescent Penetrant Inspection (FPI) method or an alternative Eddy Current Method, R R see Fig.1. In shop, the mount lug run-outs can either be inspected using a local FPI,R local eddy current or through a full FPI of the TBH.
In shop the top core vanes and central male catcher runoutR are to be inspected by a full FPI of the TBH.
Results of the Inspections are to be returned to Rolls-Royce. Return Appendix 1 (or similar form) to your Rolls-Royce Service representative.
D. Compliance ALERT This Non-Modification Service Bulletin isR the subject of an EASA Airworthiness Directive AD 2013-0240.R Rolls-Royce recommends that the following action is undertaken to maintain continued airworthiness.
This NMSB applies to both on-wing and in-shop activities.
(1) On-wing - Localised Mount Lug Run-Outs Inspection:
Accomplish the first inspection in accordance with section 3.A. Accomplish the first inspection within 2200 cycles for the TBH mount lug run-outs if it is not to be done in-shop. Subsequent inspections whether in-shop or on-wing should be within 2200 cycles of previous inspection. Any TBH mount lug run-outs that were inspected to TV124801 or TV124851 prior to initial issue of this NMSB are deemed as compliant with the NMSB.
(2) In-shop - Localised Mount Lug Run-outs Inspection:
Accomplish the first inspection in accordance with section 3.B. Accomplish the first inspection within 2200 cycles for the TBH mount lug run-outs if it is not to be done on-wing or in-shop through full FPI of the TBH.
Subsequent inspections whether in-shop or on-wing should be within 2200 cycles of previous inspection. Any TBH mount lug run-outs that were inspected to TV124801 or TV124851 prior to initial issue of this NMSB are deemed as compliant with the NMSB.
Printed in Great Britain RB.211−72−AG971 Page 2 Sep 20/12 May. 5/16R
(3) In-shop - Top Core Vanes and Mount Lug Run-outs Inspection through full FPI of the TBH:
Accomplish the first inspection of the Top Core Vanes and central male catcher runout R R in accordance with section 3.C. Accomplish the first inspection within 3800 cycles for the TBH top core vanes and central male catcher runout.
R R Subsequent inspections should be within 3800 cycles of previous inspection.
Inspection of the mount lug run-outs can also be accomplished in accordance with section 3.C. Accomplish the first inspection within 2200 cycles for the TBH mount lug run-outs if it is not to be done on-wing or through a localised in-shop inspection. Subsequent inspections whether in-shop or on-wing should be within 2200 cycles of previous inspection.
E. Approval The technical content of this Non-Modification Service Bulletin was approved under the authority of Design Organisation Approval EASA.21J.035 on Sep.4/12, Sep.13/13 R R and was re-approved on Apr.29/16.
The inspection procedures described in this SB are reviewed and technically accepted by Airbus Design Office to apply to the Airbus fleet affected.
This SB does not contain any change information that revises the equipment definition covered by Airbus approved modifications.
F. Manpower
(1) On-wing:
(a) Time to gain access 1 hour (1 person)
(b) Time to inspect TBH Mount Lug Run-outs (FPI Method)R 3 hours (2 persons)
(c) Time to inspect TBH Mount Lug Run-outs (Eddy Current Method)R 1 hour (1 person)R
(d) Time to restore to serviceable condition 1 hour (1 person) Printed in Great Britain RB.211−72−AG971 Page 3 Sep 20/12 May. 5/16R
(2) In-shop:
(a) Time to locally inspect TBH Mount Lug Run-outs (FPI Method)R 2 hours (2 persons)
(b) Time to locally inspect TBH Mount Lug Run-outs (Eddy Currrent Method)R 1 hour (1 person)R
(c) Inspection of TBH through full FPI Level 2 workscope The FPI defined in this NMSBR shall only be performed by personnel qualified to FPI level 2 or higher and in possession of an up to date eyesight record in accordance with EN4179/NAS410 or alternative standards/guidelines accepted by the applicable National Aviation Authority.
The eddy current defined in this NMSB shall only be performed by personnel qualified to eddy current level 2 or higher and in possession of an 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 G. Material Price and Availability
(1) For Local FPIR Material/ Compounds R R DescriptionR OMat 651 (Aerosol) R R Aerosol penetrant - Commercially availableR OMat 617 (Aerosol) R R Aerosol Developer - Commercially availableR OMat 150R AcetoneR OMat 2/101R Lint-Free ClothR OMat 677R Penetrant Test PanelR
(2) For Eddy CurrentR Material/ Compounds R R DescriptionR OMat 2/30R PTFE Tape - Minimum width of 10 mmR H. Tooling Price and Availability
(1) For Local FPIR Material/ Compounds R R DescriptionR Printed in Great Britain RB.211−72−AG971 Page 4 Sep 20/12 May. 5/16R
Dark Non-reflective cover R R R To darken the area for inspection - Commercially available R R Ultra Violet (UV) light source R R 2 alternativesR Capable of providing a minimum UV radiation intensity of 1200 micro W/sq.cm at the inspection surface.
R R Alternatively, Spectroline Tritan 365 UV/White LED Inspection Lamp, Portable, Battery Operated Version, Part Number - TRI-365MH series Kit R R R Unit Price - Approximately £1200, Supplier - RSL NDT Ltd.
R R
(2) For Eddy CurrentR Material/ Compounds R R DescriptionR HU82371R Eddy Current Inspection KitR Rohmann Eddy current instrument capable of showing an X-Y display R R NOTE: The eddy current instrument must be subject to annual calibration in accordance with the manufacturer instructions.
R R I. References
(1) Aircraft Maintenance Manual (AMM)
(a) 71-13-00, Maintenance Practices, Opening of Fan Cowl Doors
(b) 78-26-00, Maintenance Practices, Opening/Closing of the Fan Exhaust Cowl or Thrust Reverser
(c) 78-30-00, Deactivation/Reactivation, Make the Thrust Reverser Unserviceable for Maintenance
(d) 70-20-02, Maintenance Processes - Inspection - Maintenance Practices, Fluorescent Penetrant Inspection
(2) Engine Manual (EM)
(a) 70-00-00, Overhaul Process 102, Primary Cleaning Aqueous, Overhaul Process 121, Alkaline Derusting and Descaling, Overhaul Process 134, Acidic Descalers, Overhaul Process 210, Fluorescent Penetrant Inspection.
(b) 72-52-00-030-802, Engine Data Task, Disassemble the LP Turbine
(c) 72-52-51-200-801, Cleaning/Inspection and Repair Data Task, Examine the LP Turbine Exhaust Case Printed in Great Britain RB.211−72−AG971 Page 5 Sep 20/12 May. 5/16R
2. Material Information A. None Printed in Great Britain RB.211−72−AG971 Page 6 Sep 20/12 Sep.27/13R
3. Accomplishment Instructions A. On-wing - Localised Mount Lug Run-outs InspectionR WARNING: YOU MUST BE CAREFUL WHEN YOU WORK ON THE ENGINE AFTER THE ENGINE IS SHUTDOWN. THE ENGINE CAN STAY HOT FOR ALMOST ONE HOUR.
R R 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.
R R R CAUTION: IN ORDER TO REDUCE THE POTENTIAL FOR MULTIPLE ENGINE IN FLIGHT SHUTDOWN,
POWER LOSS OR OTHER ANOMALIES 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 ENSURE THAT MAINTENANCE TASKS HAVE BEEN COMPLETED AS DEFINED.
MAINTENANCE GUIDELINES SHOULD BE REVISED, WHERE POSSIBLE, TO PROMOTE THIS RECOMMENDATION.
R R R R R R R R R
(1) Flourescent Penetrant InspectionR NOTE: Eddy current inspections in accordance with step 3.A.(2) is a valid alternative inspection method to the local FPI of the mount lug run-outs.
R R R
(a) To get access to the Tail Bearing Housing (TBH) mount lug run-outs:R
(i) Open the fan cowl doors in accordance with AMM Task 71-13-00, Maintenance Practices to get access R R
(ii) Make the thrust reverser unserviceable for maintenance in accordance with AMM 78-30-00, Deactivation/Activation.
R R WARNING: YOU MUST MAKE THE THRUST REVERSER UNSERVICEABLE (INSTALL
AND SAFETY THE INHIBITION DEVICE) BEFORE YOU DO WORK ON OR AROUND THE THRUST REVERSER. IF YOU DO NOT INSTALL
AND SAFETY THE INHIBITION DEVICE, THERE IS A RISK THAT THE THRUST REVERSER CAN OPERATE ACCIDENTALLY. THIS CAN CAUSE INJURY TO PERSON AND/OR DAMAGE TO THE EQUIPMENT.
R R R R R R
(iii) Open the fan exhaust cowls in accordance with the AMM, 78-26-00.
R R
(iv) Use appropriate staging to gain access to the TBH.R
(b) Carry out the inspection on the mount lug run-outs:R Printed in Great Britain RB.211−72−AG971 Page 7 Sep 20/12 May. 5/16R
WARNING: PROTECTIVE GLOVES AND SAFETY GLASSES MUST BE WORN AT ALL TIMES DURING THE INSPECTION. IF YOU GET AN INJURY, SEEK MEDICAL AID
IMMEDIATELY R R R
(i) This inspection must be performed in accordance with the requirements of AMM 70-20-02, Maintenance Processes - Inspection - Maintenance Practices, Fluorescent Penetrant Inspection.
R R R R
(ii) Clean the inspection areas (see Fig.1) with a clean OMat 2/101 lint-free cloth moistened with OMat 150 acetone.
R R
(iii) Discard the soiled cloth after use.R
(iv) Repeat the swabbing using fresh OMat 150 acetone and a fresh OMat 2/101 lint-free cloth until all deposits have been removed.
R R R 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, affect process performance or produce an unacceptable background.
R R R R R R
(v) Allow five minutes for the area to completely dry prior to penetrant application.
R R
(vi) Penetrant application - Apply OMat 651 penetrant to the inspection areas (Fig.1) by brush or sponge applicator. The penetrant must be dispensed from a sealed aerosol can and any unused penetrant must go to waste.
R R R R
(vii) Make sure that the inspection area is fully covered with penetrant with the aid of a UV lamp.
R R
(viii) Apply OMat 651 penetrant to the OMat 677 penetrant test panel.R
(ix) Leave the penetrant in contact with the components for 30 minutes.
R R NOTE: The penetrant contact time must not exceed one hour. If it does, the penetrant must be re-applied and 5 minutes contact time allowed.
R R R
(x) Penetrant Removal - After the 30 minutes contact time, remove the excess penetrant from the inspection surface and the OMat 677 penetrant test panel by wiping thoroughly with a clean OMat 2/101 lint-free cloth.
R R R R Printed in Great Britain RB.211−72−AG971 Page 8 Sep 20/12 May. 5/16R
(xi) Whilst illuminating with UV light, wipe off the penetrant with a clean OMat 2/101 lint-free cloth moistened with OMat 150 acetone. Use the minimum application necessary to achieve acceptable background fluorescence and make sure that acetone is not allowed to flow on the inspection surface.
R R R R R
(xii) Make sure that all traces of the OMat 150 acetone have been completely removed.
R R
(xiii) Develop - Apply a light, even coating of OMat 617 non-aqueous wet developer from a sealed aerosol can to the inspection area and the OMat 677 penetrant test panel.
R R R
(xiv) Allow 10 minutes contact time for the developer prior to inspection.
R R
(xv) Cover the region of the engine with a dark non-reflective cover in order to reduce the white light levels.
R R
(xvi) Make sure there are no white light sources or fluorescent items (including clothing) within the inspection area or the inspector's field of vision.
R R R
(xvii) Do not wear darkened or light sensitive glasses.R
(xviii)Allow one minute for eye adaptation to the darkened area.R
(xix) Illuminate the OMat 677 penetrant test panel in the darkened area with one of the allowed UV light sources listed in 1.H.
Tooling Price and Availability.
R R R
(xx) Inspect the OMat 677 penetrant test panel and check that the four largest indications are visible and match the control photograph for that individual panel.
R R R
(xxi) Illuminate the inspection surface with the same UV light in the darkened area.
R R
(xxii) Inspect the mount lug run-outs for crack indications.R
(xxiii)The Wipe Off technique can be used to aid the evaluation of any indications:
R R
(1) Dampen a cotton swab with acetone.R
(2) Wipe once across the indication.R
(3) Allow the acetone to evaporate and inspect immediately.R Printed in Great Britain RB.211−72−AG971 Page 9 Sep 20/12 May. 5/16R
(4) If the indication reappears then record it is a crack. If the indications does not reappear then apply a light, even coating of OMat 617 non-aqueous wet developer from a sealed aerosol can to the area.
R R R R
(5) Allow the solvent in the developer to evaporate and inspect immediately.
R R
(6) If the indication reappears then record it as a crack. If the indication does not reappear then allow 10 minutes contact time for the developer.
R R R
(7) If the indication reappears after the 10 minutes contact time then record it as a crack. If the indication does not reappear then that area is acceptable.
R R R
(xxiv) The cause of all indications must be evaluated under white light using visual aids, such as magnification, as appropriate.
R R
(xxv) Photograph any suspected crack indications and record them in Appendix 1.
R R
(1) No cracks detected - AcceptR
(2) Any cracks less than or equal to 2mm length - Remove engine within 10 flight cycles R R
(3) Any cracks greater than 2mm length - Remove engine or refer to Rolls-Royce R R NOTE: Any findings outside the above limits can be referred to Rolls-Royce to determine if up to 10 flight cycles additional fly on can be granted in order to facilitate engine removal.
R R R R
(xxvi) Post Clean - Once all indications have been evaluated and recorded, remove the penetrant processing materials from the inspection surface by wiping with a clean OMat 2/101, lint-free cloth moistened with OMat 150 acetone.
R R R R
(xxvii)Restore the OMat 677 penetrant test panel to a completely clean condition and make sure there is no residual fluorescence.
R R
(c) Close access to the tail bearing housing:R
(i) Make sure the work area is clean and clear of tools and other items.
R R Printed in Great Britain RB.211−72−AG971 Page 10 Sep 20/12 May. 5/16R