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This document transmits the Initial Issue of Service Bulletin RB211-72-J024 and the Initial Issue of the Supplement Bulletin Initial Issue Remove Incorporate Reason for change Pages 1 to 22 of the Service Bulletin Initial Issue Supplement Initial Issue Remove Incorporate Reason for change Page 1 Initial Issue Printed in Great Britain Mar. 1/16 RB211 TRENT 900 SERIES PROPULSION SYSTEMS SERVICE BULLETIN RB.211−72−J024 Transmittal - Page 1 of 2 Date
LIST OF EFFECTIVE PAGES The effective pages to this Service Bulletin are as follows:
Page Revision Number Revision Date Bulletin 1 Mar.1/16 2 Mar.1/16 3 Mar.1/16 4 Mar.1/16 5 Mar.1/16 6 Mar.1/16 7 Mar.1/16 8 Mar.1/16 9 Mar.1/16 10 Mar.1/16 11 Mar.1/16 12 Mar.1/16 13 Mar.1/16 14 Mar.1/16 15 Mar.1/16 16 Mar.1/16 17 Mar.1/16 18 Mar.1/16 19 Mar.1/16 20 Mar.1/16 21 Mar.1/16 22 Mar.1/16 Supplement 1 Mar.1/16 Printed in Great Britain RB.211−72−J024 Transmittal - Page 2
1. Planning Information A. Effectivity Airbus A380 RB211 TRENT970-84 Engines RB211 TRENT972-84 Engines RB211 SE100006, SE100444, SE100560, SE100562, SE100563, SE100577, SE100578, SE100767, SE100768, SE100802, SE100803, SE100804, SE100828, SE100829, SE100830, SE100831, SE100832, SE100885, SE100886, SE100887, SE100888, SE100889, SE100897, SE100898, SE100899, SE100900, SE100904, SE100905, SE100906, SE100907, SE100909, SE100910, SE100924, SE100925 Core Engines RB211 M08100014, M08100443, M08100911 Modules 52 (08) B. Concurrent Requirements None.
C. Reason
(1) Problem and Evidence Premature fatigue cracking, on a number of LP Turbine Exhaust Case and Support Assemblies at vanes 1 and 14 leading edge fillets, have been observed during in-service fluorescent penetrant inspections.
This is attributed to high thermal peak stress at initial ramps during the flight cycle.
(2) Substantiation The changes introduced by this Service Bulletin have been the subject of satisfactory engineering evaluation, including stress and thermal analysis.
(3) Objective Incorporation of this Service Bulletin (Modification) is designed to maintain reliability.
ENGINE - EXHAUST CASE - INTRODUCTION OF LP TURBINE EXHAUST CASE AND SUPPORT ASSEMBLIES ACCOMPLISHED BY REWORK OF EXISTING ASSEMBLIES - MOD.72-J024 Printed in Great Britain RB.211−72−J024 Page 1 of 22 Mar. 1/16 Mar. 1/16
(4) Effect of Bulletin on:
(a) Operation Not affected
(b) Maintenance Not affected
(c) Overhaul Not affected
(d) Repair Schemes Affected (Repairs will be revised to include the part(s) introduced by this Service Bulletin)
(e) Interchangeability Not affected D. Description
(1) The changes are:
(a) Revised LP Turbine Exhaust Case and Support Assemblies are introduced similar to the existing items except they are produced by reworking existing assemblies by machining scallops at the leading edge fillets of vanes 1 and 14.
(2) This Service Bulletin is in three parts as follows:
(a) Part 1 Rework of LP turbine exhaust case and support assembly to Service Bulletin 72-F250 standard.
(b) Part 2 Rework of LP turbine exhaust case and support assembly to Service Bulletin 72-E439 standard.
(c) Part 3 Rework of LP turbine exhaust case and support assembly to pre-Service Bulletin 72-F250 standard.
Printed in Great Britain RB.211−72−J024 Page 2 Mar. 1/16 Mar. 1/16
E. Compliance
(1) ON-WING Not applicable
(2) IN-SHOP
OPTIONAL This Service Bulletin introduces alternative and fully interchangeable parts.
F. Approval The technical content of Service Bulletin 72-J024 was approved by a representative of the European Aviation Safety Agency (EASA) on Jul.2/15, EASA certificate No.10053525.
The technical content under the JAR 25 regulation of this document is approved under the authority of DOA ref. EASA.21J.031.
G. Manpower
(1) On-wing Not applicable
(2) In-shop 12 hours NOTE: The parts affected by this Service Bulletin are accessible on-wing and 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 not required.
J. Weight and Balance
(1) Weight change None.
Printed in Great Britain RB.211−72−J024 Page 3 Mar. 1/16 Mar. 1/16
(2) Moment arm No effect.
(3) Datum Power Plant Station (PPS) 100.
K. References
(1) This Service Bulletin is subject to aircraft Modification No 75499 T85479 (classified minor).
(2) Rolls-Royce Service Bulletins:
(a) 72-E439 Engine - Exhaust Case - Introduction of a revised tail bearing support structure to flight test standard.
(b) 72-F250 Engine - Exhaust Case - Introduction of an LP turbine exhaust case and support assembly with revised manufacturing methods.
(3) Rolls-Royce Non-Modification Service Bulletins:
72-AH154 Engine - LP Turbine Exhaust Case and Support Assembly (Tail Bearing Housing) Mount Lug Forging Leading Edge Inspections - Non-Modification Service Bulletin
(4) Engine Manual, 72-52-00, 72-52-50, Disassembly and Assembly L. Other Publications Affected For effect on Engine Illustrated Parts Catalogue (EIPC) refer to 2. Material Information.
M. Interchangeability of Parts Not affected.
Printed in Great Britain RB.211−72−J024 Page 4 Mar. 1/16 Mar. 1/16
2. Material Information A. The kit required consists of the following parts:
None.
B. Parts to be reworked:
All Engines, Core Engines and Modules 72-52-51 Part 1 of SB FIG ITEM NO.
NEW PART NO.
QTY PART TITLE MAT OLD PART NO.
INSTR DISP 03300 KH46678 1 Case, & support assy of - LP turbine exhaust
- FW51434 (1) Part 2 of SB FIG ITEM NO.
NEW PART NO.
QTY PART TITLE MAT OLD PART NO.
INSTR DISP 03300 KH45090 1 Case, & support assy of - LP turbine exhaust
- FW27718 (1) Part 3 of SB FIG ITEM NO.
NEW PART NO.
QTY PART TITLE MAT OLD PART NO.
INSTR DISP 03300 KH46677 1 Case, & support assy of - LP turbine exhaust
- FW35923 (1) C. New production parts:
The following parts will be made available as future spares in addition to those listed under B:
None.
Printed in Great Britain RB.211−72−J024 Page 5 Mar. 1/16 Mar. 1/16
D. Instruction disposition codes:
(1) Two-Way Interchangeable. Old and new parts are fully interchangeable.
Printed in Great Britain RB.211−72−J024 Page 6 Mar. 1/16 Mar. 1/16
3. Accomplishment Instructions A. The revised LP turbine exhaust case and support assemblies introduced by this Service Bulletin are interchangeable with the existing items (see 1.M.
Interchangeability of Parts). Remove and install in accordance with current overhaul procedures (Engine Manual, 72-52-00, 72-52-50, Disassembly and Assembly). Rework the LP turbine exhaust case and support assemblies in accordance with Part B thru Part D of these Accomplishment Instructions.
B. This TASK gives the procedure to rework the Low Pressure (LP) Turbine Bearing and Support Exhaust Case by machining the Vane Leading Edge at Vanes 1 and 14.
The reworked Low Pressure (LP) Turbine Bearing and Support Exhaust Case introduced by this Service Bulletin is interchangeable with existing.
This TASK can be accomplished in the following circumstances:
A) When the engine is removed from the airframe but assembled and is located on an engine build stand, or on a all purpose stand, or on a multi purpose stand or on a gantry, accomplish in accordance with paragraph 3.C of these accomplishment instructions.
B) When the component is at a piece part level and is located vertically in a suitable stand with the engine mount lugs located at top dead centre, accomplish in accordance with paragraph 3.D of these accomplishment instructions.
General Data Source demonstration is necessary for this rework modification. Only those personnel who hold Certificates of Competence and Valid Approval Documentation from Rolls-Royce plc are authorised to do this rework modification. This source controlled rework modification is classified as a fixed process document and must be controlled as specified in RRES90000.
Material of components
PART IDENTIFICATION SYMBOL MATERIAL Low Pressure (LP) Turbine Bearing and Support Exhaust Case RGB IN718 TASKS identified by OP TASK are in the Overhaul Processes Manual (TSD594-J).
TASKS identified by SPM TASK are in the Standard Practices Manual.
This TASK can only be applied one time on the Vane 1 and one time on the Vane 14.
This TASK is controlled by RPR52361.
Printed in Great Britain RB.211−72−J024 Page 7 Mar. 1/16 Mar. 1/16
EQUIPMENT AND MATERIALS Standard Equipment degreasing equipment hand tools inspection equipment penetrant crack test equipment suction equipment swab etch equipment vibration peen equipment Consumable Material
REFERENCE NAME OMat 1249 polyethylene sheet OMat 262 temporary marker OMat 283B polyester masking tape OMat 670 marker pen OMat 632 fluorescent penetrant, high sensitivity water washable To identify the consumable materials refer to the Overhaul Materials Manual (OMat) Other necessary consumable materials are referred to in the OP TASKS in these accomplishment instructions.
Special Tools
TOOL NUMBER TOOL DESCRIPTION QTY HU45506 T900 TBH vane scallop kit 1 Off This kit contains:
HU45500 T900 TBH vane inspection kit 1 Off HU45501 T900 TBH vane polishing kit 1 Off HU45502 T900 TBH vane machining kit 1 Off HU45507 T900 TBH vane primary fixture kit 1 Off Expendable Parts
FIG/ITEM PART NO PART IDENT QTY None.
Re-work Parts
FIG/ITEM PART NO PART IDENT QTY None.
Printed in Great Britain RB.211−72−J024 Page 8 Mar. 1/16 Mar. 1/16
C. OFF-WING. Rework the Low Pressure (LP) Turbine Bearing and Support Exhaust Case when the engine is removed from the airframe but is assembled.
(1) Clean the part. Locally clean the repair area. Refer to OP TASK 70-00-00-100-101. Use swab method.
Use degreasing equipment.
(2) Fluorescent Penetrant Inspect. Do a penetrant crack test on the Low Pressure (LP) Turbine Bearing and Support Exhaust Case vanes 1 and 14 in accordance with NMSB 72-AH154.
Refer to OP TASK 70-00-00-200-210.
If cracked refer to FRSH741.
If crack is not in the limits of FRSH741 then refer to NMSB72-AH154 for acceptance criteria. Do not complete this rework modification.
(3) Mask the Part Refer to Figure 1, Figure 2 and Figure 3.
Mask the repair area between vane number 11 and vane number 3 and the rear edge of the LP turbine stage 5 blades. Use OMat 1249 polyethylene sheet and OMat 283B polyester masking tape.
(4) Set up the machining equipment. Refer to Figure 1, Figure 2 and Figure 3.
Assemble the Tooling Refer to HU45506 OMSD. Assemble HU45507 and HU45502 to Vane 1 on the Low Pressure (LP) Turbine Bearing and Support Exhaust Case. Assemble the flexible drive to Vane 13 and 14.
Make sure that the debris removal system is installed.
Test the tooling. Refer to the OMSD.
Make sure the debris removal, electric motor, cooling and tool movement systems all function correctly.
Printed in Great Britain RB.211−72−J024 Page 9 Mar. 1/16 Mar. 1/16
(5) Machine Vane 1 Refer to Figure 1, Figure 2 and Figure 3.
Machine the part.
Refer to vendor data cards. Run the electric motor at 3000 rpm +/- 250 rpm. Cut for 3 sec +/- 1 sec per contact of the cutting tool to the Tail Bearing Housing. Machine vane 1 to the dimensions specified. Make sure that the cutting tool is supplied with adequate water coolant.
Make sure the cutting tool has a rest period to remove debris using suction equipment and cool the cutting tool between contact periods with the part.
(6) Remove the machining equipment. Refer to Figure 1, Figure 2 and Figure 3.
Remove the Tooling Refer to HU45506 OMSD. Remove HU45502 from Vane 1 on the Low Pressure (LP) Turbine Bearing and Support Exhaust Case. Remove the flexible drive from Vane 13 and 14. Make sure that the debris removal system is removed.
(7) Clean the part. Locally clean the repair area. Refer to OP TASK 70-00-00-100-101. Use swab method.
Use degreasing equipment.
(8) Break Sharp Edges on Vane 1 Refer to Figure 1, Figure 2 and Figure 3.
Remove the sharp edges from the vane machining.
Refer to vendor data cards. Use HU45501 T900 TBH Vane Polishing Kit.
Break the sharp edges by using 120 grit Policap for 20 seconds per side at 11000 rpm +/- 500rpm.
Printed in Great Britain RB.211−72−J024 Page 10 Mar. 1/16 Mar. 1/16