72-ah465 engine - lp compressor - regulations.gov

All pages ofAppendix 2

Page 1 of Appendix 2 To amend 1.C. Description,1.D. Compliance, 1.E.Approval, 1.F. Manpower,1.H. Tooling and 1.I.References.

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RB.211−72−AH465Transmittal -

LIST OF EFFECTIVE PAGES

The effective pages to this Service Bulletin following incorporation of Revision5 are as follows:

Page Revision Number Revision Date

BulletinR 1 5 Jul.26/18R 2 5 Jul.26/18R 3 5 Jul.26/18R 4 5 Jul.26/18R 5 5 Jul.26/18R 6 5 Jul.26/18R 7 5 Jul.26/18R 8 5 Jul.26/18R 9 5 Jul.26/18R 10 5 Jul.26/18R 11 5 Jul.26/18R 12 5 Jul.26/18R 13 5 Jul.26/18R 14 5 Jul.26/18R 15 5 Jul.26/18

Appendix 1R 1 5 Jul.26/18

Appendix 2R 1 5 Jul.26/18

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RB.211−72−AH465Transmittal -

1. Planning Information

A. Effectivity

Airbus A330

RB211 TRENT768-60, TRENT768-60/15, TRENT768-60/16 Engines

RB211 TRENT772-60, TRENT772-60/15, TRENT772-60/16 Engines

RB211 TRENT772B-60, TRENT772B-60/15, TRENT772B-60/16 Engines

RB211 TRENT772C-60, TRENT772C-60/15, TRENT772C-60/16 Engines.

B. Reason

Problem

Following in-service LP Compressor (LPC) blade release events it is recommendedthat an in-service inspection (ultrasonic) is undertaken to mitigate againstrelease events. The ultrasonic inspection is capable of detecting sub-surfaceanomalies in the LP compressor blade aerofoil. This inspection is available forTrent 700 LP compressor blades at shop visit but the intervals between shopvisits are too large to only use shop visit opportunities therefore on-goingin-service repeat inspections are required.

C. Description

(1) This Non-Modification Service Bulletin (NMSB) is issued to instruct anultrasonic inspection of LP compressor blades aerofoil.

Accomplishment of this NMSB must be recorded against the individual bladesand compliance, blades serial numbers and associated lives (TSN/CSN)logged with your assigned Rolls-Royce Service Representative using theproforma in Appendix 1.

(2) The Accomplishment Instructions for ultrasonic inspection of LP compressorblades is dependent on where the inspection is undertaken as follows:

(a) Accomplishment instructions for removal and installation of LPcompressor blades from an engine on-wing or spare engine forinspection in accordance with Section 3.C. or 3.F - refer to Section3.B.

(b) Accomplishment instructions for C-Scan inspection of LP compressorblades, removed from an engine on-wing or spare engine undertakenin-shop - refer to Section 3.C.

ENGINE - LP COMPRESSOR - INSPECTION OF LP COMPRESSOR BLADES - NON-MODIFICATIONSERVICE BULLETIN - NON - MOD.72-AH465

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(c) Accomplishment instructions for C-Scan inspection of LP compressorblades, removed from an engine in-shop, refer to Section 3.D.

(d) Accomplishment instructions for phased array inspection of LPcompressor blades, installed on an engine, refer to Section 3.E.

(e) Accomplishment instructions for phased array inspection of LPcompressor blades, removed from an engine on-wing or spare engine,refer to Section 3.F.

NOTE: Section 3.B. is only applicable if blades are to be inspectedin accordance with Section 3.C. or 3.F. For Section 3.D, bladesare removed and installed in accordance with Engine Manualprocedures. For Section 3.E, blades are inspected in-situ andtherefore do not require removal.

NOTE: The Engine Manual Task 72-31-11-200-806 was updated at Revision94, dated 10th March 2017, to improve the C-scan inspectioncalibration with the use of calibration blade HU82386. Themanual procedure changes were issued in advance under RepeatTechnical Variance 165864, dated 12th July 2016.

NOTE: The Aircraft Maintenance Manual Tasks 72-31-41-270-801-A and72-31-41-270-802-A were updated at manual revision, dated 1stApril 2017, to improve the Phased Array inspection calibrationwith the use of working standard plate RRT095623. The manualprocedure changes were issued in advance under Repeat TechnicalVariance 166196, dated 9th September 2016.

Revision 1 of this NMSB was issued to remove some of the options to undertakeC-scan inspection of LP Compressor blades, which were no longer required. Theinspection procedures for the phased array technique were replaced with areference to the applicable Aircraft Maintenance Manual inspection proceduretasks. A procedure was added to the Accomplishment Instructions for LPCompressor blades rejected from phased array inspection. Additionally, thetraining requirements for inspection were updated.

Revision 2 of this NMSB was issued to reduce the initial inspection thresholdfrom 3,600 cycles since new to 2,400 cycles since new. An alleviation periodwas included for LP compressor blades that were affected by this change. ThePhased Array inspection training requirements were updated for clarification.

Revision 3 of this NMSB was issued to make reference to the changes implementedto the C-scan and Phased Array inspection procedures. The changes implementeddid not however change the effectiveness of past or future inspections. TheAccomplishment Instructions step 3.B.8 and the Note in 3.A. regarding thevibration survey requirements for replacement blades were also updated to be inline with the Aircraft Maintenance Manual (AMM).

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Revision 4 of this NMSB was issued to reduce the initial and repeat inspectionthreshold from 2,400 cycles to 1,200 cycles. An alleviation period was includedfor LP compressor blades that were affected by this change.

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Revision 5 of this NMSB is issued to specify the requirements for operatorsconducting Standard and Non-Standard Operations (as defined in Time LimitsManual, 05-00-01) in the Compliance section of this NMSB. Futhermore,additional changes have been applied to the Compliance Section to ensure allblades are inspected at an interval of 1,200 cycles by Dec.31/18. Changes havealso been made to the Phased Array training requirements and an alternative tothe current LP compressor training blade standard has been introduced.

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D. Compliance

ALERT

This Non-Modification Service Bulletin is anticipated to be subject to anEASA/FAA Airworthiness Directive.

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Rolls-Royce recommends that the following action is undertaken to maintainreliability.

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This section is in two parts to specify the requirements for operatorsconducting Standard and Non-Standard Operations.

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(1) For operators who conduct Standard Operations (as defined in Time LimitsManual, 05-00-01).

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This NMSB should be accomplished on all LP compressor blades to partnumbers FK23411, FK25441, FK25968, FW11901, FW15393, FW23643, FW23741,FW23744, KH23403 or KH23404 and is in two parts as follows:

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(a) Part 1 - Initial InspectionR

(i) On the issue date of Revision 4 of this NMSB, Oct. 3/17, any LPcompressor blade that had exceeded 600 cycles since new, do aninitial inspection within 600 cycles, no later than 2,400cycles since new or by Dec.31/18, whichever is the sooner,unless previously inspected.

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For LP compressor blades that are above 600 cycles since new buthave not exceeded 1,200 cycles since new on Dec.31/18, inspectthose blades before exceeding 1,200 cycles since new.

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(ii) For LP compressor blades that are not affected by step 1.D.1Part 1 (1), do an inital inspection no later than 1,200 cyclessince new unless previously inspeced.

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NOTE: Previous inspection must have been in accordance with theAccomplishment Instructions of NMSB 72-G702 or NMSB 72-G872or NMSB 72-H311 or NMSB 72-AH465 or Engine Manual Task72-31-11-200-806 or AMM Task 72-31-41-270-801 or AMM Task72-31-41-270-802.

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(b) Part 2 - Repeat InspectionR

(i) On the issue date of Revision 4 of this NMSB, Oct. 3/17, any LPcompressor blade that had exceeded 600 cycles since lastinspection must be re-inspected within 600 cycles, no laterthan 2,400 cycles since last inspection or by Dec.31/18,whichever is the sooner, and thereafter at an interval thatdoes not exceed 1,200 cycles since last inspection.

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For LP compressor blades that are above 600 cycles since lastinspection but have not exceeded 1,200 cycles since lastinspection on Dec.31/18, inspect those blades before exceeding1,200 cycles since last inspection.

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(ii) For LP compressor blades that are not affected by step 1.D.Part 2 (1), re-inspect at an interval that does not exceed1,200 cycles since last inspection.

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NOTE: Last inspection must have been in accordance with theAccomplishment Instructions of NMSB 72-G702 or NMSB 72-G872or NMSB 72-H311 or NMSB 72-AH465 or Engine Manual Task72-31-11-200-806 or AMM Task 72-31-41-270-801 or AMM Task72-31-41-270-802.

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(2) For operators who conduct Non-Standard Operations (as defined in TimeLimits Manual, 05-00-01).

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This NMSB should be accomplished on all LP compressor blades to partnumbers FK23411, FK25441, FK25968, FW11901, FW15393, FW23643, FW23741,FW23744, KH23403 or KH23404 and is in two parts as follows:

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(a) Part 1 - Initial InspectionR

(i) On the issue date of Revision 4 of this NMSB, Oct. 3/17, any LPcompressor blade that had exceeded 600 cycles since new, do aninitial inspection within 600 cycles, no later than 2,400cycles since new or by Dec.31/18, whichever is the sooner,unless previously inspected.

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For LP compressor blades that are above 600 cycles since new buthave not exceeded 1,200 cycles since new on Dec.31/18, inspectthose blades before exceeding 1,200 cycles since new.

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The cycles consumed are calculated by multiplying the number offlights flown by the applicable Beta factors defined in Table 1.

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BetaR

Profile M1R Profile M2R

1R 1.5R

Table 1: Beta FactorsR

(ii) For LP compressor blades that are not affected by 1.D.(2) (a),do an initial inspection no later than 1,200 cycles since newunless previously inspected. The cycles are calculated bymultiplying the flight cycles by the applicable Beta factorsdefined in Table 1.

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NOTE: Previous inspection must have been in accordance with theAccomplishment Instructions of NMSB 72-G702 or NMSB 72-G872or NMSB 72-H311 or NMSB 72-AH465 or Engine Manual Task72-31-11-200-806 or AMM Task 72-31-41-270-801 or AMM Task72-31-41-270-802.

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(b) Part 2 - Repeat InspectionR

(i) On the issue date of Revision 4 of this NMSB, Oct. 3/17, any LPcompressor blade that had exceeded 600 cycles since lastinspection must be re-inspected within 600 cycles, no laterthan 2,400 cycles since last inspection or by Dec.31/18,whichever is the sooner, and thereafter at an interval thatdoes not exceed 1,200 cycles since last inspection. The cyclesare calculated by multiplying the flight cycles by theapplicable Beta factors defined in Table 1.

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For LP compressor blades that are above 600 cycles since lastinspection but have not exceeded 1,200 cycles since lastinspection on Dec.31/18, inspect those blades before exceeding1,200 cycles since last inspection.

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(ii) For LP compressor blades that are not affected by step 1.D. (2)(b), re-inspect at an interval that does not exceed 1,200cycles since last inspection.

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The cycles are calculated by multiplying the number of flightsflown by the applicable Beta factors defined in Table 1.

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NOTE: Last inspection must have been in accordance with theAccomplishment Instructions of NMSB 72-G702 or NMSB 72-G872or NMSB 72-H311 or NMSB 72-AH465 or Engine Manual Task72-31-11-200-806 or AMM Task 72-31-41-270-801 or AMM Task72-31-41-270-802.

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E. ApprovalR

The technical content of this Non-Modification Service Bulletin was approvedunder the authority of Design Organisation Approval EASA.21J.035 on Jul.10/13,and re-approved on Jul.9/15, May.10/16, Apr.25/17, Sep.29/17 and Jul.19/18.

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F. ManpowerR

On-wing:R

(1) Time to remove LP compressor blades:R

3 hours per LP compressor blade set (2 persons)R

(2) Time to inspect LP compressor blades:R

(a) Visual inspection - 4 hours per LP compressor blade set (1 person)R

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(b) C-Scan inspection - 28 hours per LP compressor blade set (1 person)R

NOTE: The C-scan ultrasonic inspection defined in 3. AccomplishmentInstructions shall only be performed by personnel who havereceived specific training either directly by Rolls-Royce orfrom personnel trained by an approved Rolls-Royce supplier.Training records are to be retained and kept up to dateaccording to both local and any Rolls-Royce policies.

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(c) Phased array inspection - 12 hours per LP compressor blade set (1person)

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NOTE: The Phased Array ultrasonic inspection defined in Section 3.Accomplishment Instructions must be performed by personnelqualified to ultrasonic testing (UT) level 2 in accordance withEN4179/NAS-410 or alternative standards/guidelines accepted bythe applicable National Aviation Authority.

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Additionally, all inspection personnel utilising this techniquemust have received specific training and approval eitherdirectly by the Rolls-Royce NDE Laboratory or from Rolls-Royceapproved trainers.

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If an inspector has not performed a complete LP compressorblade set inspection within three months the inspector mustwatch the inspection DVD (DV 131748) prior to performingin-service inspections.

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If an inspector has not performed a complete LP compressorblade set inspection within six months, the inspector mustwatch the inspection DVD (DV 131748) and be re-assessed by a UTLevel 3 who is familiar with the phased array inspectiontechnique, prior to perfoming in-service inspections.Re-assessment must be done using the bench-top set up and LPcompressor training blades that contain known EDM notches(RRT078028 / RRT078029 or as an alternativeRRT078033/RRT078034). The inspector must follow the procedurecorrectly and must successfully identify all known EDM notches.

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If an inspector has not performed three complete LP compressorblade set inspections within twelve months, the inspector mustbe re-assessed by a UT Level 3 who is familiar with the phasedarray inspection technique, prior to performing in-serviceinspections. Re-assessment must be done using the technique tobe undertaken (blades installed or removed) and LP compressortraining blades that contain known EDM notches (RRT078028 /RRT078029 or as an alternative RRT078033/RT078034). Theinspector must follow the procedure correctly and mustsuccessfully identify all known EDM notches.

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(3) Time to install LP compressor blades:R

3 hours per LP compressor blade set (2 persons)R

NOTE: A vibration ground run will be required.R

G. Material Price and AvailabilityR

None.R

H. Tooling Price and AvailabilityR

(1) Tooling for LP compressor blade inspection:R

Tool No.R DescriptionR QtyR

M403TR Triple head ultrasonicimmersion system

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1 offR

RRT076133R Phased array inspectionkit

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1 offR

(2) Consumable Materials:R

Consumable No.R DescriptionR

OMat 655R Ultrasonic CouplantR

(3) Tooling for training purposes:R

Tool No.R DescriptionR QtyR

RRT078028R EDM notched LPcompressor blade

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1 offR


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1 offR

Or as an alternative:R

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1 offR


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1 offR

Please contact your assigned Rolls-Royce field service office for priceand availability.

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I. ReferencesR

(1) Rolls-Royce RB211 Non-Modification Service Bulletins:R

(a) 72-G702R

Engine - LP Compressor - Inspection of LP Compressor Blades -Non-Modification Service Bulletin

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(b) 72-G872R


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(c) 72-H311R


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(2) Aircraft Maintenance Manual (AMM):R

(a) 72-00-00, Test No.11 The Engine Vibration SurveyR

(b) Task 70-20-01-100-802, Non-Aqueous Liquid Degreasing - MaintenanceProcess 101

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(c) 72-31-41, Removal/Installation of LP Compressor Blades and DampersR

(d) Task 72-31-41-200-801, Inspection/Check of LP Compressor BladesR

(e) 72-31-41, LP Compressor Rotor Blade - Re-apply the Dry Film Lubricant(FRSA031)

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(f) 72-31-51, LP Compressor Disc - Re-apply the Dry Film Lubricant(FRSA017)

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(g) 72-31-41, Ultrasonic Inspection of the LP Compressor BladesR

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(3) Engine Manual (EM):R

(a) Task 70-00-00-100-102, Overhaul Process 102, Primary Cleaning -Aqueous (TSD594J)

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(b) Task 70-00-00-200-237, Overhaul Process 237, Procedure for Maintenanceof C-Scan Equipment and for Investigating C-Scan Rejected Blades

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(c) Task 72-31-11-100-801, Clean the Low Pressure (LP) Compressor BladesR

(d) Task 72-31-11-200-801, General data for the Inspection/Check of theLow Pressure (LP) Compressor Blades and Fillers

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(e) Task 72-31-11-200-806, C-Scan Inspection of the Low Pressure (LP)Compressor Blades for Sub-Surface Cracks

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(4) Time Limits Manual (TLM) - 05-00-01.R

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2. Material Information

A. None

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3. Accomplishment Instructions

A. Determine which method of inspection is to be undertaken as follows:

(1) For C-scan inspection of LP compressor blades, removed from an engineon-wing or spare engine, undertaken in-shop use Sections 3.B and 3.C.

(2) For C-scan inspection of LP compressor blades, removed from an enginein-shop use Section 3.D.

(3) For phased array inspection of LP compressor blades installed on an engineuse Section 3.E.

(4) For phased array inspection of LP compressor blades removed from an engineon-wing or spare engine use Sections 3.B and 3.F.

NOTE: If LP compressor blades are replaced in accordance with theseinspections, a vibration survey may be required before the enginereturns to service. Refer to AMM 72-31-41, Removal/Installation forfurther details.

B. Accomplishment Instructions for Removal and Installation of LP CompressorBlades from an Engine On-wing or Spare Engine for inspection in accordance withSections 3.C. or 3.F.

CAUTION: IN ORDER TO REDUCE THE POTENTIAL FOR MULTIPLE ENGINE IN FLIGHT SHUTDOWN,POWER LOSS OR OTHER ANOMALIES DUE TO MAINTENANCE ERROR, ROLLS-ROYCERECOMMENDS THAT OPERATORS AVOID PERFORMING MAINTENANCE ON MULTIPLEENGINES INSTALLED ON THE SAME AIRCRAFT AT THE SAME TIME. IF IT IS NOTPOSSIBLE TO AVOID MAINTENANCE ON MORE THAN ONE ENGINE AT THE SAME TIME,ROLLS-ROYCE RECOMMENDS THAT ADDITIONAL CONTROLS ARE APPLIED IN ORDER TOENSURE THAT MAINTENANCE TASKS HAVE BEEN COMPLETED AS DEFINED.MAINTENANCE GUIDELINES SHOULD BE REVISED, WHERE POSSIBLE, TO PROMOTETHIS RECOMMENDATION.

NOTE: Section 3.B. is only applicable if LP compressor blades are to beinspected in accordance with Sections 3.C. or 3.F.

(1) Remove LP Compressor blades:

(a) Remove the applicable LP compressor blades in accordance with AMM72-31-41, Removal/Installation.

(2) Visually inspect the LP compressor blades in accordance with AMM Task72-31-41-200-801, Inspection/Check.

(3) Accomplish ultrasonic inspection of LP compressor blades in accordancewith Sections 3.C. or 3.F.

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(4) Re-apply the dry film lubricant to the LP compressor blade roots inaccordance with AMM Task 72-31-41-300-802 (FRSA031).

(5) Re-apply the dry film lubricant to the LP compressor disc in accordancewith AMM Task 72-31-51-300-801 (FRSA017).

(6) Install the LP compressor blades in accordance with AMM 72-31-41,Removal/installation.

(7) Restore the engine to serviceable condition in accordance with AMM72-31-41, Removal/Installation.

(8) If replacement LP compressor blades have been installed refer to AMM72-31-41, Removal/Installation to determine if a vibration survey isrequired.

NOTE: If an engine trim balance is undertaken, then the post balancevibration survey may be waived provided the trim balance have beenaccomplished using Rolls-Royce balancing software VX77 and no morethan 6 trim balance bolts have been added/removed. If furtherengine running is not undertaken then engine LP vibration should bemonitored for the next 10 days.

C. Accomplishment Instructions for C-Scan inspection of LP Compressor Blades,removed from an Engine On-Wing or Spare Engine, undertaken in-shop.

(1) Clean the LP compressor blades:

(a) Clean the LP compressor blades in accordance with EM Task72-31-11-100-801, Subtask 72-31-11-110-006-001 (non-aqueous vapour andliquid degreasing OP Task 70-00-00-100-101) or Subtask72-31-11-110-006-002 (primary clean OP Task 70-00-00-100-102, Subtask70-00-00-110-102-001).

(b) If there is the presence of Dry Film Lubricant (DFL) on the LPcompressor blade aerofoil, mask the LP compressor blade root and cleanas follows:

CAUTION: TO MAINTAIN THE CLEANLINESS OF THE WIPING SOLVENT, YOUMUST POUR THE SOLVENT ONTO THE WIPING CLOTH. THE CLOTHMUST NOT BE DIPPED INTO THE SOLVENT CONTAINER.

(i) Apply the solvent to the area to be cleaned using an OMat 2/101lint-free cloth moistened with either OMat 150 Acetone, OMat1/40 Isopropyl alcohol. Discard the soiled cloth after use.

(ii) Repeat the swabbing using fresh cloth and solvent until thearea is clean and free of DFL.

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(iii) Allow the parts to dry. Drying may be assisted by removingexcess solvent using a clean dry lint-free cloth (Material No.OMat 2/101) or a clean oil-free air blast to help dry the part.

(iv) Remove masks from the LP compressor blade root.

(2) Carry out C-Scan inspection of LP compressor blades.

(a) Carry out C-Scan inspection of LP compressor blades in accordance withEM Task 72-31-11-200-806.

(b) If a LP compressor blade is rejected by the C-Scan inspection,inspection and blade data should be entered on the LP compressor bladerejection proforma (Appendix 2) and returned to Rolls-Royce with acopy of the archived scan data.

NOTE: If a LP compressor blade is rejected by the C-scan inspection,the cause of the indication should be investigated inaccordance with Overhaul Process 237.

(3) Dry LP compressor blades.

(a) Dry LP compressor blades in accordance with EM Task 70-00-00-100-102,Subtask 70-00-00-110-102-007.

(4) Accomplishment of NMSB 72-AH465 must be recorded against the individualblades.

D. Accomplishment Instructions for C-Scan inspection of LP Compressor Blades,removed from an Engine In-Shop.

(1) Visually and C-Scan inspect LP compressor blades in accordance with EngineManual 72-31-11.

(2) If a LP compressor blade is rejected, inspection and blade data should beentered on the LP compressor blade rejection proforma (Appendix 2) andreturned to Rolls-Royce with a copy of the archived scan data.

NOTE: If a LP compressor blade is rejected by the C-scan inspection, thecause of the indication should be investigated in accordance withOverhaul Process 237.


E. Accomplishment Instructions for phased array inspection of LP Compressor Blades

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installed on an Engine.

(1) Inspect the LP compressor blades in accordance with AMM Task72-31-41-270-801-A.

NOTE: The Omniscan must be calibrated annually either to themanufacturer's specification or to a relevant national standard oran approved supplier's standard that is equivalent to a relevantnational standard.


F. Accomplishment Instructions for phased array inspection of LP Compressor Bladesremoved from an Engine On-wing or Spare Engine.

(1) Inspect the LP compressor blades in accordance with AMM Task72-31-41-270-802-A.

NOTE: The Omniscan must be calibrated annually either to themanufacturer's specification or to a relevant national standard oran approved supplier's standard that is equivalent to a relevantnational standard.


G. Accomplishment Instructions for LP Compressor Blades Rejected by Phased ArrayInspection in accordance with Section 3.E. or 3.F.

NOTE: Common causes for fan blade rejections by phased array inspection areprovided during training and details are included in the training DVD(DV 131748) and the Operation, Maintenance, Storage and Disposal Manual.

(1) LP compressor blades rejected from phased array inspection in accordancewith section 3.E.or 3.F. should be clearly marked as reject and sent to anoverhaul facility for further inspection and evaluation.

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Ultrasonic Inspected Trent 700 LP Compressor Blade Details

ESN Serial Number TSN CSN NMSB Number

APPENDIX 1

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LP Compressor Blade C-scan Rejection Proforma

Results to be sent to Rolls-Royce via your Service Representative.

Blade Rejection Date:

Blade Part Number: Blade Serial Number:

Blade Time Since New (Hrs/Cycles):

Engine Serial Number: Module Serial Number:

Airline:

C-Scan Results:

1st Indication 2nd Indication 3rd Indication

Percentage of Height

Weighting

Blade Side (A/B)*

(*) A = Convex sideB = Concave side

APPENDIX 2

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72-ah465 engine - lp compressor - regulations.gov

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