rb.211−72−j024 - regulations.gov

This document transmits the Initial Issue of Service Bulletin RB211-72-J024 andthe Initial Issue of the Supplement

Bulletin Initial Issue

Remove Incorporate Reason for changePages 1 to 22 of theService Bulletin

Initial Issue

Supplement Initial Issue

Remove Incorporate Reason for change Initial Issue

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RB211 TRENT 900 SERIES PROPULSION SYSTEMS SERVICE BULLETIN

RB.211−72−J024Transmittal - Page 1 of 2

Date

LIST OF EFFECTIVE PAGES

The effective pages to this Service Bulletin are as follows:

Page Revision Number Revision Date

Bulletin1 Mar.1/162 Mar.1/163 Mar.1/164 Mar.1/165 Mar.1/166 Mar.1/167 Mar.1/168 Mar.1/169 Mar.1/1610 Mar.1/1611 Mar.1/1612 Mar.1/1613 Mar.1/1614 Mar.1/1615 Mar.1/1616 Mar.1/1617 Mar.1/1618 Mar.1/1619 Mar.1/1620 Mar.1/1621 Mar.1/1622 Mar.1/16

Supplement1 Mar.1/16

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RB.211−72−J024Transmittal -

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 andSupport Assemblies at vanes 1 and 14 leading edge fillets, have beenobserved during in-service fluorescent penetrant inspections.

This is attributed to high thermal peak stress at initial ramps during theflight cycle.

(2) Substantiation

The changes introduced by this Service Bulletin have been the subject ofsatisfactory engineering evaluation, including stress and thermalanalysis.

(3) Objective

Incorporation of this Service Bulletin (Modification) is designed tomaintain reliability.

ENGINE - EXHAUST CASE - INTRODUCTION OF LP TURBINE EXHAUST CASE AND SUPPORTASSEMBLIES ACCOMPLISHED BY REWORK OF EXISTING ASSEMBLIES - MOD.72-J024

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(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 bythis Service Bulletin)

(e) Interchangeability

Not affected

D. Description

(1) The changes are:

(a) Revised LP Turbine Exhaust Case and Support Assemblies are introducedsimilar to the existing items except they are produced by reworkingexisting assemblies by machining scallops at the leading edge filletsof 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 ServiceBulletin 72-F250 standard.

(b) Part 2

Rework of LP turbine exhaust case and support assembly to ServiceBulletin 72-E439 standard.

(c) Part 3

Rework of LP turbine exhaust case and support assembly to pre-ServiceBulletin 72-F250 standard.

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E. Compliance

(1) ON-WING

Not applicable

(2) IN-SHOP

OPTIONAL

This Service Bulletin introduces alternative and fully interchangeableparts.

F. Approval

The technical content of Service Bulletin 72-J024 was approved by arepresentative of the European Aviation Safety Agency (EASA) on Jul.2/15, EASAcertificate No.10053525.

The technical content under the JAR 25 regulation of this document is approvedunder 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-wingand 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.

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(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 supportstructure to flight test standard.

(b) 72-F250

Engine - Exhaust Case - Introduction of an LP turbine exhaust case andsupport assembly with revised manufacturing methods.

(3) Rolls-Royce Non-Modification Service Bulletins:

72-AH154

Engine - LP Turbine Exhaust Case and Support Assembly (Tail BearingHousing) Mount Lug Forging Leading Edge Inspections - Non-ModificationService 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. MaterialInformation.

M. Interchangeability of Parts

Not affected.

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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

FIGITEMNO.

NEWPARTNO.

QTY PART TITLE MAT OLDPARTNO.

INSTRDISP

03300 KH46678 1 Case, & supportassy of -LP turbine exhaust

- FW51434 (1)

Part 2 of SB

FIGITEMNO.

NEWPARTNO.


INSTRDISP


- FW27718 (1)

Part 3 of SB

FIGITEMNO.

NEWPARTNO.


INSTRDISP


- FW35923 (1)

C. New production parts:

The following parts will be made available as future spares in addition tothose listed under B:

None.

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D. Instruction disposition codes:

(1) Two-Way Interchangeable. Old and new parts are fully interchangeable.

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3. Accomplishment Instructions

A. The revised LP turbine exhaust case and support assemblies introduced by thisService Bulletin are interchangeable with the existing items (see 1.M.Interchangeability of Parts). Remove and install in accordance with currentoverhaul procedures (Engine Manual, 72-52-00, 72-52-50, Disassembly andAssembly). Rework the LP turbine exhaust case and support assemblies inaccordance with Part B thru Part D of these Accomplishment Instructions.

B. This TASK gives the procedure to rework the Low Pressure (LP) Turbine Bearingand Support Exhaust Case by machining the Vane Leading Edge at Vanes 1 and 14.

The reworked Low Pressure (LP) Turbine Bearing and Support Exhaust Caseintroduced 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 onan engine build stand, or on a all purpose stand, or on a multi purpose stand oron a gantry, accomplish in accordance with paragraph 3.C of these accomplishmentinstructions.

B) When the component is at a piece part level and is located vertically in asuitable stand with the engine mount lugs located at top dead centre, accomplishin accordance with paragraph 3.D of these accomplishment instructions.

General Data

Source demonstration is necessary for this rework modification. Only thosepersonnel who hold Certificates of Competence and Valid Approval Documentationfrom Rolls-Royce plc are authorised to do this rework modification. This sourcecontrolled rework modification is classified as a fixed process document and mustbe controlled as specified in RRES90000.

Material of components

PART IDENTIFICATION SYMBOL MATERIAL

Low Pressure (LP) Turbine Bearingand 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.

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EQUIPMENT AND MATERIALS

Standard Equipment

degreasing equipmenthand toolsinspection equipmentpenetrant crack test equipmentsuction equipmentswab etch equipmentvibration peen equipment

Consumable Material

REFERENCE NAMEOMat 1249 polyethylene sheetOMat 262 temporary markerOMat 283B polyester masking tapeOMat 670 marker penOMat 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 theseaccomplishment instructions.

Special Tools

TOOL NUMBER TOOL DESCRIPTION QTYHU45506 T900 TBH vane scallop kit 1 Off

This kit contains:HU45500 T900 TBH vane inspection kit 1 OffHU45501 T900 TBH vane polishing kit 1 OffHU45502 T900 TBH vane machining kit 1 OffHU45507 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.

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C. OFF-WING. Rework the Low Pressure (LP) Turbine Bearing and Support Exhaust Casewhen the engine is removed from the airframe but is assembled.

(1) Clean the part. Locally clean the repair area. Referto OP TASK 70-00-00-100-101. Use swabmethod.Use degreasing equipment.

(2) Fluorescent Penetrant Inspect. Do a penetrant crack test on the LowPressure (LP) Turbine Bearing andSupport Exhaust Case vanes 1 and 14in 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 ofFRSH741 then refer to NMSB72-AH154for acceptance criteria. Do notcomplete this rework modification.

(3) Mask the Part Refer to Figure 1, Figure 2 andFigure 3.Mask the repair area between vanenumber 11 and vane number 3 and therear edge of the LP turbine stage 5blades. Use OMat 1249 polyethylenesheet and OMat 283B polyester maskingtape.

(4) Set up the machining equipment. Refer to Figure 1, Figure 2 andFigure 3.

Assemble the ToolingRefer to HU45506 OMSD. AssembleHU45507 and HU45502 to Vane 1 on theLow Pressure (LP) Turbine Bearing andSupport Exhaust Case. Assemble theflexible drive to Vane 13 and 14.Make sure that the debris removalsystem is installed.Test the tooling. Refer to the OMSD.Make sure the debris removal,electric motor, cooling and toolmovement systems all functioncorrectly.

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(5) Machine Vane 1 Refer to Figure 1, Figure 2 andFigure 3.

Machine the part.Refer to vendor data cards. Run theelectric motor at 3000 rpm +/- 250rpm. Cut for 3 sec +/- 1 sec percontact of the cutting tool to theTail Bearing Housing. Machine vane 1to the dimensions specified. Makesure that the cutting tool issupplied with adequate water coolant.Make sure the cutting tool has a restperiod to remove debris using suctionequipment and cool the cutting toolbetween contact periods with thepart.

(6) Remove the machining equipment. Refer to Figure 1, Figure 2 andFigure 3.

Remove the ToolingRefer to HU45506 OMSD. Remove HU45502from Vane 1 on the Low Pressure (LP)Turbine Bearing and Support ExhaustCase. Remove the flexible drive fromVane 13 and 14. Make sure that thedebris removal system is removed.


(8) Break Sharp Edges on Vane 1 Refer to Figure 1, Figure 2 andFigure 3.

Remove the sharp edges from the vanemachining.Refer to vendor data cards. UseHU45501 T900 TBH Vane Polishing Kit.Break the sharp edges by using 120grit Policap for 20 seconds per sideat 11000 rpm +/- 500rpm.

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(9) Polish Vane 1 Refer to Figure 1, Figure 2 andFigure 3.

Polish Vane 1.Refer to vendor data cards. Polishvane 1 to create the surface finishspecified. Use HU45434 T900 TBH VanePolishing Kit. Polish the machinedsurfaces by using 2 off 120 gritPoliroll for 60 seconds each at 11000rpm +/- 500rpm.

(10) Inspect Vane 1 Refer to Figure 1, Figure 2 andFigure 3.

Inspect the part.Refer to vendor data cards. Refer toHU45506 OMSD for installation andremoval instructions. Inspect vane 1.Use HU45500 T900 TBH vane inspectionkit and inspection equipment. If notin the limits then contactRolls-Royce.



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Polish the part.Refer to vendor data cards. Polishvane 14 to create the surface finishspecified. Use HU45434 T900 TBH VanePolishing Kit. Polish the machinedsurfaces by using 2 off 120 gritPoliroll for 60 seconds each at 11000rpm +/- 500rpm.


Inspect the part.Refer to vendor data cards. Refer toHU45506 OMSD for installation andremoval instructions. Inspect vane14. Use HU45500 T900 TBH vaneinspection kit and inspectionequipment. If not in the limits thencontact Rolls-Royce.

(18) Clean the part. Locally clean the repair area on vane1 and vane 14. Refer to OP TASK70-00-00-100-101. Use swab method.Use degreasing equipment.

(19) Etch the part. Swab etch vane 1 and vane 14. Referto OP TASK 70-00-00-100-148 and usethe ferric chloride etch paste. Useswab etch equipment.

(20) Fluorescent Penetrant Inspect. Do a local penetrant crack test onthe Low Pressure (LP) Turbine Bearingand Support Exhaust Case vane 1 andvane 14 in the machined area. UseOMat 632 fluorescent penetrant, highsensitivity water washable.Refer to OP TASK 70-00-00-200-210.Reject if cracked.

(21) Remove the Masking Refer to Figure 1, Figure 2 andFigure 3.

Remove the masking in the repair areabetween vane number 11 and vanenumber 3 and the rear edge of the LPturbine stage 5 blades.

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(22) Re-identify the Low Pressure (LP)Turbine Bearing and Support ExhaustCase.

Refer to Figure 1, Figure 2 andFigure 3.

Strike out the part number andvibration peen the new part number inthe position specified. Use vibrationpeen equipment.

Existing PartNumber

New Part Number

FW27718 KH45090FW35923 KH46677FW51434 KH46678

Record the accomplishment of thisService Bulletin in the engine logbook.

D. OFF-WING. Rework the Low Pressure (LP) Turbine Bearing and Support Exhaust Casewhen it is at piece part level.


(2) Fluorescent Penetrant Inspect. Do a penetrant crack test on the LowPressure (LP) Turbine Bearing andSupport Exhaust Case vanes 1 and 14in 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 ofFRSH741 then refer to NMSB72-AH154for acceptance criteria. Do notcomplete this rework modification.

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Polish Vane 1.Refer to vendor data cards. Polishvane 1 to create the surface finishspecified. Use HU45434 T900 TBH VanePolishing Kit. Polish the machinedsurfaces by using 2 off 120 gritPoliroll for 60 seconds each at 11000rpm +/- 500rpm.


Inspect the part.Refer to vendor data cards. Refer toHU45506 OMSD for installation andremoval instructions. Inspect vane 1.Use HU45500 T900 TBH vane inspectionkit and inspection equipment. If notin the limits then contactRolls-Royce.



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Polish the part.Refer to vendor data cards. Polishvane 14 to create the surface finishspecified. Use HU45434 T900 TBH VanePolishing Kit. Polish the machinedsurfaces by using 2 off 120 gritPoliroll for 60 seconds each at 11000rpm +/- 500rpm.


Inspect the part.Refer to vendor data cards. Refer toHU45506 OMSD for installation andremoval instructions. Inspect vane14. Use HU45500 T900 TBH vaneinspection kit and inspectionequipment. If not in the limits thencontact Rolls-Royce.

(17) Clean the part. Locally clean the repair area on vane1 and vane 14. Refer to OP TASK70-00-00-100-101. Use swab method.Use degreasing equipment.

(18) Etch the part. Swab etch vane 1 and vane 14. Referto OP TASK 70-00-00-100-148 and usethe ferric chloride etch paste. Useswab etch equipment.

(19) Fluorescent Penetrant Inspect. Do a local penetrant crack test onthe Low Pressure (LP) Turbine Bearingand Support Exhaust Case vane 1 andvane 14 in the machined area. UseOMat 632 fluorescent penetrant, highsensitivity water washable.Refer to OP TASK 70-00-00-200-210.Reject if cracked.

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(20) Re-identify the Low Pressure (LP)Turbine Bearing and Support ExhaustCase.

Refer to Figure 1, Figure 2 andFigure 3.

Strike out the part number andvibration peen the new part number inthe position specified. Use vibrationpeen equipment.

Existing PartNumber

New Part Number

FW27718 KH45090FW35923 KH46677FW51434 KH46678

Record the accomplishment of thisService Bulletin in the engine logbook.

E. A record of accomplishment is required.

The Service Bulletin number and relevant Service Bulletin parts shall be recordedin the engine log book when the Service Bulletin part is fitted in its entirety.

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Rework detailsFigure 1

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SUPPLEMENT - PRICE AND AVAILABILITY

This is a technical document not a quotation; any prices and delivery given are ingood faith without engagement.

Alternative parts may be supplied instead of parts listed. See Material Informationdisposition instructions.

1. Modification Kit

Not applicable. Parts supplied as single line items.

2. New production or rework parts:

Part No. QtyUnit PriceUS Dollars

KH45090 1 Price will be supplied on requestKH46677 1 Price will be supplied on requestKH46678 1 Price will be supplied on request

3. Tools

None.

ENGINE - EXHAUST CASE - INTRODUCTION OF LP TURBINE EXHAUST CASE AND SUPPORTASSEMBLIES ACCOMPLISHED BY REWORK OF EXISTING ASSEMBLIES - MOD.72-J024

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rb.211−72−j024 - regulations.gov

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