Why is EASA Mandating New Inspections for Rolls-Royce Trent 1000 Engines?

The European Union Aviation Safety Agency (EASA) has issued a critical Airworthiness Directive (AD) for certain Rolls-Royce Trent 1000 engines. The directive mandates immediate, repetitive inspections of specific engine components. This action addresses an unsafe condition identified by the engine manufacturer, Rolls-Royce. The AD applies to numerous Trent 1000 engine models installed on the Boeing 787 Dreamliner aircraft.

Unsafe Condition and Required Action

The AD was prompted by the possibility of a specific part releasing into the engine. Rolls-Royce identified that the high-pressure compressor (HPC) mini-disc anti-rotation block could potentially release. This release could enter the HPC assembly stage 5 and 6 discs and the cone rotor rear shaft.

If this condition is not detected and corrected, it could lead to structural failures of critical engine parts. The ultimate risk is an engine in-flight shut-down (IFSD), which could reduce control of the airplane.

To mitigate this risk, EASA's directive requires operators to perform repetitive borescope inspections (BSIs).

• Inspections must focus on the HPC rear drum cavity and the spaces between each HPC rotor disc.
• Depending on the inspection results, the engine may require immediate removal from service.
• The directive allows an alternative compliance method for operators using the Rolls-Royce Engine Health Monitoring (EHM) service.

Impact on Airlines and Operations

This regulatory action places a significant increased maintenance burden on airlines globally. The Trent 1000 engine powers a large segment of the Boeing 787 fleet, a key long-haul aircraft for many carriers.

Operators must comply with the AD's strict deadlines and inspection intervals. Failing to comply means the aircraft cannot legally operate. This can lead to unscheduled engine removals and potential Aircraft on Ground (AOG) situations. Such delays are costly and disrupt flight schedules for passengers.

Rolls-Royce continues to work on a permanent engineering solution for this issue. The AD is a mandatory interim measure to ensure the continued airworthiness of the affected fleet. Operators must follow the instructions detailed in the relevant Rolls-Royce service bulletin (SB) or Non-Modification Service Bulletin (NMSB) referenced in the AD.

Regulatory Context

EASA, as the design approval holder for the engine, issued this AD (EASA AD 2024-0122). The Federal Aviation Administration (FAA) in the United States has also issued a corresponding AD, known as a Mandatory Continuing Airworthiness Information (MCAI). This dual regulatory action highlights the global safety priority of addressing the Rolls-Royce Trent 1000 engine component integrity. The directive underscores the aviation industry's commitment to proactive safety management.

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