TRENT 1000 SERIES

SERVICE BULLETIN

ENGINE - HP TURBINE NOZZLE GUIDE VANE (NGV) - FLAP SEAL ASSEMBLY BORESCOPE
INSPECTION - ALERT NON-MODIFICATION SERVICE BULLETIN - NON - MOD.72-AK269

1. Planning Information
Printed in Great Britain

A. Effectivity

(1) Boeing 787

TRENT 1000-AE3 Engines

TRENT 1000-CE3 Engines

TRENT 1000-D3 Engines

TRENT 1000-G3 Engines

TRENT 1000-H3 Engines

TRENT 1000-J3 Engines

TRENT 1000-K3 Engines

TRENT 1000-L3 Engines

TRENT 1000-M3 Engines

TRENT 1000-N3 Engines

TRENT 1000-P3 Engines

TRENT 1000-Q3 Engines

TRENT 1000-R3 Engines

(2) Airbus A330

TRENT 7000-72 Engines

TRENT 7000-72C Engines

B. Reason

(1) Problem

High Pressure Turbine (HPT) Nozzle Guide Vane (NGV) Flap Seal assemblies
have exhibited wear that may lead to HPT NGV cooling air blockages. This
could cause premature degradation of the HPT NGV aerofoils which could
potentially lead to HPT Blade fracture.

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
SERVICE BULLETIN

(2) Safety Intent

The safety intent of this Non-Modification Service Bulletin (NMSB) is to

instruct an inspection to the HPT NGV Flap Seal Assembly for Flap Seal
Spring Clip loss to prevent the risk of HP Turbine blade failure. This
method will reduce the risk of HPT NGV Flap Seal Spring Clip release and

Printed in Great Britain

the potential subsequent HPT NGV cooling air blockage in the affected
fleets.

C. Description

This NMSB instructs the mandatory inspection of the HPT NGV Flap Seal assembly.
Ongoing repeat inspections are to be carried out in accordance with section
1.D. Compliance.

Accomplishment of this NMSB should be recorded in accordance with local Service

Bulletin tracking procedures.

Return the borescope inspection report and any available photos and/or videos
to your Rolls-Royce Airline Support Team.

Revision 1 of this Non-Modification Service Bulletin (NMSB) has been issued to

extend the 1.A. Effectivity to include Trent 1000 TEN engine variant, to update
the compliance statement and to revise the Accomplishment Instructions to
include an on-wing inspection.

D. Compliance

(1) On-Wing

ALERT

(a) For engines that have exceeded 950 engine flight cycles from new on
the date of issue for Revision 1 of this NMSB, this task should be
completed at the next available maintenance opportunity but not
exceeding 50 engine flight cycles after the issue of this NMSB and
then repeated at every 250 engine flight cycles.

(b) For engines below 950 engine flight cycles from new on the date of the
issue for Revision 1 of this NMSB, this task should be completed at no
more than 1000 engine flight cycles from new and then repeated at
every 250 engine flight cycles.

(c) For engines previously inspected in accordance with NMSB 72-K296 Rev 1
or Technical Variance TV199974 or TV200108; inspection shall be
performed in accordance with the sections (a) and (b) of 1.D
Compliance or prior to reaching 250 engine cycles since incorporating
NMSB 72-K296 Rev 1, TV199974 or TV200108,whichever is later.

Dec 19/18
Aug. 2/19
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SERVICE BULLETIN

(2) In-Shop

Not Applicable

E. Approval
Printed in Great Britain

The technical content of this Non-Modification Service Bulletin was approved

under the authority of Design Organisation Approval EASA.21J.035 on Dec.19/18
and was re-approved under the authority of Design Organisation Approval EASA
21J.065 on Xxx.XX/XX.

F. Manpower

(1) On-Wing

(a) Time to gain access:

0.5 man-hours (0.5-hour x 1 person) - Estimated

(b) Time to inspect:

3 man-hours (3 hours x 1 person) - Estimated

(c) Time to restore to serviceable condition:

0.5 man-hours (0.5-hour x 1 person) - Estimated

(2) In-Shop

(a) Not affected

G. Material Price and Availability

Not applicable.

H. Tooling Price and Availability

(1) 4 mm diameter flexible videoscope with a minimum length of 3 metres.

(2) RRT116715 (or Locally Manufactured Equivalent) - Inspection Nylon Guide

Tube.

(3) 6mm Borescope Probe Holder.

Prices are available on request.

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
SERVICE BULLETIN

I. References

(1) Aircraft Maintenance Manual (AMM):

(a) TRENT 1000

Printed in Great Britain

(i) DMC-B787-A-R72-00-00-22C-280C-A, High Pressure Nozzle Guide
Vanes (with a Borescope) - Special Detailed Inspection

(ii) DMC-B787-A-R72-00-00-32C-520A-A, Borescope Blanking Plug (Task

Selection) - Removal

(iii) DMC-B787-A-R72-00-00-32C-720A-A, Borescope Blanking Plug (Task

Selection) - Installation

(b) TRENT 7000

(i) AMM TASK 72-00-00-290-843-A, Special Detailed Inspection of the

HP Turbine Nozzle Guide Vanes

(ii) AMM TASK 72-00-01-000-801-A, Removal of the Borescope Blanking

Plugs

(iii) AMM TASK 72-00-01-400-801-A, Installation of the Borescope

Blanking Plugs

(2) Engine Manual (EM):

(a) TRENT 1000

72-41-14-200-801, Intrascope Inspection of the High Pressure (HP)

Nozzle Guide Vanes

(b) TRENT 7000

72-41-14-200-801, Intrascope Inspection of the High Pressure (HP)

Nozzle Guide Vanes

(3) Technical Publications:

(a) TRENT 1000 NMSB 72-K296

(b) TV199974

(c) TV200108

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
SERVICE BULLETIN

2. Material Information

A. Consumable Materials

OMat Description Qty

Printed in Great Britain

4/62 Compound - Anti-seize, As required

High Temperature

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
SERVICE BULLETIN

3. Accomplishment Instructions

A. On-Wing

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. DO NOT

Printed in Great Britain

TOUCH HOT PARTS WITHOUT THE APPLICABLE GLOVES. HOT PARTS CAN
CAUSE INJURIES TO PERSONNEL.

CAUTION: IN ORDER TO REDUCE THE POTENTIAL FOR MULTIPLE ENGINE IN-FLIGHT

SHUTDOWNS, POWER LOSS, OR OTHER ANOMALY 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.

(1) Prepare the aircraft for maintenance:

(a) For TRENT 1000

Prepare for the inspection in accordance with

DMC-B787-A-R72-00-00-22C-280C-A, HP Nozzle Guide Vanes (with a
Borescope) Special Detailed Inspection.

(b) For TRENT 7000

Prepare for the inspection in accordance with AMM TASK

72-00-00-290-843-A, Special Detailed Inspection of the HP Turbine
Nozzle Guide Vanes.

(2) Procedure:

CAUTION: DO NOT START THE INSPECTION UNTIL THE ENGINE HAS COOLED TO
WITHIN THE BORESCOPE MANUFACTURERS RECOMMENDATIONS. THE
ENGINE IS HOT IMMEDIATELY AFTER THE ENGINE IS STOPPED AND
CAN CAUSE BURNS AND DAMAGE TO BORESCOPE INSPECTION
EQUIPMENT.

CAUTION: DO NOT START THE INSPECTION UNTIL THE ENGINE HAS COOLED TO
WITHIN THE INSPECTION NYLON GUIDE TUBE TEMPERATURE
SPECIFICATION. THE ENGINE IS HOT IMMEDIATELY AFTER THE
ENGINE IS STOPPED AND CAN CAUSE BURNS AND DAMAGE TO THE
NYLON GUIDE TUBE.

Dec 19/18
Aug. 2/19
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(a) Perform the following tasks to gain access and inspect the HPT NGV
Flap Seal Assemblies.

(i) Remove the combustor borescope blanking plug from the 3 o'clock
position (rear looking forward) and the HPT borescope blanking
plug in accordance with the following:
Printed in Great Britain

(1) For TRENT 1000:

DMC-B787-A-R72-00-00-32C-520A-A, Borescope Blanking Plug

(Task Selection) - Removal

(2) For TRENT 7000:

AMM TASK 72-00-01-000-801-A, Removal of the Borescope

Blanking Plugs

(ii) Assemble the applicable borescope:

(1) Prepare the borescope equipment to the manufacturer's

instructions.

(iii) Prepare the Inspection Guide Tube RRT116715 (or locally

manufactured equivalent).

(1) Insert the Stainless Steel Bar into the straight end of the
shaped Nylon Guide Tube to straighten the pre-formed curve at
the far end of the tube. Refer to Fig. 1.

NOTE: The Stainless Steel Bar should reach the far end of
the Nylon Guide Tube, but should not extend outside
the far end of the tube.

NOTE: Deformation of the Stainless Steel Bar is likely. The

Stainless Steel Bar is intentionally malleable to aid
insertion of the Nylon Guide Tube into the engine.

(iv) Position the Inspection Guide Tube RRT116715 (or locally

manufactured equivalent) into the engine.

(1) Insert the straightened Nylon Guide Tube through the 3

o'clock combustor inspection port, into the combustion
chamber.

(2) Continue to advance the Nylon Guide Tube in a straight line

through the Dilution Chute on the inner wall of the
Combustion Chamber until the end of the guide tube hits the
Combustion Rear Inner Case (CRIC). There should be
approximately 175mm (7.0 inches) of the Nylon Guide Tube
remaining outside the engine when it is fully inserted. Refer
to Fig. 2.

Dec 19/18
Aug. 2/19
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 TRENT 1000 SERIES
SERVICE BULLETIN

(3) Optional - To aid insertion of the Nylon Guide Tube through

the Dilution Chute of the Combustor Chamber, insert the
borescope through the HPT borescope port to provide in-engine
visibility. Remove the borescope from the HPT port once the
Nylon Guide Tube is in position. Refer to Fig. 3.

Printed in Great Britain

(4) Rotate the Nylon Guide Tube until the slot on the straight
end of the tube is facing the rear of the engine and at
approximately 45 degrees down from the horizontal. Refer to
Fig. 3.

(5) Hold the Nylon Guide Tube in place and remove the Stainless
Steel Bar from the centre of the tube, allowing the end of
the tube to return to its curved shape.

(6) Hold the Nylon Guide Tube in position and insert the 4 mm
borescope through the Nylon Guide Tube until the borescope
exits the tube.

(7) Re-position the Nylon Guide Tube such that the borescope can
be advanced rearwards towards the inspection cavity. Refer to
Fig. 2.

(8) Optional - Use a 6mm Borescope Probe Holder to secure the

Nylon Guide Tube in position.

(v) Insert the borescope.

(1) Advance the borescope towards the inspection cavity. Refer to

Fig. 2.

(2) Feed the borescope 360 degrees down and around the inspection
cavity highlighted in Fig. 2 until the borescope entry is
visible. Make sure all 18 of the HPT NGV Flap Seal Assemblies
will be visible when withdrawing the borescope. Refer to Fig.
4.

NOTE: Almost 3m of borescope cable length is required to

reach 360 degrees around the engine.

(vi) Inspect the HPT NGV Flap Seal Assemblies for Flap Seal Spring
Clip loss.

(1) Inspect each of the HPT NGV Flap Seal Assemblies by slowly
withdrawing the borescope from the engine. Refer to Fig. 5.

NOTE: There are 18 off Flap Seal Assemblies (Seal Plate,

Overlap Plate and Spring Clips) with two retaining
pins on each.

Dec 19/18
Aug. 2/19
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 TRENT 1000 SERIES
SERVICE BULLETIN

(2) Inspection findings are to be assessed against the following

criteria:

A Any type of damage to the flap seal plate, overlap plate,

flap seal spring clip, flap seal retainer pins and RIDN
lugs, ACCEPT the engine and proceed to the next step.
Printed in Great Britain

Refer to Fig. 5.

B Any mis-built flap seals (incorrect position), ACCEPT the

engine and proceed to next step. Refer to Fig. 5.

C If there are no flap seal spring clips missing, ACCEPT

the engine and proceed to step 3.A.(3). Inspection of the
HPT NGVs is not required.

D If not more than two flap seal spring clips are missing,
ACCEPT the engine subject to satisfactory inspection of
the HPT NGVs. Proceed to step 3.A.(2)(b). inspection of
the HPT NGV is required.

E If three or more flap seal spring clips are missing,

REJECT the engine within 20 flight cycles subject to
satisfactory inspection of the HPT NGVs. Proceed to step
3.A.(2) (b). Inspection of the HPT NGV is required.

(3) Carefully remove the borescope fully from the Nylon Guide
Tube and then remove the Probe Holder (if fitted) and Nylon
Guide Tube from the engine.

(4) Re-install the Combustor and HPT borescope plugs:

A For TRENT 1000

Install in accordance with

DMC-B787-A-R72-00-00-32C-720A-A, Borescope Blanking Plug
(Task Selection) - Installation

B For TRENT 7000

Install in accordance with AMM TASK 72-00-01-400-801-A,

Installation of the Borescope Blanking Plugs.

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Aug. 2/19
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 TRENT 1000 SERIES
SERVICE BULLETIN

(b) Borescope inspect the HPT NGVs Leading Edge (Area A), Trailing Edge
(Area B, Concave side only), and Concave Surfaces (Area C) in
accordance with the applicable AMM task. Damage observed on the NGVs
outside of these specified areas is also to be sentenced against the
AMM.

Printed in Great Britain

NOTE: Use of a 4mm borescope is not required for the inspection of
the HPT NGVs.

(i) For TRENT 1000:

(1) Inspect in accordance with AMM Task

DMC-B787-A-R72-00-00-22C-280C-A, High Pressure Nozzle Guide
Vanes (with a Borescope) Special Detailed Inspection.

(ii) For TRENT 7000:

(1) Inspect in accordance with AMM TASK 72-00-00-290-843-A,

Special Detailed Inspection of the HP Turbine Nozzle Gude
Vanes.

(3) Return the engine to a serviceable condition:

(a) Make sure that the work area is clean and clear of tools and other
items.

(b) Return the engine to a serviceable condition in accordance with the

following:

(i) For TRENT 1000:

Use AMM Task DMC-B787-A-R72-00-00-22C-280C-A, High Pressure Nozzle

Guide Vanes (with a Borescope) Special Detailed Inspection.

(ii) For TRENT 7000:

Use AMM TASK 72-00-00-290-843-A, Special Detailed Inspection of

the HP Turbine Nozzle Guide Vanes.

(4) Accomplishment of this NMSB should be recorded in accordance with local

Service Bulletin tracking system procedures.

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
Printed in Great Britain SERVICE BULLETIN

RRT116715 (or locally manufactured equivalent)

Fig.1

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
SERVICE BULLETIN

Printed in Great Britain

Inspection Cavity
HPT NGV Flap Seal Assembly - Inspection cavity
Fig.2 (Sheet 1 of 3)

Dec 19/18
Aug. 2/19
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 TRENT 1000 SERIES
Printed in Great Britain SERVICE BULLETIN

Inspection Cavity
HPT NGV Flap Seal Assembly - Inspection cavity
Fig.2 (Sheet 2 of 3)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
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Printed in Great Britain

Inspection Cavity
HPT NGV Flap Seal Assembly -Inspection cavity
Fig.2 (Sheet 3 of 3)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
Printed in Great Britain SERVICE BULLETIN

Nylon Guide Tube installation (visible using a borescope inserted through the HPT
borescope port)
Fig.3 (Sheet 1 of 2)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
SERVICE BULLETIN

Printed in Great Britain

Nylon Guide Tube installation (end on view when installed in the engine)
Fig.3 (Sheet 2 of 2)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
Printed in Great Britain SERVICE BULLETIN

OVERLAP FLAP SEAL FLAP SEAL FLAP

SEAL RETAINER SPRING SEAL
PLATE PIN CLIP PLATE

dej0031154

HPT NGV Flap Seal Assembly

Fig.4 (Sheet 1 of 2)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
Page 17
 TRENT 1000 SERIES
SERVICE BULLETIN

Printed in Great Britain

FLAP SEAL
SPRING CLIP

FLAP SEAL
RETAINER PIN

FLAP SEAL OVERLAP

PLATE PLATE

dej0031161

HPT NGV Flap Seal Assembly - Cross Section

Fig.4 (Sheet 2 of 2)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
Printed in Great Britain SERVICE BULLETIN

HP NGV Flap Seal Assembly - Typical Types of Damages

Fig.5 (Sheet 1 of 2)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
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 TRENT 1000 SERIES
SERVICE BULLETIN

Correct Flap Seal Position

Printed in Great Britain

Incorrect Flap Seal Position

HP NGV Flap Seal Assembly - Flap Seal Location

Fig.5 (Sheet 2 of 2)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
Page 20
 TRENT 1000 SERIES
SERVICE BULLETIN

APPENDIX 1

This form (or similar) should be returned to Rolls-Royce via your Airline Support
Team.

Information Feedback Sheet NMSB 72-AK269 Revision 1

Printed in Great Britain

Date of Inspection:

Engine Serial Number:

Engine Mark:

Operator:

Engine Hours Since New:

Engine Cycles Since New:

Inspection Findings and Comments

Number of Flap Seal Spring Clips

Missing

HPT NGV Condition

(if outside the AMM Accept criteria)

Dec 19/18
Aug. 2/19
TRENT 1000 72−AK269
Appendix 1 - Page 1 of 1