Trent 1000 Borescope Inspection

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Rolls-Royce
Trent 1000 (Boeing 787 - Dreamliner)

Borescope Inspection
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CONTENTS
Book Issue 4
PREFACE Issue 3
SECTION 1 Engine Introduction Issue 4
SECTION 2 Powerplant Maintenance Practices Issue 4
SECTION 3 Borescope Inspection Practices Issue 3
SECTION 4 Engine Internal Inspection — Cold Section Issue 4
SECTION 5 Engine Internal Inspection — Hot Section Issue 4
SECTION 6 Part Condition Terminology Issue 3
Issue 4— February 2014

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Issue 4 - February 2014

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PREFACE
©Rolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder Page
Trent 1000 Borescope Inspection Preface
Notice to Holders
The information in this training material is the property of Rolls-Royce plc and may not be copied, or communicated to a third party,
or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc. To the
extent Rolls-Royce plc has an agreement covering the control and disclosure of information with the company, organization or
individual receiving this training material then this training material shall be held in confidence and controlled in accordance with
such agreement's terms.
A portion of the information in this training material is the property of Boeing and has been included with their permission. It may not
be copied, or communicated to a third party, or used for any purpose other than that for which it is supplied without the express
written consent of Boeing. In this regard, the Boeing training material herein is not an official publication of Boeing and must not be
used for operating or maintaining the equipment described. Official Boeing Company publications and manuals must be used for
those purposes.
To the extent Boeing has an agreement covering the control and disclosure of information with the company, organization or
individual receiving this training material then Boeing portion of the training material must be held in confidence and controlled in
accordance with such agreement's terms. Whilst this information is given in good faith based Upon the latest information available
to Boeing, no warranty or representation is given concerning such information, which must not be taken as establishing any
contractual or other commitment binding upon Boeing or any of its subsidiary or associated companies."
This training material is not on an official publication, no revision service will be provided and must not be used for operating or
maintaining the equipment herein described. The official publications and manuals must be used for those purposes: they may also
be used for up-dating the contents of the training material.
Positional Referencing
It is to be noted that throughout these course notes any reference to a position or unit location is referred to as being viewed from
the rear, unless otherwise stated. This is presuming the student is standing at the rear of the engine and/or aircraft and looking
forward.
Issue 3-. February 2014 Page 1
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COURSE OBJECTIVES
At the end of the course, students will be able to:
Describe the configuration of the Trent 1000 engine.
Describe the tasks necessary to carry out a Borescope Inspection (BSi).
Describe & use the tooling to prepare for borescope inspection.
Describe & use the tooling to rotate the engine shafts.
Locate, remove and refit the borescope access Plugs.
Carry out a Borescope Inspection of the engine.
Compare damage limits in the AMM to typical damage found in service.
Identify damage using the standardised terminology.
Issue 3 — February 2014 Page 2

ABBREVIATIONS
NC Aircraft FOGV Fan Outlet Guide Vanes
AMM Aircraft Maintenance Manual FO HE Fuel Oil Heat Exchanger
AOHE Air Oil Heat Exchanger FRTTV Fuel Return To Tank Valve
ATA Air Transport Association HMU Hydro-Mechanical Unit
AVM Airborne Vibration Monitor HP High Pressure
B787 Boeing 787 HPC High Pressure Compressor
BITE Built In Test Equipment HPM Hydraulic Power Module
BV Bleed Valve HPT HP Turbine
BPH Boeing Provided Hardware IFSD In Flight Shut Down
CDCV Coupling Directional Control Valve IGB Internal Gear Box
CEC Coupling Electronic Controller IGN Ignition
CMCS Central Maintenance Computer System IP Intermediate Pressure
CMS Central Maintenance System IPC Intermediate Pressure Compressor
CMSC Common Motor Start Controller IPT Intermediate Pressure Turbine
DCV Directional Control Valve IV Isolation Valve
DDG Dispatch Deviation Guide LE Leading Edge
DEP Data Entry Plug LH Left Hand
DPT Differential Pressure Transducer LP Low Pressure
EAI Engine Anti-Ice [PC Low Pressure Compressor
EEC Electronic Engine Control LPT Low Pressure Turbine
EECS Electronic Engine Control System [RU Line Replaceable Unit
EGT Exhaust Gas Temperature LVDT Linear Variable Differential Transducer
EICAS Engine Indicating and Crew Alerting System MAINT Maintenance
EMU Engine Monitor Unit MAX Maximum
ESOC Engine Surface Oil Cooler MM Maintenance Manual
ESS Engine Section Stator MME[ Master Minimum Equipment List
ESSAIV Engine Section Stator — Anti Ice Valve MN Mach Number
ESN Engine Serial Number MOD Modification
ETOPS Extended Twin Operation System MTO Maximum Take-Off
FADEC Full Authority Digital Engine Control N/A Not Applicable
FBH Front Bearing Housing N/C Normally Closed
FCSB Fan Cowl Support Beam N/0 Normally Open
FIM Fault Isolation Manual Ni Low Pressure Shaft Speed
Issue 3— February 2014 Page 3
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N2 Intermediate Shaft Speed ILA Thrust (Throttle) Lever Angle

N3 High Pressure Shaft Speed TR Thrust Reverser
NOV Nozzle Guide Vane IRA Throttle (lever) Resolver Angle
NH HP Shaft Speed TSN Time Since New
NI IP Shaft Speed ISO Time Since Overhaul
NLC LP Compressor Shaft Speed U'S Unserviceable
NLT LP Turbine Shaft Speed VFSG Variable Frequency Starter Generator
NMSB Non-Mod Service Bulletin VIGV Variable Inlet Guide Vane
OGV Outlet Guide Vane VSVA Variable Stator Vane Actuator
PO Ambient Pressure
P160 Fan Exit Pressure
P20 Engine Intake Pressure
P25 IP Compressor Exit Pressure
P30 HP Compressor Delivery Pressure
P50 LP Turbine Exit Pressure
Pamb Ambient Pressure
PMA Permanent Magnet Alternator
QAD Quick Attach Detach
Right
REV Reverser
SASV Secondary Air System Valve
SPC Start Power Coupling
SPCAS Start Power Coupling Actuation System
125 IP Compressor Exit Temperature
130 HP Compressor Exit temperature
150 LP Turbine Exit Temperature
TBH Tail Bearing Housing
TCAF Turbine Cooling Air Front
TCAR Turbine Cooling Air Rear
TCC Turbine Case Cooling
TDC Top Dead Centre
TE Trailing Edge
TGT Turbine Gas Temperature
Issue 3 — February 2014 Page 4
Issue 3— February 2014 Page 5

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Section 1 - ENG
©Rolls-Royce plc 2014. Rolls-Royce plc proprietary information
Trent 1000 Borescope Inspection Engine Introduction
Leading Particulars LP System

Take-Off Thrust (lbf Net) International Standard Atmosphere Single Stage Compressor (the Fan) driven by 6 stages of
(ISA) / Sea Level Static (SLS) turbine that is seen as Ni speed on the flight deck.
Trent 1000-A 69194 IP System
Trent 1000-C 74511 8 Stage Axial Flow Compressor, driven by a single stage
Trent 1000-D* 74511 Turbine that is seen as N2 on the flight deck.
Trent 1000-E 59631
Trent 1000-G 72066 HP System
Trent 1000-H 63897 6 Stage Axial Flow Compressor driven by a single stage
Trent 1000-J 77966 Turbine that is seen as N3 on the flight deck.
Trent 1000-K* 77966
Bypass Ratio - 10:1
Overall Pressure Ratio
Max Continuous (lbf Net) ISA/SLS
Between 35 and 44:1 dependant on Engine rating
Trent 1000-A 64722
Trent 1000-C 69523 Overall length - 161.5 inches.
Trent 1000-D* 69523 Fan Diameter- 112 inches
Trent 1000-E 58866
Trent 1000-G 64722 Dry Weight - 13400 lbs
Trent 1000-H 61758 Direction of rotation
Trent 1000-J 69380
Trent 1000-K* 69380 LP & IP Shafts - Counter-clockwise
As viewed from the rear
" The Flat Rating (kink point) is at ISA+15 deg C for all Engine
Marks except for the Trent 1000-D, which is ISA+20 deg C HP shaft Clockwise
and the -K which is ISA+18 deg C. As viewed from the rear
Shaft rotation speeds at 100%
LP (Ni) 2683 rpm
IP (N2) - 8937 rpm
HP (N3) - 13391rpm
Issue 4— February 2014 Page 1-1

IP Shaft
IP Compressor HP Shaft
Ma 9 LP Shaft
LP Compressor
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1-4!
LP Shaft
HP Compressor
T1 000_M01_3D1_0 01_02
Intermediate Gearbox (SAGB)

External Gearbox
Lower Bevel Box IP Drive Shaft
THE TRENT 1000 ENGINE

Propulsion System Outline The combustion system is of annular construction

The Boeing 787 is powered by two propulsion systems incorporating 18 fuel spray nozzles through which fuel is
attached to pylons on the underside of each wing. supplied from the engine fuel system, in response to engine
throttle setting and aircraft operating conditions.
The Rolls-Royce Trent 1000 engine is described as a 3-shaft
high by-pass ratio turbofan engine. The External Gearbox (EGB) is mounted on the fan case and
driven from the IP system. Located on the EGB are the
Each shaft is identified as the Low Pressure (LP) system, following accessories:
Intermediate Pressure (IP) system and High Pressure (HP)
system. LP/HP Fuel Pumps.
Engine Oil Pumps.
The LP system consists of a single stage wide chord fan
assembly driven by a 6-stage turbine. Centrifugal Breather.
The IP system consists of an 8-stage axial flow compressor Hydraulic Pump.
driven by a single stage turbine. Dedicated Alternator.
The HP system consists of a 6-stage axial flow compressor Two Variable Frequency Starter Generators (VFSG).
driven by a single stage turbine
Free stream air entering through the air inlet cowl passes Both the dual purpose EGB mounted VFSGs operate as
through the LP compressor (Fan). The splitter fairing then electrical motors to drive the drive the IP system during
divides the airflow into by-pass and core airflows. ground start while a single VFSG is used for assisted in-flight
starting.
The by-pass flow passes the raked Fan Outlet Guide Vanes
(OGV's) into the by-pass duct before exiting the cold nozzle. Once the engine has started, then the VFSGs will be
The core airflow passes through the engine core and is configured to provide electrical power for the aircraft.
heated before exiting the hot nozzle.
For ventilation and fire protection purposes the engine is
divided into three compartments. These compartments are
called:
Zone 1 — area under fancase.
Zone 2 — area under core fairings.
Zone 3 — area under thrust reverser.
Issue 4 — February 2014 Page 1-3

ZONE 1 ZONE 3
afrailint
T1000_3DA_M01_001_02
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PROPULSION SYSTEM OUTLINE

Main Rotating Assemblies The Low Pressure (LP) system comprises of a single stage
LP Compressor connected by a shaft to a six (6) stage LP
Introduction
Turbine.
To enable the engine to operate three rotating assemblies are
utilised. These assemblies allow air to be drawn and The Intermediate (IP) system comprises of an eight (8)-stage
compressed into the engine to produce thrust to power the compressor connected by a shaft to a single stage IP turbine.
aircraft in flight. The High Pressure (HP) system comprises of a six (6)-stage
compressor connected by a shaft to a single stage turbine.
Location
Each of the rotating assemblies is supported independently by
The three rotating system are located inside the engine.
a combination of roller bearings and ball (location) bearings.
Purpose
The External Gearbox (EGB) is driven from the IP system
The purpose of the rotating assemblies are to compress the through the Internal Gearbox (IGB) and the Intermediate
air entering the engine to allow thrust to be produce by the Gearbox (also known as the SAGB (Step-Aside Gearbox)).
natural cycle of operation. The rotating systems also allow
A drive shaft connects the SAGB to the External Gearbox and
other components to be driven to allow aircraft systems to be
a radial drive shaft connects the IGB to the SAGB.
operated.
Description
The three rotating assemblies are called the Low Pressure
(LP), Intermediate Pressure (IP) and High Pressure (HP)
systems. Each system operates independently from the other
but each system can affect the other two.
The systems are mounted within each other with the HP
system being on the outside, the IP system in the middle, and
the LP system in the centre. Each system has a compressor,
a shaft and a turbine.
By inducing fuel into the air that has been compressed the
volume can be increased. This allows the energy from the
gas flow to be extracted using the turbine. The turbine then
drives the compressor by the shaft that is connected between
the two.
•
IP Compressor
LP Compressor
IP Turbine LP Turbine
HP Turbine
HP Compressor
T1000_M04_301_001_03
Intermediate Gearbox
Radial Drive Shaft

External Gearbox
MAIN ROTATING ASSEMBLIES

Engine Main Bearing Arrangement LP Rotor Assembly

Introduction LP rotor system is supported by two roller bearings and a
Bearings are used within engineering assemblies to allow single ball bearing. The front roller bearing supports the LP
rotational movement between two parts i.e. the shaft and the compressor and the rear roller bearing supports the LP
engine structure. turbine. The central ball (location) bearing positions the shaft
Location and also transmits the thrust developed by the LP system.
The bearings are located inside the engine in four main areas. IP Rotor Assembly
These areas are: The IP rotor system is supported by two rollers bearings and a
The Front Bearing Housing (module 32) single ball bearing. The front roller bearing supports the IP
compressor and the rear roller bearing supports the IP turbine.
The Internal Gearbox (Module 33)
The central ball (location) bearing positions the shaft and also
The HP/IP Bearing Chamber (module 51) transmits the thrust developed by the IP system.
The Tail Bearing Housing (module 52) HP Rotor Assembly
The three ball (location) bearings are situated in the Internal The HP rotor system is supported in two positions. A roller
Gearbox (IGB), which is located in the Intermediate Case bearing supports the HP turbine. The ball (location) bearing
module. supports the HP compressor, locates the HP system, and also
Purpose transmits the thrust developed by the HP rotor system.
Bearings provide a means of accurately supporting and
locating the rotors whilst transmitting force and offering
minimal rotational resistance.
Description
Two types of bearings are used in a gas turbine engine. They
are ball bearings and roller bearings.
Ball bearings can withstand radial and axial forces and are
therefore suitable for transmitting thrust and locating shafts.
Roller bearings transmit radial loads while allowing axial
movement of the shaft.
The LP and IP rotor assemblies are each supported by three
bearings. The HP rotor is supported by two bearings.
••
Front Bearing
Housing
Internal Gearbox
Compressor
Roller Bearings
LP and IP ILP IP and HP Location I
Bearings
HP & IP
Intermediate Gearbox Turbine
Roller
Bearings
Radial Drive LP Turbine

T1000_M04_3D1_002_03
Shaft HP/IP Roller

Bearing Bearing
Chamber
External Gearbox Tail Bearing

Housing
ENGINE MAIN BEARING ARRANGEMENT

Trent Modular Breakdown The Trent engine consists of eight modules as follows:
Introduction Module 31 - LP Compressor Rotor.
The Trent 1000 is designed as a series of modules to ease Module 32 - IP Compressor Case.
assembly and overhaul. A module consists of a number of
Module 33 - Intermediate Case.
parts in a self-contained unit that interface with other modules
and systems. Module 41 - HP System.
Purpose Module 51 - IF Turbine.
The purpose of building the Trent 1000 Engine in a modular
Module 52 - LP Turbine.
format is to ease manufacture, engine assembly, maintenance
and repair. Module 61 - External Gearbox.
Description Module 62 - Intermediate Gearbox.
There are eight (8) modules, that when assembled together,
Note: To prevent ambiguity these course notes have
are connected to the associated engine systems to form the
designated the Intermediate Gearbox Module 62 as the
Trent 1000 engine. Each module is numbered in accordance
Step-Aside Gear Box or SAGB.
with the Air Transport of America (ATA) numbering
convention. This type of construction using a modular Non-Modular Components
approach offers a number of important benefits such as: Components that are not part of the module are described as
being non-modular such as tubes, harnesses and in the case
Decreasing repair turn-round time. of the Trent 1000 the LP Compressor Case.
Lowering overall maintenance costs. The fan blades, annulus fillers and spinner assembly all
Reducing spare engine holdings. classed as non-modular but are treated as part of module 31.
Maximizing module life.

Easier transportation and storage.
More economical transportation and storage.
•
LP Fan Blade
(Non-Modular) LP Compressor
Case
(Non-Modular)
Intermediate Case
Module (33)
HP System
Module (41)
IP Turbine
Module (51)
LP Compressor
Module (31)
IP Compressor
Module (32)
Intermediate Gearbox or
cn
o Step A Side Gearbox (SAGB) (62) A•
I
49 LP Turbine
Module (52)
External Gearbox
Module (61)
TRENT 1000 MODULAR BREAKDOWN

LP Compressor Module (31) LP vibration when trim balancing the LP system.

Introduction A non-load carrying fan retention shaft is fitted inside the fan
The LP Compressor, commonly called the fan, sucks air into shaft to retain the fan assembly should the LP shaft fail.
the engine. Nose Cone Support Ring
Location The nose cone support ring has a number of concentric rings
The LP Compressor (fan) can be seen from the front of the of boltholes. The outermost ring has 20 bolts, which provide
engine. axial retention of the annulus fillers a dowel hole is used to
Purpose align the annulus fillers during installation.
The fan induces air into the engine to raise the pressure The nose cone assembly is attached to the support ring by 30
bolts at the second ring of holes.
sufficiently for operation of the remainder of the engine and
produces approximately 75-80% of the thrust. A third ring of 20 holes is used to attach the support ring to
Description the front face of the LP Compressor disc and the innermost
ring of holes provides a location for the installation of fan
The LP compressor module consists of the fan disc, fan shaft, blade compensation weights if required.
and nose cone support ring and fan air seal. The fan blades
Two offset alignment pins fitted to the rear face of the support
and annulus fillers are non-modular, but are generally
considered as part of this module. ring ensure the ring can only be installed onto the disc in one
position.
Fan Disc
To assist in removal of the nose cone support ring there are 6
The fan disc retains the fan blades in position using 20 extraction inserts.
dovetail shaped slots and reacts to the loads from the blades.
LP Fan Air Seal
The disc is bolted to the LP compressor shaft through a curvic
coupling at the rear of the disc and provides attachment for Bolted to the LP Compressor shaft is the rotating component
the nose cone at the front. of the fan air seal. The seal is used to control bearing loads in
the Front Bearing Housing (FBH).
LP Compressor Shaft
Identification of Number 1 Fan Blade.
The steel LP Compressor shaft is bolted to the fan disc
through a curvic coupling and is connected to the LP turbine A number one (1) etched onto the LP Compressor Disc
shaft through a helical spline coupling. identifies number one (1) Fan Blade. The second and third
fan blades are also identified in this manner and are written
A phonic wheel is machined on the LP compressor shaft for
anti-clockwise, forward looking rear.
measurement of LP speed. One tooth on the phonic wheel is
machined slightly shorter than the rest. This provides a 'once-
per-rev' signal that is used to calculate the phase angle of any
Annulus Filler
(20 off)
LP Compressor Shaft
Nose Cone Support Ring
Curvic Coupling
Fan Air Seal
Fan Blade
(20 off)
0
1
Fan Disc
a
51
0
LP COMPRESSOR MODULE (31)

IP Compressor Module (32) internally through the ESS vanes. Other vanes contain tubes
Introduction to supply oil to and from the roller bearings. Behind the ESS
vanes are the Variable Inlet Guide Vanes (VIGVs).
The IP compressor module induces air from the LP
compressor to pressurise the air further before entering the IP Compressor Stage 1-4 Case
HP compressor. The stage 1-4 case is made from titanium that is split
Location horizontally into two semi-circular half cases to aid production
and repair. Two stages of variable stator vanes (VSVs) are
The IP compressor is located between the LP compressor and installed in the half casings and are connected to the
the Intermediate Case. VSVNIGV mechanism.
Purpose IP Compressor Stage 5-8 Case
The front bearing housing provides support to the front of the
LP and IP rotating systems. The steel IP Compressor Stage 5-8 case is bolted between
the Stage 1-4 case and the HP Compressor case and can
Description also be split into two semi-circular half cases.
The IP compressor module is an eight-stage axial compressor The compressor rotor blades run in abradable linings, which
assembly consisting of four main sections:- are designed to minimise tip clearances and maximise
compressor efficiency.
Front Bearing Housing (FBH)
IP Compressor Rotor
The IP Compressor Stage 1-4 case
The IP Compressor Stage 5-8 case Eight titanium discs are welded together to form a drum. The
rotor blades are secured to the disc by axial and dovetail slots.
The IP Compressor rotor Stages 1-6 are axial, 7and 8 are circumferential. A stubshaft
Front Bearing Housing (FBH) is bolted to the Stage 1 disc to form the inner race of the IPC
The FBH contains the LP and IP compressor front roller roller bearing. At the front of the stubshaft a toothed wheel is
bearings, and the LP and IP shaft speed probes. Around the used to measure IP speed measurement.
hub is a number of hollow titanium Engine Section Stator The stage 6 disc is attached to a stub shaft by a curvic
(ESS) that is heated with hot air from the last stage of the IP coupling. Splines in the stubshaft engage with a locking
compressor. coupling, to which the IP turbine shaft is secured.
The ESSs are welded together and fixed to the fan outlet
guide vanes (OGV) to form the FBH/OGV joint.
The FBH/OGV joint holds the LP compressor case to the core
engine. Electrical cables, from the shaft speed probe; pass
Engine Section Stators FBH -01.1-- Front —0 Rear Case

(ESS) Case
'Thvq1
-/4\gi3/4..3/444
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Variable Inlet Guide Vanes (VIGV) k4FAV Li I 7 Li Ja
Variable Stator Vanes (VSV)
Stages 1 & 2 N—IPC Rotor
otir, "a 4 IPC Curvic
Ati 4
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c( 41/4 V1 /41e
LP Front Roller Bearing
IP Front Roller Bearing

TI 000_M 04" D L007_03
Stage 1 IPC Blades

Fan Air Seal
FBH/OGV Joint
IP COMPRESSOR MODULE (32)

Intermediate Case Module (33) lugs to provide torsional stability between the intermediate
Introduction case and the LP compressor case.
The intermediate case is at the heart of the engine. It The rear flange of the intermediate case also features an
provides a location where all three rotating systems are joined inner V- groove that locates the thrust reverser in position.
together and provides a gearbox from which the external The inner structure of the intermediate case incorporates the
gearbox can be driven. internal gearbox housing, which is supported by a hub formed
Location by eight hollow aerofoil shaped struts. Some of the struts
The intermediate case is located between the IP compressor provide locations for tubes that take oil to and from the
case and the HP system. internal gearbox housing. Others supply air to the internal
areas for cooling and sealing. There is also instrumentation
Purpose within the two other struts.
The purpose of the intermediate case is to provide support for Internal Gearbox
the IP and HP compressor cases, a structure through which
the thrust of the engine can be transmitted to the aircraft and The internal gearbox housing contains the LP, IP and HP
location of the internal gearbox to allow the IP system to drive location bearings for the three rotating assemblies.
the external gearbox. There are also gears from the IP and HP rotating systems that
Description drive shafts connected to the Intermediate Gearbox. This
allows the IP rotating system to drive the external gearbox
The intermediate case is one of the major structural parts of and the HP rotating system to be turned for maintenance.
the engine and is made from a single titanium casting to form
an aerodynamic duct that connects the IP & HP compressors.
Intermediate Case
The front part of the intermediate case is installed over the IP
compressor and is bolted to a flange at the rear of the IP
compressor. The rear part of the intermediate case is
installed around the front part of HP compressor case and is
bolted to a flange on the combustor outer case.
The front of the intermediate case incorporates a stiff
triangular box that features integral lugs. Engine thrust loads
are transmitted to the aircraft via thrust links attached to two of
the lugs.
Two 'A' frames are attached to the intermediate case by four
Module 32
Module 41 Attachment Flange
Attachment Flange
IPC Bevel Gear

Intermediate Case
HPC Bevel Gear
HP Location Bearing
IP Curvic Coupling
Ti 000_M04_3D1_008_01
IP Location Bearing
LP Location Bearing
Intermediate Gearbox Mounting Flange
INTERMEDIATE CASE MODULE (33)

HP System Module (41) for rotor blade tip sealing, and circumferential slots to retain
Introduction the stator vanes.
Module 41 is described as a system due to the module Combustion Chamber and Outer Case
containing three (3) major assemblies that work together to The combustor consists is of an annular design with tiled inner
form the HP rotating system. and outer walls. The tiles are coated with a Thermal Barrier
Location Coating (TBC) to protect the base metal of the tile from the
The HP system is located between the intermediate case and heat in the combustor. They are also cooled by HP
the IP turbine. compressor stage 6 air.
Purpose At the rear of the combustor are the 18 dual vane HP Nozzle
Guide Vanes (HPNGV) assemblies. They are cooled
The purpose of the HP system is to further compress the air internally by air from the HP compressor stage 6 and allow the
from the IP compressor and deliver it to into the combustor gas flow from the combustor to enter the HP turbine at the
where fuel is mixed and burnt. The resulting increase in correct speed and angle.
temperature raises the volume of air. The turbine extracts the
energy from the gas flow in order to drive the compressor. Fuel is supplied into the combustor by 18 Fuel Spray Nozzles
(FSN), which bolt to the combustion outer case, and protrude
Description into the front combustion liner head section.
The HP system comprises the HP compressor, the combustor The single skin combustor case outer casing (CCOC)
section and the HP turbine. attaches to the intermediate case and IP Turbine module at its
HP Compressor front and rear flanges respectively.
The HP compressor rotor is manufactured in three sub- A cooling manifold on the outside of the combustion case
assemblies bolted together; the last sub-assembly also allows fan air to cool the casing around the HP turbine to
incorporates the HP rotating assembly drive shaft. reduce the turbine blade tip clearance for improvement in
The compressor blades are installed into the sub-assemblies performance.
in either axial or circumferential dovetail slots. Stage 1 is an HP Turbine
axial dovetail and stages 2-6 are circumferential. 66 shrouded single crystal HP turbine blades are mounted by
A stub shaft connected by a curvic coupling to the stage 1 disc firtree roots to a disc. They are internally cooled by air from
is supports the front of the HP system in the intermediate the HP compressor stage 6 and have a thermal barrier coating
gearbox. applied to the blade surfaces. The single disc is bolted to the
The drive shaft is connected to the HP turbine disc. HP drive shaft at the front of the disc. A stubshaft at the rear
The HP compressor case is composed of a series of bolted of the disc forms the inner race of the HPT roller bearing in the
cylindrical casings that locate the abradable rotor path linings HP/IP bearing chamber.
S .
Annular Tiled Combustor HP Nozzle Guide Vanes (18 off)
HP Turbine Blades
HP Compressor HP Turbine Disc

Curvic Coupling
Combustor Outer Case

T1 000_M 04_3D1_009_03
Fuel Spray Nozzles

(18 off)
HP Compressor
Stage 1 Blades
HP Bleed Valve Location
HP SYSTEM MODULE (41)

IP Turbine Module (51) At the hub of the disc a drive arm extends rearwards to which
Introduction the IP turbine shaft and stub shaft are bolted. The IPT stub
The IP turbine module contains a single rotating turbine to shaft provides the inner race for the IPT roller bearing. The IP
turbine shaft runs forward and is connected to the IP
provide the motive force to drive the IP compressor.
compressor stub shaft with helical splines.
Location
Passing through one of the IP NGVs and into the area at the
The IP turbine module is located between the HP system and front of the turbine disc is a thermocouple assembly that is
the LP turbine. part of the turbine overheat detection system. This area is
Purpose cooled by air from the HP compressor stage 3 to cool the front
The purpose of the IP turbine is to extract energy from the gas of the IPT disc and the rear of the HPT disc.
flow exiting the HP turbine to drive the IP compressor. Located in the module casing, to the rear of the IPT blades
Description are the LP1 NGVs. They consist of 34 hollow triple span vane
The IP Turbine case houses the single stage IP turbine, the assemblies. Located in 12 of the NGVs are the
IPNGVs, LP Turbine Stage 1 NGVs and the HP/IP bearing thermocouples used to measure the temperature of the gas
housing. flowing through the turbine section. This temperature is
indicated on the flight deck.
The front flange of the IPT case bolts to the HP system and
the rear flange bolts to the front of the LP turbine case. Passing through one of the LP NGVs is the second
thermocouple assembly of the turbine overheat detection
The IPNGVs feature a thermal barrier coating to protect the
system. This thermocouple senses the temperature of the IP8
blade form the hot gas flow. The IPNGVs are hollow and
cooling air at the rear of the IPT disc.
internally cooled with air from the HP compressor stage 3.
Internal to 11 of the NGVs is a bar, or spoke, that supports the Attached to the outer surface of the IPT casing is the IPT case
HP/IP bearing chamber. cooling manifold. Fan air from the manifold impinges on the
casing, resulting in a reduction in turbine blade tip clearance,
There are also tubes inside the IPNGVs that take oil and
with subsequent improvement in performance.
cooling air to and from the HP/IP bearing chamber.
The 114 shrouded single crystal IP turbine blades are
attached to the disc by firtree roots. The blades are internally
cooled using air from the HP compressor stage 3 and are
covered with an aluminised coating.
The shrouds of the IPT blades run in abradable seal segments
that are internally cooled with air from the HP compressor
stage 3.
•
Module 52 Attachment Flange
LP Stage 1 Nozzle Guide Vanes
IP Nozzle Guide Vanes
IP Turbine Disc
HP Turbine Roller Bearing
IP Turbine Roller Bearing

IP Turbine Shaft
Module 41 Attachment Flange —/
T1000_M04_31)1_010_02
IP TURBINE MODULE (51)

LP Turbine Module (52) LP turbine shaft with a bolted curvic coupling. The LP turbine
Introduction shaft goes forward through the centre of the IF shaft and
The LP turbine module contains six stages of turbine that connects with the LP compressor shaft with splines and a
extract energy from the gas flow exiting the IP turbine to threaded nut.
provide the motive force to drive the LP Compressor. The LP turbine stubshaft is attached at the same flange joint
Location and provides radial support for the LP turbine roller bearing in
the TBH.
The LP turbine module is located at the rear of the engine
after the IF turbine. The TBH support structure includes a hub, which is held
concentric in an outer case by twelve radial hollow struts. The
Purpose struts contain service tubes, which take oil and IP8 air to and
The purpose of the LP turbine is to extract energy from the from the bearing chamber.
gas flow exiting the IF turbine to drive the LP compressor. The TBH struts also locate the sensors that measure LP
Description turbine outlet pressure and temperature and which are used
The LPT module consists of a 6-stage disc, blade and shaft as part of the Engine Health Monitoring System (EHM).
assembly contained within an LP turbine casing, to which is The TBH struts also act as outlet guide vanes (OGVs) to
bolted, the tail bearing housing (TBH) support structure straighten the gas flow from the LP turbine before it exits the
The LPT casing provides location for the LP Stage 2-6 NGVs engine.
and seal segments. The NGVs are solid and retained in The front flange of the TBH is bolted to the rear flange of the
circumferential slots in the LPT casing. LP turbine case. The rear flange is bolted to the primary
Blades from all six stages of the turbine are solid, welded in exhaust nozzle.
pairs and retained by firtree roots to the discs. The blades are At the top of the TBH support structure are three integral
also shrouded and feature seal fins that run in honeycomb mounting lugs, which are used to locate the rear engine
lined seal segments. mount.
Attached to the outer surface of the LPT casing is the LPT
case cooling manifold. Fan air from the manifold impinges on
the casing, providing a reduction in turbine blade tip
clearance, with subsequent improvement in performance.
The six individual LP turbine discs are bolted together and
feature circumferential seal fins that act to control cooling air
and hot gas leakage in the LP turbine.
The stage 5 disc incorporates a drive arm that attaches to the
•
Rear Engine Mount Lug

LP Stage 2 Nozzle Guide Vanes
7 LP Stage 6 Turbine Blades
LP Stage 1 Turbine Blades
LP Stage 5 Disc + Drive Arm
LP Turbine Curvic Coupling
LP Turbine Roller Bearing
LP Turbine
Shaft
TBH Support Structure
T1000_M04_3D1_011_02
LP Turbine Case
LP TURBINE MODULE (52)

Trent 1000 Borescope inspection Engine Introduction
External Gear Box Module (61) Components Mounted on the Rear Face
Introduction Variable Frequency Starter Generator (VFSG) 1 & 2
To enable the engine to operate and provide the motive force (Number 1 on the left and Number 2 on the right as viewed
for some aircraft systems units such as pumps and generators from the rear).
need to be driven by the engine. The IP rotating system Hydro-Mechanical Unit (1-IMU)
therefore drives the external gearbox to accomplish this task LP/HP Fuel Pump Assembly
Location During a ground engine start, power is transmitted from the
The external gearbox is mounted to the bottom of the LP two VFSGs, through the EGB and to the SAGB via a drive
compressor case. shaft. Only one VFSG is used during an in-flight start.
Purpose The Centrifugal Breather housing provides a means of hand
The external gearbox provides a mounting point and turning the IP rotor system for maintenance purposes.
mechanical power for the engine driven accessories. It also The drive shafts for the gearbox-mounted accessories are
provides a means to rotate the engine IP system during the sealed and supplied with IP8 air, augmented with HP3 air at
start cycle and maintenance. low engine speeds.
Description All the accessory interfaces are protected by a drains system.
The External Gearbox (EGB) is a cast aluminium housing
installed on the lower part of the LP compressor case.
Power from the IP system is transmitted via the intermediate
gearbox and a drive shaft to drive the external gearbox. The
power is used to drive the accessory gear train inside the
gearbox to drive a total of eight accessories mounted on the
EGB. These components are as follows:
Components Mounted on the Front Face
Permanent Magnet Alternator (PMA)
Oil Pump, Pressure Filter & Pressure Filter Differential
Pressure Transducers
One Hydraulic Pump
Centrifugal Breather
Drains Tank and Ejector
• •
R ORolls- oyce plc 2014. Rolls-Royce plc proprietary information
Front Face View
Intermediate
Gearbox —No
Centrifugal Breather
Hydraulic Pump
Gearbox
/— Mount
Gearbox
Mount Radial Drive Shaft
Permanent
Magnet
Alternator
Engine
or
Hydro-Mechanical Unit Oil Pump
VFSG 1
5
a LP/HP Fuel Pump
VFSG 2
§ Rear Face View
EXTERNAL GEARBOX MODULE (61)

©Rolls-Royce plc 2014. Rolls-Royce plc proprietary Information
Intermediate Gearbox Module (62)

The Intermediate Gearbox incorporates design improvements
that have reduced its weight and simplified its operation.
The SAGB has two main functions:
To transfer drive from the IP system to the External
Gearbox during engine running,
To transfer drive from the VFSGs to the IP system
during the engine start sequence.
Engine Starting
In order to start the engine the IP system must be driven by
the starting system. This is achieved by the use of the
VFSG's via a drive shaft, the SAGB and a radial drive shaft.
The IP drive shaft helical gear meshes with the IP radial drive
shaft helical gear to transfer power from the VFSG to the IP
system.
Engine Running
The IP radial drive shaft gear meshes with the IP drive shaft
gear to rotate the driveshaft to transfer power to the External
Gearbox (EGB) during engine running.
•
@Rolls-Royce plc 2014. Rolls-Royce plc proprietary information
IP Drive Shaft
IP Drive Shaft Gear

IP Drive Shaft Gear
T1000_M04_301_023_02
IP Drive Shaft
\_ Oil Scavange Line
INTERMEDIATE GEARBOX MODULE (62) - SAGB

Issue 4 — February 2014 Page 1- 26
LP Compressor Case (Non-Modular) a fan track for which the fan is able to cut its own seal to
Introduction prevent fan tip air losses.
The LP compressor is manufactured from three assemblies to Front Mount Ring & Fan Outlet Guide Vanes
contain a fan blade if released, provide a mounting point to The front mount ring is bolted between the containment case
mount the engine to the pylon and reduce noise. and the rear fan case. There are 44 Fan Outlet Guide Vanes
Location (FOGVs) bolted to the front mount ring. The hollow FOGVs
The LP compressor case is at the front of the engine and are welded in position and bolted to the IP compressor FBH.
covers the LP compressor. This structure provides radial support for the LP compressor
Purpose case assembly and aerodynamic control to the airflow
entering the bypass duct. The engine front mount is located
LP compressor case must be able to withstand the extreme at the top of the front mount ring.
force of a fan blade release, reduce noise from the fan when
the engine is running and be able to provide a mounting Rear Fancase
position for engine systems components. The rear fancase is bolted to the front mount ring. The lower
Description inner surface of the rear fancase features apertures for the left
and right VFSG AOHE.
The LP compressor casing assembly consists of three main
sub-assemblies and is a non-modular assembly: The upper rear fancase features apertures for the two fin-type
engine EOSCs (Engine Oil Surface Coolers) on its inner
A Containment (front) case surface.
The Front Mount Ring & Fan Outlet Guide Vanes Acoustic panels are secured to the inside surface of rear fan
The Rear Fan Case case to absorb noise from the LP compressor.
Containment Case Assembly The A frame struts are attached to the rear fancase to provide
The containment system is designed to absorb the energy of torsional stiffness to the LP compressor case.
a fan blade release and contain the debris within the confines
of the engine.
The containment case consists of forged titanium ring with
three circumferential stiffening ribs to provide reinforcement in
the area of the fan track.
The inner surface of the containment case features front and
rear acoustic panels to absorb noise generated by the fan and

S

Fan Outlet
Guide Vanes
(44 off)
Acoustic
Panels
Rear Fan Case
Front Mount ring

Fan Track
Front Case
(Containment)
N
0
1
Zt
o
1 Ice Impact
Panels
3
m
i
i'l
LP COMPRESSOR CASE (NON MODULAR)

Borescope Access
With the exception of the IP compressor inlet to rotor one,
which is accessed though the LP fan, borescope inspections
can be performed on all compressor and turbine stages
though special access ports all positioned along the right
hand side of the engine at the 3 o'clock position.
Note: For access to the IP compressor ports, then the gas
generator (core) fairings must be removed.
In addition, for the combustion chamber inspection, the zone
is accessed though six ports spaced around the combustion
chamber outer casing.

COMBUSTOR
LPT HPT HPC
IPT Il il
I
II 1—I-1
T1000_M04_3D1_1 05_03
BORESCOPE ACCESS POSITIONS

©Roils-Royce plc 2014. Rolls-Royce plc proprietary information
End of Section

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©Rolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder page
Trent 1000 Borescope Inspection Engine Maintenance Practices
Maintenance Practices — Warning & Cautions Note: When you look from the rear, the HP-system rotor turns
clockwise. This is opposite to the LP and IP system rotors,
WARNING: Be careful when you do work on the engine parts which turn in a counterclockwise direction.
after the engine is stopped. The engine parts can stay hot for
over one hour. Do not touch hot parts without applicable
gloves as this may cause injuries to personnel.
WARNING: Obey the temperature limits for the borescope
equipment as specified in the manufacturers instructions if the
engine is too hot, damage to the equipment can occur. It is
recommended that you do not start a borescope inspection for
2-3 hours after the engine has been shut down.
WARNING: Carryout the specified tasks in the correct
sequence to open the thrust reverser. Failure to comply with
this instruction may cause injuries to personnel and damage
to equipment can occur.
WARNING: Obey the manufacturers health-and-safety data
for the materials, oils and lubricants. Also, refer to local
regulations to make sure that you follow procedures and work
safely. Failure to comply may cause injuries to personnel.
CAUTION: When inspecting rotating sections, you must make
sure that the borescope tip is not in the path of the blades
when you turn the engine. If the borescope and the blades
touch, then damage to the blades/borescope will occur.
CAUTION: When refitting the borescope blanking plugs, do
not use the bolts to pull the borescope blanking plug(s) into
position. Failure to comply with this instruction may result in
damage to the plug and/or the engine.

Maintenance Tasks—References All Start with B787-A-

Task Description _ _ AMM Reference
Task Description AMM Reference 1
Thrust Reverser Activation After R78-31-00-20G-730B-A
Leading Edge Slat Deactivation 27-81-00-24A -5108-A
Ground Maintenance
Leading Edge Slat Reactivation 27-81-00-24A -7308-A
Gas Generator Fairing Installation R72-03-11-00A-720A-A
Leading Edge Slat Retraction 27-81-00-27B-110A -A
Gas Generator Fairing Removal R72-03-11-00A-520A-A
Non-Aqueous Liquid Degreasing R70-20-01-00A-258A -A
Torque Tightening Techniques R70-51-00-00A -950A-A
Open the Fan Cowl R71-11-04-00 B-540A-A
Close the Fan Cowl R71-11-04-00B-740A-A Access Panels
Turn the Low Pressure System R72-00-00-26A-950A-A Name Location Number
Turn the Intermediate Pressure R72-00-00-01A-950A-A Left Fan Cowl, Left/Right Engine 413AL/423AR
System
Right Fan Cowl, Left/Right 414AR/424AR
Turn the High Pressure System R72-00-00-26A-950A-A Engine
Open the Thrust Reverser R78-31-00-20B-540A-A Left Thrust Reverser, Left/Right 415AL/425AR
Thrust Reverser Deactivation For R78-31-00-20H-510B-A Engine
Ground Maintenance Right Thrust Reverser, Left/Right 416AR/426AR
Close the Thrust Reverser R78-31-00-20B-740A-A Engine

Nacelle Major Units

The nacelle comprises of the following items:
Air intake cowl.

Left and right fan cowl doors.
Left and right thrust reverser halves (C-ducts).
Exhaust Nozzle Assembly and Plug.
Engine including the front and rear mounts.
The above components are installed to the aircraft pylon
and provide inlets and outlets for engine ventilation flows.

Right Thrust Reverser Half
Right Fan
Cowl Door
Left Fan
Left Thrust Reverser Half Cowl Door
Trent 1000 Engine
Inlet Cowl
NACELLE MAJOR UNITS

Thrust Reverser Inhibition

Thrust Reverser Inhibition for Maintenance.
AMM Task B787A-R78-31-00-20H-510B-A
Introduction
The thrust reverser may require inhibiting for safety reasons
during maintenance or when the thrust reverser becomes
unserviceable. To perform this task access to the Hydraulic
Control Unit (HCU) located in the pylon aft fairing will be
required.
Ground Thrust Reverser Inhibition
The Isolation Valve, which is part of the HCU, has an
inhibition lever that must be pushed in towards the valves
body to the inhibit position. A pin, stowed and lanyarded to
the 1-ICU, is then installed through the lever and into the HCU
body.
By moving the lever to the inhibit position and installing the
inhibition pin the aircraft hydraulic system will be mechanically
isolated from the thrust reverser.
When correctly installed the access panel could then be
installed if required.

Isolation Valve
Inhibition
Lever
THRUST INHIBITION FOR MAINTENANCE

Power Door Opening System (PDOS) fancase, to open and close the doors. . The actuators lock
Introduction when extended to hold the Fan Cowl Doors open during
To allow maintenance to occur the fan cowl doors and thrust maintenance. A pop out pin indicates that the actuator is
reverser halves can be opened using hydraulic power by a a locked and a 'T' bar that allows the lock to be released
self-contained hydraulic system is utilised. manually if required. If a fault occurs with the PDOS system
then the Fan Cowl Doors must be opened by manpower (2
Location mechanics).
The Power Door Operating System has a number of Thrust Reverser Cowl Hydraulic Opening Actuators
components located in the pylon and on the engine.
Description Each Thrust Reverser (T/R) C-duct half has a hydraulic
actuator to open and close the C-duct for maintenance. The
The PDOS system comprises of the following components: C Duct hydraulic opening actuator is attached between a
Electrically powered hydraulic power pack bracket on the engine fancase and the C-duct. If a fault
occurs with the PDOS system then the C-ducts can be
Hydraulic tubes and hoses
opened by connecting a hand pump to a quick disconnect
Hydraulic actuators mounted to each fan cowl door and connector at the base of the actuator.
thrust reverser half.
Fan cowl and thrust reverser actuator operating switches Fan Cowl Actuation and Control Switch
Each fan cowl door has its own operating switch located on
Hydraulic Power Pack
the outer surface of the air inlet cowl to allow the fan cowl
Each engine has one power pack. The power pack is an doors to be opened independently. The right fan cowl door
independent unit located in the pylon. The power pack switch is at the 4 o'clock position; the left door switch is at the
consists of an oil reservoir, electric motor, pump and valves. 8 o'clock position.
Hydraulic Tubes and Hoses
Thrust Reverser Actuation & Control Switches
The hydraulic tubes and hoses allow oil to be sent from the Each C Duct actuator has its own operating switch located on
power pack to the actuators. the rear bulkhead of the air inlet cowl. The switch for the right
half is at the 4 o'clock position and the switch for the left half is
Fan Cowl Hydraulic Actuators
at the 8 o'clock position.
Each fan cowl door has a hydraulic actuator, attached
between a bracket on the fan cowl door and the engine
Power Pack Hydraulic Tubes and Hoses
_
/
Nil I lir "sr Salaraigi
Note
Right Side fated
with Identical System
Thrust Reverser Cowl Actuator
N. Fan Cowl Actuator

TIDDO _MO2_301_ 003_02
Thrust Reverser Control Switch

(Mounted on AFT Bulkhead)
Fan Cowl Control Switch (Mounted on Inlet)
POWER DOOR OPERATING SYSTEM (P DOS)

Maintenance Practices Close Fan Cowl Doors After Access

Open and Close Fan Cowl Doors (PDOS Method) AMM Task B787-A-R71-11-04-00C-740A-A
The following is a brief description of these tasks. Refer CAUTION:
to the AMM for the full description. MAKE SURE THE THRUST REVERSERS ARE FULLY
Open Fan Cowl Doors For Access CLOSED BEFORE YOU CLOSE THE FAN COWL DOORS.
AMM Task B787-A-R71-11-04-00C-540A-A IF YOU DO NOT OBEY THIS INSTRUCTION, DAMAGE TO
Carry out the steps required to ensure that the Engine THE FAN COWL DOORS AND THE THRUST REVERSER
Start switch and Fuel Control switch are not operated. CAN OCCUR.
Open the four Fan Cowl Latches in order starting from the Disconnect the aft Hold Open Rod and place in the
rear latch and working forwards. stowage position on the Fan Cowl Door.
Push the Fan Cowl PDOS switch to open the Fan Cowl Install an unlock pole to the collar of the forward
Door until it stops in the fully open position. telescopic hold open rod and move it to the unlock
position.
Ensure that the forward telescopic hold open rod is fully
extended and locked. Ensure the hold open rod is fully unlocked. A RED safety
stripe will be seen below the locking collar when the hold
NOTE: The hold open rod is fully locked when a open rod is fully unlocked.
safety stripe is seen above the locking collar.
Push and hold the Fan Cowl PDOS switch until the fan
Release the Fan Cowl PDOS switch to let the actuator cowl stops in the fully open position.
hold the weight of the fan cowl door.
Release the Fan Cowl PDOS switch to close the Fan
Release the aft hold open rod from its stowage position on Cowl Door.
the Inlet Cowl and connect it to a bracket and the Fan
Case. NOTE: Gravity causes the fan cowl's descent. The actuator
controls the descent speed of the fan cowl.
WARNING:
Ensure the Fan Cowl is fully closed before closing the Fan
DO NOT KEEP THE FAN COWL DOORS OPEN IF THE Cowl Latches.
WIND IS MORE THAN 40 KNOTS (74 KM/H). THE WIND
CAN BREAK THE HOLD-OPEN RODS, AND RELEASE Close the four Fan Cowl Latches in order starting from the
THE FAN COWL. INJURIES TO PERSONNEL AND forward latch and working rearwards.
DAMAGE TO EQUIPMENT CAN OCCUR. NOTE: If the PDOS system is unserviceable the Fan Cowl
Doors can be opened and closed manually. Refer to AMM
task B787-A-R71-11-04-00D-540A-A.
Right Fan Cowl Door

Latches
3/ /
42- Aft Core Cowl Latch

Translating Sleeve Latch
No 1 Latch
Left Fan
T1000_M02_3D1_1 05_0 1
Vee Blade Latch No 4

Cowl Door
Latches No 3, No 2 & Bumper Latch
Unlatch
atch
Note: Gearbox removed for clarity.
OPEN AND CLOSE THE FAN COWL DOORS

Fan Cowl Door Actuator Locks WARNING:

Introduction DO NOT KEEP THE FAN COWL DOORS OPEN IF THE
To enable the fan cowl doors to be safely secured in the open WIND IS MORE THAN 40 KNOTS (74 KM/H). THE WIND
position the actuators have an integral locking mechanism. CAN BREAK THE HOLD-OPEN RODS, AND RELEASE
THE FAN COWL. INJURIES TO PERSONNEL AND
Location DAMAGE TO EQUIPMENT CAN OCCUR.
The locks are integral to each of the actuators. To release the actuator lock hold open rods should first be
Purpose stowed into position. The actuator can then be extended to its
longest length by the operation of the PDOS system. This
The purpose of the actuator locks is to lock the actuators in operation will release the actuator lock and a RED safety
the extended position allowing the fan cowl doors to be held stripe will be seen below the locking collar to indicate the
open for maintenance. actuator is fully unlocked.
Description The fan cowl PDOS switch can then be released and the fan
The fan cowl door actuator locks operate in a similar fashion cowl doors will lower using their own weight and gravity.
to a retractable ballpoint pen mechanism.
When the actuator is extended by the operation of the PDOS
system the actuator will extend to just beyond its furthest
length where the lock will engage.
Upon release of the PDOS switch the actuator will retract
slightly and the weight of the fan cowl doors will be taken on
the actuator and lock.
To ensure the actuator is fully locked a YELLOW safety stripe
can be seen above the locking collar.
When it is confirmed that the actuators are fully extended and
locked release the hold open rods from their stowage
positions on the fan cowl doors and connect to the brackets
on the Inlet Cowl and the Fan Case.

Hold open rod
Rear to forward to unlatch

Forward to rear to latch
Locked Unlocked
FAN COWL DOORS ACTUATOR LOCKS

Fan Cowl Doors Combined right VFSG (No2 VFSG) service access door
Introduction and Zone 1 vent.
The fan cowl doors cover the front of the engine to form the Centrifugal breather outlet
forward section of the nacelle. They provide a smooth
aerodynamic surface for the airflow during flight and can be Hold-Open Rods
opened independently for maintenance of the engine. Each door has two hold-open rods that attach to brackets on
Location the fan case and to fittings on the fan cowl doors. The
forward hold open rod is of a telescopic design and the aft is a
The fan cowl doors are located between the air inlet cowl and
fixed length type. The hydraulic actuator takes the weight of
the thrust reverser.
the fan cowl door once it has opened and has locked in
Description position.
There are two (2) fan cowl doors covering the left and right Centrifugal Breather Outlet
sides of the engine. They are made from a composite
construction and are mounted to the pylon by four hinges at The centrifugal breather outlet allows air from the oil system to
the top and held together during flight by four (4) latches at be discharged overboard during engine operation.
the bottom.
The area underneath the fan cowl is a designated as Fire
Zone 1 and is isolated from the other areas of the engine.
The air that ventilates fire zone 1 is exhausted through an
outlet that is part of the No 2 Variable Frequency Starter
Generator (VFSG) servicing door.
Each door has a number of panels and outlets as follows:
Left Fan Cowl Door
Left VFSG (No 1 VFSG) Air Oil Heat Exchanger (AOHE)
exhaust.
Left VFSG (No 1 VFSG) service access door
Right Fan Cowl Door
Engine Oil tank access door
Right VFSG (No2 VFSG) Air Oil Heat Exchanger exhaust
LEFT RIGHT
Oil Tank
Access Door
Telescopic Right VFSG

Left VFSG Hold Open Rods AOHE Outlet
AOHE Outlet
Hold Open Rods

Hold Open Rods
T1000_M02_301_004_03
Centrifugal Breather Outlet
Left VFSG Service Access Door

Combined Right VFSG Service
Access Door & Zone 1 Outlet
FAN COWL DOORS

Open and Close Thrust Reverser (PDOS METHOD). Note: The hold open rod is fully locked when a YELLOW
The following is a brief description of these tasks. Refer safety band is seen above the locking collar.
to the AMM for the full description.
Open Thrust Reverser for Access
AMM Task B787-A-R78-31-00-20C-540A-A
WARNING:
DO THE DEACTIVATION PROCEDURE TO PREVENT THE
OPERATION OF THE THRUST REVERSER. ACCIDENTAL
OPERATION OF THE THRUST REVERSER CAN CAUSE
INJURIES TO PERSONNEL AND DAMAGE TO
EQUIPMENT.
1. Ensure the Fan Cowl Doors are open.
2. Disengage the latches in order, as follows:
Open Bifurcation Latch System (BLS) Handle.
Open the Translating sleeve latch.
Open the Core Cowl latch.
Open C-duct latches 4, 3 and 2.
Open the number 1 Latch.
Open the V-blade latch.
3. Push and hold the PDOS switch until the thrust reverser
stops and is in the fully open position, then release the
switch to let the actuator hold the weight.
4. Remove the telescopic hold open rod from its stowed
position, extend and locate to a bracket on the fan case.

Right Fan Cowl Door

Latches
4, Aft Core Cowl Latches

Translating Sleeve Latches
No 1 Latch
Left Fan
T1000_M02_3D1_105_02

Cowl Door
Latches No 3, No 2 & Bifurcation Handle
OPEN THE THRUST REVERSER

Open and Close Thrust Reverser (PDOS METHOD). area.

The following is a brief description of these tasks. Refer Note: If the PDOS system is unserviceable the thrust
to the AMM for the full description, reverser cowls can be open and closed manually. Refer to
Close Thrust Reverser after Access AMM task B787-A-R78-31-00-20D-540A-A.
AMM Task B787-A-R78-31-00-20C-740A-A

1 Remove the hold open rod from the bracket on the fan
case and place into its stowage position.
Note: The hold-open rod is fully unlocked when a RED safety
band is seen below the locking collar.
Push and hold the thrust reverser PDOS switch until the
thrust reverser stops and is in the fully open position.
Release the PDOS switch to close the thrust reverser.
Note: Gravity causes the thrust reversers descent. The
actuator controls the descent speed of the thrust reverser.
3. Engage the latches in order, as follows:
Close the V-blade latch.
Close the number 1 Latch.
Close C-duct latches 2, 3 and 4.
Close the Core Cowl latch.
Close the Translating sleeve latch.
Close the Bifurcation Latch System (BLS) Handle.
Activate the Thrust Reverser after maintenance (AMM
Task B787-A-R78-31-00-20G-730B-A).
Remove all safety equipment and tools from the work
© Rolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder page
Trent 1000 Line and Base Maintenance Engine Maintenance Practices
Right Fan Cowl Door
1
A„,/ / /•w?*
Latches
Aft Core Cowl Latches

Translating Sleeve Latches
No 1 Latch
Left Fan
Cowl Door
Latches No 3, No 2 & Bifurcation Handle
CLOSE THE THRUST REVERSER

Q Rolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder page
Trent 1000 Line and Base Maintenance Nacelle
Thrust Reverser Assembly of the fan duct and the outer sleeve forms the exterior contour
of the T/R. The inner and outer sleeves are joined together at
Purpose
the chevron-designed trailing edge. This type of design helps
The Thrust Reverser (T/R) system allows the flight crew to to reduce aircraft cabin noise.
redirect the engines LP Compressor outlet air (fan air) in a
forward direction to create a controllable reverse thrust to aid The sleeves are located to the rear of the fan cowl and are
attached to the C-ducts by sliders and tracks.
the aircraft braking system in decreasing the speed of the
aircraft on the ground. The translating sleeves are mechanically linked together by a
crossover flex-shaft to ensure the sleeves deploy and stow
Description
together. The crossover shaft is connected to the actuator
There are two halves to each T/R assembly, called C-ducts, synchronisation system.
through which the fan air flows.
Hydraulic Actuators
Cascade Segments
Two hydraulic actuators that are synchronised by flex-shafts
The cascade segments control the direction of the fan air operate each C Duct. Both actuators have internal locks with
exhaust when the translating sleeves are deployed. The the lower actuators also incorporating a manual drive unit to
cascades are graphite-epoxy assemblies located between the enable movement of the sleeves for maintenance.
torque box and the cascade segment attachment ring.
Hydraulic Control Unit (HCU)
Blocker Door and Drag Links
The HCU is part of the hydraulic module that is located in the
The blocker doors prevent fan air exiting rearwards when the pylon aft fairing. The HCU consists of the Isolation Valve (IV)
translating sleeve is extended. The blocker doors are to isolate the hydraulic pressure to the thrust reverser system
attached at the forward end to the translating sleeve and at and a Directional Control Valve (DCV) to control the direction
the rear to the inner fixed structure by a drag link. (deploy or stow) of the thrust reverser system.
The six-blocker doors are made from epoxy-graphite. Four of
the doors are a common shape. The remaining two doors
positioned at the 12 and 6 o'clock position are contoured to
the shape of the upper and lower bifurcations.
Translating Sleeves
The translating sleeves are composite assemblies with an
inner and outer sleeve. The inner sleeve forms the outer wall
@ Rolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder page
Trent 1000 Line and Base Maintenance Engine Maintenance Practices
7Torque Box
Upper Hydraulic
Actuators
Translating Sleeve
Cascades (8 per half)

Inner Fixed Structure
Blocker Doors (6 per half)
Lower Hydraulic
Actuators and Manual
Driver Units
THRUST REVERSER ASSEMBLY

End of Section

m.
8
01
nspection Practices
©Rolls-Royce plc 2014 Use or disclosure is subject to the legend on the Notice to Holder Page
Trent 1000 Borescope Inspection Borescope Inspection Practices
Borescope Inspection Practices Continues in service to next scheduled inspection

Introduction Continues in service with reduced periodicity
Is removed, immediately or within a specified time
Borescope equipment permits the inspection of gas turbine
engine parts which would otherwise be inaccessible with the Special Inspections
engine installed and in service. Defects may be highlighted by either service experience or
Engine removal, either due to suspected internal damage or shop inspection and by the introduction of special inspections
because of Maintenance Schedules based on "Hard Time these particular defects can be monitored whilst the engine
Life" philosophy, involves high costs to operators. It is an remains in service.
obvious advantage to allow an engine to remain in service Non-scheduled Inspections
until defects are revealed by one or more of the following:
Borescope inspection can be used to great effect to assess
Performance analysis the serviceability of an engine after such incidents as:
Oil analysis
Ingestion of foreign objects
Borescope inspection
Engine surge
Repetitive monitoring of allowable damage
TGT or RPM exceedances.
Borescope inspection requirements basically fall into 3
categories:
Scheduled Inspections
Special Inspections
Non-scheduled Inspections
Scheduled Inspections
These are regular inspections carried out as part of an
approved Maintenance Schedule, the frequency of which is
dependent upon either engine cycles or flight times.
The combustion & turbine sections are of primary concern
due to the high stresses and temperatures in these areas. All
defects should be recorded, ideally on a specific chart, to
record any deterioration and assessments can then be made
to establish whether the engine:

Trent 1000 Borescope Equipment
PROBE 1 2 3 41 > 5 Fr>

SPECIFICATION No.
DIAMETER A 0.315 INCH 0.315 INCH 0.394 INCH 0.238 INCH 0.236 INCH
(MAXIMUM OUTER (8.00 mm) (8.00 mm) (10.00 mm) (6.00 mm) (6.00 mm)
DIAMETER)
LENGTH A 15.433 INCHES 4.528 INCHES 6299 INCHES 19.885 INCHES 78.740 INCHES
(MINIMUM LENGTH (392.00 mm) (115.00 mm) (160.00 mm) (500.00 mm) (2000.00 mm)
AVAILABLE TO GO
INTO THE ENGINE)
ANGLE A 70° 110' 90' 90' 90°

(DIRECTION OF
VIEW)
ANGLE B 60' 55° 35 60' 60'
(FIELD OF VIEW)
FLEXIBLE BORESCOPE NECESSARY (NOT A RIGID BORESCOPE)
ANGLE B
FOCUS
TN
ADJUSTMENT
PROBE
DIAMETER A
LENGTH A EYEPIECE
LIGHT SOURCE
CONNECTOR

Borescope Visual Inspection Equipment Flexible Borescopes

Borescope Probes Flexible borescopes are used for viewing internal components
High precision optical instruments which enable the inspection which are not clearly visible, due to inherent obstruction, when
of otherwise inaccessible areas. They fall into two main viewed through rigid probes.
categories - Rigid and Flexible. The flexible probe is used in conjunction with a guide tube -
Light Source aptly named, for the tube is inserted into the engine access
point to guide the flexible probe into the viewing position.
Light sources are designed to concentrate as much light as
possible into the instruments light guide cable. Most light The stop should be set as necessary before inserting the
sources utilise a standard 100 or 150 watt tungsten-halogen probe to ensure correct positioning for positive viewing and to
projector lamp. However for large cavities or where prevent the probe from encroaching into the path of rotating
components.
photography/CCTV is required a much higher illumination
level is needed and in this case metal-halide and xenon arc
lamps will provide the necessary results.
Most light sources are usually powered by 110-240 volt AC,
50-400 Hz AC supplies but additionally there are some which
use 12-15 volts DC supplies for portability.
Light Guide Cable
The light guide cable interconnects the light source to each
rigid or flexible borescope. However in many flexible
borescopes the light guide cable is an integral part of the unit
in order to reduce light loss. i.e. the light guide fibres run from
the light guide connector to the fiberscope tip without any
other connection.
Right-Angled Viewer
Viewers of different section lengths are available to facilitate
access into operator confined locations.

STEADY HANDLE
RIGHT ANGLED
VIEWER
STORAGE CASE
STORAGE LIGHT GUIDE CABLE

CASE
LIGHT
SOURCE BOX 0000
RIGID
BORESCOPES
a
co
a
BORESCOPE INSPECTION EQUIPMENT
Rigid Borescopes — Use, Care & Maintenance Always

Inspection before use Follow the manufacturers instructions &
recommendations.
Remove protective cap & inspect the objective and
eyepiece windows. Clean if necessary with lens tissues
or cotton applicators moistened with a solvent of 70% Handle with care at all times. Shocks or bends can
ether/30% methylated spirits. damage the optics.
Check focus control. Check the end faces of the light source cable for
Check the end faces of the light guide cable for clearness - clean as necessary.
clearness - clean if necessary. Clean the equipment before use & also prior to
Check the light guide cable for broken, bent or crushed stowage on completion.
areas. Always fit protective caps when the scope is not in use.
Check the length of the borescope visually for any Never
abnormalities.
Subject the instrument to any unnecessary force.
Operation
Use in a flammable atmosphere.
On introduction of the borescope, view through the
eyepiece and confirm direction. Force the focusing barrel or rotational control against
the stops.
Adjust illumination to a comfortable level and focus to
give a sharp image. Totally immerse the scope into liquids (the outer
insertion tube is liquid proof but not the main body).
Take care when removing scope.
Lay the scope on hard surfaces where it could be
Clean after use, following manufacturers exposed to pressure or weight which could bend the
recommendations. Fit protective caps and store in shaft.
an appropriate stowage to prevent damage.

©Rolls-Royce plc 2014. Use or disclosure's subject to the legend on the Notice to Holder Page
ORBITAL ORBITAL SCAN FOCUS EYE CUP

FIELD SCAN CONTROL DIRECTION INDICATOR CONTROL
OF
ir VIEW N.
DIAMETER
WORKING LENGTH
PROTECTION
CAP COLOUR SERIAL NUMBER
CODING AND
IDENTIFICATION RING
DIRECTION OF VIEW
0000 S DIRECT (Coded blue) LIGHT
GUIDE CONNECTOR
045° i>rS FORE - OBLIQUE (Coded green) (Inside handle)
0900 LATERAL (Coded red)

OES BORESCOPE IDENTIFICATION
110° RETRO (Coded yellow)
1 0 0 0 2 4 0 0 0
F - NO DIAMETER NOMINAL DIRECTION FIELD OF

ORBITAL SCAN 0.1mm WORKING OF VIEW VIEW
G - ORBITAL (0.0041n) LENGTH (cm) (Degrees) (Degrees)
SCAN
TYPICAL RIGID BORESCOPES

Flexible Fibrescopes — Use, Care & Maintenance Always

Inspection before use Follow the manufacturers instructions, recommendations
Turn the diopter adjustment ring until the network of fibres and handle with care at all times.
is its sharpest. Ensure that the 0-ring seal on the optical adapter (or
Rotate the focusing ring to the stop and check that an distal hood) is in good condition and correctly fitted.
object 20mm from objective lens can be seen clearly. Ensure that the equipment is clean before use and also
Rotate fully in opposite direction and check that an object prior to stowage on completion.
lm from the lens can be seen clearly.
Fit protective caps when the scope is not in use.
Inspect the insertion tube for dents, deformity and other
Never
irregularities.
Subject the distal end to shocks and impacts. Sharply
Operate the angle knob slowly and to the limit in each
bend or strain the light guide cable.
direction, making sure that the bending section flexes
smoothly and correctly without abnormal friction, Twist the bending section by hand or Insert into live
resistance etc. electrical equipment.
Operate the angle free knob and check that the bending Leave finger on angle knobs when removing the scope.
section is freed or locked properly.
Apply excessive force when inserting or removing the
Operation insertion tube.
Prior to insertion, set the angle free knob(s) to the free
position.
Confirm the insertion direction by looking through the
ocular, advancing the insertion tube slowly and never
forcing it.
Adjust the focus and brightness controls to obtain sharp
images at best illumination.
During withdrawal of the fibrescope, put the bending
section at the neutral state and ensure lock is in the free
position. Ease out the scope whilst viewing through it.

OBJECTIVE ANGULATION ANGULATION INTERCHANGEABLE
FOCUSING CONTROL BRAKE TIP
RING UP AND DOWN LEFT AND RIGHT ADAPTORS
MODEL
IDENTIFICATION DIAMETER
EYE
CUP
WORKING
DIOPTER LENGTH
FOCUSING (Insertion tube)
RING
ANGULATION BRAKE LIGHT GUIDE ANGULATION LIGHT GUIDE

UP AND DOWN CABLE CONTROL CONNECTOR
LEFT AND RIGHT
OVERALL LENGTH
OES INDUSTRIAL FIBERSCOPE IDENTIFICATION INTERCHANGEABLE TIP ADAPTOR IDENTIFICATION
8 4 8 4 A 0
INDUSTRIAL DIRECT WORKING LENGTH INDUSTRIAL MK 4 FIELD

FIBERSCOPE VIEW (x 100 mm) FIBERSCOPE (OES) OF VIEW
(x 3.937 in) RANGE (Degrees)
NOMINAL MK 4 NOMINAL DIRECTION OF VIEW
DIAMETER (OES) DIAMETER S = SIDE (Lateral)
RANGE D = DIRECT
C‘
0
La,;)
TYPICAL FIBERSCOPES
However, if a borescope
becomes trapped, DO NOT
PANIC.

ID
END OF SECTION

Trent 1000 Borescope Inspection Cold Section Inspection
IP Compressor Inspection Blanking Plugs

Introduction Where appropriate, the impact extractor & adaptor may be
This describes gives the procedure to do a borescope used to assist with removal of the plugs.
inspection of the IF compressor blades. You can do an Although incorrect fitting of plugs is designed to be
inspection of the front surface of the stage 1 IP compressor impossible, it is an advantage to identify them to their
blades through the front of the engine. This must be done
respective ports.
using a flexible borescope. The inspection of the remaining IP
compressor blades is through eight borescope access holes On completion of the inspection, the plugs should be refitted
with appropriate borescope inspection equipment. To gain in accordance with AMM instructions, paying particular
access to the Borescope plug, remove the right upper, centre attention to torque loading of securing bolts. Never use the
compressor fairings (TASK B787-A-R72-03-11-00A — 520A- securing bolts to pull the plugs into position. This may result in
A). damage to the engine or the plug. Ref. Standard Practices
B787-A-R72-00-0027A-950A-A.
Note: If blade damage is found in the IP compressor, then it is
recommended that a full borescope inspection of the HP Viewing Area from each Position
compressor (TASK B787-A-R72-00-00-21B-280C-A) is also
carried out. Port Access Viewing Area
Letter
Equipment
IP1S IF Stator 1 Rear— Stage 1
Reference Description
HU 29255 Extractor — Impact & adaptor IP25 IP Stator 2 Rear — Stage 2 + Front —Stage 3
RRT036128 IP Turning Tool IP35 IP Stator 3 Rear — Stage 3 + Front —Stage 4
STD-1014 Torque wrench 0 to 150 in-lbs (0 to
16.9Nm) IP45 IP Stator 4 Rear — Stage 4 + Front —Stage 5
STD-7028 Equipment — Borescope Inspection IP55 IP Stator 5 Rear — Stage 5+ Front —Stage 6
Consumable Materials IP6S IP Stator 6 Rear — Stage 6 + Front —Stage 7
Reference Description IP7S IP Stator 7 Rear — Stage 7 + Front —Stage 8
°Mat 1011 Engine Lubricating Oil
°Mat 4/62 High Temperature Anti-seize IP8S IP Stator 8 Rear — Stage 8

n.1
IP8S IP7S IP6S IP5S IP4S IP3S IP2S IP1S
Flexible
Intrascope
T100tM04_3D1_106_01
St
Borescope Access Plug
IP COMPRESSOR BORESCOPE PLUGS

Turning of the IP System Complete the following:

TASK B787-A-R72-00-00- 01A-950A-A Remove the bolts, the washers and the blanking plate.
Preparation (for all borescope procedures) Remove and discard the seal ring.
Warning: When opening the Thrust Reverser you must Install the turning tool.
complete the operations in the correct sequence. If you do not
comply with instruction, injuries to personnel and damage to Turn the turning tool by hand, until the tri-lobe drive
equipment can occur. engages in the gearbox and push into position.
Complete the following: Install the slave bolts and then attach the turning tool,
to the breather housing.
Retraction Leading Edge Slats (TASK B787-A-27-81-
27B-110A-A). Use a wrench to turn the turning tool. This will turn the
IP system via the accessory gearbox.
Deactivation Leading Edge Slat System (TASK B787-
A- 27-81-00-24A-510B-A).
Deactivation Thrust Reverser for Ground Maintenance
(TASK B787-A-R78-31-00-20H-510B-A).
For the applicable Engine - Open Fan Cowls for
Access (TASK B787-A-R71-11-04-00B-540A-A).
For the applicable Engine - Open Thrust Reverser for
Access (TASK B787-A-R78-31-00-20B-540A-A).
Install Ground Support Equipment
Warning: Make sure that the applicable covers are installed
at the rear of the engine. The movement of air through the
engine can cause the LP compressor to turn very quickly and
cause injury. Put the air intake-cowl protective-mat the core
exhaust plug and the thrust reverser air-discharge plug in their
positions. Make sure that the red warning flags are visible.

External Gearbox
Breather Housing
0_03
T1000_M04_3131_11
IP Turning Tool
Seal Ring
ii
Breather Cover
IP SYSTEM MANUAL TURNING

t Rolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder Page
IP Compressor Inspection Do a borescope inspection of the IP compressor blades:

Use dimensions below to help when you do an inspection of For the leading edge and front surface of the IP
the IP compressor blades. compressor stage 1, carefully put a 0.320 in. (8.13 mm)
Note: The approximate widths of the compressor blades diameter probe (flexible) between the LP compressor
measured in a straight line at the blades. For all other stages, carefully remove the
associated borescope-blanking plug.
mid-height position are as follows:
Carefully insert the correct diameter probe into the
IP Compressor Blade Reference & Dimensions engine. This will to let you view the trailing edge and
rear surface of the rotor stage in front and after rotating
Rotor Number Width (Mid Height (Vertical
the viewer though 180deg, the leading edge and front
Stage Height) Centre Line) surface of the rotor stage behind.
4.57 in (116.1 mm) 6.97 in (177.0 mm)
1 34
Carefully rotate the IP compressor to inspect all blades
2 2.56 in (65.0 mm) 5.31 in (134.9 mm) at all stages ensuring that the borescope tip does not
49
2.17 in (55.1 mm) 4.37 in (111.0 mm) come into contact with the compressor blades.
3 58
1.93 in (49.0 mm) 3.70 in (94.0 mm)
4 53
53 1.89 in (48.0 mm) 3.15 in (80.0 mm)
5
1.69 in (42.9 mm) 2.83 in (71.9 mm)
6 60
7 1.77 in (45.0 mm) 2.56 in (65.0 mm)
58
1.93 in (49.0 mm) 2.36 in (59.9 mm)
8 53
Issue 4 - February 2014 Page 4-5

I r•--)
cS3—na---_CELT
IP8S IP7S IP6S IP5S IP4S IP3S IP2S IP1S
Flexible
Intrascope
T1 000_M04_3131_1 06_01
er".

sti
IP COMPRESSOR BLADE BORESCOPE POINTS

Issue 4 - February 2014 Page 4-6
Damage Assessment
The IF compressor should be inspected and classified in
accordance with the AMM with reference to the zones,
platform and tip.
Inspect for the following damage:
Bent
Broken
Burned
Burrs
Cracked
Curled
Dented
Eroded
Missing material
Nicked
Rounded
Rubbed
Torn
Tip Failures
The terminology applied to damage is defined in Standard
PracticesB787-A-A-R72-00-00-27A-950A-A.

BLADE TIP
ZONE D
10% OF
AIRFOIL
TRAILING
EDGE
ZONE C
30% OF
AIRFOIL
CONVEX
AIRFOIL
SURFACE
ZONE B
CONCAVE 50% OF
AIRFOIL AIRFOIL
SURFACE
ZONE A
10% OF
AIRFOIL
BLADE
PLATFORM ROOT
RADIUS
IP COMPRESSOR BLADE ACCEPTANCE ZONES


HP Compressor Inspection

HP Compressor Inspection Blanking Plugs

Introduction Where appropriate, the impact extractor & adaptor may be
This describes gives the procedure to do a borescope used to assist with removal of the plugs.
inspection of the HP compressor blades. The inspection of the Although incorrect fitting of plugs is designed to be
HP compressor blades is through five borescope access impossible, it is an advantage to identify them to their
holes with appropriate borescope inspection equipment. respective ports.
Equipment On completion of the inspection, the plugs should be refitted
Reference Description in accordance with AMM instructions, paying particular
SPL-2221 Extractor — impact & adaptor attention to torque loading of securing bolts. Never use the
RRT034446 HP Turning tool securing bolts to pull the plugs into position. This may result in
STD-1014 damage to the engine or the plug. Ref. Standard Practices
Torque wrench 0 to 150 in-lbs (0 to
B787-A-R72-00-00-27A-950A-A
16.9 Nm)
STD-1016 Torque wrench 0 to 300 in-lbs (0 to Viewing Area from Each Position
33.89 Nm)
STD-7028 Equipment — Borescope Inspection Port Access Viewing Area
Letter
Consumable Materials HP1 HP Stator 1 Front —Stage 1only
Reference Description HP1/HP2 HP Stator 2 Rear — Stage 1 + Front —Stage 2
()Mat 1011 Engine Lubricating Oil
0Mat 4/62 High Temperature Anti-seize HP2 HP Stator 3 Rear — Stage 2 + Front —Stage 3
HP3 HP Stator 4 Rear — Stage 3 + Front —Stage 4
HP4 HP Stator 5 Rear — Stage 4 + Front —Stage 5

„
ilET_Ian-licrii---Fr
tmM aSs
jc-ss-ent.„?-exa..1
ji \
.1
HP4 HP3 HP2 HP1/HP2 HP1

T1000_M04_3D1_107_01
Borescope Access Plugs
HP COMPRESSOR BORESCOPE PLUGS

Maintenance Practices Note: The Trent 1000 does not have any Carbon Seals
The following is a brief description of rotating the HP installed, as such if it is required to do so, the HP Turning Tool
system. Refer to the AMM for the full description. can be turned clockwise or counter-clockwise.
Turn the HP System When the task is complete remove the HP Turning Tool
AMM Task B787-A-R72-00-00-27C-950A-A from the shaft.
The warnings and cautions relating to the temperature of Install the nut onto the shaft. Make sure that anti-rotation
the engine and installation of covers and plugs are the plate flats on the nut retainer are correctly aligned with
same as for turning the LP System. flats on the shaft.
Ensure the Thrust Reverser has been deactivated for Torque tighten the nut and safety with safety cable
ground maintenance. (recommended) or lockwire (alternative).
Open the right Fan Cowl Door (TASK B787-A-R71-11-04- Install the lower right compressor fairing (TASK B787-A-
00B-540A-A). R72-03-11-00A-720A-A).
Open the Thrust Reverser for maintenance (TASK B787- Remove the engine inlet cover, exhaust and fan air plugs
A-R78-31-00-20B-540A-A) and ensure the area is clear of tools and equipment.
Install the engine inlet cover, engine exhaust and engine Close the Thrust Reverser (TASK B787-A-R78-31-00-
fan plugs in position. These will help to prevent the LP 20B-740A-A).
system from windmilling. Close the right Fan Cowl Door (TASK B787-A-R71-11-04-
Remove the lower right compressor fairing (TASK B787- 00B-740A-A).
A-R72-03-11-00A-520A-A). Re-activate the Thrust Reverser.
Remove the nut from the shaft.
Note: The nut is attached by a lanyard.
Install the HP Turning Tool (RRT046961) onto the end of
the shaft. Make sure that the splines on the shaft and
turning tool engage correctly and attach to the adapter
using the bolts provided.
Use the correct size wrench to turn the HP Turning Tool to
rotate the HP System.
Integral HP
Turning Tool
\_
I Integral HP
Turning Tool
Adaptor
Locking Nut
T1000_M 04_3171_121_03A
11\_ Splined Tooth Captive

Drive Washer
TURN THE HP SYSTEM

Sipa
Integral HP
Turning Tool
Bi-directional Rotation
Locking
Nut
Adaptor
T1000_M04_301_121_03B
Splined Tooth Drive
TURN THE HP SYSTEM

T1000_M04_2D1_105_01
TURN THE HP SYSTEM

Issue 4- February 2014 Page 4-16
HP Compressor Inspection rear surface of the rotor stage in front and after rotating
TASK B787-A-R72-00-00-21B-280C-A the viewer though 180deg, the leading edge and front
surface of the rotor stage behind.
Use dimensions below to help when you do an inspection of
the HP compressor blades. Carefully rotate the HP compressor to inspect all
blades at all possible stages ensuring that the
Note: The approximate widths of the compressor blades borescope tip does not come into contact with the
measured in a straight line at the compressor blades.
mid-height position are as follows:
HP Compressor Blade Reference & Dimensions
Rotor Number Width (Mid Height) Height (Vertical

Stage Centre Line)
1 48 1.924 in. (48.86 mm) 1.423 in. (36.14 mm)
2 68 1.396 in. (35.46 mm) 1.606 in. (40.79 mm)
3 72 1.292 in. (32.82 mm) 1.292 in. (32.82 mm)
4 74 1.345 in. (34.16 mm) 1.105 in. (28.07 mm)
5 68 1.267 in. (32.17 mm) 1.041 in. (26.44 mm)
Note: Stage 6 has 66 blades, but you are not able to

complete a borescope inspection on the stage.
Do a borescope inspection of the HP compressor blades:
For all stages, carefully remove the associated
borescope-blanking plug.
engine. This will to let you view the trailing edge and
HP4 HP3 HP2 HP1/HP2 HP1
§' Borescope Access Plugs
HP COMPRESSOR BLADE BORESCOPE POINTS

Damage Assessment
The HP compressor should be inspected and classified in
accordance with the AMM with reference to the zones,
platform and tip.
Inspect for the following damage:
Bent
Broken
Cracked
Curled
Dented
Missing Material
Nicked
Rubbed
Torn
Practices B787-A-R72-00-00-27A-950A-A

ZONE C BLADE TIP

10% OF AIRFOIL
TRAILING EDGE
LEADING EDGE
CONCAVE AIRFOIL
SURFACE
CONVEX AIRFOIL
ZONE B SURFACE
80% OF AIRFOIL
ROOT RADIUS
ZONE A
10% OF AIRFOIL
BLADE
PLATFORM
HP COMPRESSOR BLADE ACCEPTANCE ZONES

End of Section

Trent 1000 Borescope Inspection Hot Section Inspection
Combustion Chamber Consumable Materials

TASK B787-A-R72-00-00-06B-280C-A Reference Description
Introduction °Mat 1011 Engine Lubricating Oil
Routine inspection of hot sections is expected to be carried out °Mat 4/62 High Temperature Anti-seize
at 1000hr intervals.
Blanking Plugs
This describes the procedure to carry out a borescope
inspection of the Combustion System. You can do a general The combustion chamber blanking plugs are designed to be
inspection of the combustion system though six borescope removed and refitted using a 1/4 inch (6.35 mm) square drive.
access plugs located around the combustion chamber outer They are then located into one of two dedicated holes in the
casing. This should be carried out using a rigid 8mm borescope casing.
with a more detailed supporting inspection being done using
On completion of the inspection the plugs should be refitted in
flexible borescope equipment. accordance with AMM instructions.
Preparation Note. When refitting the borescope blanking plugs, offer up
Warning: When opening the Thrust Reverser you must the plugs to the casing and manually turn the borescope
complete the operations in the correct sequence. If you do not blanking plugs clockwise until the spigot locates into one of
comply with instruction, injuries to personnel and damage to the two combustion chamber outer casing holes.
equipment can occur. Use the correct square drive to tighten the borescope blanking
Complete all tasks as listed for Turning of the IP System for plugs then continue to turn the borescope blanking plugs
the opening of the Fan Cowl Doors and Thrust Reversers. clockwise until you hear continuous clicks.
Equipment Viewing Area from each Position
Reference Description Port Access Viewing Area
STD-7028 Equipment — Borescope Inspection Letter
All Comb system mid point General

TI 000_V 04_31)1_108_01
Borescope
Access Plug Borescope (6 off)
Access Plug
COMBUSTION SYSTEM BORESCOPE PLUGS

Combustion System Inspection Cracked

Carefully insert the correct borescope probe into the Burned
combustion chamber and view its general condition though
the six-borescope access ports and assess & record if Eroded
necessary, all observed damage. Missing material
The borescope inspection should be checked for the 5. Fuel spray nozzles:
following:
Cracked
1. Heatshields:
Incorrect position
Cracked
Burned
Burned
Eroded
Eroded
Missing material
Not aligned
Each of the above damage criteria has a related action that
• Burn holes must be carried out before the specified maximum time limit.
2. Burner seal Flares: These time limits are provided in the AMM in hours and cycles
with the limit that occurs first being the limiting factor.
Cracked.
Damage Assessment
Burned.
Any combustion system damage should be assessed and
• Eroded. classified in accordance with the AMM applying restrictions as
• Missing material necessary.
3. Rear inner combustion liner: The Rolls-Royce plc, Operations Room — Technical Helpdesk
or a Rolls-Royce representative should also be informed as
• Cracked instructed by the AMM if required.
• Burned
• Eroded
• Missing material
4. Rear outer combustion liner:
HP OCV AND
COMBUSTION
BURNER FRONT INNER CASE
SEAL FLARE ASSEMBLY
HEATSHIELD
FRONT
INNER FUEL
COMBUSTION SWIRL SPRAY
LINER VANES NOZZLE
COMBUSTION TILES
DILUTION
CHUTES
REAR INNER
COMBUSTION
LINER
COOLING
SUPPLY
HOLES
FRONT
OUTER
COMBUSTION
DORLSOOPE LINER
ACCESS
HP TURBINE
NOZZLE TILE COMBUSTION
GUIDE RETAINING OUTER CASE
VANES STUDS
REAR OUTER
COMBUST/ON
LINER
COMBUSTION SYSTEM CHAMBER SECTION

Combustion Chamber Inspection

Combustor Tile Inspection
The combustor tiles should be inspected for the following
damage:
Inner and outer combustor tiles and dilution chutes:
Cracked
Burned
Eroded
Distorted
Missing Material
Burn Holes
must be carried out before the specified maximum time limit.
These time limits are provided in the AMM in hours and cycles

COMBUSTION TILE 0.5 INCH

(BAT I) (12.7 mm)
COMBUSTION TILE
(BAY 21
COMBUSTION TILE
(BAT 3)
ZONE B
COMBUSTION TILE
(BAY 4)
C
DISTORTED TILE
AXIAL LENGTH
i OF CRACKS an INCH
' (23.3 mm)
AREA OF MISSING
MATERIAL
DISTANCE COOLING FEED

BETWEEN HOLES 0.5 INCH
CRACKS V (12 7 mall
LINER
ATTACHMENT
STUDS
HOLE
ZONE A
1.57 INCHES 1.61 INCHES

(40.0 mm) (46.0 mml,
1.45 INCHES 1.81 INCHES
DISTORTED TILE (37.0 mm) (48 0 mm)
COMBuSTiON LINER OUTER OCINIBUSTION LINER

(DAMAGE)
depot agm
sccov7,607. VI
COMBUSTION CHAMBER TILE INSPECTION

Issue 4-'February 2014 Page 5-6
Combustion System Inspection

Burner Head Inspection
After a bird strike or a suspected bird strike, inspect the
combustion section particularly the Fuel Spray Nozzles (FSN)
for and surrounding area for the following damage:
1. Heat shields:
Not aligned or Movement out of position
Burned
2. Fuel spray nozzles:
Incorrect position
must be carried out before the specified maximum time limit.
These time limits are provided in the AMM in hours and cycles
Damage Assessment
Any combustion system damage should be assessed and
classified in accordance with the AMM applying restrictions as
necessary.

Rolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder Page
POSSIBLE FAILURE
POSITION
CAP A
(CONSTANT - METERPANEL
AROUND
DECREES)
HEATSHIELD
(NO AXIAL MOVEMENT
POSITION BETWEEN
ADJACENT HEATSHIELDS)
ZONED
FUEL SPRAY NOZZLE

(MUST NOT BECOME
DISENGAGED FROM
BURNER SEAL)
BURNER SEAL FLARE
ZONED
HEAT SHELD BORE
GAP A
(CONSTANT AROUND
380
COMBUSTION SYSTEM BURNER HEAD SECTION


High Pressure (HP) Nozzle Guide Vanes

HP Nozzle Guide Vane Inspection Consumable Materials

TASK B787-A-R72-00-00-22B-280C-A Reference Description
Introduction 0Mat 1011 Engine Lubricating Oil
This describes the procedure to carry out a borescope ()Mat 4/62 High Temperature Anti-seize
inspection of HP Nozzle Guide Vanes (NGVs). You can do a
general inspection of the NGVs though six borescope access
plugs located equally around the combustion chamber outer Blanking Plugs
casing. This should be carried out using a rigid 8mm
The combustion chamber blanking plugs are designed to be
borescope with a more detailed supporting inspection being
removed and refitted using a % inch (6.35 mm) square drive.
done using flexible borescope equipment. In addition, a closer
They are then located into one of two dedicated holes in the
but restricted inspection though the dedicated NGV access casing.
port can be carried out on certain vanes only.
On completion of the inspection the plugs should be refitted in
Preparation accordance with AMM instructions.
Warning: When opening the Thrust Reverser you must Note 1: When refitting the combustion chamber borescope
complete the operations in the correct sequence. If you do not
blanking plugs, offer up the plugs to the casing and manually
comply with instruction, injuries to personnel and damage to
turn the borescope blanking plugs clockwise until the spigot
equipment can occur. locates into one of the two combustion chamber outer casing
Complete all tasks as listed for Turning of the IP System for holes.
the opening of the Fan Cowl Doors and Thrust Reversers. Use the correct square drive to tighten the combustion
Equipment chamber borescope blanking plugs then continue to turn the
borescope blanking plugs clockwise until you hear continuous
clicks.
33.89 Nm) Note 2: When installing the dedicated NGV blanking plug,
STD-7028 Equipment — Borescope Inspection ensure that the central rod is correctly aligned at the
hexagonal (threaded) end and the HP NGV blanking hole on
the engine casing before securing and torque loading into its
final location.

ORolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder Page
HP NGV
IF NGV
t '
T1000_M04_3131_108_01
Borescope
Access Plug
HP NOZZLE GUIDE VANE INSPECTION

HP Nozzle Guide Vane Inspection Any NGV damage should be assessed and classified in
TASK B787-A-R72-00-00-228-280C-A accordance with the AMM applying restrictions as necessary.
Do a borescope inspection of the HP Nozzle Guide Vanes

(NGVs).
Carefully insert the correct diameter probe into the engine via
the six combustion chamber borescope inspection ports and
view the general condition of the HP NGVs. Assess & record if
necessary, all observed damage.
Do an inspection of the leading edge, trailing edge platform,
and concave airfoil surface. Look for the following type of
damage:
Cracked
Nicked.
Gauged.
Missing Material
Battered
Dented
Holes
Peeled
Missing Thermal Barrier Coating (TBC)
Damage Assessment
To assist in making an assessment of any damage, refer to
the diagrams below for essential NGV dimensions and
categorization of type of damage.

AXIAL CRACK OUTER

PLATFORM
'(I
RADIAL CRACK 1.87 INCHES J ) i
475 nun)
TRAILING
EDGE ---...... )
) 194 INCHES
LEADING
1 1 II EDGE (49.3 rem)
PLATFORM
CRACKS
AEROFOIL CONCAVE
SURFACE
LEADING FILM COOLING
EDGE HOLES
ZONE 114NER
PLATFORM
HP NOZZLE GUIDE VANE DIMENSIONS AND CATEGORIZATION

©Rolls-Royce plc 2014. Use or disclosure Is subject to the legend on the Notice to Holder Page

High Pressure (HP) Turbine Blades

High Pressure (HP) Turbine Blades

Blanking Plugs
Introduction
The two borescope plugs are distinctively different but have
The following is an overview of the procedure to carry out a similar securing threads. Although incorrect fitting of plugs is
borescope inspection of the HP turbine blades. You can view designed to be impossible, it is an advantage to identify them
the leading edge of the HP turbine blades through the HP to their respective ports.
Nozzle Guide Vane (NGV) borescope access port and the
Note: Carry out a visual inspection of the vane boss in the IP
trailing edge of the blades can be viewed though the IF
NGV to ensure that the bush is in position. Refer to the AMM
borescope access port. Both ports are located on the HP/IF
if the bush is found to be missing.
turbine casing.
On completion of the inspection, the plugs should be refitted
Preparation
in accordance with AMM instructions, paying particular
Warning: When opening the Thrust Reverser you must attention to torque loading of securing bolts. Ref. Standard
complete the operations in the correct sequence. If you do not Practices B787-A-R72-00-00-27A-950A-A
comply with instruction, injuries to personnel and damage to
Note: When installing the dedicated NGV blanking plug,
equipment can occur.
ensure that the central rod is correctly aligned at the
Complete all tasks as listed for Turning of the IP System for hexagonal (threaded) end and the HP NOV blanking hole on
the opening of the Fan Cowl Doors and Thrust Reversers. the engine casing before securing into its final location.
Equipment Viewing Area from Each Position
Port Access Viewing Area
RRT034446 HP Turning tool
STD-1016 Torque wrench 0 to 300 in-lbs (0 to HP NOV HP/IP Turbine Case HPT Leading Edge
33.89 Nm) IPT HP/IF Turbine Case HPT Trailing Edge
STD-7028 Equipment — Borescope Inspection
Consumable Materials
()Mat 1011 Engine Lubricating Oil
()Mat 4/62 High Temperature Anti-seize
Issue 4— February 2014

BORESCOPE
ACCESS HOLE
TYPO& NOV
NUM IN
POMPON VIOIE SOU
VANE SOBS
This 's SERVICEABLE THIS 'SNOT PERMITTED

Borescope VANE BOSS
Borescope Access Plug (EXAMPLES)
Access Plug Borescope (6 off) A

Access Plug
HP NGV & IP TURBINE BORESCOPE PLUGS

HP Turbine Inspection Carefully insert the correct diameter probe into the
Install Ground Support Equipment engine at the IP borescope port to inspect the trailing
edge and rear surface of the HP turbine.
Warning: Make sure that the applicable covers are installed
at the rear of the engine. The movement of air through the Rotate the HP system to inspect all HP turbine blades
engine can cause the LP compressor to turn very quickly and ensuring that the borescope tip does not come into
cause injury. Put the air intake-cowl protective-mat the core contact with the turbine blades.
exhaust plug and the thrust reverser air-discharge plug in their For both front and rear inspections of the HP turbine look for
positions. Make sure that the red warning flags are visible. the following type of damage:
Gain Access to the HP System Turning Point Cracked
For associated tasks to turn the HP System complete all tasks Burned
as listed and covered for Cold Section Inspection, Turning of
the HP System for the inspection of the HP compressor. Eroded
HP Turbine Inspection Missing material
Use dimensions below to help when you do an inspection of Corroded
the HP turbine blades. Dimension A is for the blade trailing Pitted
edge height, B is the mid-height blade width and C is the
blade leading edge height. Missing Thermal Barrier Coating (TBC)
Note: The dimensions given are strait line approximations and Dents
do not account for curved surfaces.
Do a borescope inspection of the 66 HP turbine blades:
engine at the HP NGV borescope port to inspect the
leading edge and front surface of the HP turbine.
Rotate the HP system (as discussed in section 4, AMM
TASK B787-A-R72-00-00-27A-950A-A) to inspect all
HP turbine blades ensuring that the borescope tip does
not come into contact with the turbine blades.

A
2.11 INCHES
(b3Onir)
22o INCHEb
572 m}
1.C4 INCA SS
(204m0
Combustor
HP NGV
IP NGV
Borescope
Bcrescope Access Plug
Access Plug
HP TURBINE BORESCOPE POINTS & DIMENSIONS

ORolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder Page
Damage Assessment
To assist in making an assessment of any damage, refer to
the diagrams below. Any HP turbine damage should be
assessed, classified and in accordance with the AMM, apply
the relevant restrictions as necessary.
Practices B787-A-R72-00-00-27A-950-A-A.

BURN'ERCS ON
AX A_ LEWITH
AREA DI
AIWA B L •
LEADING EDGE •
HADIALCHACK
WM 130 LOSS
11, ••
CRACK
AX A_
, LENG-11-1
CONVEX ,
AIRFOIL
SUIT ACE LEADING EDGE P_ATFO*1
AREAS RADIALCRACK CARAa<
vER TRAIL PIG EDGE

RLATFOFIXA _EADINEI AXIAL •I'Recv.
GCNCAVE TII IBC LOSS
AREA E LUGE AIRFO L
ARFA A SURI-ADG
AR FA C
I HAII Inn
Ft A-A
EDGE
AREA
AREA Di
I 4N
ARCA B D STANCE BETWEEN
TWO CRACKS1HAT
CAN POSSIBLY CONNECT
CUI Hit
SHIELD
CRACiS
AXIA
031 INCH I FROTH
;ILO mrnl
TYPCAL TRAILING EDGE
OLFTER SI !ROW AOLIVENT
FACE EROSIOA
TRAI INC
EDGE
HP TURBINE ACCEPTANCE ZONES & EXAMPLE DAMAGE


Intermediate Pressure (IP) Turbine Blades

Intermediate Pressure (IP) Turbine Blades

Blanking Plugs
TASK 8787-A-R72-00-00-24B-280C-A
The two borescope plugs are distinctively different but have
Introduction similar securing threads. Although incorrect fitting of plugs is
The following is an overview of the procedure to carry out a designed to be impossible, it is an advantage to identify them
borescope inspection of the IP turbine blades. You can view to their respective ports.
the leading edge of the IP turbine blades through the IP Note: Carry out a visual inspection of the vane boss in the IP
borescope access port and the trailing edge of the blades can NGV to ensure that the bush is in position. Refer to the AMM
be viewed though the LP1 turbine borescope access. Both if the bush is found to be missing.
ports are located on the HP / IP turbine casing.
On completion of the inspection, the plugs should be refitted
Preparation in accordance with AMM instructions, paying particular
Warning: When opening the Thrust Reverser you must attention to torque loading of securing bolts. Ref. Standard
complete the operations in the correct sequence. If you do not Practices B787-A-R72-00-00-27A-950A-A.
comply with instruction, injuries to personnel and damage to Viewing Area from Each Position
equipment can occur.
Complete all tasks as listed for Turning of the IP System for
the opening of the Fan Cowl Doors and Thrust Reversers. IPT HP/IP Turbine Case IPT Leading Edge
Equipment LP1 HP/IP Turbine Case IPT Trailing Edge
RRT036128 IP Turning tool
33.89 Nm)
°Mat 4/62 High Temperature Anti-seize

T1000_M04_ 301_10801
Borescope
Access Plug
IP TURBINE BORESCOPE POSITION

Flexible
Intrascope —•
\
,
LP1 TURBINE BORESCOPE PLUG & POSITION

BOA ESCOPE
ACCESS HOLE
TYPICAL NOV
BUSH
BUSH IN MISSING
POSITION
VANE BOSS
THIS IS SERVICEABLE THIS IS NOT PERMITTED
DEJ0013886
2099299 50000934943_91
EXAMPLE OF BUSH IN POSITION ON VANE BOSS

Install Ground Support Equipment Carefully insert the correct diameter probe into the
Warning: Make sure that the applicable covers are installed engine. At the LP1 borescope port to inspect the
at the rear of the engine. The movement of air through the trailing edge and rear surface of the IP turbine.
engine can cause the LP compressor to turn very quickly and Rotate the IP system to inspect all IF turbine blades
cause injury. Put the air intake-cowl protective-mat the core ensuring that the borescope tip does not come into
exhaust plug and the thrust reverser air-discharge plug in their contact with the turbine blades.
positions. Make sure that the red warning flags are visible.
For both front and rear inspections of the IF turbine look for
Gain Access to the IP System Turning Point: the following types of damage:
For associated tasks to turn the IF System complete all tasks Cracked
as listed and covered for Cold Section Inspection, Turning of
the IP System for the inspection of the IP compressor. Dents
IP Turbine Inspection Nicked

Use dimensions below to help when you do an inspection of Scratched
the IP turbine blades. Dimension A is for the blade leading Torn
edge height, B is the mid-height blade width and C is the
blade trailing edge height. Scored
Note: The dimensions given are straight line approximations Damage Assessment
and do not account for curved surfaces. Any IF turbine damage should be assessed and classified in
Do a borescope inspection of the 114 IF turbine blades: accordance with the AMM and any restrictions applied as
necessary.
engine. At the IP borescope port to inspect the leading The terminology applied to damage is defined in Standard
edge and front surface of the IP turbine blades. Practices B787-A-R72-00-00-27A-950-A-A.
Rotate the IP system (as discussed in section 4, AMM

TASK B787-A-R72-00-00-01A-950A-A) to inspect all IF
turbine blades ensuring that the borescope tip does not
come into contact with the turbine blades.

NOTE: TH=SF AqF ETRA1CHT 1 US ArnROKIVIATF

Dim.Nsio s AND NU I 11 It C-HVE:i
EUR=ACE DIVENS1ONE.
3.093 INC-ES
c7B.67rnint
[Th A
-<<"-
0 NCH
(PEAR -rim)
1 1
A
I I> "N•
jet ',Qs,
IMER ZONED
\
C-1
iletprrni1
LEADING
F F
KA LING t2l.-it
AREAS
0.39 INCH
(-090 91r4
CONVFX
SJRFACE
AREA C
INCICS CONCAVE
SIJR1-ACt
:61.713inm) AREA C
0.91 IN.CH
93.3 min;
I F-
RADII
HEI GHT OF BLADE MEASURED A- LEADI G EDGE LEADING EDGE

I)WIDTh Q= BLADE MEASURED A- V D-HEIGHT 0= BLADE AREA A
A-A
1E131 rr OF DLC•E MEASURED AT TRA LING EDGE
IP TURBINE DIMENSIONS & AREAS


Low Pressure (LP) Turbine Blades

Low Pressure (LP) Turbine Blades impossible, it is an advantage to identify them to their
Introduction respective ports.
The following is an overview of the procedure to carry out a On completion of the inspection, the plugs should be refitted
borescope inspection of the LP turbine blades. You can view in accordance with AMM instructions, paying particular
the LP turbine blades through the six LP turbine borescope attention to torque loading. Ref. Standard Practices B787-A-
access ports. The first port (LP1) is located on the HP/IP R72-00-00-27A-950A-A.
turbine casing, while the remainder is located on the LP Viewing Area from each Position
turbine case.
Preparation
Warning: When opening the Thrust Reverser you must LP1 HP/IP Turbine Case Front —Stage 1+ Rear of the IPT
complete the operations in the correct sequence. If you do LP2 LP Turbine Case Rear — Stage 1 + Front —Stage 2
not comply with instruction, injuries to personnel and damage
LP3 LP Turbine Case Rear — Stage 2 + Front —Stage 3
to equipment can occur.
Complete all tasks as listed for Turning of the IP System for LP4 LP Turbine Case Rear — Stage 3 + Front —Stage 4
the opening of the Fan Cowl Doors and Thrust Reversers. LP5 LP Turbine Case Rear — Stage 4 + Front —Stage 5
Equipment LP6 LP Turbine Case Rear — Stage 5 + Front —Stage 6
Reference Description Via the exhaust Rear — Stage 6
67.78 Nm)
0Mat 4/62 High Temperature Anti-seize
Blanking Plugs
The six borescope plugs are all very similar in appearance
Although incorrect fitting of plugs is designed to be
LP1
Flexible
Intrascope
f LP4 Ns,
LP5
Av
1 LP6 4
LP TURBINE BORESCOPE PLUGS

CRolls-Royce plc 2014. Use or disclosure is subject to the legend on the Notice to Holder Page
Install Ground Support Equipment Carefully insert the correct diameter probe into the
Warning: Make sure that the applicable covers are installed engine at each of the remaining LP turbine borescope
at the rear of the engine. The movement of air through the ports (LP2 to LP6) to inspect the trailing edge and rear
engine can cause the LP compressor to turn very quickly and surface of the IP turbine stage in front. Rotate the
cause injury. Put the air intake-cowl protective-mat the core probe though 180deg to inspect the leading edge and
exhaust plug and the thrust reverser air-discharge plug in their front surface of the IP turbine behind.
positions. Make sure that the red warning flags are visible. The trailing edge and rear surface of the LP turbine
Warning: Make sure that you use suitable gloves before you stage 6 can be inspected from the rear of the exhaust
hold the LP compressor blades as the leading edges of the unit.
blades are sharp and can cause injury. At each stage, rotate the LP system to inspect all LP
Go into the air intake and while remaining in contact with other turbine blades ensuring that the borescope tip does not
personnel, who are performing the inspection, turn the LP come into contact with the turbine blades.
Compressor slowly with your hand. For all LP turbine stages, both front and rear inspections of
LP Turbine Inspection the turbine look for the following type of damage:
Use dimensions below to help when you do an inspection of Cracks
all LP turbine blades of all stages. For each blade, dimension Nicks
A is for the blade leading edge height, B is the mid-height
blade width and C is the blade trailing edge height. Scratches
Note: The dimensions given are strait line approximations and Dents
do not account for curved surfaces. Other damage
Do a borescope inspection of all LP turbine blades:
engine the LP1 turbine borescope port to inspect the
leading edge and front surface of the stage one LP
turbine blades.
Rotate the LP system (as discussed in section 4, AMM
TASK B787-A-R72-00-00-26A-950A-A) to inspect all
LP turbine blades ensuring that the borescope tip does
not come into contact with the turbine blades.
csiurr
auRui OOP
S-ROLID
TAMING TIM
I FAL AG
EGE EDGE
\A. NFR011
4.56 IPENES SURFACES
ILS.9 f AMAX IENAS
/SURFACES ROACHES
113€1 nil EDGE
A
deNj 11) Ai\ 115 IACHED
ci) FALAI
Obt2rIP
IRALE4
'AA LNG EWE
A 450 II.ENFS EDGE APAR
0211 IKE ES 1 -14.3 rrnp APEALB LISAVIA
NAME
821 INCHES SUTAGE
112.71m) AHRAG
GONER NAME AIDOE.
SURFACE DARER
ARIA G WAG
II LEARNS
EDGE
GONGAV
A ARIL
SURFACE
AREAL
CONCAVE
AIRFOIL I
&APACE
AREAC
GONCAVEAIRMIL
SUAFACE
FASIE AREA G
L' IU1IlN
ELME
LEMINS EMIRS
k LEAGN3
EDGE MGR
STALES FM: C-C
AIER A AREA A AREAA
FLAI -ORM I FT.RIVIF
IOTP: INGER MAX wri
T-BSEARESTRAGHTUNEARRCANATEDIMBSIODS PIA KIM PLATIAM
/CM NOE
AlfINDT 111F SIIRFACF DINIFNACIe. A-A
TNEEME STANGE WEAPPROXIIAME CURSORS TIEGAESTRAtal uPEAPPIMARTE DARWIN
APE/NOTTHFCIINFINIFEACFRIVENSIGNE NIO ICE TFECURVEOSJAFAGEOIMENEICAS.
a HOG-TOE BUCLUEASUREDAT LAD ND MK
D VED1110.11 MP WOMAN) AT MEDHFAI-TOP I 11M-TCF I MF RIFEE.RFORTI FEW MGR
I HESWOCBIAD:EASUTIMA-LEAGAG
2) HEIGH-OF LADE AGAWAM TRA. ND TEDSE WITH OF BLADE IF:WAWA- M DDEIGHTOFBEADE
tiartiar R AlIFIWPS-FIMATNICHFIGHTEER Anr
FRED-OEFIE.LIFAARRI-RAI EEC.
HED-TGEBLAXMEAS.REDTRVU \ MOE
LP TURBINE STAGES 1,2 & 3 DIMENSIONS & AREAS

LP Turbine Stage Number of Blades

1 158
7e.or,
2 164
3 156
4 154
ke) LP1
Flexible
5 146 logesCoPe
LP2
6 142 LP3
Damage Assessment LP4
Any LP turbine damage should be assessed classified and in

accordance with the AMM, apply restrictions as necessary.
Practices B787-A-R70-01-02-00-030A-A.

CORR 0.1 I di
SHROUD SHROUD
OWER
/WOOD
/ X
77 ----- r
'MILK IF/CLEO
LEG EN MR:01_ -RMJNG GE TRAIIIKC
MARACA BCE
EPEE 9 AnrtiL ECRE
RCM SURFAGE7 ANOL A47A13
-Ft11 GAG S7RFACES
EDGE \
LEE
MOAB
ani NOSS
It072rorl
GOtNet A& NOES
AWOL n TO
3.1114a
72910E9 AREA C
ON DM
cctif:AvF
MR1:01
SURFACE
Alim1D
pAninr,
EE
Likvs/a
ECGE F-F
MING AP
EDGE DD
An A
STAGE.
LrUMIRE
STAGE4 BLADE AMER
_PTURBNE EA I HMV
NOTE 2 ME MEE NOTE
tIOM WESEARESTPAS IT UNEAPPTIMATE AMMO
TREE klE SEMIGC1 ESE APPOMWEDOEMION: ITROPli T 0EATESTREGIOLIKEAPTAONANTEDIMENEONS ANOICITT-ECURVEOLRFACEDIMEGIO%
WITHE CAM REFACE MEADE. ANON:111E CURVEDEJEFACEDIERIEME.
liFt-TOF RIDOT OFAEUTFOAT I FAD IsE Fru
1 HESH-Of RADE MEASUREDE LEAD1 \ GENE HEC-TOF1 AOC 1.1FAS-FIRT AT I FAIONCEDOT YON 0:6LADE MEISGRITAT VINIEIGHTO,BLADE
2 MIER BLADDERS,. EC ATMID.H3GHT7BIAX WIDTH OF MAX he SUREDEW OMEIGIrOF BLADE HT CHTOT RI ACE liFISURMIFEI INCEICF
7 IMO ef REX MEA.c-U;EDTRAILIl0 ENE E IEVIIT OF II ACT FACER] -RAI EC F1CT
LP TURBINE STAGES 4, 5 & 6 DIMENSIONS & AREAS

End of Section

Trent 1000 Borescope Inspection Part Condition Terminology
BORESCOPE INSPECTION - PART CONDITION

TERMINOLOGY
Your attention is drawn to AMM B787-A-R70-01-02-00A-
030A-A.
This section provides the names and descriptions of specific
types of damage. This is to prevent errors which can occur
when different names are used for the same type of damage.
Always use the correct name for the specified type of
damage or condition when an inspection is made on a
component.
The following pages list types of damage which may be seen
during borescope inspection.

ANGULAR CHANGE FROM THE INITIAL

SHAPE OR CONTOUR USUALLY
THE CAUSE IS A LATERAL FORCE
DAMAGE CAUSED TO A PART (EXAMPLE)
THAT IS CONSTANTLY HIT
(EXAMPLE)
BATTERED BENT
THE SEPARATOR OF A PART BY FORCE COMPLETE STRUCTURAL FAILURE

INTO TWO OR MORE PIECES OF THE MATERIAL BECAUSE OF
(EXAMPLE)
VERY HOT TFJAPF_RATURES
(EXAMPLE)
BROKEN BURNED
A QUANTITY OF CARBON PARTICLES

COLLECTED ON THE SURFACE
OF THE MATERIAL A LINEAR OPENING THAT CAN CAB LY BE SEEN AND
(EXAMPLE) WHICH CAN CAUSE THE MATERIAL 10 BREAK
(EXAMPLE)
CARBONED CRACKED
A ROUNDED FOLD IN THE MATERIAL SUCH AS A BLADE DAMAGE TO THE SURFACE OF A PART WHEN IT IS HIT WITH
TIP THAT HAS RUBBED AGAINST THE ENGINE CASING AN OBJECT. THE MATERIAL IS DISTORTED BUT NOT REMOVED
(EXAMPLE) (EXAMPLE)
CURLED DENTED
A LARGE ROUGH CUT OF LARGE

DEPTH WITH SOME REMOVAL OF
MATERIAL CAUSED BECAUSE A
PARTICLES Of- MM ERIAL COLLEC TED ON SHARP OBJECT HAS HIT THE PART
A PART, FROM A DIFFERENT PART OR MATERIAL (EXAMPLE)
IEXAMPLEI
El
DEPOSITS GOUGE
©Rolls-Royce plc 2014, Use or disclosure is subject to the legend on the Notice to Holder Page
A SMALL CUT ON THE SURFACE OR EDGE OF A PART

CAUSED WHEN THE PART IS HIT WITH AN OBJECT THE PART HAS BECOME TOO HOT.
(EXAMPLE) USUALLY SEEN AS A CHANGE IN COLOR OR CONDITION
(EXAMPLE)
111
NICKED OVERHEATED
A SMALL SURFACE CUT MADE WITH A SHARP

THE SCRATCH OR SCRATCHES OF LARGE DEPTH OBJECT OR PARTICLE. MATERIAL 15 NOT
USUALLY REMOVED
SOME REMOVAL OF MATERIPL) MADE DURING
Tr OPERATION OF TM PART VRTH A SHARP OBJECT
(EXAMPLE)
(EXAMPLE)
SCORE SCRATCH
End of Section

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Trent 1000 Borescope Inspection

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GEED

Trent 1000 (Boeing 787 - Dreamliner)

SECTION 1 Engine Introduction Issue 4

SECTION 2 Powerplant Maintenance Practices Issue 4

SECTION 3 Borescope Inspection Practices Issue 3

SECTION 4 Engine Internal Inspection — Cold Section Issue 4

SECTION 5 Engine Internal Inspection — Hot Section Issue 4

SECTION 6 Part Condition Terminology Issue 3

Issue 4— February 2014

Issue 4 - February 2014

Issue 3-. February 2014 Page 1

Describe the configuration of the Trent 1000 engine.

Describe the tasks necessary to carry out a Borescope Inspection (BSi).

Describe & use the tooling to prepare for borescope inspection.

Describe & use the tooling to rotate the engine shafts.

Locate, remove and refit the borescope access Plugs.

Carry out a Borescope Inspection of the engine.

Compare damage limits in the AMM to typical damage found in service.

Identify damage using the standardised terminology.

Issue 3 — February 2014 Page 2

N2 Intermediate Shaft Speed ILA Thrust (Throttle) Lever Angle

Page intentionally left blank

Issue 3— February 2014 Page 5

Leading Particulars LP System

Issue 4— February 2014 Page 1-1

Intermediate Gearbox (SAGB)

Lower Bevel Box IP Drive Shaft

THE TRENT 1000 ENGINE

Propulsion System Outline The combustion system is of annular construction

Issue 4 — February 2014 Page 1-3

PROPULSION SYSTEM OUTLINE

Radial Drive Shaft

MAIN ROTATING ASSEMBLIES

Engine Main Bearing Arrangement LP Rotor Assembly

Issue 4 — February 2014 Page 1-7

Radial Drive LP Turbine

Shaft HP/IP Roller

External Gearbox Tail Bearing

ENGINE MAIN BEARING ARRANGEMENT

Maximizing module life.

Issue 4— February 2014 Page 1-9

TRENT 1000 MODULAR BREAKDOWN

LP Compressor Module (31) LP vibration when trim balancing the LP system.

Nose Cone Support Ring

LP COMPRESSOR MODULE (31)

Engine Section Stators FBH -01.1-- Front —0 Rear Case

IP Front Roller Bearing

Stage 1 IPC Blades

IP COMPRESSOR MODULE (32)

IPC Bevel Gear

HPC Bevel Gear

INTERMEDIATE CASE MODULE (33)

Annular Tiled Combustor HP Nozzle Guide Vanes (18 off)

HP Compressor HP Turbine Disc

Combustor Outer Case

Fuel Spray Nozzles

HP SYSTEM MODULE (41)

Module 52 Attachment Flange

LP Stage 1 Nozzle Guide Vanes