[Docket No. FAA-2015-3778; Directorate Identifier 2015-NE-27-ADl 

RIN 2120-AA64 

Airworthiness Directives; Rolls-Royce pic Turbofan Engines 

AGENCY: Federal Aviation Administration (FAA), DOT. 

ACTION: Notice of proposed rulemaking (NPRM). 

SUMMARY: We propose to adopt a new airworthiness directive (AD) for all RollsRoyce pic (RR) RB21 1-535E4-37, RB211-535E4-B-37, and RB211-535E4-C-37 

turbofan engines. This proposed AD was prompted by a review of operational data that 

determined certain RR RB211 -535E4-37 engines have been operated to a more severe 

flight profile than is consistent with the flight profile used to establish the cyclic life 

limits for the rotating parts. This proposed AD would require recalculating the cyclic life 

for certain engine life-limited rotating parts and removing those parts that have exceeded 

their cyclic life limit within specified compliance times. We are proposing this AD to 

prevent failure of life-limited rotating parts, which could result in uncontained parts 

release, damage to the engine, and damage to the airplane. 

DATES: We must receive comments on this proposed AD by [INSERT DATE 30 

DAYS AFTER DATE OF PUBLICATION IN THE FEDERAL REGISTER]. 
New Jersey Avenue SE., West Building Ground Floor, Room W12-140, Washington, DC 

20590-0001. 

• Hand Delivery: Deliver to Mail address above between 9 a.m. and 5 p.m., 

Monday through Friday, except Federal holidays. 

• Fax: 202-493-2251. 

For service information identified in this proposed AD, contact Rolls-Royce pic, 

Corporate Communications, P.O. Box 31, Derby, England, DE24 phone: 011-44-

1332-242424; fax: 011-44-1332- 249936; email: http://www.rollsroyce.com/contact/civil_team.jsp; Intemet: https://customers.rollsroyce.com/public/rollsroycecare. You may view this service information at the FAA, 

Engine & Propeller Directorate, 12 New England Executive Park, Burlington, MA. For 

information on the availability of this material at the FAA, call 781-23 8-7125. 

Examining the AD Docket 

You may examine the AD docket on the Intemet at http://www.regulations.gov by 

searching for and locating Docket No. FAA-2015-3778; or in person at the Docket 

Operations office between 9 a.m. and 5 p.m., Monday through Friday, except Federal 

holidays. The AD docket contains this proposed AD, the mandatory continuing 

airworthiness information (MCAI), the regulatory evaluation, any comments received, 

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Executive Park, Burlington, MA 01803; phone: 781-238-7754; fax: 781-238-7199; email: 

robert. green@faa. gov. 

SUPPLEMENTARY INFORMATION: 

Comments Invited 

We invite you to send any written relevant data, views, or arguments about this 

proposed AD. Send your comments to an address listed under the ADDRESSES section. 

Include "Docket No. FAA-2015-3778; Directorate Identifier 2015-NE-27-AD" at the 

beginning of your comments. We specifically invite comments on the overall regulatory, 

economic, environmental, and energy aspects of this proposed AD. We will consider all 

comments received by the closing date and may amend this proposed AD based on those 

comments. 

We will post all comments we receive, without change, to 

http://www.regulations.gov, including any personal information you provide. We will 

also post a report summarizing each substantive verbal contact with FAA personnel 

concerning this proposed AD. 

Discussion 

The European Aviation Safety Agency (EASA), which is the Technical Agent for 

the Member States of the European Community, has issued EASA AD 2015-0148, dated 

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(life limits) within which the corresponding critical parts are 

allowed to remain installed. 

This condition, if not corrected, may lead to critical part failure, 

possibly resulting in release of high energy debris, damage to the 

aeroplane and/or injury to the occupants. 

To preclude failure of an engine life-limited part, the MCAI specifies, and this 

proposed AD would require, recalculating the cyclic life for certain parts, and removing 

from service those parts that have exceeded their cyclic life limit within specified 

compliance times. This proposed AD would establish a new default Flight Profile G for 

RB211-535E4-37 engine life-limited parts. If, however, operators meet the requirements 

of Appendix 6 of RR Alert Non-Modification Service Bulletin (NMSB) No. RB.211-72-

AH972, Revision 3, dated August 28, 2015, they may operate to Flight Profile A or B. 

You may obtain further information by examining the MCAI in the AD docket on the 

Internet at http://www.regulations.gov by searching for and locating Docket No. FAA2015-3778. 

Related Service Information under 1 CFR Part 51 

RR has issued Alert NMSB No. RB.211-72-AH972, Revision 3, dated August 28, 

2015. The NMSB describes a new flight profile, the consumed cyclic life corrections for 

prior operation of affected parts, and the removal from service recommendations for parts 

that have exceeded their cyclic life limit. This service information is reasonably available 

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and is approved for operation in the United States. Pursuant to our bilateral agreement 

with the European Community, EASA has notified us of the unsafe condition described 

in the MCAI and service information referenced above. We are proposing this AD 

because we evaluated all information provided by EASA and determined the unsafe 

condition exists and is likely to exist or develop on other products of the same type 

design. This proposed AD would require recalculation of the remaining cyclic life for the 

affected engine life-limited parts and removal from service of parts that exceed their 

cyclic life limit. 

Costs of Compliance 

We estimate that this proposed AD affects 1 07 engines installed on airplanes of 

U.S. registry. Pro-rated cost of the lost cyclic life as a result of the corrections would be 

about $25,417,324. We estimate it will take 1 hour to recalculate the consumed cyclic life 

and revise the engine records. The average labor rate is $85 per hour. Based on these 

figures, we estimate the cost of this proposed AD on U.S. operators to be $25,426,419. 

Authority for This Rulemaking 

Title 49 ofthe United States Code specifies the FAA's authority to issue rules on 

aviation safety. Subtitle I, section 106, describes the authority ofthe FAA Administrator. 

"Subtitle VII: Aviation Programs," describes in more detail the scope of the Agency's 

authority. 

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necessary for safety in air commerce. This regulation is within the scope of that authority 

because it addresses an unsafe condition that is likely to exist or develop on products 

identified in this rulemaking action. 

Regulatory Findings 

We determined that this proposed AD would not have federalism implications 

under Executive Order 13132. This proposed AD would not have a substantial direct 

effect on the States, on the relationship between the national Government and the States, 

or on the distribution of power and responsibilities among the various levels of 

government. 

For the reasons discussed above, I certify this proposed regulation: 

( 1) Is not a "significant regulatory action" under Executive Order 12866, 

(2) Is not a "significant rule" under the DOT Regulatory Policies and Procedures 

(44 FR 11034, February 26, 1979), 

(3) Wi II not affect intrastate aviation in Alaska to the extent that it justifies 

making a regulatory distinction, and 

( 4) Will not have a significant economic impact, positive or negative, on a 

substantial number of small entities under the criteria of the Regulatory Flexibility Act. 

List of Subjects in 14 CFR Part 39 

Air transportation, Aircraft, Aviation safety, Incorporation by reference, Safety. 

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1. The authority citation for part 39 continues to read as follows: 

Authority: 49 U.S.C. 106(g), 40113,44701. 

§ 39.13 [Amended] 

2. The FAA amends§ 39.13 by adding the following new airworthiness directive 

(AD): 

Rolls-Royce pic: Docket No. FAA-2015-3778; Directorate Identifier 201 5-NE-27-AD. 

(a) Comments Due Date 

We must receive comments by (INSERT DATE 30 DAYS AFTER DATE OF 

PUBLICATION IN THE FEDERAL REGISTER]. 

(b) Affected ADs 

None. 

(c) Applicability 

This AD applies to all Rolls-Royce plc (RR) RB211-535E4-37, 

RB211-535E4-B-37, and RB211-535E4-C-37 turbofan engines. 

(d) Reason 

This AD was prompted by a review of operational data that determined that 

certain RR RB211-535E4-37 engines have been operated to a more severe flight profile 

than is consistent with the flight profile used to establish the cyclic life limits for the 

rotating parts. We are issuing this AD to prevent failure of life-limited rotating parts, 

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Within 21 days after the effective date of this AD: 

(1) For RR RB211-535E4-37 engines, establish a new flight profile, Flight Profile 

G, as the new default profile for flight operations and new part lives for life-limited parts. 

(i) Use Appendix 6 ofRR Alert Non-Modification Service Bulletin (NMSB) No. 

RB.211-72-AH972, Revision 3, dated August 28, 2015, to define Flight Profile G. 

(ii) Use the definition of Flight Profile Gin Appendix 6 and the maximum 

approved cyclic lives in Appendix 2 of RR Alert NMSB No. RB.211-72-AH972, 

Revision 3, dated August 28, 2015, to identify the new lives for life-limited parts. 

(iii) If operators meet the requirements of Appendix 6 ofRR Alert NMSB No. 

RB.211-72-AH972, Revision 3, dated August 28,2015, they may operate to Flight 

Profile A or B. 

(2) For all RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-C-37 

engines, determine if any part identified by part number and serial number in Appendix 4 

of RR Alert NMSB No. RB.211-72-AH972, Revision 3, dated August 28, 2015, is 

installed on the engine. 

(i) Do not return to service any engine with a part identified in paragraph (e)(2) of 

this AD after the part reaches the "Compliance Time" date or cycles, whichever occurs 

first, as specified in Appendix 4 ofRR Alert NMSB No. RB.21 1-72-AJ-1972, Revision 3, 

dated August 28, 2015. 

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(3) For RB211-535E4-37 engines operated to Flight Profile G with parts listed in 

Appendix 4 ofRR Alert NMSB No. RB.211-72-AH972, Revision 3, dated August 28, 

2015, do the following: 

(i) Re-calculate the consumed cyclic life of the low-pressure (LP) compressor 

shaft, LP turbine shaft, LP turbine disk Stage 2, intermediate-pressure compressor rotor 

shaft Stage 1 to 6, high-pressure (HP) compressor rotor disk Stage 1 and 2, HP 

compressor rear rotor shaft assembly, and HP turbine disk as follows. 

(ii) Determine the Flight Profile G cycles in service (CIS). Count all CIS 

accumulated since April 1, 2015, inclusive. 

(iii) Use the Flight Profile G cycles in service from paragraph (e)(3)(ii) of this 

AD, the maximum approved lives in Appendix 2 of RR Alert NMSB No. RB.211-72-

AH972, Revision 3, dated August 28, 2015, and Figure 1 to paragraph (e) ofthis AD to 

calculate the new consumed cyclic lives. 

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FLUn = 

Cycles in 2nd EM or FP 

2nd EM or FP Declared Life 

Cycles In nth EM or FP 

nih EM or FP Declared Ute 

Continue unt11111e FLU has been calculated !()( all Engine Marlls and flight profiles 

In wtlldl the component has been operated 

Step (b) Calculate the total traction of IHe u$00 (TFLU) 

Trt.U = FLU1 + FLU2 + ...... + FLUn 

Step (c) Calculate &quiVatent cycles since new (CSN) for the component rn the nBW Engine 

Mark or fttght profile 

Equivalent CSN " TFLU x Deol&ed LHe '" the new Engane Mark or profile 

(d) II roquarod, oo.lcubto tho oyoloo remaining to tho Ooclurod Lito In tho now Englllo 

Mark or flight profile 

Cycles remaining = Dectrued Life in tha nuw Enotna Mark or flight profile 

- Equivalent CSN 

(f) Alternative Methods of Compliance (AMOCs) 

The Manager, Engine Certification Office, FAA, may approve AMOCs for this 

AD. Use the procedures found in 14 CFR 39.19 to make your request. You may email 

your request to: ANE-AD-AMOC@faa.gov. 

(g) Related Information 

(1) For more information about this AD, contact Robert Green, Aerospace 

Engineer, Engine Certification Office, FAA, Engine & Propeller Directorate, 12 New 

England Executive Park, Burlington, MA 01803; phone: 781-238-7754; fax: 781-238-

7199; email: robert.green@faa.gov. 

(2) Refer to MCAl European Aviation Safety Agency AD 2015-0148, dated July 

23, 2015 (Corrected July 24, 2015), for more information. You may examine the MCAI 

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2015, ofthe RR RB211-535E4 Time Limits Manual (TLM), publication reference T211(535)-6RR, Revision 49, dated July 1, 2015, can be obtained from RR using the 

contact information in paragraph (g)(4) of this proposed AD. 

(4) For service information identified in this proposed AD, contact Rolls-Royce 

pic, Corporate Communications, P.O. Box 31, Derby, England, DE24 8BJ; phone: 011-

44- 1332-242424; fax: 011-44-1332- 249936; email: http://www.rollsroyce.cornlcontactlcivil_team.jsp; Internet: https://customers.rollsroyce.com/public/rollsroycecare. 

(5) You may view this service information at the FAA, Engine & Propeller 

Directorate, 12 New England Executive Park, Burlington, MA. For information on the 

availability of this material at the FAA, call 781-238-7125. 

Issued in Burlington, Massachusetts, on October 28, 2015. 

Cdlf}tt '- m 'j) rli.£.44 avt r;,W. 

Colleen M. D' Alessandro, 

Directorate Manager, Engine & Propeller Directorate, 

Aircraft Certification Service. 

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