### D EPA RTM ENT OF TRANSPORTATIO N Fed e ra l Aviation Administrati on 14 CF R Part 39 [4910-13-PJ

!D ocket No. FAA -2015-3778; Direc torat e ld e ntifi e • · 2015-NE-27-AD ; Amendme nt 39-18391; AD 2016-03-041 RIN 2 120-AA64 A irworthin ess Directives ; Rolls - Royce pic T urb ofan E n g in es AGENC Y : Federa l Aviat ion Adm in istrat ion (FAA) , DOT. ACTION: F in al rule. SUM MARY: We are adopti n g a new airworthiness direct i ve (AD) for a ll Rolls-Royce pi c (R R) RB211-535E4-37, RB 211-535E4 -B- 37 , and RB211-535E4-C-37 turbofan engines. Thi s AD requires recalculating the cyclic li fe for ce t tain eng i ne life-lim i ted rotating patts and removing those parts that have exceeded their cyc lic life limit within specified comp lianc e times. This AD was prompted by a review of operational data that determined ce rtain RR RB2 11- 535E4-37 engines have been operated to a more severe fli g ht profil e th a n is co n s is t e nt w ith th e Hight pro!ile u se d to estab li s h the cyclic life limits fo r th e rotating parts . We a r e iss uing thi s AD to prevent fail ur e of li fe- limited
ro ta tin g parts, uncontained parts release, damage to the eng in e, and damage to the
a irp lane. DATES: This AD becomes effective [INSERT DAT E 35 DAYS AFTE R DAT E OF P UBLICAT ION IN THE FEDERAL REGISTER]. The Dir ector of the Federa l Register approved the incorporation by reference of a
c e r ta i n publication li sted in thi s A D as of [INSERT DATE 35 DAYS AFT E R DATE OF PUBLICATION IN THE FEDERAL REGISTER].

### ADDRESSES: Fo r se r vice information identified i n thi s AD , co nt act Roll s -Royce pic , Co rporat e Co mmuni cat io n s, P.O. Box 31, Derby , E ngland , DE 24 8BJ; ph o n e : 011-4 4

- 1332-24 2424; fax: 01 1-44-1332

- 249936; emai l : http: // www.ro ll s royce . com/eo ntac t/ci v i I
_ tea m.j sp; Internet: h ttps :/ /c u sto m ers . r o ll s royce.com / public/ ro ll s royceca r e . You m ay view thi s se rvi ce inf o rm at i o n at th e FAA , E ngine 

### & Propeller Directorate , 1200 District Avenue , Burlington, MA. r:o r informati on
o n the ava ilability ofthis material a t th e FA A, ca ll781- 238-7125. It is a l so availabl e o n the Internet at http: //www. r egu la ti ons.gov by searc hin g fo r and loca tin g Docket No
. F AA-20 15

- 3778. Examining the AD Docket You ma y exam in e the AD docket o n th e Inte rnet a t http: // www.regul a ti ons.gov by
searc hin g for a nd l ocat ing Dock et No. FAA

- 20 I 5-3 778; or in perso n at th e Dock et Managem e nt Fac ility be twee n 9 a.m . a nd 5 p.m. , Monday through Friday , except Federa l holida ys . The A D d ocket conta in s this AD, th e mandatory co ntinuin g a ir worth ine ss inform a ti o n (MCAI) , th e r egulatory ev aluation , a n y comme n t s rec eived , a nd o th er inf o rm ation. Th e addre ss for the Docket O ffice (p h one : 800-647-5527 ) i s Doc um ent Manageme nt Fac ility , U .S. D e pa rtm e nt of Tran spo rtation , D ocket Op e ra ti o n s, M-30 , West Buildin g Ground Fl oo r , R oom W12-140. 1200 New Jersey Avenue SE., Washi n g ton , DC 20590. 

### FOR 

### FURTHER INFORMATION CONT A CT : Rober t Gree n , Ae r ospace E ngin ee r , Engine Ce rtification Office, FAA , E n g in e 

### & Propeller Directorate , 1200 D i s tri c t Avenue , Burlin gto n , MA 01803 ; phone : 78 1- 238 -77 54; fax: 78 1- 238

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

### SUPPLEMENTARY INFORMATION:



### 2

### Di scuss io n We i ss u e d a not ice of propo se d rul e mak ing (NP R M) to amend 14 CFR part 39 by add i ng an AD that would apply to th e speci fied p roducts. The NPRM was published in the Federal R eg i ster o n Nove mb er 4. 2015 (80 FR 68284)
. The NPRM proposed to
co rrec t a n un safe condit ion for th e s pec i fied products. Th e MCA J sta tes: A r ev i ew of operatio n a l ni g ht data has r evealed th a t so me RB 2 11- 535 e n g in es may have been operated beyond the fl ig ht p r ofi le (FP) ass um e d by the ope rator when es tablishi n g t h e operatio n a l l im i ts ( lif e lim its) w ithin which th e co rr espo n ding cri tical p art s are a ll owe d to rema in in s ta ll ed. This condition, if not correc ted , may lead to critical part failure, possib ly res ultin g in rel ease of high e n e rgy debris. damage to the aerop lane and/or injury to th e occupant s.
To prec lud e fa il u r e of an e n gi n e li f e- limited par t , the M C A I s p ec ifies , and th i s AD would require , reca lculating th e cycl ic life for certa in pa rts and re mov ing from
se r v ic e th ose parts that h ave exceeded their cyc li c lif e limit wi thin specified compliance ti mes. T hi s AD would estab li s h a new de f aul t Fli g ht Profil e G for RR RB 21 1- 535E4

- 37 engine lif e- limited parts. If , howeve r , o pera to rs meet the requireme nt s of Appendix 6 of RR Ale rt Non-Mod i ficat ion Se r vice Bu ll et in (NMSB) No. RB. 2 11 -72-A H 972, Revis ion 3, dated A u g u s t 28,2 015 , th ey may ope ra te to F li ght Profile A o r B. You may obta in fu rth e r inform a ti on by examinin g the MCA T in th e AD docket on th e Internet at http: //www.regula ti ons . gov by searching for and locat in g Docket No
. 

# rAA

- 20 15- 3778
. 

### R e lated Se 1 -v ic c Inf o rm a tion und e r 1 CF R 

### Pa r t 51 We reviewed RR A lert NMSB No. RB. 2 1 1-72-AH972 , R ev i s io n 3, da ted Aug u st 28 , 2015. Th e A l e rt NMSB de s c rib es a n ew fl ig ht profi l e, p rovides p r ocedu res 

### tor the consumed cyc li c lif e co rrec tion s f or prior ope ration o f affected parts , and provides the removal from se r v ice recommendations fo r parts that ha ve exceeded th e ir cycl ic li fe limit. Thi s serv i ce information i s reasonably ava il ab le because th e inte rested parties h ave 3

### access to it tl u· o ug h th e ir normal course of business or by the m eans id e ntified i n the AD DRESS ES sec tion of this AD
. C omments 

### We gave the public the opportunity to partic ipate in developing this AD. We
co ns id e red th e com m e nt s recei ved. S upport fo r th e 

### N PRM (80 F R 6 8 2 84, N o ve mber 4, 2015 ) 

### The Bo e ing Compan y , FedEx, Uni t ed A irlin es, and Ame ri can Ai rlin es exp r essed
s u pport fo r the N PRM. Requ es t to C h a n ge Ac tion s a nd Co mplian ce 

### United Parcel Serv ice (UPS) requested th at the N PRM r ecognize d ig ital fli gh t data take n fr o m e ith e r th e di g ital flight data r eco rd e r (DFDR) or th e di g it al fli g ht data acquis it ion unit (DFDAU) as va li d d ata for RR RB2 1 1 flig ht pro1il e mon ito ring purpo ses . The dat a captu red by the D F DAU is rec o r ded on the DFDR , but Df7DAU s a re regula rl y do w nlo aded for U PS ' flight operations quality assura nce program. The DFD AU data is easier to access th an pu lli ng a DF DR f or data download purposes. We ag ree. We added a new pa r ag r a ph t o paragraph (e)( l ) of thi s A D as follows: "(e) (l)(iv) You m ay us e data from e ither a di g ita l flig h t data acquis it io n u ni t or a digita l ili g bt data r ec o rd e r for il ight p r ofi le monitor in g . ". C onclu s i o n 

### We reviewed th e available data , including the comments r eceived , and dete rmined that air safety a nd th e pub lic int e rest requ ire adoptin g thi s AD with th e c han ges d escrib ed p r

eviously. We determ ined that th ese changes will not increase th e eco nom i c b urde n on any ope rator or increas e t he scope of thi s AD. C o s t s of C omplian ce 

### We est imate that thi s AD affects I 07 e ngines installed on a irp lanes o f U
. S
. r eg istry. Pro-rated cost of th e l ost cycl i c lif e as a result of the co rrect io ns wou ld be abo ut

4$25 ,417 , 324
. We estimate it will take I hour to recalculate th e consumed cyc li c lif e and revi s e the engine records which include 5 minutes (0.083 hours) for record entries. The average labor rate i s $85 per hour. Based on these figures , we estimate th e cost of this AD o n U
. S. operators to be $25,426 , 419. A uth ori ty fo•· T hi s Rulcmaking Ti tle 49 of the United State s Code specifies the FAA's authority to issue ru les on aviation safety. S ubtitl e I , sect ion I 06 , desc ri bes the a uthority of th e FAA Ad mini s trator.

" Subt itl e VII : Aviat ion Programs, " de s crib es in more detail the scope ofthe Agency ' s authority. We are issuing this rulemaking under the authority described in "Subt it l e VII , Part A , S ubpart Ill , Sect ion 4470 I: Genera l requireme nt s." Under th a t sec tion, Congress charg e s the FAA with promoting s afe ni ght of civi l a ircraft in a ir co m merce by pres cribing regulation s for practice s, methods , a nd procedures the Adm ini strator finds necessary for safely in a ir commerce. T hi s regulation i s wi thin the scope o r that author ity because it addresse s an unsafe condition that is likely to ex i st or develop on products id e ntified in this rul e making action. 

### Regulatory Findings We determined that this AD w ill not have federalism implicati ons unde r Executive Order 1313 2
. This AD will not have a sub s tantial direct effect on the States , on the relationship betw e en the national gove rnm ent and the States, or on the distribution or power and r espo n s ibilities among the various leve l s o f gove rnment. Fo r the rea s ons discussed above , l certify this AD: 

### ( 1 ) Is not a ' · s ign i ficant regul a tory act ion " under E xecutive Order 12866 , (2) I s not a " s ig nific ant ru le " under the DOT Regu l ato ry Pol ic i es a nd Procedures (44 FR I I 034, February 26 , 1 979) ,
5(3) Will not affect intrastate av ia ti o n in Al as ka to the exten t th at it justifies making a r egu lato ry d i stinction , and (4) Will n ot h ave a s ignificant eco n o mic impact, po s itive o r n ega ti ve, on a
s ub s tanti a l num be r of s m all e n t iti es un der th e c rit eria of th e Reg u lato ry F lexib ili ty Act. 

### Li s t of S ubj ec t s in 1 4 CFR Part 

### 39 Ai r transportation , A ircraft , Av iat i on s afe t y , Incorporat i on by reference , Saf e ly. 

### Adoption of the Amendment Acco rdin g l y , und e r th e authorit y d elegate d to me b y th e Admin i s tr ato r , the FAA
a m e nd s 14 CFR part 39 as fo llo ws: 

### PART 

### 39- AIRW ORTHINESS DIRE C TIVES 1. The au th o rity citation for part 39 co n t inue s to read as follows: A u thori ty : 49 U.S.C
. 1 06(g) , 40 1 1 3 , 4470 1. 

### § 39 .1 3 [Amended! 2. Th e FAA amends§ 39.13 by addi n g th e following new ai r wo rthin ess dir ect ive (A D ) : 20 15

- XX

- XX 

### Ro ll s -R oyce pic: A mendmen t 39 -18 XXX ; D oc k et No
. FAA-2015-3778; Dir ec torate T dentifier 2 0 15-N E-27-AD. 

### (a) E ffective Date This AD becomes effect ive [INSE RT DATE 35 D AYS AfTER DATE OF P U BLICATION TN TH E FE D ERA L REG I STER]. 

### (b) 

### Affected AD s None. 

### (c) A pplicabili ty Thi s AD applies to all Roll s -R oyce pic (R R) RB 2ll

- 535E4-37 , RB211

- 535E4-B-37 , and RB 2 11- 535E4-C-37 turbofan eng in es .


### 6

### ( d ) Reaso n This AD was prompted by a review of operational data that determined that certain RR RB 2 11- 535E4 -37 engines have been operated to a more severe flight profile than is consistent with the fl ig h t p r ofi le used to es tab li s h the cyclic l ife l i mits for th e
rotati n g parts . We are issuing thi s AD to prevent failure of lif e -lim i ted r o tatin g parts,
w hi c h could resu l t in uncontained parts release, damage to the engine, and damage to th e ai rpla n e. 

### (c) Action s and Co mp l ian ce Comply wit h this AD within th e compliance times spec ified , unl ess already done. Within 21 days after the effective dat e of this AD: ( 1 ) For RR RB21 1 -535E4-37 e ng ines , establ i s h a new flight profile , F li ght Profi le G , as the new default profi le for flight operations and new part lives for life-limited parts. (i) Use Appendix 6 of RR Alert Non

- Modification Service Bull e tin (NMSB) No. R £3.21 1 -72-Al-1972 , Rev i s i on 3, dated August 28 , 20 1 5 , to defi n e F l ight Pro fil e G. ( ii ) Use the definition of Flight Profile G in Append ix 6 and th e maximum approved cyclic li ves in A ppendix 2 of RR A lert NMSB No. RB.21 1 -72-A H 972, Revision 3, dated August 28, 2015, to i dentif

- y the new li ves for li fe-lim ited parts. (iii) I f operators meet the r equi r ements of Appendix 6 of RR Alert NMSB No. RB. 2 1 I-72

-AH9 72. R ev i s ion 3 , dated August 28 , 20 1 5, they ma y operate to Flight Profil e A or 

### B. (iv) You may use data from e ither a d igita l flig h t da ta acquis it ion u ni t o r a d igita l 

### f1 ig ht data recorder for flight profile monitoring. (2) For all RR RB21 1- 535E4-37, RB211-5 35E4 -B-37 , and RB211- 535E4

- C-37 engines, dete rm ine if any par t iden tified by part numb e r and serial numb e r in Appendix 4 ofRR A ler tNMSB No. RB.21 1-72-All972 , Revi s ion 3, dated August 28 , 2015, i s in sta ll ed on the engine. 

### 7(i) Do n o t r e turn to service any eng i ne w ith a part identified in paragraph (e)(2) of t hi s AD after th e pa rt reaches the " Compliance T im e" date or cyc les, w hi c hever occurs first , as s pec i fied in Append ix 4 of RR A le rt NMSB No. RB.21 

### J -72-AI-1972, Revision 3 , dated Aug u s t 28 , 20 15. (ii) Fo r each part id e ntifi ed in paragraph (e)(2) of th i s A D w ith o ut a " C omplianc e Time" that h as a li fin g correcti on identifi ed, a ppl y the lifing correction fo r each part using th e " Add it io nal L i fe Co nsumed F li g ht Cycles" specified in App e ndix 4 ofRR Alert NMSB No. RB. 2 1 1-72-AH972 , R ev i s ion 3 , dated August 28 , 2 0 15
. (3) fo r RR RB 2 11-535 E4

- 37 engines ope rated to Flight Pro fil e G w ith parts li sted in A pp e n dix 4 of RR Alert NMS B No
. RB. 2 11- 72

- A H972 , Re v i sio n 3 , dated August 28 , 2015 , do the foll ow in g : (i) R e -calcu late the co n sumed cyclic l ife of the low-pressure ( LP) compresso r shaft, LP turbin e s haft , LP turbine di sk Stage 2 , inte rmediate-pre ss ur e comp ressor rotor
s haft Stage l to 6 , high-pressure ( HP ) co mpre sso r rotor di s k S t age I and 2, HP compresso r rear rotor s haft assembly , a nd HP turbine di sk as follows. (ii) D e te rmin e th e Flight Profil e G cy cl es in service (C I S). Co unt all CIS accumulated s inc e April 

### I , 2015 , inclu s ive . (iii) Use the Flight Profile G cyc les in se rvice from para g r a ph ( e)(3) (ii) of thi s AD, the maximum approved li ves in Appendix 2 ofRR Alert NMSB No. RB.211-72- A H97 2 , Rev i s ion 3 , dated August 28 , 20 15, and Figure 1 to para g r ap h (e) of thi s A D to calculate the new co n s um ed cyclic li ves.



### 8

### F ig ur e 1 to Paragra ph 

### (e), Ca l c ul a t io ns to Move G ro up ' A ' a n d G ro up ' B ' Parts B e twee n Engi n e M ar l <s a nd /or Fli g ht Pr · ofile s
S t op (a) Ca lctJfate the fraction o l t h e compo n ents lt' e used (FLU} n each o l tn e origin a l Eng.no M arl<s ( E M ) o r fl ig ht prohtos (FP)
FL U I •

F LU 2 •

F L Un = Cycles in ts: E M o· FP l SI E M Of F P Oeclrued U t e Cycles in 2 nd E M or FP 2 nd EM or FP D ecl a r ed li fe Cyc le s I n nt h E M or F P
n t h EM o r F P D cc r or oo U t e Continu e u nUI I ha FL U has boon calc u l a t e d t or !Il l Engln o M arl<s and fli g h t pro fi l es in w h i ch thO com po nent hn s boo n opc rotcd St ep (b) Ca l cul ato t he tot a l i rac tl on of lr f o**u~ .o<l**  (rr L U ) TF L U c FL U I + FL U 2 + . . .... + F L Un S t ep (c) Calcul ate eq Ui va l en t cyc le s since ne w (CS N ) I O< the componen t I n t h e nsvt En g 1 ne M ark 0< ft1g h t p rofi'o E quivalent C S N = TF L U JC Ooclarcd l.do 1 n tho oow Eno.no M ar k o r O l{)h t profile
S t op (d) II roqw od

. c:llcu b to t ho cycloc rorn:umn9 to t ho**~f::uod** lJ i o '" U 1o n ow Engno Marl< or fight prol lfo Cycles ro matnno • Ood nrod L.rro In t ho rtow EniJlno Mmk or lh!Jhl pmr, to

- E q wva lent CSN 

### ( f) A l te rnativ e M e thod s of Co mpli anc e (AMO Cs ) T h e M a na ge r , E n g ine Ce r tifica tion Offic e , fA A, ma y a pprov e AMOCs fo r this AD. Use th e p r oce dure s fo un d in 1 4 CF R 39. 19 to ma ke yo u r re q u e st. Yo u m ay e m a il y o ur re q u es t to : ANE-A D- A MO C @ faa.gov. ( g ) 

### R e l ate d Inf ormation ( I) Fo r more i nformation about thi s A D , c ont a ct R o b e rt G re e n , Aero s pace E n g i n ee r , En g ine Ce rt ification Offic e , FAA , E n g in e 

### & Pro p e ll e r Di r ec torat e, 1200 Di s tri c t Ave nu e , B urlin gton , M A 0 1803 ; ph o n e: 78 1

- 23 8

- 77 5 4; fa x : 78 1

- 23 8

- 7199 ;
e m a il: ro b e rt. g ree n @ faa
. g o v . (2 ) Ref e r to MCA I E uropean Av iati o n S af e ty Age ncy 

### 1\D 2 01 5

- 0 148 , d ate d J ul y 23 , 2 015 (C orr e c te d Jul y 24 , 20 1 5 ) , f o r mo r e inf o rm a ti o n. Y o u ma y e xamin e the MC A I



### 9in the AD docket on th e Internet at http: //www .regulations.gov by sea rching for and locatin g it in Docket No. FAA

- 20 1 5-3778
. 

### ( h) Ma ter ia l In co rp orated 

### b y Ref e re nce 

### (1) The Director of the Federal R eg i s te r app ro ved th e in corporation by reference ( IBR) of th e se r v ice information liste d in thi s parag raph under 5 U.S.C. 552(a) and 1 CF R part 51.(2) You mu s t us e thi s se rv ice inf o rm a tio n as app li cable to do th e act io n s required by thi s AD , un less the AD spec ifics o th e rw i se . ( i) Roll s- R oyce 

### ( RR) A lert Non-Mod ifi cation Ser v ic e Bull e tin No. RB.211

- 72

- A H972 , R ev i s io n 3 , including Appendices 

### I throu g h 6, dated August 28, 2015. ( ii ) Re se rved. (3) For RR serv ice in format io n id entified in this AD , conta ct Ro ll s- Royce pic , Corpo rate Comm unic a ti ons , 

### P
. O. Bo x 3 1 , Derby , Eng l a nd , DE24 88 .1 ; phone: 01 1 -44- 1 332

- 242424; fax: 01 1-44- 13 32

- 249936; e mai l : http: // vvww.roll sroyce.com / contac t / ci v i 

### I

_ te am.j s p ; I nternet: https: //customer s .roll s royce.com / publ ic/ r ollsroycecare. (4) You ma y view th i s se rvice info rm at i on 

### at FAA, E n g in e 

### & Prop e ller Directo rat e , 1 2 00 D i s trict Avenue , Burlin g ton , MA. For information o n the ava il abili ty of th i s material a t the 

## r: 1\A, ca ll 781-238-71 25. (5) Y o u m ay v iew this se r v ice inf o rm a ti on a t the Nat ional A r c hi ves and Reco rd s Adm ini s tratio n 

### (N/\RA)
. For information on th e a vailability o f thi s m a t e ri al at 

### NARA , ca ll 202-741-6030 , o r go to: http: //www.archivcs.gov/ fecleral-reg i s te rlc fr/ i brlocation s. ht m l.

10

### Iss ued in Burlin gto n , Massac hu setts , o n Februar y 2, 20 1 6.

Co ll ee n M. 

### D ' A l essa ndr o , Ma nage r. Eng in e & 

### Prope ll er Dir ec t orate, A ircraf t Certifi cat io n Serv ice.

1 1