DEPARTMENT OF TRANSPORTATION 

Fede ral Aviation Administration 

14 CFR Part 39 

[4910-13-PJ 

!Docket No. FAA-2015-3778; Directorate ldentifie•· 2015-NE-27-AD; Amendment 

39-18391; AD 2016-03-041 

RIN 2 120-AA64 

Airworthiness Directives; Rolls-Royce pic Turbofan Engines 

AGENCY: Federal Aviation Administration (FAA), DOT. 

ACTION: Final rule. 

SUMMARY: We are adopting a new airworthiness directive (AD) for all Rolls-Royce 

pic (RR) RB211-535E4-37, RB211-535E4-B-37, and RB211-535E4-C-37 turbofan 

engines. This AD requires recalculating the cyclic life for cettain engine life-limited 

rotating patts and removing those parts that have exceeded their cyclic life limit within 

specified compliance times. This AD was prompted by a review of operational data that 

determined certain RR RB2 11-535E4-37 engines have been operated to a more severe 

fli ght profile than is consistent with the Hight pro!ile used to establish the cyclic life 

limits for the rotating parts. We are issuing this AD to prevent fail ure of life-limited 

rotating parts, uncontained parts release, damage to the engine, and damage to the 

airplane. 

DATES: This AD becomes effective [INSERT DATE 35 DAYS AFTER DATE OF 

PUBLICATION IN THE FEDERAL REGISTER]. 

The Director of the Federal Register approved the incorporation by reference of a 

certain publication listed in this AD as of [INSERT DATE 35 DAYS AFTER DATE OF 

PUBLICATION IN THE FEDERAL REGISTER]. 
ADDRESSES: For service information identified in this AD, contact Rolls-Royce pic, 

Corporate Communi cations, P.O. Box 31, Derby, England, DE24 8BJ; phone: 011-44-

1332-242424; fax: 01 1-44-1332- 249936; email: http://www.rollsroyce.com/eontact/ci vi I_ team.jsp; Internet: https:/ /customers. rollsroyce.com/public/rollsroycecare. You may view this service information at the FAA, 

Engine & Propeller Directorate, 1200 District Avenue, Burlington, MA. r:or information 

on the ava ilability ofthis material at the FAA, call781-238-7125. It is also available on 

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

F AA-20 15-3778. 

Examining the AD Docket 

You may examine the AD docket on the Internet at http://www.regul ations.gov by 

searching for and locating Docket No. F AA-20 I 5-3 778; or in person at the Docket 

Management Facility between 9 a.m. and 5 p.m., Monday through Friday, except Federal 

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

information (MCAI), the regulatory evaluation, any comments received, and other 

information. The address for the Docket Office (phone: 800-647-5527) is Document 

Management Facility, U.S. Department of Transportation, Docket Operations, M-30, 

West Building Ground Floor, Room W12-140. 1200 New Jersey Avenue SE., 

Washi ngton, DC 20590. 

FOR FURTHER INFORMATION CONTACT: Robert Green, Aerospace Engineer, 

Engine Certification Office, FAA, Engine & Propeller Directorate, 1200 District Avenue, 

Burlington, MA 01803; phone: 78 1-238-7754; fax: 78 1-238-7199; email: 

robert.green@faa.gov. 

SUPPLEMENTARY INFORMATION: 

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Discussion 

We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR part 39 by 

adding an AD that would apply to the specified products. The NPRM was published in 

the Federal Register on November 4. 2015 (80 FR 68284). The NPRM proposed to 

correct an unsafe condition for the specified products. The MCAJ states: 

A review of operational night data has revealed that some RB2 11-

535 engines may have been operated beyond the fl ight profi le (FP) 

assumed by the operator when establishing the operational limits 

(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 fa il ure of an engine li fe-limited part, the MCA I specifies, and this 

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

service those parts that have exceeded their cyc li c life limit within specified compliance 

times. This AD would establish a new de fault Flight Profile G for RR RB21 1-535E4-37 

engine life-limited parts. If, however, o perators meet the requirements of Appendix 6 of 

RR Alert Non-Modification Service Bull etin (NMSB) No. RB.2 11 -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 MCAT in the AD docket on the Internet at 

http://www.regulations.gov by searching for and locating Docket No. r AA-20 15-3778. 

Related Se1-vicc Information under 1 CFR Part 51 

We reviewed RR Alert NMSB No. RB.2 11-72-AH972, Revision 3, dated August 

28, 2015. The Alert NMSB describes a new fl ight profile, provides procedures tor the 

consumed cyclic life corrections for prior operation of affected parts, and provides the 

removal from service recommendations for parts that have exceeded their cyclic life 

limit. This service information is reasonably ava ilable because the interested parties have 

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access to it tlu·ough their normal course of business or by the means identified in the 

ADDRESSES section of this AD. 

Comments 

We gave the public the opportunity to participate in developing this AD. We 

considered the comments received. 

Support for the NPRM (80 FR 68284, November 4, 2015) 

The Boeing Company, FedEx, United Airlines, and American Airlines expressed 

support for the NPRM. 

Request to Change Actions and Compliance 

United Parcel Service (UPS) requested that the NPRM recognize digital flight 

data taken from either the digital flight data recorder (DFDR) or the digital fli ght data 

acquisition unit (DFDAU) as valid data for RR RB2 11 flight pro1ile monitoring purposes. 

The data captured by the DFDAU is recorded on the DFDR, but Df7DAUs are regularl y 

downloaded for UPS' flight operations quality assurance program. The DFDAU data is 

easier to access than pulling a DFDR for data download purposes. 

We agree. We added a new paragraph to paragraph (e)(l) ofthis AD as follows: 

"(e)(l)(iv) You may use data from either a digita l flight data acquisition unit or a digital 

iligbt data recorder for ilight profile monitoring.". 

Conclusion 

We reviewed the available data, including the comments received, and determined 

that air safety and the public interest require adopting this AD with the changes described 

previously. We determined that these changes will not increase the economic burden on 

any operator or increase the scope of this AD. 

Costs of Compliance 

We estimate that this AD affects I 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 

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

revise the engine records which include 5 minutes (0.083 hours) for record entries. The 

average labor rate is $85 per hour. Based on these figures, we estimate the cost of this 

AD on U.S. operators to be $25,426,419. 

Authority fo•· This Rulcmaking 

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

aviation safety. Subtitle I, section I 06, descri bes the authority of the FAA Administrator. 

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

authority. 

We are issuing this rulemaking under the authority described in "Subtitle VII, 

Part A, Subpart Ill , Section 4470 I: General requirements." Under that section, Congress 

charges the FAA with promoting safe night of civil aircraft in air commerce by 

prescribing regulations for practices, methods, and procedures the Administrator finds 

necessary for safely in air commerce. This regulation is within the scope o r 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 AD will not have federalism implications under 

Executive Order 13132. This AD will not have a substantial direct effect on the States, on 

the relationship between the national government and the States, or on the distribution or 

power and responsibilities among the various levels of government. 

For the reasons discussed above, l certify this AD: 

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

(2) Is not a "significant ru le" under the DOT Regulatory Pol icies and Procedures 

( 44 FR I I 034, February 26, 1979), 

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(3) Will 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 negati ve, 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, Safely. 

Adoption of the Amendment 

Accordingly, under the authority delegated to me by the Administrator, the FAA 

amends 14 CFR part 39 as follows: 

PART 39- AIRWORTHINESS DIRECTIVES 

1. The au tho rity citation for part 39 continues to read as follows: 

Authority: 49 U.S.C. 1 06(g), 40 113, 4470 1. 

§ 39.13 [Amended! 

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

(AD): 

2015-XX-XX Rolls-Royce pic: Amendment 39-18XXX; Docket No. FAA-2015-3778; 

Directorate Tdentifier 20 15-NE-27-AD. 

(a) Effective Date 

This AD becomes effective [INSERT DATE 35 DAYS AfTER DATE OF 

PUBLICATION TN THE FEDERAL REGISTER]. 

(b) Affected ADs 

None. 

(c) Applicability 

This AD applies to all Rolls-Royce pic (RR) RB2ll-535E4-37, 

RB211 -535E4-B-37, and RB2 11-535E4-C-37 turbofan engines. 

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(d) Reason 

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

certain RR RB2 11-535E4-37 engines have been operated to a more severe flight profile 

than is consistent with the fl ight 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, 

whi ch could result in uncontained parts release, damage to the engine, and damage to the 

airplane. 

(c) Actions and Compliance 

Comply with this AD within the compliance times specified, unless already done. 

Within 21 days after the effective date of this AD: 

( 1) For RR RB21 1-535E4-37 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 of RR Alert Non-Modification Service Bulletin (NMSB) No. 

R £3.21 1-72-Al-1972, Revision 3, dated August 28, 20 15, to defi ne Flight Profil e G. 

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

approved cyclic li ves in Appendix 2 of RR Alert NMSB No. RB.21 1-72-AH972, 

Revision 3, dated August 28, 2015, to identif-y the new li ves for life-limited parts. 

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

RB.2 1 I-72-AH972. Revision 3, dated August 28, 20 15, they may operate to Flight 

Profile A or B. 

(iv) You may use data from either a digital flight data acquisition unit or a digital 

f1 ight data recorder for flight profile monitoring. 

(2) For all RR RB21 1-535E4-37, RB211-535E4-B-37, and RB211-535E4-C-37 

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

ofRR AlertNMSB No. RB.21 1-72-All972, Revision 3, dated August 28, 2015, is 

install ed on the engine. 

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(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, whi chever occurs 

first, as specified in Appendix 4 of RR Alert NMSB No. RB.21 J -72-AI-1972, Revision 3, 

dated August 28, 20 15. 

(ii) For each part identified in paragraph (e)(2) of this AD without a "Compliance 

Time" that has a li fing correction identified, apply the lifing correction for each part 

using the "Additional Life Consumed Flight Cycles" specified in Appendix 4 ofRR Alert 

NMSB No. RB.2 11-72-AH972, Revision 3, dated August 28, 20 15. 

(3) for RR RB2 11-535E4-37 engines operated to Flight Profil e G with parts listed 

in Appendix 4 of RR Alert NMSB No. RB.2 11-72-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 l to 6, high-pressure (HP) compressor rotor disk Stage I 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 I, 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 ofRR Alert NMSB No. RB.211-72-

AH972, Revision 3, dated August 28, 20 15, and Figure 1 to paragraph (e) ofthis AD to 

calculate the new consumed cyclic lives. 

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Figure 1 to Paragraph (e), Calculations to Move Group 'A' and Group 'B' 

Parts Between Engine Marl<s and/or Flight Pr·ofiles 

Stop (a) CalctJfate the fraction ol the components lt'e used (FLU} n each ol tne original 

Eng.no Marl<s (EM) or flight prohtos (FP) 

FLUI • 

FLU2 • 

FLUn = 

Cycles in ts: EM o· FP 

lSI EM Of FP Oeclrued U te 

Cycles in 2nd EM or FP 

2nd EM or FP Declared life 

Cycles In nth EM or FP 

nth EM or FP Dccroroo Ute 

Continue unUI Iha FLU has boon calculated tor !Ill Englno Marl<s and flight profiles 

in which thO component hns boon opcrotcd 

Step (b) Calculato the total i ractlon of lrfo u~.o<l (rr LU) 

TFLU c FLU I + FLU2 + ...... + FLUn 

Step (c) Calculate eqUivalent cycles since new (CSN) IO< the component In the nsvt Eng1ne 

Mark 0< ft1ght profi'o 

Equivalent CSN = TFLU JC Ooclarcd l.do 1n tho oow Eno.no Mark or Ol{)ht profile 

Stop (d) II roqwod. c:llcub to tho cycloc rorn:umn9 to tho ~f::uod lJio '" U1o now Engno 

Marl< or fight prollfo 

Cycles romatnno • Oodnrod L.rro In tho rtow EniJlno Mmk or lh!Jhl pmr,to 

- Eqwvalent 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 

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

Engineer, Engine Certification Office, FAA, Engine & Propeller Directorate, 1200 

District Avenue, Burlington, MA 0 1803; phone: 78 1-23 8-7754; fax: 78 1-238-7199; 

email: robert.green@faa.gov. 

(2) Refer to MCAI European Aviation Safety Agency 1\D 201 5-0 148, dated July 

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

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in the AD docket on the Internet at http://www.regulations.gov by searching for and 

locating it in Docket No. FAA-20 15-3778. 

(h) Material Incorporated by Reference 

(1) The Director of the Federal Register approved the incorporation by reference 

(IBR) of the service information listed in this paragraph under 5 U.S.C. 552(a) and 1 CFR 

part 51. 

(2) You must use this service info rmation as applicable to do the actions required 

by this AD, unless the AD specifics otherwise. 

(i) Rolls-Royce (RR) Alert Non-Modification Service Bulletin No. RB.211 -72-

AH972, Revision 3, including Appendices I through 6, dated August 28, 2015. 

(ii) Reserved. 

(3) For RR service information identified in this AD, contact Ro lls-Royce pic, 

Corporate Communications, P.O. Box 3 1, Derby, England, DE24 88.1 ; phone: 01 1-44-

1332- 242424; fax: 01 1-44-1332- 249936; emai l: http://vvww.rollsroyce.com/contact/ci vi I_ team.jsp; Internet: https://customers.rollsroyce.com/publ ic/rollsroycecare. 

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

Directorate, 1200 District Avenue, Burlington, MA. For information on the availability of 

this material at the r: 1\A, call 781-238-71 25. 

(5) You may view this service information at the National Archives and Records 

Administratio n (N/\RA). For information on the availability o f this material at NARA, 

call 202-741-6030, o r go to: http://www.archivcs.gov/fecleral-registerlcfr/ibrlocations.html. 

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Issued in Burlington, Massachusetts, on February 2, 2016. 

Colleen M. D' Alessandro, 

Manager. Engine & Propeller Directorate, 

Aircraft Certification Service. 

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