LIST OF EFFECTIVE PAGES

The effective pages to this Service Bulletin are as follows:

Page Revision Number Revision Date

Bulletin

1 Dec.13/12

2 Dec.13/12

3 Dec.13/12

4 Dec.13/12

5 Dec.13/12

6 Dec.13/12

7 Dec.13/12

8 Dec.13/12

Appendix 1

1 Dec.13/12

Appendix 2

1 Dec.13/12

2 Dec.13/12

3 Dec.13/12

Appendix 3

1 Dec.13/12

2 Dec.13/12

Printed in Great Britain

RB.211−72−AH029

Transmittal - Page 2
1. Planning Information

A. Effectivity

(1) Boeing 757

(a) RB211-535E4-37, 535E4-37/10, 535E4-37/11, 535E4-37/12, 535E4-37/14,

535E4-37/16, 535E4-37/17, 535E4-37/19, 535E4-37/20, 535E4-37/23,

535E4-37/24, 535E4-37/25, 535E4-37/39, 535E4-37/43, 535E4-37/44

Engines

RB211 M05621AA, M05622AA, M05623AA M05 Modules

(b) RB211-535E4-B-37, 535E4-B-37/15, 535E4-B-37/19, 535E4-B-37/20,

535E4-B-37/21, 535E4-B-37/25, 535E4-B-37/35, 535E4-B-37/39,

535E4-B-37/41, 535E4-B-37/44 Engines

RB211-M05623AA, M05627AA M05 Modules

(c) RB211-535E4-C-37, 535E4-C-37/43 Engines

RB211 M05640AA M05 Modules

(2) Tupolev TU204

RB211-535E4-B-75, 535E4-B-75/25 Engines

RB211 M05623AA, M05627AA M05 Modules

B. Reason

(1) Problem

Due to instances of operation outside of currently published flight

profiles a review of Group A part lives has been conducted. As a result of

this investigation changes to the thermal profile and stresses in certain

features of the LP Turbine stage 2 disc have been identified. This

increase in stress level has resulted in a reduction in the cyclic life of

the LP Turbine stage 2 discs.

This Non-Modification Service Bulletin (NMSB) is issued to introduce

reduced cyclic lives for all RB211-535E4 series engines LP Turbine stage 2

discs. The reduced cyclic lives have been designated as provisional lives

until incorporated into the Time Limits Manual (TLM).

The provisional lives will be added to the TLM on the 30th November 2016.

ENGINE - LOW PRESSURE (LP) TURBINE STAGE 2 DISC - LIFE REDUCTION - NON-MODIFICATION

SERVICE BULLETIN - NON - MOD.72-AH029

Printed in Great Britain

RB.211−72−AH029

Page 1 of 8

Dec.13/12

Dec.13/12
Failure to comply with this NMSB will introduce a risk of exceeding the

Group A part life limits and can lead to component failure.

This NMSB should be reviewed together with SB 72-D365 Revision 5 or later

revisions, NMSB 72-AG875 and the current published TLM.

C. Description

This NMSB introduces reduced (provisional) cyclic lives for the RB211-535E4

series engines LP Turbine stage 2 discs.

The provisional lives and their applicable part numbers are detailed in

Appendix 1.

D. Compliance

ALERT

Rolls-Royce recommends that the following actions are under taken on LP Turbine

stage 2 discs within 6 weeks of the initial issue date of NMSB 72-AH029. For

engines which will be built up during this specified time, this NMSB should not

be applied. This NMSB shall be considered live six weeks after Initial issue

and the instructions given in 3. Accomplishment Instructions must be followed

thereafter.

The LP Turbine stage 2 disc lives defined in Appendix 1, together with the

lives currently published within the TLM must be utilised until the TLM is

updated.

On 30th November 2016 the reduced LP Turbine stage 2 disc life limits will be

added to Chapter 05 of the Time Limits Manual (TLM). After this date all

previously published life limits will no longer be applicable.

This NMSB and in particular, the provisional life limits given in Appendix 1

are anticipated to be the subject of EASA and FAA Airworthiness Directives (AD)

E. Approval

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

under the authority of Design Organisation Approval EASA.21J.035 on Dec.13/12.

F. Manpower

Not applicable

G. Material Price and Availability

Not applicable

Printed in Great Britain

RB.211−72−AH029

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Dec.13/12

Dec.13/12
H. Tooling Price and Availability

Special tools are not required.

I. References

(1) Rolls-Royce Non-Modification Service Bulletins:

(a) 72-D181

Engine - LP Turbine Rotor - Stage 2 turbine disc reduced cyclic life -

Engine Management and On-wing Inspection - Non-Modification Service

Bulletin

(b) 72-AG875

Changes to Time Limits Manual and Aircraft Maintenance Manual

resulting from changes to the RB211-535E4-B Flight Profile -

Non-Modification Service Bulletin

(2) Rolls-Royce Service Bulletin:

72-D365

Engine - LP turbine stage 2 Disc - Introduction of Rework to Maintain

Cyclic Life

(3) Time Limits Manual (TLM), Chapter 05-00-01, 05-10-01

Printed in Great Britain

RB.211−72−AH029

Page 3

Dec.13/12

Dec.13/12
2. Material Information

None

Printed in Great Britain

RB.211−72−AH029

Page 4

Dec.13/12

Dec.13/12
3. Accomplishment Instructions

A. The provisional life limits detailed in Appendix 1 are to be used together with

the current published TLM and the guidance given in section 3.B., 3.C. and 3.D.

below by all operators to make sure necessary systems and controls are in place

prior to them being published in the TLM on the 30th November 2016.

NOTE: The operating life of the LP turbine stage 2 disc may be extended by the

incorporation of SB 72-D365. Artificial ageing of parts subject to life

extension re-work must be conducted in accordance with SB 72-D365

Revision 5 or later revisions.

B. On-Wing

(1) Pre SB72-D365

Engines on-wing at the time of NMSB release may continue to use the

current published applicable rework threshold life as defined in the TLM

until 30th November 2016. After that date engines on-wing will be subject

to the provisional rework threshold lives defined in Appendix 1 of this

NMSB.

(2) SB72-D365

Engines on-wing at the time of NMSB release may continue to use the

current published applicable DSCLs as defined in the TLM until 30th

November 2016. After that date engines on-wing will be subject to the

provisional lives defined in Appendix 1 of this NMSB.

(3) After release of this NMSB, should On-wing engines be removed for a shop

visit, the In-shop instructions contained in section 3.C. will then become

applicable.

Printed in Great Britain

RB.211−72−AH029

Page 5

Dec.13/12

Dec.13/12
(4) It is recommended that operators should calculate their accrued life and

then should compare it with the provisional lives defined in this NMSB

against the applicable flight profile. Operators should then use this

information to facilitate shop visit planning in order to make sure that

they will comply with the provisional lives before the 30th of November

2016.

NOTE: When a disc has previously embodied SB 72-D365 Revision 4 or

earlier revisions, it is necessary to review the life history and

retrospectively apply the provisional rework threshold life. As

defined in SB 72-D365 Revision 5 or later revisions, if the disc

life at rework is found to be above the provisional rework

threshold the accrued life post rework is unchanged. If the disc

life at rework is found to be below the provisional rework

threshold then the disc should be artificially aged in accordance

with the provisional rework threshold and the accrued life should

be re-calculated. Refer to example 1 given in Appendix 2 for

further guidance.

C. In-shop

NOTE: Overhaul refers to refurbishment where the discs are de-bladed.

(1) Pre SB72-D365 LP turbine stage 2 discs

Post release of this NMSB, engines that are inducted into the shop should

follow the instructions defined in Fig.1, which provides guidance covering

the rework or replacement of pre SB 72-D365 discs at overhaul.

(2) SB72-D365 LP turbine stage 2 discs

Post release of this NMSB, engines that are inducted into the shop should

follow the instructions defined in Fig.1, which provides guidance covering

the replacement of post SB 72-D365 discs at overhaul.

NOTE: When a disc has previously embodied SB 72-D365 Revision 4 or

earlier revisions, it is necessary to review the life history and

retrospectively apply the provisional rework threshold life. As

defined in SB 72-D365 Revision 5 or later revisions, if the disc

life at rework is found to be above the provisional rework

threshold the accrued life post rework is unchanged. If the disc

life at rework is found to be below the provisional rework

threshold then the disc should be artificially aged in accordance

with the provisional rework threshold and the accrued life should

be re-calculated. Refer to example 2 given in Appendix 2 for

further guidance.

Printed in Great Britain

RB.211−72−AH029

Page 6

Dec.13/12

Dec.13/12
D. Calculations for movement between Flight Profiles

CAUTION: LIFE CALCULATIONS FOR THE MOVEMENT BETWEEN FLIGHT PROFILES OF COMPONENTS

WITH MID LIFE REWORKS CAN BE CALCULATED INCORRECTLY, WHICH CAN

POTENTIALLY LEAD TO COMPONENT FAILURE. IF YOU ARE NOT SURE HOW TO DO THE

CALCULATION, CONTACT YOUR LOCAL ROLLS-ROYCE FIELD SERVICE OFFICE FOR

ADVICE.

When a disc has been operated in more than one flight profile it will be

necessary to perform a movement between flight profiles calculation. See Appendix

3 for guidance and examples when necessary. Further guidance and examples can be

Printed in Great Britain

found in the chapter 05-00-01 of the Time limits Manual.

RB.211−72−AH029

Page 7

Dec.13/12

Dec.13/12
LP Turbine Stage 2 Disc Replacement Logic During Overhaul

Fig.1

Printed in Great Britain

RB.211−72−AH029

Page 8

Dec.13/12

Dec.13/12
Maximum Approved Lives of LP Turbine Stage 2 Disc

The life of the following components can be extended by artificial ageing as defined

in and by the incorporation of SB72-D365.

NOTE: Until the TLM is updated the pre rework provisional life will act as the

rework threshold life

It is permissible to rework a LP turbine stage 2 disc that has a greater cyclic life

than the threshold for 'Flight Profile B, D or E' in accordance with SB72-D365.

1. Pre SB72-D365

The following LP turbine stage 2 disc lives are subject to MANDATORY NMSB

72-D181

EIPC FIG/ITEM PART NO. EFFECTIVITY 535E4 FLIGHT

PROFILE PROVISIONAL

PRE-REWORK

THRESHOLD LIVES

(FLIGHT CYCLES)

72-51-61,

01-350

UL11508,

UL17141,

UL18947,

UL29029,

UL37352

E4

Flight Profile A 16,700

Flight Profile B 13,300

E4-B

Flight Profile C 16,700

Flight Profile D Refer to NMSB

72-AG875

Flight Profile E Refer to NMSB

72-AG875

E4-C Flight Profile F 16,700

2. SB72-D365

EIPC FIG/ITEM PART NO. EFFECTIVITY 535E4 FLIGHT

PROFILE PROVISIONAL POST

REWORK LIVES

(FLIGHT CYCLES)

72-51-61,

01-350

FW16685

FW16686,

FW16687,

FW16688,

FW16689,

E4 Flight Profile A 26,300

Flight Profile B 20,900

E4-B Flight Profile C 26,300

Flight Profile D Refer to NMSB

72-AG875

Flight Profile E Refer to NMSB

72-AG875

E4-C Flight Profile F 26,300

APPENDIX 1

Printed in Great Britain

RB.211−72−AH029

Appendix 1 - Page 1 of 1

Dec.13/12

Dec.13/12
Revision of Artificially Aged Component Records

1. Example 1:

The example RB211-E4-37 engine is on-wing with a post SB72-D365 Low Pressure

Turbine Disc. It has an accrued life of 20,400 cycles whilst operating in

'Flight Profile A'. It has a further 8000 cycles remaining before it reaches

the 'Flight Profile A' DSCL currently published in the TLM (28,400 cycles).

A. Step 1: Gather component life history:

(1)Establish the accrued life of the disc before rework in accordance with

SB72-D365:

The LP turbine stage 2 disc was operating in 'Flight Profile A' and had

SB72-D365 Revision 4 embodied during its last overhaul at an accrued

life of 17,500 cycles.

(2)Establish whether the component life was artificially aged at rework:

In accordance with the SB72-D365 revision and TLM published at the time

of the rework, the disc was subject to artificial ageing to a rework

threshold life of 18,100 cycles for a component operated in 'Flight

Profile A'.

(3)Establish the accrued life post the rework:

The disc has since flown a further 2,300 cycles in 'Flight Profile A'

and has a current recorded accrued life of 20,400 cycles.

B. Step 2: Recalculate the accrued life of the disc to account for the new

provisional lives introduced by this NMSB:

(1)Compare the accrued life before rework with the provisional threshold

life published in this NMSB and establish whether the disc needs to be

retrospectively artificially aged to this new value:

(1) 17,500 cycles is greater than the provisional rework life of

16,700 cycles as defined in Appendix 1.

(2) In accordance with SB72-D365 Revision 5 (and Appendix 1) as the

life at rework was greater than the provisional rework threshold

limit the disc will not be artificially aged and the rework

accrued life would remain 17,500 cycles.

(2)Establish the new accrued life post the rework:

Adding the additional post rework 2,300 cycles means the new accrued

life of the disc is 19,800 cycles.

APPENDIX 2

Printed in Great Britain

RB.211−72−AH029

Appendix 2 - Page 1 of 3

Dec.13/12

Dec.13/12
C. Step 3: Calculate the new cycles remaining of the component:

In accordance with Appendix 1, the provisional life limit introduced by

this NMSB reduces the post rework life limit to 26,300 cycles which means

there is 6500 cycles remaining against the provisional life in Flight

Profile A.

D. Step 4: Apply the instructions defined in section 3.B. or 3.C as

applicable:

(1)As this engine is on-wing the accomplishment instructions detailed in

3.B. will need to be followed.

(2)In accordance with these instructions the Engine can remain on-wing and

use the existing limits defined by the current published TLM, providing

the LP turbine disc will comply with the new limits defined within this

NMSB before 30th of November 2016 (Note this may require the engine to

complete a shop visit before this date). The information gathered and

calculated in the above should be used for shop visit planning purposes.

2. Example 2:

The example RB211-E4-37 engine is off wing and is to be inducted for overhaul

where the LP turbine module will be refurbished (discs are debladed). It has a

post SB72-D365 Low Pressure Turbine Disc. It has an accrued life of 20,400

cycles whilst operating in 'Flight Profile A'. It has a further 8000 cycles

remaining before it reaches the 'Flight Profile A' DSCL currently published in

the TLM (28,400 cycles). The engine has a planned build life of 6000 cycles.

A. Step 1: Gather component life history:

(1)Establish the accrued life of the disc before rework:

The LP turbine stage 2 disc was operating in 'Flight Profile A' and had

SB72-D365 embodied during its last overhaul at an accrued life of

14,200 cycles.

(2)Establish whether the component life was artificially aged at rework:

In accordance with SB72-D365 Revision 4 and TLM published at the time

of the rework, the disc was subject to artificial ageing to a rework

threshold life of 18,100 cycles for a component operated in 'Flight

Profile A'.

(3)Establish the accrued life post the rework:

The disc has since flown a further 2,300 cycles in 'Flight Profile A'

and has a current recorded accrued life of 20,400 cycles.

Printed in Great Britain

RB.211−72−AH029

Appendix 2 - Page 2

Dec.13/12

Dec.13/12
B. Step 2: Recalculate the accrued life of the disc to account for the new

provisional lives introduced by this NMSB:

(1)Compare the accrued life before rework with the provisional threshold

life published in this NMSB and establish whether the disc needs to be

retrospectively artificially aged to this new value:

(1) 14,200 cycles is less than the provisional rework threshold life

of 16,700 cycles as defined in Appendix 1.

(2) In accordance with SB72-D365 Revision 5 (and Appendix 1) as the

life at rework was less than the provisional rework threshold

limit the disc will be artificially aged and the rework accrued

life would become 16,700 cycles.

(2)Establish the new accrued life post the rework:

Adding the additional post rework 2,300 cycles means the new accrued

life of the disc is 19,000 cycles.

C. Step 3: Calculate the new cycles remaining of the component:

In accordance with Appendix 1, the provisional life limit introduced by

this NMSB reduces the post rework life limit to 26,300 cycles which means

there is 7300 cycles remaining against the provisional life in 'Flight

Profile A'.

D. Step 4: Apply the instructions defined in section 3.B. or 3.C as

applicable:

(1)As this engine is in the shop the accomplishment instructions detailed

in 3.C. will need to be followed.

(2)In accordance with these instructions and using the logic diagram in

Fig.1, the new accrued life of the LP turbine stage 2 disc (19,000

cycles) plus the engine build life (6,000 cycles) equates to 25,000

cycles which will be less than the post rework life limit of 26,300

cycles.

(3)Therefore the LP turbine stage 2 disc does not need to be replaced and

the engine can return to service with no further action required on this

component. The new accrued life should be recorded against the component

records and the provisional life limits should be used in place of the

current limits published in the DSCL.

Printed in Great Britain

RB.211−72−AH029

Appendix 2 - Page 3

Dec.13/12

Dec.13/12
NOTE: The movement of LP Turbine Stage 2 discs between engine marks or published

operating flight profiles requires pro-rata calculations to determine the

pre-rata disc life

1. Calculations for movement of engines between flight profiles

A. Calculate the Fraction of the component's Life Used (FLU) in the original

flight profile monitoring procedure:

FLU =

Cycles used in original flight profile monitoring

procedure

----------------------------------------------------------------

Declared Life in original flight profile monitoring

procedure

NOTE: It is not necessary to record a value for the FLU (it may remain as

the fraction above) however if one is recorded, it should be

calculated to a minimum of three decimal places.

B. Calculate equivalent Cycles Since New (CSN) for the component in the new

flight profile monitoring procedure.

Equivalent CSN =

FLU x Declared Life in the new flight profile

monitoring procedure

NOTE: Record the equivalent CSN as an integer, calculated to the next

highest whole number, against the component.

C. If required, calculate the cycles remaining to the Declared Life in the new

flight profile monitoring procedure.

Cycles remaining =

Declared Life in the new flight profile monitoring

procedure - Equivalent CSN

2. Example Movement between flight profile monitoring procedures

LP turbine stage 2 disc part number UL29029 (pre SB 72-D365), having originally

flown 1,000 cycles in profile 'Flight Profile A', it is then moved to flight

profile 'Flight Profile B' and has completed a further 14,000 cycles. It is

proposed that this disc is reworked in accordance with SB 72-D365. Post rework,

the engine will continue in service in 'Flight Profile B' flight profile.

A. Fraction of the component's Life Used (FLU):

APPENDIX 3

Printed in Great Britain

RB.211−72−AH029

Appendix 3 - Page 1 of 2

Dec.13/12

Dec.13/12
FLUn =

Cycles used in original flight profile monitoring

procedure n

-----------------------------------------------------------

Declared Life in original flight profile monitoring

procedure *n

FLU1 =

1000 Flight Cycles

---------------------

16700 Flight Cycles

FLU2 =

14000 Flight Cycles

---------------------

13300 Flight Cycles

* For pre-rework calculation this value is the applicable provisional

rework threshold life.

B. Total Equivalent CSN:

Total Equivalent CSN

=

(FLU1 x Declared Life in the 'Flight Profile B'

flight profile) + (FLU2 x Declared Life in the

'Flight Profile B' flight profile)

Total

Equivalent

CSN =

1000 14000

(---- X 13300 ) + (---- X 13300 ) = 14796.41 Flight Cycles

16700 13300

Rounding up gives equivalent CSN in the 'Flight Profile B' flight profile

of 14797 Flight Cycles

NOTE: Accomplishment of SB 72-D365: 14797 Flight Cycles is greater than

the 'Flight Profile B' provisional threshold life of 13300 (Appendix

1). However it is permissible to rework a disc that has a greater

cyclic life than the threshold for 'Flight Profile B'. For this

example, SB72-D365 instructs that the part will retain its existing

life.

C. If required, calculate the cycles remaining to the Provisional Life in the

'Flight Profile B':

20900 - 14797 = 6103 Flight Cycles remaining in profile 'Flight Profile B'

(NOTE: Quoted lives are for example only)

Printed in Great Britain

RB.211−72−AH029

Appendix 3 - Page 2

Dec.13/12

Dec.13/12