Document ID: FAA-2013-0029-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Rolls-Royce plc Turbofan Engines
Posted Date: 2013-04-05T04:00Z

[Federal Register Volume 78, Number 66 (Friday, April 5, 2013)]
[Proposed Rules]
[Pages 20509-20511]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2013-07935]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2013-0029; Directorate Identifier 2013-NE-01-AD]
RIN 2120-AA64

Airworthiness Directives; Rolls-Royce plc Turbofan Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to adopt a new airworthiness directive (AD) for all 
Rolls-Royce plc (RR) RB211-535E4-B-37 series turbofan engines. This 
proposed AD was prompted by recalculating the life of certain life 
limited parts operated to certain flight profiles. This proposed AD 
would require removal of affected parts using a drawdown plan. We are 
proposing this AD to prevent the failure of critical rotating parts, 
which could result in uncontained failure of the engine and damage to 
the airplane.

DATES: We must receive comments on this proposed AD by June 4, 2013.

ADDRESSES: You may send comments, using the procedures found in 14 CFR 
11.43 and 11.45, by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
     Fax: 202-493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this proposed AD, contact 
Rolls-Royce plc, Corporate Communications, P.O. Box 31, Derby, England, 
DE248BJ; phone: 011-44-1332-242424; fax: 011-44-1332-249936 or email 
from http://www.rolls-royce.com/contact/civil_team.jsp, or download 
the publication from https://www.aeromanager.com. 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.

[[Page 20510]]

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov; 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 proposed AD, the regulatory 
evaluation, any comments received, and other information. The street 
address for the Docket Office (phone: 800-647-5527) is in the ADDRESSES 
section. Comments will be available in the AD docket shortly after 
receipt.

FOR FURTHER INFORMATION CONTACT: Robert Green, Aerospace Engineer, 
Engine Certification Office, FAA, Engine & Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803; email: 
robert.green@faa.gov; phone: 781-238-7754; fax: 781-238-7199.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2013-0029; 
Directorate Identifier 2013-NE-01-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 because of 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 we 
receive about 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 2012-0265, dated December 18, 2012 (referred to herein after as 
``the MCAI''), to correct an unsafe condition for the specified 
product. The MCAI states:

    Flight Profiles (FP) define the limits of engine operation 
within which the engine will qualify for use of an associated set of 
Critical Parts life limits. The Rolls-Royce RB211-535E4-B-37 engine 
previously had only one such FP and associated set of life limits 
published in the applicable RR Time Limits Manual.
    However, a recent review of operational flight data has revealed 
that some engines may have been operated beyond the currently valid 
datum FP.
    Failure to account for the correct rate of fatigue damage 
associated with engine operation may lead to Critical Parts failure, 
possibly resulting in release of high energy debris, damage to the 
aeroplane and/or injury to occupants.

    We are proposing this AD to prevent the failure of critical 
rotating parts, which could result in uncontained failure of the engine 
and damage to the airplane. You may obtain further information by 
examining the MCAI in the AD docket.

Relevant Service Information

    RR has issued Alert Non-Modification Service Bulletin (NMSB) No. 
RB.211-72-AG875, dated December 13, 2012. The Alert NMSB introduces two 
new datum flight profiles (Flight Profile D and Flight Profile E) and 
the life-limited part lives that are the drawdown plan retirement 
thresholds.

FAA's Determination and Requirements of This Proposed AD

    This product has been approved by the aviation authority of the 
United Kingdom, 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 removal of 
affected parts using a drawdown plan.

Differences Between the AD and the MCAI or Service Information

    This AD differs from EASA AD 2012-0265, dated December 18, 2012, as 
follows: The EASA AD specifies replacing the affected critical parts 
during the module disassembly if the subsequent, anticipated time on 
wing (time before next shop visit) plus current life of the part will 
exceed the new provisional lives published in the RR Alert NMSB. We 
specify replacing at next shop visit (defined by the separation of a 
major flange).

Costs of Compliance

    We estimate that this proposed AD would affect about 377 engines 
installed on airplanes of U.S. registry. Of these 377 engines, we 
estimate 95 engines operate to Flight Profile D or E. The average labor 
rate is $85 per work hour. We do not estimate any labor cost is 
associated with this proposed AD because the affected parts are 
replaced at the next shop visit. Prorated cost of parts adjusted to 
Flight Profile D operation, would cost about $77,672 per engine. 
Prorated cost of parts adjusted to Flight Profile E operation, would 
cost about $204,981 per engine. Based on these figures, we estimate the 
cost of the proposed AD on U.S. operators to be $11,834,655.

Authority for this Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, section 106, describes the 
authority of the FAA Administrator. Subtitle VII: Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    We are issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701: ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds 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) 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 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this proposed AD and placed it in the AD docket.

[[Page 20511]]

List of Subjects in 14 CFR Part 39

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

The Proposed Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA proposes to amend 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

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

Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive (AD):

Rolls-Royce plc: Docket No. FAA-2013-0029; Directorate Identifier 
2013-NE-01-AD.

(a) Comments Due Date

    We must receive comments by June 4, 2013.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to Rolls-Royce plc (RR) RB211-535E4-B-37 series 
turbofan engines.

(d) Unsafe Condition

    This AD was prompted by recalculating the life of certain life 
limited parts operated to certain flight profiles. We are issuing 
this AD to prevent the failure of critical rotating parts, which 
could result in uncontained failure of the engine and damage to the 
airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.
    (1) Within 30 days after the effective date of this AD for 
engines that have operated to Flight Profile D or E, recalculate the 
life of the low-pressure (LP) turbine disc stage 2, intermediate-
pressure (IP) compressor rotor shaft (stage 1 to 6), high-pressure 
(HP) compressor rear rotor shaft assembly, and HP turbine disc 
installed on that engine. Use the part lives, prorated life 
formulas, and flight profiles in Appendices 2, 4, and 5 of RR Alert 
Non-Modification Service Bulletin (NMSB) No. RB.211-72-AG875, dated 
December 13, 2012, to make that calculation.
    (2) Within 30 days after the effective date of this AD for 
engines that will operate to Flight Profile D or E, assign the 
Maximum Approved Lives defined in Appendix 2 of RR Alert NMSB No. 
RB.211-72-AG875, dated December 13, 2012, to the LP turbine disc 
Stage 2, IP compressor rotor shaft (stage 1 to 6), HP compressor 
rear rotor shaft assembly, and HP turbine disc based on the flight 
profile that will be flown.
    (3) For engines that have only operated to, and will continue to 
operate to, Flight Profile C, as defined in Appendix 5 of RR Alert 
NMSB No. RB.211-72-AG875, dated December 13, 2012, no further action 
is required by this AD.
    (4) For engines that incorporate an LP turbine disc stage 2, IP 
compressor rotor shaft (stage 1 to 6), HP compressor rear rotor 
shaft assembly, or HP turbine disc whose part life is defined by 
paragraph (e)(1) of this AD that have an engine shop visit (ESV) 
after the effective date of this AD, remove each part from service 
before the part exceeds the part life assigned in paragraph (e)(2) 
of this AD.
    (5) For those engines that incorporate an LP turbine disc stage 
2, IP compressor rotor shaft (stage 1 to 6), HP compressor rear 
rotor shaft assembly, or HP turbine disc whose part life is defined 
by paragraph (e)(1) of this AD, that do not have an ESV after the 
effective date of this AD before the part exceeds the part life 
assigned in paragraph (e)(2) of this AD, remove the part from 
service at the next ESV.

(f) Installation Prohibition

    After the effective date of this AD, any LP turbine disc stage 
2, IP compressor rotor shaft (stage 1 to 6), HP compressor rear 
rotor shaft assembly, or HP turbine disc whose part life is defined 
by paragraph (e)(1) of this AD that is re-installed in any engine 
after the effective date of this AD must be removed from service 
before the part exceeds the part life assigned in paragraph (e)(2) 
of this AD.

(g) Definitions

    For the purpose of this AD, ESV is whenever engine maintenance 
performed prior to reinstallation requires the separation of a pair 
of major mating engine module flanges. Separation of flanges solely 
for the purpose of shipment without subsequent internal maintenance, 
is not an ESV.

(h) Alternative Methods of Compliance (AMOCs)

    The Manager, Engine Certification Office, may approve AMOCs for 
this AD. Use the procedures found in 14 CFR 39.19 to make your 
request.

(i) 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; email: robert.green@faa.gov; phone: 781-238-7754; fax: 781-
238-7199.
    (2) Refer to EASA AD 2012-0265, dated December 18, 2012, for 
related information.
    (3) For service information identified in this AD, contact 
Rolls-Royce plc, Corporate Communications, P.O. Box 31, Derby, 
England, DE248BJ; phone: 011-44-1332-242424; fax: 011-44-1332-249936 
or email from http://www.rolls-royce.com/contact/civil_team.jsp, or 
download the publication from https://www.aeromanager.com. 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 March 29, 2013.
Colleen M. D'Alessandro,
Assistant Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2013-07935 Filed 4-4-13; 8:45 am]
BILLING CODE 4910-13-P