Document ID: FAA-2015-3778-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Rolls-Royce plc Turbofan Engines
Posted Date: 2015-11-04T05:00Z

[Federal Register Volume 80, Number 213 (Wednesday, November 4, 2015)]
[Proposed Rules]
[Pages 68284-68286]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2015-28080]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2015-3778; Directorate Identifier 2015-NE-27-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) RB211-535E4-37, 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 December 4, 
2015.

ADDRESSES: You may send comments by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 1200 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 plc, Corporate Communications, P.O. Box 31, Derby, England, 
DE24 8BJ; phone: 011-44-1332-242424; fax: 011-44-1332-249936; email: 
http://www.rolls-royce.com/contact/civil_team.jsp; Internet: https://customers.rolls-royce.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 781-238-7125.

Examining the AD Docket

    You may examine the AD docket on the Internet 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, 
and other information. The 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; 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 July 23, 2015 (corrected July 24, 2015), referred 
to hereinafter as ``the MCAI'', to correct an unsafe condition for the 
specified products. The MCAI states:

    A review of operational flight data has revealed that some 
RB211-535 engines may have been operated beyond the flight profile 
(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 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

[[Page 68285]]

on the Internet at http://www.regulations.gov by searching for and 
locating Docket No. FAA-2015-3778.

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 
because the interested parties have access to it through their normal 
course of business or by the means identified in the ADDRESSES section 
of this NPRM.

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 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 107 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 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.

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-2015-3778; Directorate Identifier 
2015-NE-27-AD.

(a) Comments Due Date

    We must receive comments by December 4, 2015.

(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, which could result in uncontained parts release, 
damage to the engine, and damage to the airplane.

(e) 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 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 of RR 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 G in 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 of RR 
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 of RR Alert NMSB No. RB.211-72-AH972, 
Revision 3, dated August 28, 2015.
    (ii) For each part identified in paragraph (e)(2) of this AD 
without a ``Compliance Time'' that has a lifing correction 
identified, apply the lifing correction for each part using the 
``Additional Life Consumed Flight Cycles'' specified in Appendix 4 
of RR Alert NMSB No. RB.211-72-AH972, Revision 3, dated August 28, 
2015.
    (3) For RB211-535E4-37 engines operated to Flight Profile G with 
parts listed in Appendix 4 of RR Alert NMSB No. RB.211-72-AH972, 
Revision 3, dated August 28, 2015, do the following:

[[Page 68286]]

    (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) of this AD to calculate the new 
consumed cyclic lives.
[GRAPHIC] [TIFF OMITTED] TP04NO15.000

(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 MCAI European Aviation Safety Agency AD 2015-0148, 
dated July 23, 2015 (Corrected July 24, 2015), for more information. 
You may examine the MCAI in the AD docket on the Internet at http://www.regulations.gov by searching for and locating it in Docket No. 
FAA-2015-3778.
    (3) RR Alert NMSB No. RB.211-72-AH972, Revision 3, dated August 
28, 2015, and Task 05-00-01-800-000, ``Recording and Control of the 
Lives of Parts'', dated July 1, 2015, of the RR RB211-535E4 Time 
Limits Manual (TLM), publication reference T-211(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 plc, Corporate Communications, P.O. Box 31, 
Derby, England, DE24 8BJ; phone: 011-44-1332-242424; fax: 011-44-
1332-249936; email: http://www.rolls-royce.com/contact/civil_team.jsp; Internet: https://customers.rolls-royce.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.
Colleen M. D'Alessandro,
Directorate Manager, Engine & Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 2015-28080 Filed 11-3-15; 8:45 am]
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