AD 2000-08-12

This amendment supersedes an existing airworthiness directive (AD), applicable to certain General Electric Company CF6-80A, CF6-80C2, and CF6-80E1 series turbofan engines, that currently requires revisions to the Airworthiness Limitations Section (ALS) of the manufacturer s Instructions for Continued Airworthiness (ICA) to include required enhanced inspection of selected critical life-limited parts at each piece-part exposure. This action adds additional eddy current inspections (ECI) for the high pressure turbine rotor (HPTR) Stage 1 and 2 disks for all affected engine models, and would add fan forward shaft inspections for the CF6-80C2 engine model only. This amendment is prompted by additional focused inspection procedures for critical life-limited rotating engine parts that have been developed by the manufacturer. The actions specified by this AD are intended to prevent critical life-limited rotating engine part failure, which could result in an uncontained engine failure and damage to the airplane.

Final rule.

2000-08-12 General Electric Company: Amendment 39-11698. Docket No. 98-ANE-49-AD. Supersedes AD 99-08-13, Amendment 39-11119.

Applicability: General Electric Company (GE) CF6-80A, CF6-80C2, and CF6-80E1 series turbofan engines, installed on but not limited to Airbus Industrie A300, A310, and A330 series, Boeing 747 and 767 series, and McDonnell Douglas MD-11 series airplanes.

Note 1: This airworthiness directive (AD) applies to each engine identified in the preceding applicability provision, regardless of whether it has been modified, altered, or repaired in the area subject to the requirements of this AD. For engines that have been modified, altered, or repaired so that the performance of the requirements of this AD is affected, the owner/operator must request approval for an alternative method of compliance in accordance with paragraph (c) of this AD. The request should include an assessment of the effect of the modification, alteration, or repair on the unsafe condition addressed by this AD; and, if the unsafe condition has not been eliminated, the request should include specific proposed actions to address it.

Compliance

Required as indicated, unless accomplished previously.

To prevent critical life-limited rotating engine part failure, which could result in an uncontained engine failure and damage to the airplane, accomplish the following:

Inspections

(a) Within the next 30 days after the effective date of this AD, revise the manufacturer's Life Limits Section of the Instructions for Continued Airworthiness (ICA) for the CF6-80A model and the Airworthiness Limitations Section of the ICA for CF6-80C2/-80E1 models. For air carrier operations, revise the approved continuous airworthiness maintenance program, by adding the following:

"MANDATORY INSPECTIONS

(1) Perform inspections of the following parts at each piece-part opportunity in accordance with the instructions provided in the applicable manual provisions:Part Nomenclature
Part number (P/N)
Inspect per Engine Manual Chapter
For CF6-80A Engines:

Disk, Fan Rotor
Stage 1
All
72-21-03 Paragraph 3. Fluorescent-Penetrant Inspect, and 72-21-03
Paragraph 4. Eddy Current Inspect
Disk, HPT Rotor
Stage One
All
72-53-02 Paragraph 3. Fluorescent-Penetrant-Inspect Disk/Shaft per
70-32-02, and 72-53-02 Paragraph 6. Eddy Current Inspection,
and 72-53-02 Paragraph 6.D. Disk Bore Area Eddy Current Inspection
Disk, HPT Rotor
Stage Two
All
72-53-06 Paragraph 3. Fluorescent-Penetrant Inspection, and
72-53-06 Paragraph 6. Eddy Current Inspection of Rim Boltholes
for Cracks, and 72-53-06 Paragraph 7. Disk Bore Area Eddy Current
Inspection

Part Nomenclature
Part number (P/N)
Inspect per Engine Manual Chapter
For CF6-80C2 Engines:

Disk, Fan Rotor
Stage 1
All
Task 72-21-03-200-000-004 Fluorescent-Penetrant Inspection,
and Task 72-21-03-200-000-008 Eddy Current Inspect Fan Rotor
Disk Stage 1 Bore, Forwardand Aft Hub Faces, and Bore Radii
Shaft, Fan Forward
All
Task 72-21-05-200-000-001 Fluorescent Penetrant Inspection, and
Task 72-21-05-200-000-005 Vent Hole Eddy Current Inspection
Disk, HPT Rotor
Stage One
All
Task 72-53-02-200-000-001 Fluorescent-Penetrant Inspect the
HPT Rotor Stage 1 Disk/Shaft, and Task 72-53-02-200-000-005
Eddy Current Inspection, and Task 72-53-02-200-000-006 Disk
Bore Area Eddy Current Inspection
Disk, HPT Rotor
Stage Two
All
Task 72-53-06-200-000-002 Fluorescent-Penetrant Inspect the
Stage 2 Disk, and Task 72-53-06-200-000-006 Eddy Current
Inspection of the HPTR Stage 2 Rim Boltholes, and Task
72-53-06-200-000-007 Disk Bore Area Eddy Current Inspection
For CF6-80E1 Engines:

Disk, Fan Rotor
Stage One
All
Task 72-21-03-230-051 Fluorescent-Penetrant Inspection, and
Task 72-21-03-250-051 or 72-21-03-250-052 Eddy Current
Inspection
Shaft, Fan Forward
All
Task 72-21-05-230-051 Fluorescent Penetrant Inspection, and
Task 72-21-05-250-051 Vent Hole Eddy Current Inspection
HPT Disk
Stage One
All
Task 72-53-02-230-51 Fluorescent-Penetrant Inspection, and
Task 72-53-02-200-001-005 Eddy Current Inspection, and
Task 72-53-02-250-054 Disk Bore Area Eddy Current Inspection
HPT Disk
Stage Two
All
Task 72-53-06-230-051 Fluorescent-Penetrant Inspection, and
Task 72-53-06-200-001-006 Eddy Current Inspection of the
HPTR Stage 2 Rim Boltholes, and Task 72-53-06-250-054 Disk
Bore Area Eddy Current Inspection

(2) For the purposes of these mandatory inspections, piece-part opportunity means:

(i) The part is considered completely disassembled when accomplished in accordance with the disassembly instructions in the manufacturer's engine manual; and

(ii) The part has accumulated more than 100 cycles in service since the last piece-part opportunity inspection, provided that the part was not damaged or related to the cause for its removal from the engine."

(b) Except as provided in paragraph (c) of this AD, and notwithstanding contrary provisions in section 43.16 of the Federal Aviation Regulations (14 CFR 43.16), these mandatory inspections shall be performed only in accordance with the Life Limits Section of the Instructions for Continued Airworthiness (ICA) for the CF6-80A model and the Airworthiness Limitations Section of the ICA for CF6-80C2/-80E1 models.

Alternative Methods of Compliance

(c) An alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Engine Certification Office (ECO). Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector (PMI), who may add comments and then send it to the ECO.

Note 2: Information concerning the existence of approved alternative methods of compliance with this airworthiness directive, if any, may be obtained from the ECO.

Ferry Flights

(d) Special flight permits may be issued in accordance with sections 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the airplane to a location where the requirements of this AD can be accomplished.

Continuous Airworthiness Maintenance Program

(e) FAA-certificated air carriers that have an approved continuous airworthiness maintenance program in accordance with the record keeping requirement of 121.369 (c) of the Federal Aviation Regulations [14 CFR 121.369 (c)] must maintain records of the mandatory inspections that result from revising the Life Limits Section of the Instructions for Continued Airworthiness (ICA) for the CF6-80A model and the Airworthiness Limitations Section of the ICA for CF6-80C2/-80E1 models and the air carrier's continuous airworthiness program. Alternately, certificated air carriers may establish an approved system of record retention that provides a method for preservation and retrieval of the maintenance records that include the inspections resulting from this AD, and include the policy and procedures for implementing this alternate method in the air carrier's maintenance manual required by 121.369 (c) of the Federal Aviation Regulations [14 CFR 121.369 (c)]; however, the alternate system must be accepted by the appropriate PMI and require the maintenance records be maintained either indefinitely or until the work is repeated. Records of the piece-part inspections are not required under 121.380 (a) (2) (vi) of the Federal Aviation Regulations [14 CFR 121.380 (a) (2) (vi)]. All other Operators must maintain the records of mandatory inspections required by the applicable regulations governing their operations.

Note 3: The requirements of this AD have been met when the engine manual changes are made and air carriers have modified their continuous airworthiness maintenance plans to reflect the requirements in the engine manuals.

(f) This amendment becomes effective on October 23, 2000.

A proposal to amend part 39 of the Federal Aviation Regulations (14 CFR part 39) by superseding (AD) 99-08-13, Amendment 39-11119 (64 FR 1795, April 13, 1999), that is applicable to General Electric Company (GE) CF6-80A, CF6-80C2, and CF6-80E1 series turbofan engines, was published in the Federal Register on October 7, 1999 (64 FR 54594) . That action proposed to require revisions to the Life Limits Section of the manufacturer's Instructions for Continued Airworthiness (ICA) for GE CF6-80A, CF6-80C2, and CF6-80E1 series turbofan engines to include required enhanced inspection of selected critical life-limited parts at each piece-part exposure. New Inspection Procedures
Since the issuance of that AD, additional focused inspection procedures for other critical life-limited rotating engine parts have been developed by GE. This AD will require modification of the airworthiness limitations section in the manufacturers manual and an air carrier's approved continuous airworthiness maintenance program to incorporate these inspection procedures.
Interested persons have been afforded an opportunity to participate in the making of this amendment. Due consideration has been given to the thirteen comments received. Addition to Required Inspections
One commenter recommends adding the -80E1 Fan Forward Shaft (FFS) vent holes to the list of required inspections because it is similar to the -80C2 FFS, which will require the mandatory inspection. The FAA agrees and the inspection will be added to the Final Rule. "Unsafe Condition"
One commenter objects to the language in the preamble of the NPRM supersedure for the second phase of enhanced inspections which includes a finding of an "unsafe condition." The commenter asks that the term "unsafe condition" be deleted and replaced with the justification language from the original NPRM. The FAA does not agree. This commenter does not disagree with the proposed rule itself but rather with the term"unsafe condition" contained in the preamble to the NPRM. It is not the intent of the FAA to completely change the enhanced disk inspection program established by the current AD, which evolved as a cooperative effort between the FAA and industry.
This intervention strategy was designed to reduce the number of uncontained engine failures by mandating enhanced nondestructive inspections of critical components that could most likely result in a hazard to the airplane in the event of a disk failure. Since the engine maintenance manuals did not mandate these enhanced inspections, the current AD was necessary to establish the inspection program as an airworthiness limitation. Regardless of the fact that it was not stated explicitly in the original NPRM, the FAA determined that an "unsafe condition" existed because the engine maintenance manuals did not contain enhanced inspections as an airworthiness limitation. There was no intent to imply any defect in the actual engine hardware, but simply to state that the maintenance manuals, that form part of the approved engine design, must be revised to mandate the enhanced inspections. The supersedure repeats that finding with respect to the additional parts being added to the enhanced inspection program. Because a finding of an "unsafe condition" is required for the FAA to issue an AD, future NPRM's adding parts to the program will also include that finding. Request to Change all References from "Time Limits Section" to "Airworthiness Limitations Section"
One commenter recommends replacing references to the "Life Limits" section with references to the "Airworthiness Limitations" section because Chapter 5 now contains two subsets, 05-11 for Life Limits, and 05-21 for the mandatory inspection. The FAA agrees in part. The manufacturer recently revised their engine manual to include the heading "Airworthiness Limitations" for Chapter 05-00-00 for the CF6-80C2/-80E1 models and, therefore, they can be referenced as such. Shouldthe manufacturer revise the section headings in the CF6-80A manual, any future AD's could then reference the revised section headings. Request for Clarification of When FAA Approval or AMOC is Required
One commenter requests clarification be added to this AD on when equivalent substitutes for tools, equipment, or procedures used for performing the mandatory enhanced inspections require FAA approval or an approved alternate method of compliance (AMOC).
The FAA does not agree that further clarification is necessary in the AD. When allowed for in an AD, an AMOC provides a method by which an operator may secure FAA approval for complying with the requirements of that AD in a manner or at a time other than specified by the AD. This AD, and other similar AD's issued as part of the so-called Disk Inspection Initiative of the Safer Skies Program, are intended to address the need to include mandatory detail inspections in the FAA approved portion of the engine maintenance manual. This portion of the engine maintenance manual is sometimes referred to as the Airworthiness Limitations Sections (ALS) of the Instructions for Continued Airworthiness. The FAA does not intend that this AD specify the exact method or tools with which to conduct the inspection. Rather, the AD requires only that the ALS be revised to include a mandatory opportunistic inspection. The FAA also does not intend that this AD change the manner in which operators seek approval to use tools or methods of inspections other than those provided for in the engine manufacturer's manual. Operators, particularly air carriers, should follow the procedures already in place to secure FAA review and approval to use such substitutes, if needed, and to document that approval if necessary. Therefore, the AMOC paragraph in the AD will remain as proposed. Request to Extend the Comment Period
One commenter requests that the NPRM comment period be extended until after the proposed inspections are published to allow time for the operators to review the specific inspections that will be required. The FAA does not agree. The FAA believes that the nature and scope of the added inspections will not be significantly different from existing inspections. In addition, the effective date of this AD has been extended to 180 days after publication to allow time for the specific procedures to be published. Operators may submit comments on the specific procedures once they are published and the FAA will consider extending the effective date further or additional rulemaking, as necessary. The FAA does not believe, however, that this final rule need be delayed pending the publication of the inspection procedures. Effective date of Final rule
Six commenters requested that the AD effectivity date be set to allow sufficient time for publication of the procedures, procurement of the equipment, and training. The FAA agrees. The effective date for the Final rule has been extended to 180 days after publication to allow sufficient time for the publication of the inspection procedures and for operators to prepare. Support
Two commenters expressed support for the enhanced inspections at piece part exposure. Removal of "of this chapter" from Paragraph (e) of the Compliance Section
The statement "of this chapter" has been removed from the first sentence of paragraph (e) to improve the clarity of the paragraph. Economic Analysis
No comments were received on the economic analysis contained in the proposed rules. The FAA has determined that the annual cost of complying with this AD does not create a significant economic impact on small entities. Adoption of the Proposed Rule
After careful review of the available data, including the comments noted above, the FAA has determined that air safety and the public interest require the adoption of the rule with the changes described previously. The FAA has determined that these changes will neither increase the economic burden on any operator nor increase the scope of the AD.

Regulatory Impact
This final rule does not have federalism implications, as defined in Executive Order No. 13132, because it does 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. Accordingly, the FAA has not consulted with state authorities prior to publication of this final rule.
For the reasons discussed above, I certify that this action (1) is not a "significant regulatory action" under Executive Order 12866; (2) is not a "significant rule" under DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); and (3) 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. A final evaluation has been prepared for this action and it is contained in the Rules Docket. A copyof it may be obtained from the Rules Docket at the location provided under the caption "ADDRESSES." List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Safety.
Adoption of the Amendment
Accordingly, pursuant to the authority delegated to me by the Administrator, the Federal Aviation Administration amends part 39 of the Federal Aviation Regulations (14 CFR part 39) as follows: PART 39 - AIRWORTHINESS DIRECTIVES
1. The authority citation for part 39 continues to read as follows: Authority: 49 U.S.C. 106(g), 40113, 44701.
39.13 [Amended]
2. Section 39.13 is amended by removing Amendment 39-11119 (64 FR 17951, April 13, 1999), and by adding a new airworthiness directive, Amendment 39-11698, to read as follows: