AD 2000-16-12

This amendment adopts a new airworthiness directive (AD) that is applicable to General Electric Company (GE) CF6-45, -50, -80A, -80C2, and -80E1 turbofan engines with certain high pressure compressor rotor (HPCR) stage 3-9 spools installed. This action requires initial ultrasonic and eddy current inspections of certain HPCR stage 3-9 spools for cracks. This amendment is prompted by an uncontained failure of an HPCR 3-9 spool. The actions specified in this AD are intended to detect cracks which can cause separation of the HPCR stage 3-9 spool and result in an uncontained engine failure.

Final rule; request for comments.

2000-16-12 General Electric Company: Amendment 39-11868 Docket 2000-NE-31-AD. Applicability \n\tThis airworthiness directive is applicable to General Electric Company (GE) CF6-45, -50, -80A, -80C2, and -80E1 turbofan engines with high pressure compressor rotor stage 3-9 spools with the following part numbers (P/N's). These engines are installed on, but not limited to, Airbus A300, A310, and A330 series, Boeing 747 and 767 series, and McDonnell Douglas DC-10 and MD-11 series airplanes. \n\n\nEngine Model\n\n\n\nHPCR 3-9 Spool P/N\nCF6-45/50 Series Engines\n9136M89G02, 9136M89G08, 9136M89G19, 9273M14G01,\n9136M89G03, 9136M89G09, 9136M89G21, 9331M29G01,\n9136M89G06, 9136M89G17, 9136M89G22, 9253M85G01,\n9136M89G07, 9136M89G18, 9136M89G27, 9253M85G02\nCF6-80A Series Engines\n9136M89G10, 9136M89G22,\n9136M89G11, 9136M89G27\n9136M89G20, \n9136M89G21, \nCF6-80C2 Series Engines\n1333M66G01, 1781M52P01, 1854M95P03, 1854M95P07,\n1333M66G03, 1781M53G01, 1854M95P04, 9380M28P05\n1333M66G07, 1854M95P01, 1854M95P05, \n1333M66G09, 1854M95P02, 1854M95P06, \nCF6-80E1 Series Engines\n1669M22G01,\n1669M22G03,\n1782M22G01,\n1782M22G02\n\n\tNote 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 (j) 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.\n\nCompliance\n\tCompliance with this AD is required as indicated below, unless already done.\n\tTo detect cracks which can cause separation of the HPCR stage 3-9 spool and result in an uncontained engine failure, perform the following inspections:\n\nCF6-45/50 Series Engines\n\t(a)\tFor HPCR stages 3-9 spools installed in CF6-45/50 series engines that have not been inspected in accordance with AD 99-24-15, do the following:\n\n\nNumber of Cycles-Since-New (CSN)\nAction\nBy the earliest of\n(1)\tMore than 7,000 CSN but fewer than 10,500 CSN after the effective date of this AD.\nEddy current and ultrasonic inspect bores for cracks in accordance with ASB 72-A1108, Revision 3, dated November 12, 1999.\n(i)\tWithin the next 1,000 cycles-in-service (CIS) after the effective date of this AD, OR\n\n(ii)\tAt the next engine shop visit (ESV) after the effective date of the AD, OR\n\n(iii)\tBefore July 29, 2001.\n(2)\t10,500 or more CSN, after the effective date of this AD, on HPCR 3-9 spools P/N 9136M89G02, 9136M89G03, 9136M89G06, 9136M89G07, 9136M89G08, 9136M89G09, 9136M89G17, 9136M89G18, 9273M14G01, 9331M29G01, 9253M85G01, 9253M85G02.\nEddy current and ultrasonic inspect bores for cracks in accordance with ASB 72-A1108, Revision 3, dated November 12, 1999.\n(i)\tWithin the next 500 CIS after the effective date of this AD, OR\n\n(ii)\tAt the next ESV after the effective date of the AD, OR\n\n(iii)\tBefore May 31, 2001.\n(3)\t10,500 or more CSN, after the effective date of this AD, on HPCR 3-9 spools P/N 9136M89G19, 9136M89G21, 9136M89G22, 9136M89G27\nReplace with a serviceable HPCR 3-9 spool.\n(i)\tWithin the next 500 CIS after the effective date of this AD, OR\n\n(ii)\tAt the next ESV after the effective date of the AD, OR\n\n(iii)\tBefore May 31, 2001.\n\n\t(b)\tRemove any HPCR 3-9 spool from service that equals or exceeds the reject criteria established by ASB 72-A1108, Revision 3, dated November 12, 1999; and replace it with a serviceable spool before further flight.\n\nCF6-80A Series Engines\n\t(c)\tFor HPCR stages 3-9 spools installed in CF6-80A series engines that have not been inspected inaccordance with AD 99-24-15, do the following:\n\n\nNumber of Cycles-Since-New (CSN)\nAction\nBy the earliest of\n(1)\tMore than 7,000 CSN but fewer than 10,500 CSN, after the effective date of this AD.\nEddy current and ultrasonic inspect bores for cracks in accordance with ASB 72-A0678, Revision 3, dated November 12, 1999.\n(i)\tWithin the next 1,000 CIS after the effective date of this AD, OR\n\n(ii)\tAt the next ESV after the effective date of the AD, OR\n\n(iii)\tBefore July 29, 2001.\n(2)\t10,500 or more CSN, after the effective date of this AD, on HPCR 3-9 spools P/N 9136M89G10, 9136M89G11.\nEddy current and ultrasonic inspect bores for cracks in accordance with ASB 72-A0678, Revision 3, dated November 12, 1999.\n(i)\tWithin the next 500 CIS after the effective date of this AD, OR\n\n(ii)\tAt the next ESV after the effective date of the AD, OR\n\n(iii)\tBefore May 31, 2001.\n(3)\t10,500 or more CSN, after the effective date of this AD, on HPCR 3-9 spools P/N 9136M89G20, 9136M89G21, 9136M89G22, 9136M89G27\nReplace with a serviceable HPCR 3-9 spool.\n(i)\tWithin the next 500 CIS after the effective date of this AD, OR\n\n(ii)\tAt the next ESV after the effective date of the AD, or\n\n(iii)\tBefore May 31, 2001.\n\t\n\t(d)\tRemove any HPCR 3-9 spool from service that equals or exceeds the reject criteria established by ASB 72-A0678, Revision 3, dated November 12, 1999, and replace it with a serviceable spool before further flight.\n\nCF6-80C2 Series Engines\n\t(e)\tFor HPCR stages 3-9 spools installed in CF6-80C2 series engines that have not been inspected in accordance with both ASB 72-A0812, Revision 2, dated October 28, 1999; and ASB 72-A0848, Revision 5, dated August 3, 2000; or AD 99-24-15, do the following:\n\n\nNumber of Cycles-Since-New (CSN)\nAction\nBy the earliest of\n(1)\tMore than 7,000 CSN but fewer than 10,500 CSN, after the effective date of this AD.\nEddy current and ultrasonic inspect the bores and webs for cracks in accordance with ASB 72-A0812, Revision 2, dated October 28, 1999; and ASB 72-A0848, Revision 5, dated August 3, 2000.\n(i)\tWithin the next 1,000 CIS after the effective date of this AD, OR\n\n(ii)\tAt the next ESV after the effective date of the AD, OR\n\n(iii)\tBefore July 29, 2001.\n(2)\t10,500 or more CSN, after the effective date of this AD.\nReplace with a serviceable HPCR 3-9 spool.\n(i)\tWithin the next 500 CIS after the effective date of this AD, OR\n\n(ii)\tAt the next ESV after the effective date of the AD, OR\n\n(iii)\tBefore May 31, 2001.\n\n\t(f)\tRemove any HPCR 3-9 spool from service that equals or exceeds the reject criteria established by ASB 72-A0812, Revision 2, dated October 28, 1999; and ASB 72-A0848, Revision 5, dated August 3, 2000, and replace it with a serviceable spool before further flight.\n\nCF6-80E1 Series Engines\n\t(g)\tFor HPCR stages 3-9 spools installed in CF6-80E1 series engines that have not been inspected in accordance with both ASB 72-A0135, Revision 1, dated October 28, 1999; and ASB 72-A0126, Revision 3, dated August 3, 2000; or AD 99-24-15, do the following:\n\n\nNumber of Cycles-Since-New (CSN)\nAction\nBy the earliest of\n\t(1)\tMore than 7,000 CSN but fewer than 10,500 CSN, after the effective date of this AD.\nEddy current and ultrasonic inspect the bores and webs for cracks in accordance with ASB 72-A0126, Revision 3, dated August 3, 2000, and ASB 72-A0135, Revision 1, dated October 28, 1999.\n\t(i)\tWithin the next 1,000 CIS after the effective date of this AD,OR\n\t(ii)\tAt the next ESV after the effective date of the AD, OR\n\t(iii)\tBefore July 29, 2001.\n\t(2)\t10,500 or more CSN after the effective date of this AD.\nReplace with a serviceable HPCR 3-9 spool.\n\t(i)\tWithin the next 500 CIS after the effective date of this AD, OR\n\t(ii)\tAt the next ESV after the effective date of the AD, OR\n\t(iii)\tBefore May 31, 2001.\n\n\t(h)\tRemove any HPCR 3-9 spool from service before further flight that equals or exceeds the reject criteria established by ASB 72-A0135, revision 1, dated October 28, 1999; or ASB 72-A0126, revision 3, dated August 3, 2000, and replace it with a serviceable spool.\n\nDefinitions\n\t(i)\tFor the purpose of this AD, an ESV is defined as any time an engine is introduced into a shop for the separation of a major engine flange.\n\nAlternative Methods of Compliance\n\t(j)\tAn alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Manager, Engine Certification Office (ECO). Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, ECO.\n\n\tNote 2: Information concerning the existence of approved alternative methods of compliance with this airworthiness directive, if any, may be obtained from the ECO.\n\nSpecial Flight Permits\n\t(k)\tSpecial flight permits may be issued in accordance with §§ 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the aircraft to a location where the requirements of this AD can be accomplished.\n\t(l)\tThe inspection shall be done in accordance with the following GE Alert Service Bulletins:\n\n\n\nDocument No.\nPages\nRevision\nDate\nGE CF6-50 ASB No. 72-A1108\n1-15\n3\nNovember 12, 1999\n\n\n\n\tTotal pages: 15\nGE CF6-80A ASB No. 72-A0678\n1-18\n3\nNovember 12, 1999\n\n\n\n\tTotal pages: 18\nGE CF6-80C2 ASB No. 72-A0812\n1-13\n2\nOctober 28, 1999\n\n\n\n\tTotal pages: 13\nGE CF6-80C2 ASB No. 72-A0848\n1-47\n5\nAugust 3, 2000\n\n\n\n\tTotal pages: 47\nGE CF6-80E1 ASB No. 72-A0126\n1-47\n3\nAugust 3, 2000\n\n\n\n\tTotal pages: 47\nGE CF6-80E1 ASB No. 72-A0135\n1-11\n1\nOctober 28, 1999\n\n\n\n\tTotal pages: 11\n\n\tThe incorporations by reference of ASB's No. CF6-50 72-A1108, Revision 3; CF6-80A 72-A0678, Revision 3; CF6-80C2 72-A0812, Revision 2; and CF6-80E1 72-A0135, Revision 1, were approved by the Director of the Federal Register on January 28, 2000 (64 FR 66554; November 29, 1999).The incorporations by reference of ASB's CF6-80C2 72-A0848, Revision 5; and CF6-80E1 72-A0126, Revision 3 were approved by the Director of the Federal Register on September 5, 2000 in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from General Electric Company via Lockheed Martin Technology Services, 10525 Chester Road, Suite C, Cincinnati, Ohio 45215, telephone (513) 672-8400, fax (513) 672-8422. Copies may be inspected at the FAA, New England Region, Office of the Regional Counsel, 12 New England Executive Park, Burlington, MA; or at the Office of the Federal Register, 800 North Capitol Street, NW, suite 700, Washington, DC.\n\t(m)\tThis amendment becomes effective on September 5, 2000.

On June 7, 2000, a Boeing 767 experienced an uncontained engine failure of a CF6-80C2 engine during takeoff. That failure resulted in a rejected takeoff. Results of an investigation indicate that the failure was due to a crack that was located in the web of the 7th stage of the spool. The FAA has issued airworthiness directive (AD) 99-24-15 (64 FR 66554; November 29, 1999) that was effective on January 28, 2000, that requires an inspection program that includes an initial inspection of bores and webs of certain CF6 HPCR 3-9 spools at the next piece-part exposure after 1000 cycles-since-new (CSN). Since that AD was issued, additional data suggests that the compliance time for the initial inspection is not adequate. This AD will decrease the compliance times for the initial inspection for those spools. This AD does not reduce the initial inspection time for HPCR 3-9 spools part numbers 1333M66G10, 1782M22G04, 1854M95P08, 9136M89G28, and 9136M89G29 because ofdifferences in manufacturing processes. The repetitive inspection schedule required by AD 99-24-15 remains in place for all HPCR 3-9 spools affected by that AD. These cracks, if not detected, could result in HPCR stage 3-9 spool separation, which can result in an uncontained engine failure and airplane damage.\n \nManufacturer's Service Information\nThe FAA has reviewed and approved the technical contents of the following GE Alert Service Bulletins (ASB's):\n\nASB CF6-50 72-A1108, Revision 3, dated November 12, 1999\nASB CF6-80A 72-A0678, Revision 3, dated November 12, 1999\nASB CF6-80C2 72-A0812, Revision 2, dated October 28, 1999\nASB CF6-80C2 72-A0848, Revision 5, dated August 3, 2000\nASB CF6-80E1 72-A0135, Revision 1, dated October 28, 1999\nASB CF6-80E1 72-A0126, Revision 3, dated August 3, 2000\n\nThose ASB's describe procedures for eddy current and ultrasonic inspections of HPCR stage 3-9 spools for cracks.\n\nDetermination of an Unsafe Condition\n\tSince an unsafe condition has been identified that is likely to exist or develop on other engines of the same type design, this AD is being issued to detect cracks which can cause separation of the HPCR stage 3-9 spool and result in an uncontained engine failure. This AD requires an initial inspection of spools with 10,500 or more CSN, within 500 cycles-in-service (CIS) after the effective date of this AD, by the next engine shop visit, or by May, 31, 2001, whichever occurs first. This AD also requires an initial inspection of spools with 7,000 CSN to 10,499 CSN within 1,000 CIS after the effective date of this AD, by the next shop visit, or by July 29, 2001, whichever occurs first. These initial inspections qualify the HPCR 3-9 spool as having been previously inspected when determining the repetitive inspection schedules under AD 99-24-15. The actions are required to be accomplished in accordance with the alert service bulletins described previously.\n\nImmediate Adoption\n\tSince a situation exists that requiresthe immediate adoption of this regulation, it is found that notice and opportunity for prior public comment hereon are impracticable, and that good cause exists for making this amendment effective in less than 30 days.\n\nComments Invited\n\tAlthough this action is in the form of a final rule that involves requirements affecting flight safety and, thus, was not preceded by notice and an opportunity for public comment, comments are invited on this rule. Interested persons are invited to comment on this rule by submitting such written data, views, or arguments as they may desire. Communications should identify the Rules Docket number and be submitted in triplicate to the address specified under the caption "ADDRESSES".\nAll communications received on or before the closing date for comments will be considered, and this rule may be amended in light of the comments received. Factual information that supports the commenter's ideas and suggestions is extremely helpful in evaluating the effectiveness of the AD action and determining whether additional rulemaking action would be needed.\n\tComments are specifically invited on the overall regulatory, economic, environmental, and energy aspects of the rule that might suggest a need to modify the rule. All comments submitted will be available, both before and after the closing date for comments, in the Rules Docket for examination by interested persons. A report that summarizes each FAA-public contact concerned with the substance of this AD will be filed in the Rules Docket. \n\tCommenters wishing the FAA to acknowledge receipt of their comments submitted in response to this notice must submit a self-addressed, stamped postcard on which the following statement is made: \nComments to Docket Number 2000-NE-31-AD. The postcard will be date stamped and returned to the commenter.\n\nRegulatory Impact\n\tThis proposed rule does not have federalism implications, as defined in Executive Order No. 13132, because it 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. Accordingly, the FAA has not consulted with state authorities prior to publication of this proposed rule.\n\tThe FAA has determined that this regulation is an emergency regulation that must be issued immediately to correct an unsafe condition in aircraft, and is not a "significant regulatory action" under Executive Order 12866. It has been determined further that this action involves an emergency regulation under DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979). If it is determined that this emergency regulation otherwise would be significant under DOT Regulatory Policies and Procedures, a final regulatory evaluation will be prepared and placed in the Rules Docket. A copy of it, if filed, may be obtained from the Rules Docket at the location provided under the caption "ADDRESSES."\n\nList of Subjects in 14 CFR Part 39\n\tAir transportation, Aircraft, Aviation safety, Incorporation by reference, Safety.\n\nAdoption of the Amendment\n\tAccordingly, 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:\n\nPART 39 - AIRWORTHINESS DIRECTIVES\n\t1. The authority citation for part 39 continues to read as follows:\nAuthority: 49 U.S.C. 106(g), 40113, 44701.\n§39.13 (Amended)\n\t2. Section 39.13 is amended by adding the following new airworthiness directive: