AD 2009-04-10

The FAA is superseding an existing airworthiness directive (AD) for General Electric Company (GE) CF6-80A, CF6-80C2, and CF6-80E1 series turbofan engines. That AD required revisions to the Airworthiness Limitations Section (ALS) of the manufacturer's Instructions for Continued Airworthiness (ICA) to include required inspection of selected critical life-limited parts at each piece-part exposure. This AD requires revisions to the CF6-80A, CF6-80C2, and CF6- 80E1 series engines ALS sections of the manufacturer's manuals and an air carrier's approved continuous airworthiness maintenance program to incorporate additional inspection requirements, and to update certain Engine Manual Inspection Task and Sub Task Number references. This AD results from the need to require enhanced inspection of selected critical life-limited parts of CF6-80A, CF6-80C2, and CF6-80E1 series engines. We are issuing this AD to prevent critical life-limited rotating engine part failure, which could result in an uncontained engine failure and damage to the airplane.

Final rule.

2009-04-10 General Electric Company: Amendment 39-15816. Docket No. FAA-2008-0952; Directorate Identifier 98-ANE-49-AD.

Effective Date

(a) This airworthiness directive (AD) becomes effective March 30, 2009.

Affected ADs

(b) This AD supersedes AD 2002-07-12, Amendment 39-12707.

Applicability

(c) This AD applies to General Electric Company CF6-80A, CF6- 80C2, and CF6-80E1 series turbofan engines. These engines are installed on, but not limited to, Airbus A300, A310, and A330 series, Boeing 747 and 767 series, and McDonnell Douglas MD-11 series airplanes.

Unsafe Condition

(d) This AD results from the need to require enhanced inspection of selected critical life-limited parts of CF6-80A, CF6-80C2, and CF6-80E1 series engines. We are issuing this AD to prevent critical life-limited rotating engine part failure, which could result in an uncontained engine failure and damage to the airplane.

Compliance

(e) You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done.

Inspections

(f) Within the next 180 days after the effective date of this AD, revise the Airworthiness Limitations Section (ALS) of the manufacturer's Instructions for Continued Airworthiness (ICA), and 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 Inspection 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
Fan Forward Shaft
All
72-21-05 Paragraph 2. Magnetic Particle Inspect
Fan Mid Shaft
All
72-24-01 Paragraph 2. Magnetic Particle Inspect
Disk, HPC Rotor, Stage One
All
72-31-04 Paragraph 3. Fluorescent-Penetrant Inspect
** Disk, HPC Rotor, Stage Two
All
72-31-05 Paragraph 4. Fluorescent-Penetrant Inspect
Spool, HPC Rotor, Stage3-9
All
72-31-06 Paragraph 3. Fluorescent-Penetrant Inspect
Disk, HPC Rotor, Stage 10
All
72-31-07 Paragraph 3. Fluorescent-Penetrant Inspect
Spool, HPC Rotor, Stage 11-14
All
72-31-08 Paragraph 3.A. Fluorescent-Penetrant Inspect
Rotating CDP Seal
All
72-31-10 Paragraph 3. Fluorescent-Penetrant Inspect
Disk Shaft, HPT Rotor Stage One
All
72-53-02 Paragraph 3. Fluorescent-Penetrant-Inspect per 70-32-02, and
72-53-02 Paragraph 6.C. Disk Rim Bolt Hole Eddy Current Inspection, and
72-53-02 Paragraph 6.D. Disk Bore Eddy Current Inspection
* Disk Shaft, HPT Rotor Stage One
All
72-53-02 Paragraph 6.E. Disk Dovetail Slot Bottom Eddy Current Inspection
* Disk Shaft, HPT Rotor, Stage One
P/Ns 2047M33G01 thru G10, and P/N 9362M58G11
72-53-02 Paragraph 7.Disk Dovetail Slot Bottom Aft Corner Chamfers 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 Bolt Holes for Cracks, and
72-53-06 Paragraph 7. Disk Bore Eddy Current Inspection
Disk, LPT Rotor Stage 1-4
All
72-57-02 Paragraph 3. Fluorescent-Penetrant Inspection
Shaft, LPT Rotor
All
72-57-03 Paragraph 3. Fluorescent-Penetrant Inspection, and
72-57-03 Paragraph 6. Eddy Current Inspection

For All 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, Forward and 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
Fan Mid Shaft
All
Task 72-24-01-200-000-003 Magnetic Particle Inspection
HPCRStage 1 Disk
All
Task 72-31-04-200-000-002 Fluorescent Penetrant Inspection
HPCR Stage 2 Disk
All
Task 72-31-05-200-000-002 Fluorescent Penetrant Inspection
HPCR Stage 3-9 Spool
All
Task 72-31-06-200-000-001 Fluorescent Penetrant Inspection
HPCR Stage 10 Disk
All
Task 72-31-07-200-000-001 Fluorescent Penetrant Inspection
HPCR Stage 11-14 Spool/Shaft
All
Task 72-31-08-200-000-002 Fluorescent Penetrant Inspection
No. 4 Bearing Rotating (CDP) Air Seal
All
Task 72-31-10-200-000-001 Fluorescent Penetrant Inspection or
Task 72-31-10-200-000-A01 Fluorescent Penetrant Inspection
HPCR Stage 10-14 Spool/Shaft
All
Task 72-31-22-200-000-002 Fluorescent Penetrant Inspection
** Disk/Shaft, HPT Rotor, Stage One
All
Task 72-53-02-200-000-001 (Inspection Configuration 1), or Task 72-53-02-230-801 (Inspection Configuration 2), Fluorescent-Penetrant Inspect, and
Task 72-53-02-200-000-005 (Inspection Configuration 1), or Task 72-53-02-250-802 (Inspection Configuration 2), Disk Rim Bolt Hole Eddy Current Inspection, and
Task 72-53-02-200-000-006 (Inspection Configuration 1), or Task 72-53-02-250-803 (Inspection Configuration 2), Disk Bore Area Eddy Current Inspection, and
Task 72-53-02-200-000-007 (Inspection Configuration 1), or Task 72-53-02-250-804 (Inspection Configuration 2), Disk Dovetail Slot Bottom Eddy Current
* Disk/Shaft, HPT Rotor, Stage One
P/N 1531M84G12 and P/Ns 2047M32G01 thru G07
Task 72-53-02-250-801 (Inspection Configuration 1), Disk Dovetail Slot Bottom Aft Corner Chamfers Eddy Current Inspection
Disk, HPT Rotor, Stage Two
All
Task 72-53-06-200-000-002 Fluorescent-Penetrant Inspect, and
Task 72-53-06-200-000-006 Disk Rim Bolt Hole Eddy Current Inspection, and
Task 72-53-06-200-000-007 Disk Bore Eddy Current Inspection
LPTR Stage 1-5 Disks
All
Task 72-57-02-200-000-001 Fluorescent-Penetrant Inspection
LPTR Shaft
All
Task 72-57-03-200-000-002 Fluorescent-Penetrant Inspect, and
Task 72-57-03-200-000-006 EddyCurrent Inspection

For CF6-80C2 Engines configured with the R88DT Turbine (Models CF6-80C2B2F, 80C2B4F, 80C2B6F, 80C2B7F, 80C2B8F):
Disk/Shaft, HPT Rotor, Stage One (R88DT, No Rim Bolt Holes)
All
Task 72-53-16-200-000-001 Fluorescent-Penetrant Inspect, and
Task 72-53-16-200-000-005 Disk Bore Area Eddy Current Inspection
Disk, HPT Rotor, Stage Two (R88DT, No Rim Bolt Holes)
All
Task 72-53-18-200-000-002 Fluorescent-Penetrant Inspect, and
Task 72-53-18-200-000-005 Disk Bore Area Eddy Current Inspection
Rotating Interstage Seal (R88DT)
All
Task 72-53-17-200-000-001 Fluorescent-Penetrant Inspect, and
Task 72-53-17-200-000-005 Seal Bore Area Eddy Current
Forward Outer Seal (R88DT)
All
Task 72-53-21-200-000-001 Fluorescent-Penetrant Inspect, and
Task 72-53-21-200-000-004 Seal Bore Area Eddy Current

For CF6-80E1 Engines:
Disk, Fan Rotor, Stage One
All
Sub Task 72-21-03-230-051 Fluorescent-Penetrant Inspection, and
Sub Task 72-21-03-250-051 or 72-21-03-250-052 Disk Bore Eddy Current Inspection
Shaft, Fan
All
Sub Task 72-21-05-230-051 Fluorescent Penetrant Inspection, and
Sub Task 72-21-05-250-051 Vent Hole Eddy Current Inspection
Compressor Rotor, Stage 1 Disk
All
Sub Task 72-31-04-230-051 Fluorescent Penetrant Inspection,
Compressor Rotor, Stage 2 Disk
All
Sub Task 72-31-05-230-051 Fluorescent Penetrant Inspection
Compressor Rotor, Stage 3-9 Spool
All
Sub Task 72-31-06-230-051 Fluorescent Penetrant Inspection
Compressor Rotor, Stage 10 Disk (Pre SB 72-0150)
All
Sub Task 72-31-07-230-051 Fluorescent Penetrant Inspection
Compressor Rotor Spool/Shaft, Stage 11-14 (Pre SB 72-0150)
All
Sub Task 72-31-08-230-051 Fluorescent Penetrant Inspection
Compressor Rotor Spool/Shaft, Stage 10-14 (SB 72-0150)
All
Sub Task 72-31-23-230-052 Fluorescent Penetrant Inspection
Compressor Rotor No. 4 Bearing Rotating Air Seal (CDP Rotating Seal)
All
Sub Task 72-31-10-230-051 Fluorescent Penetrant Inspection
HPT Disk/Shaft,
Stage 1
All
Sub Task 72-53-02-230-051 Fluorescent-Penetrant Inspection, and
Sub Task 72-53-02-250-051 Eddy Current Inspection, Rim Bolt Holes, and
Sub Task 72-53-02-250-054 Eddy Current Inspection, Disk Bore
HPT Disk, Stage 2
All
Sub Task 72-53-06-230-051 Fluorescent-Penetrant Inspection, and
Sub Task 72-53-06-250-051 Eddy Current Inspection, Rim Bolt Holes, and
Sub Task 72-53-06-250-054 Eddy Current Inspection, Disk Bore
LPT Rotor Shaft
All
Sub Task 72-55-01-240-051 Magnetic Particle Inspect
LPT Disks, Stages 1-5
All
Sub Task 72-57-02-230-051 Fluorescent-Penetrant Inspect
LPT Rotor Torque Cone
All
Sub Task 72-57-03-220-051 Fluorescent-Penetrant Inspect

For CF6-80E1 Engines configured with the R88DT Turbine:
Disk/Shaft, HPT Rotor, Stage 1 (R88DT, No Rim Bolt Holes)
All
Sub Task 72-53-16-230-052 Fluorescent-Penetrant Inspect, and
Sub Task 72-53-16-250-051 Disk Bore Area Eddy Current Inspection
Disk, HPT Rotor, Stage 2 (R88DT, No Rim Bolt Holes)
All
Sub Task 72-53-18-230-051 Fluorescent-Penetrant Inspect, and
Sub Task 72-53-18-250-051 Disk Bore Area Eddy Current Inspection
** HPT Rotor Rotating Interstage Seal (R88DT)
All
Sub Task 72-53-17-230-056 Fluorescent-Penetrant Inspect, and
Sub Task 72-53-17-250-051 Seal Bore Area Eddy Current
HPT Rotor Forward Outer Seal (R88DT)
All
Sub Task 72-53-21-230-051 Fluorescent-Penetrant Inspect, and
Sub Task 72-53-21-250-051 Seal Bore Area Eddy Current

(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.''
(g) The parts added to the table of this AD are identified by an asterisk (*) that precedes the partnomenclature. Also, parts that have an Engine Manual Inspection Task and or Sub Task Number reference updated in the table of this AD, are identified by two asterisks (**) that precede the part nomenclature.
(h) Except as provided in paragraph (i) 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 ALS of the manufacturer's ICA.

Alternative Methods of Compliance (AMOC)

(i) You must perform these mandatory inspections using the ALS of the ICA and the applicable Engine Manual unless you receive approval to use an AMOC under paragraph (j) of this AD. Section 43.16 of the Federal Aviation Regulations (14 CFR 43.16) may not be used to approve alternative methods of compliance or adjustments to the times in which these inspections must be performed.
(j) The Manager, Engine Certification Office, has the authority to approve alternativemethods of compliance for this AD if requested using the procedures found in 14 CFR 39.19.
(k) AMOCs previously approved for AD 2002-07-12, are also approved for this AD.

Maintaining Records of the Mandatory Inspections

(l) You have met the requirements of this AD when you revise the ALS of the manufacturer's ICA as specified in paragraph (f) of this AD. For air carriers operating under part 121 of the Federal Aviation Regulations (14 CFR part 121), you have met the requirements of this AD when you modify your continuous airworthiness maintenance plan to reflect those changes. You do not need to record each piece-part inspection as compliance to this AD, but you must maintain records of those inspections according to the regulations governing your operation. For air carriers operating under part 121, you may use either the system established to comply with section 121.369 or an alternative accepted by your principal maintenance inspector if that alternative:
(1) Includesa method for preserving and retrieving the records of the inspections resulting from this AD; and
(2) Meets the requirements of section 121.369(c); and
(3) Maintains the records either indefinitely or until the work is repeated.
(m) These recordkeeping requirements apply only to the records used to document the mandatory inspections required as a result of revising the ALS of the manufacturer's ICA as specified in paragraph (f) of this AD. These record keeping requirements do not alter or amend the record keeping requirements for any other AD or regulatory requirement.

Related Information

(n) Contact Robert Green, Aerospace Engineer, Engine Certification Office, FAA, Engine & Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; e-mail: robert.green@faa.gov; telephone (781) 238-7754; fax (781) 238-7199, for more information about this AD.

Material Incorporated by Reference

(o) None.

The FAA proposed to amend 14 CFR part 39 by superseding AD 2002-07-12, Amendment 39-12707 (67 FR 17279, April 10, 2002), with a proposed AD. The proposed AD applies to GE CF6-80A, CF6- 80C2, and CF6-80E1 series turbofan engines. We published the proposed AD in the Federal Register on October 23, 2008 (73 FR 63090). That action proposed to require revisions to the CF6-80A, CF6-80C2, and CF6- 80E1 series engines ALS sections of the manufacturer's manuals and an air carrier's approved continuous airworthiness maintenance program to incorporate additional inspection requirements, and to update certain Engine Manual Inspection Task and Sub Task Number references.

Examining the AD Docket

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

Comments

We provided the public the opportunity to participate in the development of this AD. We have considered the one comment received.
ABX Air requests that we add a statement to the AD, acknowledging that previously approved alternative methods of compliance (AMOCs) for AD 2002-07-12, the AD being superseded, are also approved for this AD.
We agree and added that statement to the AD.

Conclusion

We have carefully reviewed the available data, including the comment received, and determined that air safety and the public interest require adopting the AD with the change described previously. We have determined that this change will neither increase the economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

We estimate that this AD will affect 315 CF6-80A series engines and 926 CF6-80C2 series engines installed on airplanes of U.S. registry. We also estimate that it will take about 5 work-hours per CF6-80A series engine and about 2 work-hours per CF6-80C2 series engine to do the additional inspections and that the average labor rate is $80 per work- hour. The total cost of the new inspections per CF6-80A series engine will be about $400. The total cost of the new inspections per CF6-80C2 series engine will be about $160. We estimate that there will be about 42 shop visits per year for CF6-80A series engines, and about 128 shop visits per year for CF6-80C2 series engines that result in piece-part- exposure of the added affected components. Therefore, we estimate the total annual cost for the additional inspections to be $37,280.

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 have determined that this AD will not have federalism implications under Executive Order 13132. This AD will 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 that this AD:
(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.
We prepared a summary of the costs to comply with this AD and placed it in the AD Docket. You may get a copy of this summary at the address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

Accordingly, under the authority delegated to me by the Administrator, the Federal Aviation Administration amends 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.

Sec. 39.13 [Amended]

2. The FAA amends Sec. 39.13 by removing Amendment 39-12707 (67 FR 17279, April 10, 2002), and by adding a new airworthiness directive, Amendment 39-15816, to read as follows: