[Federal Register Volume 66, Number 194 (Friday, October 5, 2001)]
[Proposed Rules]
[Pages 50906-50910]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 01-25080]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 98-ANE-49-AD]
RIN 2120-AA64


Airworthiness Directives; General Electric Company CF6-80A, CF6-
80C2, and CF6-80E1 Series Turbofan Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The Federal Aviation Administration (FAA) proposes to 
supersede an existing airworthiness directive (AD), applicable to 
General Electric Company (GE) CF6-80A, CF6-80C2, and CF6-80E1 series 
turbofan engines, that currently requires revisions to the Life Limits 
Section 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 action would add additional 
mandatory inspections for certain high pressure compressor (HPC), low 
pressure turbine (LPT), and high pressure turbine (HPT) parts. An FAA 
study of in-service events involving uncontained failures of critical 
rotating engine parts has indicated the need for mandatory inspections. 
The mandatory inspections are needed to identify those critical 
rotating parts with conditions, which if allowed to continue in 
service, could result in uncontained failures. The actions specified by 
this proposed 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.

DATES: Comments must be received by December 4, 2001.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), New England Region, Office of the Regional 
Counsel, Attention: Rules Docket No. 98-ANE-49-AD, 12 New England 
Executive Park, Burlington, MA 01803-5299. Comments may also be sent 
via the Internet using the following address: ``[email protected]''. Comments sent via the Internet must contain the 
docket number in the subject line. Comments may be inspected at this 
location between 8:00 a.m. and 4:30 p.m., Monday through Friday, except 
Federal holidays.

FOR FURTHER INFORMATION CONTACT: Karen Curtis, Aerospace Engineer, 
Engine Certification Office, FAA, Engine and Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803-5299; telephone (781) 
238-7192, fax (781) 238-7199.

SUPPLEMENTARY INFORMATION:

Comments Invited

    Interested persons are invited to participate in the making of the 
proposed rule by submitting such written data, views, or arguments as 
they may desire. Communications should identify the Rules Docket number 
and be submitted to the address specified above. All communications 
received on or before the closing date for comments, specified above, 
will be considered before taking action on the proposed rule. The 
proposals contained in this action may be changed in light of the 
comments received.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the proposed 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 summarizing each FAA-public contact concerned with 
the substance of this proposal will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this action must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 98-ANE-49-AD.'' The postcard will be date stamped and 
returned to the commenter.

Availability of NPRM's

    Any person may obtain a copy of this NPRM by submitting a request 
to the FAA, New England Region, Office of the Regional Counsel, 
Attention: Rules Docket No. 98-ANE-49-AD, 12 New England Executive 
Park, Burlington, MA 01803-5299.

Discussion

    On April 14, 2000, the FAA issued AD 2000-08-12, Amendment 39-11698 
(65 FR 21638, April 24, 2000), to require revisions to the Life Limits 
Section of the manufacturer's Instructions for Continued Airworthiness 
(ICA) for General Electric Company (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.

Additional Inspection Procedures

    Since the issuance of that AD, an FAA study of in-service events 
involving uncontained failures of critical rotating engine parts has 
indicated the need for additional mandatory inspections. The mandatory 
inspections are needed to identify those critical rotating parts with 
conditions, which if allowed to continue in service, could result in 
uncontained engine failures. This proposal would modify the 
airworthiness limitations section of the manufacturer's manual and an 
air carrier's approved continuous airworthiness maintenance program to 
incorporate additional inspection requirements.
    This proposal will also differentiate between standard HPTR and 
R88DT HPTR inspections and add a dovetail slot bottom eddy current 
inspection for the -80C2 HPT Stage 1 disk.

Proposed Actions

    Since an unsafe condition has been identified that is likely to 
exist or develop on other products of this same type design, the 
proposed AD would supersede AD 2000-08-12 to add additional inspections 
for certain HPC, LPT and HPT components. These inspections would be 
required at each piece-part opportunity.

Economic Analysis

    The FAA estimates that 790 engines installed on airplanes of US 
registry would be affected by this proposed AD, that it would take 
approximately 10 work hours per engine to accomplish the proposed 
additional inspections and that the average labor rate is $60 per work 
hour. The total cost of the new inspections per engine would be 
approximately $600. The FAA estimates that there will be approximately 
327 shop visits per year that result in piece-part-exposure of the 
added affected components, therefore, the total annual cost for the 
additional inspections is estimated to be $196,200.

Regulatory Analysis

    This proposed rule does not have federalism implications, as 
defined in Executive Order 13132, because it would not have a 
substantial direct effect on the States, on the relationship between 
the national government and

[[Page 50907]]

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.
    For the reasons discussed above, I certify that 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); 
and (3) if promulgated, will not have a significant economic effect, 
positive or negative, on a substantial number of small entities under 
the criteria of the Regulatory Flexibility Act. A copy of the draft 
regulatory evaluation prepared for this action is contained in the 
Rules Docket. A copy of it may be obtained by contacting 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.

The Proposed Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration proposes to amend 
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.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by removing Amendment 39-11698 (65 FR 
21638, April 24, 2000), and by adding a new airworthiness directive, to 
read as follows:

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

    Applicability: This airworthiness directive (AD) is applicable 
to 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 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: Compliance with this AD is required as indicated, 
unless already done.
    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), 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:

------------------------------------------------------------------------
                                                     Inspect per engine
       Part nomenclature          Part No. (P/N)       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.
    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 3.
                                                    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- All..............  72-31-08 Paragraph
     14.                                            3.A. Fluorescent-
                                                    Penetrant Inspect.
    Rotating CDP Seal.........  All..............  72-31-10 Paragraph 3.
                                                    Fluorescent-
                                                    Penetrant Inspect.
    Disk Shaft, HPT Rotor       All..............  72-53-02 Paragraph 3.
     Stage One.                                     Fluorescent-
                                                    Penetrant-Inspect
                                                    per 70-32-02, and
                                                   72-53-02 Paragraph
                                                    6.C. 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.
    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 One.  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.

[[Page 50908]]

 
    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.
    HPCR Stage 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/     All..............  Task 72-31-08-200-000-
     Shaft.                                         002 Fluorescent
                                                    Penetrant
                                                    Inspection.
    No. 4 Bearing Rotating      All..............  Task 72-31-10-200-000-
     (CDP) Air Seal.                                001 Fluorescent
                                                    Penetrant Inspection
                                                    or
                                                   Task 72-31-10-200-000-
                                                    A01 Fluorescent
                                                    Penetrant
                                                    Inspection.
    HPCR Stage 10-14 Spool/     All..............  Task 72-31-22-200-000-
     Shaft.                                         002 Fluorescent
                                                    Penetrant
                                                    Inspection.
    Fan Mid Shaft.............  All..............  Task 72-24-01-200-000-
                                                    003 Magnetic
                                                    Particle Inspection.
    Disk Shaft, HPT Rotor       All..............  Task 72-53-02-200-000-
     Stage One.                                     001 Fluorescent-
                                                    Penetrant Inspect,
                                                    and
                                                   Task 72-53-02-200-000-
                                                    005 Disk Rim Bolt
                                                    Hole Eddy Current
                                                    Inspection, and
                                                   Task 72-53-02-200-000-
                                                    006 Disk Bore Area
                                                    Eddy Current
                                                    Inspection, and
                                                   Task 72-53-02-200-000-
                                                    007 Disk Dovetail
                                                    Slot Bottom Eddy
                                                    Current.
    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 Rim
                                                    Boltholes, and
                                                   Task 72-53-06-200-000-
                                                    007 Disk Bore Area
                                                    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 Eddy Current
                                                    Inspection.
For CF6-80C2 Engines
 configured with the R88DT
 Turbine (Models CF6-80C2B2F,
 80C2B4F, 80C2B6F, 80C2B7F,
 80C2B8F):
    Disk Shaft, HPT Rotor       All..............  Task 72-53-16-200-000-
     Stage One (R88DT, No Rim                       001 Fluorescent-
     Bolt Holes.                                    Penetrant Inspect,
                                                    and
                                                   Task 72-53-16-200-000-
                                                    XXX Disk Bore Area
                                                    Eddy Current
                                                    Inspection.
    Disk, HPT Rotor Stage Two   All..............  Task 72-53-18-200-000-
     (R88DT, No Rim Bolt                            002 Fluorescent-
     Holes).                                        Penetrant Inspect,
                                                    and
                                                   Task 72-53-18-200-000-
                                                    XXX Disk Bore Area
                                                    Eddy Current
                                                    Inspection.
    Rotating Interstage Seal    All..............  Task 72-53-17-200-000-
     (R88DT).                                       001 Fluorescent-
                                                    Penetrant Inspect,
                                                    and
                                                   Task 72-53-17-200-000-
                                                    XXX 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-
                                                    XXX 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 Forward........  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   All..............  Sub Task 72-31-04-230-
     Disk.                                          051 Fluorescent
                                                    Penetrant
                                                    Inspection.
    Compressor Rotor, Stage 2   All..............  Sub Task 72-31-05-230-
     Disk.                                          051 Fluorescent
                                                    Penetrant
                                                    Inspection.

[[Page 50909]]

 
    Compressor Rotor, Stage 3-  All..............  Sub Task 72-31-06-230-
     9 Spool.                                       051 Fluorescent
                                                    Penetrant
                                                    Inspection.
    Compressor Rotor, Stage 10  All..............  Sub Task 72-31-07-230-
     Disk (Pre SB 72-0150).                         051 Fluorescent
                                                    Penetrant
                                                    Inspection.
    Compressor Rotor Spool/     All..............  Sub Task 72-31-08-230-
     Shaft, Stage 11-14 (Pre                        051 Fluorescent
     SB 72-0150).                                   Penetrant
                                                    Inspection.
    Compressor Rotor Spool/     All..............  Sub Task 72-31-23-230-
     Shaft, Stage 10-14 (SB 72-                     052 Fluorescent
     0150).                                         Penetrant
                                                    Inspection.
    Compressor Rotor No. 4      All..............  Sub Task 72-31-10-230-
     Bearing Rotating Air Seal                      051 Fluorescent
     (CDP Rotating Seal).                           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 Area.
    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, RimBolt
                                                    Holes, and
                                                   Sub Task 72-53-06-250-
                                                    054 Eddy Current
                                                    Inspection, Disk
                                                    Bore Area.
    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       All..............  Sub Task 72-53-16-230-
     Stage 1 (R88DT, No Rim                         052 Fluorescent-
     Bolt Holes).                                   Penetrant Inspect,
                                                    and
                                                   Sub Task 72-53-16-250-
                                                    XXX Disk Bore Area
                                                    Eddy Current
                                                    Inspection.
    Disk, HPT Rotor Stage 2     All..............  Sub Task 72-53-18-230-
     (R88DT, No Rim Bolt                            051 Fluorescent-
     Holes).                                        Penetrant Inspect,
                                                    and
                                                   Sub Task 72-53-18-250-
                                                    XXX Disk Bore Area
                                                    Eddy Current
                                                    Inspection.
    HPT Rotor Rotating          All..............  Sub Task 72-53-17-230-
     Interstage Seal (R88DT).                       051 Fluorescent-
                                                    Penetrant Inspect,
                                                    and
                                                   Sub Task 72-53-17-250-
                                                    XXX Seal Bore Area
                                                    Eddy Current.
    HPT Rotor Forward Outer     All..............  Sub Task 72-53-21-230-
     Seal (R88DT).                                  051 Fluorescent-
                                                    Penetrant Inspect,
                                                    and
                                                   Sub Task 72-53-21-250-
                                                    XXX 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.''
    (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 manufacturer's ICA.

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 
must 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.

Continuous Airworthiness Maintenance Program

    (d) FAA-certificated air carriers that have an approved 
continuous airworthiness maintenance program in accordance with the 
record keeping requirement of Sec. 121.369 (c) of the Federal 
Aviation Regulations [14 CFR 121.369 (c)] of this chapter must 
maintain records of the mandatory inspections that result from 
revising the Life Limits Section of the Instructions for Continuous 
Airworthiness (ICA) 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 Sec. 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 Sec. 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.



[[Page 50910]]


    Issued in Burlington, Massachusetts, on October 1, 2001.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 01-25080 Filed 10-4-01; 8:45 am]
BILLING CODE 4910-13-P