[Federal Register Volume 74, Number 34 (Monday, February 23, 2009)]
[Rules and Regulations]
[Pages 7995-7998]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E9-3105]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2008-0952; Directorate Identifier 98-ANE-49-AD; 
Amendment 39-15816; AD 2009-04-10]
RIN 2120-AA64


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

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

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SUMMARY: 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.

DATES: This AD becomes effective March 30, 2009.

ADDRESSES: The Docket Operations office is located at Docket Management 
Facility, U.S. Department of Transportation, 1200 New Jersey Avenue, 
SE., West Building Ground Floor, Room W12-140, Washington, DC 20590-
0001.

FOR FURTHER INFORMATION CONTACT: Robert Green, Aerospace Engineer, 
Engine Certification Office, FAA, Engine & Propeller Directorate, 12 
New England Executive Park, Burlington, MA 01803; e-mail: 
[email protected]; telephone (781) 238-7754; (781) 238-7199.

SUPPLEMENTARY INFORMATION: 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

[[Page 7996]]

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

0
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

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 removing Amendment 39-12707 (67 FR 
17279, April 10, 2002), and by adding a new airworthiness directive, 
Amendment 39-15816, to read as follows:

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, Stage 3-9.......  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.

[[Page 7997]]

 
    *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,  72-53-02 Paragraph 7. Disk Dovetail Slot
                                         and P/N 9362M58G11.        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.
    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/Shaft......  All......................  Task 72-31-08-200-000-002 Fluorescent
                                                                    Penetrant Inspection.
    No. 4 Bearing Rotating (CDP) Air    All......................  Task 72-31-10-200-000-001 Fluorescent
     Seal.                                                          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     All......................  Task 72-53-02-200-000-001 (Inspection--
     One.                                                           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    Task 72-53-02-250-801 (Inspection--
                                         2047M32G01 thru G07.       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 Eddy Current
                                                                    Inspection.
For CF6-80C2 Engines configured with
 the R88DT Turbine (Models CF6-
 80C2B2F, 80C2B4F, 80C2B6F, 80C2B7F,
 80C2B8F):
    Disk/Shaft, HPT Rotor, Stage One    All......................  Task 72-53-16-200-000-001 Fluorescent-
     (R88DT, No Rim Bolt Holes).                                    Penetrant Inspect, and
                                                                   Task 72-53-16-200-000-005 Disk Bore Area Eddy
                                                                    Current Inspection.
    Disk, HPT Rotor, Stage Two (R88DT,  All......................   Task 72-53-18-200-000-002 Fluorescent-
     No Rim Bolt Holes).                                            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.

[[Page 7998]]

 
    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     All......................  Sub Task 72-31-07-230-051 Fluorescent
     (Pre SB 72-0150).                                              Penetrant Inspection.
    Compressor Rotor Spool/Shaft,       All......................  Sub Task 72-31-08-230-051 Fluorescent
     Stage 11-14 (Pre SB 72-0150).                                  Penetrant Inspection.
    Compressor Rotor Spool/Shaft,       All......................  Sub Task 72-31-23-230-052 Fluorescent
     Stage 10-14 (SB 72-0150).                                      Penetrant Inspection.
    Compressor Rotor No. 4 Bearing      All......................  Sub Task 72-31-10-230-051 Fluorescent
     Rotating Air Seal (CDP Rotating                                Penetrant Inspection.
     Seal).
    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      All......................  Sub Task 72-53-16-230-052 Fluorescent-
     (R88DT, No Rim Bolt Holes).                                    Penetrant Inspect, and
                                                                   Sub Task 72-53-16-250-051 Disk Bore Area Eddy
                                                                    Current Inspection.
    Disk, HPT Rotor, Stage 2 (R88DT,    All......................  Sub Task 72-53-18-230-051 Fluorescent-
     No Rim Bolt Holes).                                            Penetrant Inspect, and
                                                                   Sub Task 72-53-18-250-051 Disk Bore Area Eddy
                                                                    Current Inspection.
    ** HPT Rotor Rotating Interstage    All......................  Sub Task 72-53-17-230-056 Fluorescent-
     Seal (R88DT).                                                  Penetrant Inspect, and
                                                                   Sub Task 72-53-17-250-051 Seal Bore Area Eddy
                                                                    Current.
    HPT Rotor Forward Outer Seal        All......................  Sub Task 72-53-21-230-051 Fluorescent-
     (R88DT).                                                       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 part nomenclature. 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 alternative methods 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) Includes a 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: 
[email protected]; telephone (781) 238-7754; fax (781) 238-7199, 
for more information about this AD.

Material Incorporated by Reference

    (o) None.

    Issued in Burlington, Massachusetts, on February 5, 2009.
Peter A. White,
Assistant Manager, Engine and Propeller Directorate.
[FR Doc. E9-3105 Filed 2-20-09; 8:45 am]
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