Airworthiness Directives; General Electric Company CF6-6, CF6-45, and CF6-50 Series Turbofan Engines

[Federal Register Volume 67, Number 46 (Friday, March 8, 2002)]
[Rules and Regulations]
[Pages 10603-10606]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 02-5528]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 98-ANE-41-AD; Amendment 39-12671; AD 2002-05-03]
RIN 2120-AA64


Airworthiness Directives; General Electric Company CF6-6, CF6-45, 
and CF6-50 Series Turbofan Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

-----------------------------------------------------------------------

SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD), that is applicable to General Electric Company (GE) CF6-6, CF6-
45, and CF6-50 series turbofan engines, that currently requires 
revisions to the Time 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 
amendment modifies the airworthiness limitations section of the 
manufacturer's manual and an air carrier's approved continuous 
airworthiness maintenance program to incorporate additional inspection 
requirements. A Federal Aviation Administration (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 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: Effective date April 12, 2002.

ADDRESSES: This information may be examined, by appointment, at the 
Federal Aviation Administration (FAA), New England Region, Office of 
the Regional Counsel, 12 New England Executive Park, Burlington, MA.

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: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) by superseding AD 2000-08-11, 
Amendment 39-11697 (65 FR 21636, April 24, 2000), which is applicable 
to GE CF6-6, CF6-45, and CF6-50 series turbofan engines was published 
in the Federal Register on October 5, 2001 (66 FR 50912). That action 
proposed to 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.

Comments

    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. Due consideration has been given to 
the comments received.

Typographical Error

    One commenter states that a typographical error exists in the 
referenced eddy current inspection (ECI) manual task number for HPT 
Stage 1 disk rim boltholes. The commenter suggests the task number be 
corrected from 72-53-03-250-052 to 72-53-03-100-053.
    The FAA partially agrees. The task number in the proposal is 
incorrect, however upon further review with the manufacturer, the 
correct task number is identified as 72-53-03-250-001-053. The task 
number suggested by the commenter refers to a preparatory cleaning task 
and not the intended ECI of the disk rim bolthole. The manufacturer 
will revise Chapter 05-21 of the manual by temporary revision (TR) to 
include the correct ECI task number, and this final rule is revised 
accordingly. The review with the manufacturer also found two other task 
number errors, which have been addressed by TR's and corrections in 
this final rule.

Time Limits Not Issued Yet

    Four commenters approve of the proposal as-written. However, one of 
those commenters notes that the manufacturer has not yet issued the 
revisions to the Time Limits section of the engine manual to require 
the additional inspections in the proposal. The commenter thinks the 
revisions should already be issued.
    The FAA partially agrees. The FAA is aware that the manufacturer 
has not yet issued revisions to the Time Limits sections of the engine 
manuals. However, the existing AD and this final rule allows the 
manufacturer up to 30 days after the effective date of the AD to issue 
the necessary revisions to the Time Limits sections. Therefore, no 
action is necessary to address the commenter's observation.
    After careful review of the available data, including the comments 
noted above, the FAA has determined that air safety and the public 
interest require the adoption of the rule with the changes described 
previously. The FAA has determined that these changes will neither 
increase the economic burden on any operator nor increase the scope of 
the AD.

Economic Analysis

    The FAA estimates that 730 engines installed on airplanes of U.S. 
registry would be affected by this AD, that it would take approximately 
10 work hours per engine to accomplish the new inspections, and that 
the average labor rate is $60 per work hour for a total approximate 
cost of $600 per engine. It is further estimated that there will be 
about 299 shop visits per year that result in piece-part exposure of 
the additional affected components. Based on these figures, the total 
cost effect of the additional inspections on U.S. operators is 
estimated to be $179,400.

[[Page 10604]]

Regulatory Analysis

    This final 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 the States, or on the distribution of power and 
responsibilities among the various levels of government. Accordingly, 
the FAA has not consulted with state authorities prior to publication 
of this final rule.
    For the reasons discussed above, I certify that this action (1) is 
not a ``significant regulatory action'' under Executive Order 12866; 
(2) is not a ``significant rule'' under the DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979); and (3) if promulgated, 
will not have a significant economic impact, positive or negative, on a 
substantial number of small entities under the criteria of the 
Regulatory Flexibility Act. A final evaluation has been prepared for 
this action and it is contained in the Rules Docket. A 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.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by removing Amendment 39-11697 (65 FR 
21636, April 24, 2000) and by adding a new airworthiness directive, 
Amendment 39-12671, to read as follows:

2002-05-03  General Electric Company: Amendment 39-12671. Docket No. 
98-ANE-41-AD. Supersedes AD 2000-08-11, Amendment 39-11697.

Applicability

    This airworthiness directive (AD) is applicable to General 
Electric Company (GE) CF6-6, CF6-45, and CF6-50 series turbofan 
engines, installed on but not limited to Airbus Industrie A300 
series, Boeing 747 series, and McDonnell Douglas DC-10 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

    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, do the following:

Inspections

    (a) Within the next 30 days after the effective date of this AD, 
revise the manufacturer's Time 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)   shop manual chapter
------------------------------------------------------------------------
For CF6-6 Engines:
------------------------------------------------------------------------
    Disk, Fan Rotor, Stage One  All..............  72-21-03 Paragraph
                                                    2.F. or Paragraph
                                                    2.A.B. Flourescent-
                                                    Penetrant Inspect,
                                                    and
                                                   72-21-03 Paragraph 3
                                                    or 3.A. Eddy Current
                                                    Inspection.
------------------------------------------------------------------------
    Fan Forward Shaft.........  All..............  72-21-05 Paragraph 1.
                                                    Magnetic Particle
                                                    Inspection.
------------------------------------------------------------------------
    Fan Mid Shaft.............  All..............  72-24-01 Paragraph 1.
                                                    and Paragraph 2.
                                                    Magnetic Particle
                                                    Inspection.
------------------------------------------------------------------------
    Disk, HPC Rotor, Stage 1..  All..............  72-31-04 Paragraph 1.
                                                    Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Disk, HPC Rotor, Stage 2..  All..............  72-31-05 Paragraph 1.
                                                    Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Spool, HPC Rotor, Stages    All..............  72-31-06 Paragraph 1.
     Three thru Nine.                               Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Disk, HPC Rotor, Stage 10.  All..............  72-31-07 Paragraph 1.
                                                    Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Spool, HPC Rotor, Stages    All..............  72-31-08 Paragraph 1.
     11-13.                                         Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Spool, HPC Rotor, Stages    All..............  72-31-08 Paragraph 1.
     14-16.                                         Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    HPC Rear Shaft............  All..............  72-31-09 Paragraph 1.
                                                    and Paragraph 1.E.
                                                    Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    No. 4R Bearing Rotating     All..............  72-31-10 Fluorescent
     (CDP) Air Seal.                                Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    No. 4R Bearing Rotating     All..............  72-31-10 Fluorescent
     (CDP) Air Seal Support.                        Penetrant
                                                    Inspection.
------------------------------------------------------------------------

[[Page 10605]]

 
    Disk, HPT Rotor, Stage One  All..............  72-53-03 Paragraph 1.
                                                    Flourescent-
                                                    Penetrant Inspect,
                                                    and
                                                   72-53-03 Paragraph 4.
                                                    Eddy Current
                                                    Inspection of the
                                                    HPTR Disk Rim
                                                    Boltholes, and
                                                   72-53-03 Paragraph 5.
                                                    Disk Bore Area Eddy
                                                    Current Inspection.
------------------------------------------------------------------------
    Disk, HPT Rotor, Stage Two  All..............  72-53-04 Paragraph 1.
                                                    Flourescent-
                                                    Penetrant Inspect,
                                                    and
                                                   72-53-04 Paragraph 4.
                                                    Eddy Current
                                                    Inspection of the
                                                    Stage 2 HPTR Disk
                                                    Rim Boltholes, and
                                                   72-53-04 Paragraph 5.
                                                    Eddy Current
                                                    Inspection of the
                                                    Stage 2 Disk Inner
                                                    Boltholes and,
                                                   72-53-04 Paragraph 6.
                                                    Disk Bore Area Eddy
                                                    Current Inspection.
------------------------------------------------------------------------
    Disk, LPT Rotor, Stages     All..............  72-57-02 Paragraph 1.
     One thru Five.                                 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    LPT Forward Shaft.........  All..............  72-57-03 Paragraph 1.
                                                    Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    LPT Rear Shaft............  All..............  72-57-04 Paragraph 1.
                                                    Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
For CF6-45, CF6-50 Engines:
------------------------------------------------------------------------
    Disk, Fan Rotor, Stage One  All..............  Task 72-21-03-230-051
                                                    Fluorescent
                                                    Penetrant
                                                    Inspection, and
                                                   Task 72-21-03-250-002-
                                                    052 Manual Eddy
                                                    Current Inspection
                                                    or 72-21-03-250-003-
                                                    053 Automated Eddy
                                                    Current Inspection.
------------------------------------------------------------------------
    Forward Shaft, Fan........  All..............  Task 72-21-05-240-056
                                                    Magnetic Particle
                                                    Inspection.
------------------------------------------------------------------------
    Mid Shaft, Fan............  All..............  Task 72-24-01-240-001-
                                                    051 Magnetic
                                                    Particle Inspection.
------------------------------------------------------------------------
    Disk, HPC Rotor, Stage 1..  All..............  Task 72-31-04-230-001-
                                                    051 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Disk, HPC Rotor, Stage 2..  All..............  Task 72-31-05-230-001-
                                                    051 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Spool, HPC Rotor, Stages 3- All..............  Task 72-31-06-230-001-
     9.                                             063 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Disk, HPC Rotor, Stage 10.  All..............  Task 72-31-07-230-001-
                                                    051 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Spool, HPC Rotor, Stages    All..............  Task 72-31-08-230-001-
     11-13.                                         051 Fluorescent
                                                    Penetrant Inspection
                                                    1.
------------------------------------------------------------------------
    Disk, HPC Rotor, Stage 14.  All..............  Task 72-31-07-230-001-
                                                    055 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Rear Shaft, HPC Rotor.....  All..............  Task 72-31-09-230-001-
                                                    051 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Spool/Shaft, HPC Rotor,     All..............  Task 72-31-26-230-001-
     Stages 11-14.                                  052 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Rotating (CDP) Air Seal,    All..............  Task 72-31-10-230-059
     No. 4R Bearing.                                Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Rotating (CDP) Air Seal     All..............  Task 72-31-10-230-059
     Support, No. 4R Bearing.                       Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Disk, HPT Rotor, Stage One  All..............  Task 72-53-03-230-001-
                                                    059 Fluorescent
                                                    Penetrant Inspect
                                                    Disk, and
                                                   Task 72-53-03-250-001-
                                                    053 Eddy Current
                                                    Inspection of the
                                                    HPTR Stage 1 Rim
                                                    Boltholes, and
                                                   Task 72-53-03-250-060
                                                    Disk Bore Area Eddy
                                                    Current Inspection.
------------------------------------------------------------------------

[[Page 10606]]

 
    Disk, HPT Rotor, Stage Two  All..............  Task 72-53-04-230-001-
                                                    057 Fluorescent
                                                    Penetrant Inspect
                                                    Disk, and
                                                   Task 72-53-04-250-053
                                                    Eddy Current
                                                    Inspection of the
                                                    HPTR Stage 2 Rim and/
                                                    or Inner Boltholes,
                                                    and
                                                   Task 72-53-04-250-060
                                                    Disk Bore Area Eddy
                                                    Current Inspection.
------------------------------------------------------------------------
    Disks, LPT Rotor, Stages 1- All..............  Task 72-57-02-230-001-
     4.                                             051 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Forward Shaft, LPTR.......  All..............  Task 72-57-03-230-001-
                                                    057 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------
    Rear Shaft, LPTR..........  All..............  Task 72-57-04-230-001-
                                                    051 Fluorescent
                                                    Penetrant
                                                    Inspection.
------------------------------------------------------------------------

    (2) For the purposes of these mandatory inspections, piece-part 
opportunity means:
    (i) The part is considered completely disassembled when 
accomplished in accordance with the disassembly instructions in the 
manufacturer's engine manual; and
    (ii) The part has accumulated more than 100 cycles in service 
since the last piece-part opportunity inspection, provided that the 
part was not damaged or related to the cause for its removal from 
the engine.''
    (b) Except as provided in paragraph (c) of this AD, and 
notwithstanding contrary provisions in section 43.16 of the Federal 
Aviation Regulations (14 CFR 43.16), these mandatory inspections 
shall be performed only in accordance with the Time 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 
recordkeeping requirement of Sec. 121.369(c) of the Federal Aviation 
Regulations (14 CFR 121.369(c)) must maintain records of the 
mandatory inspections that result from revising the Time Limits 
Section of the Instructions for Continuous Airworthiness (ICA) and 
the air carrier's continuous airworthiness program. Alternatively, 
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 shop manual changes are made and air carriers have modified 
their continuous airworthiness maintenance plans to reflect the 
requirements in the engine shop manuals.

    (e) This amendment becomes effective on April 12, 2002.

    Issued in Burlington, Massachusetts, on February 27, 2002.
Mark C. Fulmer,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 02-5528 Filed 3-7-02; 8:45 am]
BILLING CODE 4910-13-P

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