Document ID: FAA-2008-1025-0005
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: General Electric Company CF6 80C2 and CF6-80E1 Series Turbofan Engines
Posted Date: 2009-03-26T04:00Z

[Federal Register: March 26, 2009 (Volume 74, Number 57)]
[Rules and Regulations]               
[Page 13092-13094]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr26mr09-8]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2008-1025; Directorate Identifier 2008-NE-31-AD; 
Amendment 39-15862; AD 2009-07-03]
RIN 2120-AA64

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

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
General Electric Company (GE) CF6-80C2 and CF6-80E1 series turbofan 
engines with high-pressure compressor rotor (HPCR) spool shaft stage 14 
disks, part number (P/N) 1703M49G02, 1703M49G03, or 1509M71G10 
installed. This AD requires a one-time eddy current inspection (ECI) of 
the HPCR spool shaft stage 14 disk web for crack indications, and 
removing from service any parts with web cracks. This AD results from 
reports of 12 HPCR spool shaft stage 14 disks with web cracks 
discovered to date. We are issuing this AD to prevent cracks from 
propagating to an uncontained failure of the disk and damage to the 
airplane.

DATES: This AD becomes effective April 30, 2009. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of April 30, 2009.

ADDRESSES: You can get the service information identified in this AD 
from General Electric Company via Lockheed Martin Technology Services, 
10525 Chester Road, Suite C, Cincinnati, Ohio 45215, telephone (513) 
672-8400, fax (513) 672-8422.
    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: Christopher Richards, Aerospace 
Engineer, Engine Certification Office, FAA, Engine & Propeller 
Directorate, 12 New England Executive Park, Burlington, MA 01803; e-
mail: christopher.j.richards@faa.gov; telephone (781) 238-7133; fax 
(781) 238-7199.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39 
with a proposed AD. The proposed AD applies to GE CF6-80C2 and CF6-80E1 
series turbofan engines with HPCR spool shaft stage 14 disks, P/N 
1703M49G02, 1703M49G03, or 1509M71G10 installed. We published the 
proposed AD in the Federal Register on November 26, 2008 (73 FR 71949). 
That action proposed to require a one-time ECI of the HPCR spool shaft 
stage 14 disk web for crack indications, and removing from service any 
parts with web cracks.

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 comments received.

Compliance Should Be at Next Engine Shop Visit

    One commenter, Amiri Flight, states that the compliance should be 
at next engine shop visit and should not have a calendar time limit, 
which may require forced removal/shop visit of low-utilization engines.
    We agree. The compliance in the proposed AD, and the AD, require 
inspection at next engine shop visit only. We did not change the AD.

Request To Correct the Boeing Airplane Models

    One commenter, The Boeing Company, requests that we correct some of 
the minor models listed in the applicability section, and add a missing 
model. They state that for their airplanes, the AD should only list 747 
and 767 models as-listed in the type certificate data sheet. We agree. 
We changed the AD to state ``Boeing 747-200B/300/400/400D/400F, 767-
200/300/400F/400ER and MD-11 airplanes''.

Costs of Compliance Is the Cost of a Single Spool Replacement

    One commenter, FedEx Express, states that it appears that the 
proposed AD costs of compliance total to U.S. operators of $594,500, is 
inaccurate and might be the cost of a single spool replacement, rather 
than the accumulated total of the proposed action, if the estimate of 
10 affected units is accurate.
    We agree that the proposed AD total is inaccurate. We had a typo in 
the proposed AD costs of compliance. The total cost should have been 
$5,594,500. We corrected the total in the final rule AD.

Conclusion

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

Costs of Compliance

    We estimate that this AD will affect 126 CF6-80C2 and CF6-80E1 
series turbofan engines installed on airplanes of U.S. registry. We 
also estimate that it will take about 10 work-hours per engine to 
perform the inspection, and about 281 hours to complete the actions if 
done at module level, and that the average labor rate is $80 per work-
hour. The pro-rated cost of a HPCR stage 10-14 spool shaft, based on 
average life remaining on disks found cracked, is $526,890. Using data 
on the percentage of the affected fleet already in compliance with the 
corrective actions, we estimate there will be 10 disks found cracked as 
a result of these inspections. Based on these figures, we estimate the 
total cost of the AD to U.S. operators to be $5,594,500.

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

[[Page 13093]]

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, Incorporation by 
reference, 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 adding the following new airworthiness 
directive:

2009-07-03 General Electric Company: Amendment 39-15862. Docket No. 
FAA-2008-1025; Directorate Identifier 2008-NE-31-AD.

Effective Date

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

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to General Electric Company (GE) CF6-80C2 
and CF6-80E1 series turbofan engines with high-pressure compressor 
rotor (HPCR) spool shaft stage 14 disks, part number (P/N) 
1703M49G02, 1703M49G03, or 1509M71G10 installed. These engines are 
installed on, but not limited to, Airbus A300-600R/F, A310-200/300, 
and A330-200/300, and Boeing 747-200B/300/400/400D/400F, 767-200/
300/400F/400ER, and MD-11 airplanes.

Unsafe Condition

    (d) This AD results from reports of 12 cracked HPCR spool shaft 
stage 14 disk webs discovered to date. We are issuing this AD to 
prevent cracks from propagating to an uncontained failure of the 
disk and damage to the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed at the next engine shop visit where the separation of a 
major engine flange will occur after the effective date of this AD, 
unless the actions have already been done.
    (f) For the purpose of this AD, introduction of an engine into a 
shop solely for the following maintenance actions is not considered 
an engine shop visit:
    (1) Removal of a compressor case for airfoil or variable stator 
vane bushing maintenance.
    (2) Removal or replacement of the stage 1 fan disk.
    (3) Replacement of the turbine rear frame.
    (4) Removal or replacement of the accessory and/or transfer 
gearbox.
    (5) Removal or replacement of the fan forward case.
    (6) Any combination of the maintenance actions listed above.

One-Time Eddy Current Inspection (ECI)

    (g) Using the following Alert Service Bulletin (ASB) 
instructions, perform a one-time ECI of the HPCR spool shaft stage 
14 disk web for crack indications, and remove from service those 
parts found to be cracked.
    (1) Use paragraphs 3.B.(1) through 3.B.(5) of the Accomplishment 
Instructions of GE ASB No. CF6-80C2 S/B 72-A1122, Revision 1, dated 
June 19, 2006, to ECI the CF6-80C2 series engine HPCR spool shaft 
stage 14 disk web at the module level.
    (2) Use paragraph 3.C.(1) of the Accomplishment Instructions of 
GE ASB No. CF6-80C2 S/B 72-A1122, Revision 1, dated June 19, 2006, 
to ECI the CF6-80C2 series engine HPCR spool shaft stage 14 disk web 
at the piece-part level.
    (3) Use paragraphs 3.B.(1) through 3.B.(5) of the Accomplishment 
Instructions of GE ASB No. CF6-80E1 S/B 72-A0258, Revision 1, dated 
June 15, 2006, to ECI the CF6-80E1 series engine HPCR spool shaft 
stage 14 disk web at the module level.
    (4) Use paragraph 3.C.(1) of the Accomplishment Instructions of 
GE ASB No. CF6-80E1 S/B 72-A0258, Revision 1, dated June 15, 2006, 
to ECI the HPCR spool shaft stage 14 disk web at the piece-part 
level.

Previous Credit

    (h) Performance of a one-time ECI of the HPCR spool shaft stage 
14 disk web for crack indications, done before the effective date of 
this AD and following the procedures defined in GE ASB No. CF6 80C2 
S/B 72-A1122, dated January 19, 2004, for CF6-80C2 series engines or 
GE ASB No. CF6 80E1 S/B 72-A0258, dated January 19, 2004, for CF6-
80E1 series engines satisfies the compliance requirements specified 
in this AD.

Alternative Methods of Compliance

    (i) 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.

Related Information

    (j) Contact Christopher Richards, Aerospace Engineer, Engine 
Certification Office, FAA, Engine & Propeller Directorate, 12 New 
England Executive Park, Burlington, MA 01803; e-mail: 
christopher.j.richards@faa.gov; telephone (781) 238-7133; fax (781) 
238-7199, for more information about this AD.

Material Incorporated by Reference

    (k) You must use the service information specified in the 
following Table 1 to perform the one-time ECI required by this AD. 
The Director of the Federal Register approved the incorporation by 
reference of the documents listed in the following Table 1 in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Contact General 
Electric Company via Lockheed Martin Technology Services, 10525 
Chester Road, Suite C, Cincinnati, Ohio 45215, telephone (513) 672-
8400, fax (513) 672-8422, for a copy of this service information. 
You may review copies at the FAA, New England Region, 12 New England 
Executive Park, Burlington, MA; or at the National Archives and 
Records Administration (NARA). For information on the availability 
of this material at NARA, call 202-741-6030, or go to: http://
www.archives.gov/federal-register/cfr/ibr-locations.html.

                   Table 1--Incorporation by Reference
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GE Alert Service Bulletin No.      Page       Revision         Date
------------------------------------------------------------------------
CF6-80C2 S/B 72-A1122 Total    ALL........            1  June 19, 2006.
 Pages: 57.
CF6-80E1 S/B 72-A0258 Total    ALL........            1  June 15, 2006.
 Pages: 57.
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[[Page 13094]]

    Issued in Burlington, Massachusetts, on March 18, 2009.
Thomas A. Boudreau,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
 [FR Doc. E9-6387 Filed 3-25-09; 8:45 am]

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