Document ID: FAA-2015-4344-0018
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: General Electric Company Turbofan Engines
Posted Date: 2016-04-27T04:00Z

[Federal Register Volume 81, Number 81 (Wednesday, April 27, 2016)]
[Rules and Regulations]
[Pages 24699-24701]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2016-09686]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2015-4344; Directorate Identifier 2015-NE-32-AD; 
Amendment 39-18486; AD 2016-08-10]
RIN 2120-AA64

Airworthiness Directives; General Electric Company Turbofan 
Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are adopting a new airworthiness directive (AD) for all 
General Electric Company (GE) CF6-80C2A1, CF6-80C2A2, CF6-80C2A3, CF6-
80C2A5, CF6-80C2A5F, CF6-80C2A8, CF6-80C2B1, CF6-80C2B1F, CF6-80C2B1F1, 
CF6-80C2B1F2, CF6-80C2B2, CF6-80C2B2F, CF6-80C2B3F, CF6-80C2B4, CF6-
80C2B4F, CF6-80C2B5F, CF6-80C2B6, CF6-80C2B6F, CF6-80C2B6FA, CF6-
80C2B7F, CF6-80C2B8F, CF6-80C2D1F, CF6-80C2L1F, CF6-80C2K1F and CF6-
80E1A1, CF6-80E1A2, CF6-80E1A3, CF6-80E1A4, and CF6-80E1A4/B turbofan 
engines. This AD was prompted by reports of a burn-through of the 
accessory heat shield during an engine fire, propagating the fire into 
the accessory compartment and igniting additional flammable fuel 
source. This AD requires replacing the accessory heat shield assembly. 
We are issuing this AD to prevent fires from propagating into the 
accessory compartment, resulting in an uncontrolled engine fire, and 
damage to the airplane.

DATES: This AD is effective June 1, 2016.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in this AD as of June 1, 2016.

ADDRESSES: For service information identified in this final rule, 
contact General Electric Company, GE Aviation, Room 285, 1 Neumann Way, 
Cincinnati, OH 45215; phone: 513-552-3272; email: 
aviation.fleetsupport@ge.com. You may view this service information at 
the FAA, Engine & Propeller Directorate, 1200 District Avenue, 
Burlington, MA. For information on the availability of this material at 
the FAA, call 781-238-7125. It is also available on the Internet at 
http://www.regulations.gov by searching for and locating Docket No. 
FAA-2015-4344.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2015-
4344; or in person at the Docket Management Facility 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 address for the Docket Office (phone: 800-647-
5527) is Document Management Facility, U.S. Department of 
Transportation, Docket Operations, M-30, West Building Ground Floor, 
Room W12-140, 1200 New Jersey Avenue SE., Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Herman Mak, Aerospace Engineer, Engine 
Certification Office, FAA, Engine & Propeller Directorate, 1200 
District Avenue, Burlington, MA 01803; phone: 781-238-7147; fax: 781-
238-7199; email: herman.mak@faa.gov.

SUPPLEMENTARY INFORMATION: 

Discussion

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 by adding an AD that would apply to GE CF6-80C2A1, CF6-80C2A2, 
CF6-80C2A3, CF6-80C2A5, CF6-80C2A5F, CF6-80C2A8, CF6-80C2B1, CF6-
80C2B1F, CF6-80C2B1F1, CF6-80C2B1F2, CF6-80C2B2, CF6-80C2B2F, CF6-
80C2B3F, CF6-80C2B4, CF6-80C2B4F, CF6-80C2B5F, CF6-80C2B6, CF6-80C2B6F, 
CF6-80C2B6FA, CF6-80C2B7F, CF6-80C2B8F, CF6-80C2D1F, CF6-80C2L1F, and 
CF6-80C2K1F turbofan engines. This AD that would also apply to CF6-
80E1A1, CF6-80E1A2, CF6-80E1A3, CF6-80E1A4, and CF6-80E1A4/B turbofan 
engines. The NPRM published in the Federal Register on December 7, 2015 
(80 FR 75952). The NPRM was prompted by reports of a burn-through of 
the accessory heat shield during an engine fire leading to an accessory 
compartment fire. A fire burns through the accessory heat shield and 
ignites the integrated drive generator (IDG) and main fuel pump, which 
supports further combustion. The existing accessory heat shield 
assembly leaves a large area above the sensitive accessories, such as 
the IDG and the main fuel pump, without adequate protection. A total of 
three burn-through events have occurred. The NPRM proposed to require 
replacing the accessory heat shield assembly. We are issuing this AD to 
prevent an uncontrolled engine fire, and damage to the airplane.

Comments

    We gave the public the opportunity to participate in developing 
this AD. The following presents the comments received on the NPRM (80 
FR 75952, December 7, 2015) and the FAA's response to each comment.

Support for the NPRM (80 FR 75952, December 7, 2015)

    The Boeing Company and the National Transportation Safety Board 
expressed support for the NPRM (80 FR 75952, December 7, 2015).

Revision to Service Information

    We revised the Discussion section and Applicability paragraph (e) 
of this AD to include all the GE CF6-80C2 and CF6-80E1 turbofan engine 
models.

Request To Change Summary

    GE requested that we revise the Summary paragraph of this AD to 
correct the number of events and clarify the event description.
    We agree. Only three of the originally specified five events 
resulted in heat shield burn-throughs. We revised the Summary paragraph 
of this AD to correct the number of events and clarify the event 
description.

Request To Revise the Other Related Service Information Paragraph

    GE requested that we revise the Other Related Service Information 
paragraph of this AD to remove GE Service Bulletin (SB) CF6-80C2 S/B 
72-1523, dated September 22, 2015. This SB only applies to the military 
variant of the engine.
    We disagree. The military variant of the engine is also certified 
by the FAA. We did not change this AD.

Request To Revise the Costs of Compliance

    GE, KLM Royal Dutch Airlines (KLM), All Nippon Airways (ANA), and 
Federal Express (FedEx) requested that we revise the Costs of 
Compliance paragraph of this AD to correct the parts cost used in the 
calculations.
    We agree. We considered the costs of all the parts needed to comply 
with this AD and revised the costs per engine to $14,207 and the total 
cost to U.S. operators to $13,680,920.

[[Page 24700]]

Request To Change Applicability

    KLM requested that we exclude GE CF6-80E1 engines from the 
Applicability paragraph of this AD. KLM reasoned that the NTSB safety 
recommendation did not address GE CF6-80E1 engines and CF6-80E1 engines 
have not experienced any sump fires to date.
    We disagree. Although the NTSB did not address GE CF6-80E1 engines, 
the designs of the GE CF6-80C2 and CF6-80E1 engines are substantially 
similar. Therefore, the unsafe condition addressed by this AD is likely 
to exist or develop on the GE CF6-80E1 engines. We did not change this 
AD.

Request To Change Compliance

    GE requests that the following part numbers (P/Ns) be removed from 
Table 1 of GE SB 72-1520: P/N 2022M47G01, P/N 2022M81P01, P/N 
2022M85G01, and P/N 2023M20G01. These P/Ns are used only on GE CF6-
80C2B6FA models, a military application, and contain a different heat 
shield design.
    We disagree. The specified P/Ns are not listed in Table 1 of GE SB 
72-1520 and therefore this comment is not applicable. We did not change 
this AD.

Request To Change Definition

    GE, United Airlines, KLM, Lufthansa, Lufthansa Cargo, Lufthansa 
Technik, and FedEx requested that we provide a more accurate 
description of flange separation and exclude certain situations from 
the definition of a shop visit. The commenters reasoned that this would 
provide clarity and reduce the undue economic and operational burden of 
complying with this AD earlier than necessary.
    We agree. We revised the Definition paragraph of this AD to clarify 
the description of flange separation and include specific conditions 
that do not qualify as shop visits.

Request To Delay the Effective Date

    GE and Delta Air Lines (Delta) requested that we delay the 
effective date of this AD. GE reasoned that the revised service 
bulletin addressing the lack of repair instructions for accessory heat 
shield assembly, P/N 1313M94G09, will not be available until after the 
expected effective date of this AD.
    We disagree. The current effective date of this AD is needed to 
address the unsafe condition for the affected fleet. Any party may make 
a request for an Alternative Method of Compliance (AMOC) to this AD 
using the procedures listed in this AD. Any requests for an AMOC are 
reviewed and responded to accordingly. We did not change this AD.

Request To Change Applicability

    ANA requested limiting the Applicability paragraph of this AD to a 
particular maintenance, repair, and overhaul (MRO) shop where improper 
maintenance occurred leading to fire. ANA reasoned that the latest 2010 
sump fire leading to heat shield burn-through was the result of 
improper maintenance at a particular MRO.
    We disagree. This AD addresses the insufficient fire protection 
design of the heat shield to prevent secondary fire damage. This is 
independent from the cause of fire in the engine. We did not change 
this AD.

Request To Change Effectivity

    Lufthansa, Lufthansa Cargo, and Lufthansa Technik requested that we 
not mandate heat shield rework or replacement. Lufthansa reasoned that 
none of their customers operating GE CF6-80C2/80A engines have 
experienced a compressor rear frame (CRF) sump fire.
    We disagree. Complying with this AD is necessary to correct the 
unsafe condition of heat shield burn-through. The heat shield rework or 
replacement is needed to prevent fires from propagating into the 
accessory compartment, leading to a larger engine fire and subsequent 
damage to the airplane. We did not change this AD.

Request for Allowance of Creating and Marking Serial Numbers

    Delta requested we allow operators to both create and mark 
identification numbers on heat shields that are not currently marked. 
Delta has received reports that there are illegible identification 
markings on heat shields.
    We partially agree. We agree there is a lack of information about 
heat shields with illegible P/Ns in this AD. We revised the Compliance 
section of this AD to address heat shields with illegible P/Ns.
    We disagree with allowing operators to create and mark 
identification numbers on heat shields as this does not resolve the 
unsafe condition and is beyond the scope of this AD.

Request To Change Applicability

    GE commented that heat shield, P/N 1643M23G12, is also affected by 
the unsafe condition described in this AD.
    We agree. We added heat shield, P/N 1643M23G12, to the 
applicability of this AD.

Conclusion

    We reviewed the relevant data, considered the comments received, 
and determined that air safety and the public interest require adopting 
this AD with the changes described previously. We have determined that 
these minor changes:
     [Agr]re consistent with the intent that was proposed in 
the NPRM (80 FR 75952, December 7, 2015) for correcting the unsafe 
condition; and
     Do not add any additional burden upon the public than was 
already proposed in the NPRM (80 FR 75952, December 7, 2015).
    We also determined that these changes will not increase the 
economic burden on any operator or increase the scope of this AD.

Related Service Information Under 1 CFR Part 51

    We reviewed GE SB CF6-80C2 S/B 72-1520, dated September 22, 2015 
and GE SB CF6-80E1 S/B 72-0525, dated September 22, 2015. These SBs 
describe the procedures for removing and replacing the accessory heat 
shield assembly. This service information is reasonably available 
because the interested parties have access to it through their normal 
course of business or by the means identified in the ADDRESSES section.

Other Related Service Information

    We reviewed GE SB CF6-80E1 S/B 72-0504, dated October 24, 2014. 
This SB describes procedures for quick-turn workscope procedure to 
replace CF6-80E1 stage 1 high-pressure turbine blades. We also reviewed 
GE SB CF6-80C2 S/B 72-1516, Revision 2, dated November 6, 2015. This SB 
describes procedures for replacement of the CRF assembly, oil manifold, 
air tubes, and support brackets. We also reviewed GE SB CF6-80C2 S/B 
72-1523, dated September 22, 2015. This SB describes procedures for 
removing and replacing the accessory heat shield assembly.

Costs of Compliance

    We estimate that this AD affects 935 engines installed on airplanes 
of U.S. registry. We also estimate that it will take about 5 hours per 
engine to comply with this AD. The average labor rate is $85 per hour. 
Parts cost about $14,207 per engine. Based on these figures, we 
estimate the total cost of this AD to U.S. operators to be $13,680,920.

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.

[[Page 24701]]

    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

    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),
    (3) Will not affect intrastate aviation in Alaska to the extent 
that it justifies making a regulatory distinction, and
    (4) 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.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA 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 (AD):

2016-08-10 General Electric Company: Amendment 39-18486; Docket No. 
FAA-2015-4344; Directorate Identifier 2015-NE-32-AD.

(a) Effective Date

    This AD is effective June 1, 2016.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to all General Electric Company (GE) CF6-80C2A1, 
CF6-80C2A2, CF6-80C2A3, CF6-80C2A5, CF6-80C2A5F, CF6-80C2A8, CF6-
80C2B1, CF6-80C2B1F, CF6-80C2B1F1, CF6-80C2B1F2, CF6-80C2B2, CF6-
80C2B2F, CF6-80C2B3F, CF6-80C2B4, CF6-80C2B4F, CF6-80C2B5F, CF6-
80C2B6, CF6-80C2B6F, CF6-80C2B6FA, CF6-80C2B7F, CF6-80C2B8F, CF6-
80C2D1F, CF6-80C2L1F, CF6-80C2K1F turbofan engines. This AD also 
applies to CF6-80E1A1, CF6-80E1A2, CF6-80E1A3, CF6-80E1A4, and CF6-
80E1A4/B turbofan engines.

(d) Unsafe Condition

    This AD was prompted by reports of a burn-through of the 
accessory heat shield during an engine fire, leading to an accessory 
compartment fire. We are issuing this AD to prevent uncontrolled 
engine fire, and damage to the airplane.

(e) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.
    (1) For CF6-80C2 engines, at the next engine shop visit after 
the effective date of this AD, remove from service accessory heat 
shield assembly, part number (P/N) 1643M23G12, and any other 
accessory heat shield assembly listed by P/N in Table 1 of GE 
Service Bulletin (SB) CF6-80C2 S/B 72-1520, dated September 22, 
2015. Install an accessory heat shield assembly eligible for 
installation.
    (2) For CF6-80E1 engines, at the next engine shop visit after 
the effective date of this AD, remove from service accessory heat 
shield assemblies listed by P/N in Table 1 of GE SB CF6-80E1 S/B 72-
0525, dated September 22, 2015. Install an accessory heat shield 
assembly eligible for installation.
    (3) Remove any heat shield assembly from service if the 
accessory heat shield assembly part number marking is illegible and 
the documentation associated with the part cannot properly identify 
the part.

(f) Installation Prohibition

    After the effective date of this AD, do not install any 
accessory heat shield assembly, P/N 1643M23G12; or any accessory 
heat shield assembly listed by P/N in Table 1 of GE SB CF6-80C2 S/B 
72-1520, dated September 22, 2015; or in Table 1 of GE SB CF6-80E1 
S/B 72-0525, dated September 22, 2015; into any engine.

(g) Definition

    For the purpose of this AD, an engine shop visit is defined as 
the induction of an engine into the shop for maintenance involving 
the separation of any major mating engine flanges, except that the 
separation of engine flanges solely for the following purposes is 
not considered a shop visit:
    (1) Transportation without subsequent engine maintenance.
    (2) Replacement of the turbine rear frame.
    (3) Removal of the top or bottom high-pressure compressor (HPC) 
case, or both, for HPC airfoil maintenance or replacement of 
variable stator vane bushing or lever arms.
    (4) Quick-turn workscope procedure to replace CF6-80E1 stage 1 
high-pressure turbine (HPT) blades per CF6-80E1 SB 72-0504 R00 
ENGINE--General (72-00-00)--Quick-Turn Workscope Procedure to 
Replace CF6-80E1 Stage 1 HPT Blades.
    (5) Replacement of compressor rear frame assembly, new oil 
manifold, air tubes and support brackets per CF6-80C2 SB 72-1516 R02 
ENGINE--Compressor Rear Frame Assembly (72-34-00)--New Oil Manifold, 
Air Tubes and Support Brackets.

(h) Alternative Methods of Compliance (AMOCs)

    The Manager, Engine Certification Office, FAA, may approve AMOCs 
to this AD. Use the procedures found in 14 CFR 39.19 to make your 
request. You may email your request to: ANE-AD-AMOC@faa.gov.

(i) Related Information

    For more information about this AD, contact Herman Mak, 
Aerospace Engineer, Engine Certification Office, FAA, Engine & 
Propeller Directorate, 1200 District Avenue, Burlington, MA 01803; 
phone: 781-238-7147; fax: 781-238-7199; email: herman.mak@faa.gov.

(j) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) General Electric Company (GE) Service Bulletin (SB) CF6-80C2 
S/B 72-1520, dated September 22, 2015.
    (ii) GE SB CF6-80E1 S/B 72-0525, dated September 22, 2015.
    (3) For GE service information identified in this AD, contact 
General Electric Company, GE Aviation, Room 285, 1 Neumann Way, 
Cincinnati, OH 45215; phone: 513-552-3272; email: 
aviation.fleetsupport@ge.com.
    (4) You may view this service information at FAA, Engine & 
Propeller Directorate, 1200 District Avenue, Burlington, MA. For 
information on the availability of this material at the FAA, call 
781-238-7125.
    (5) You may view this service information 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.

    Issued in Burlington, Massachusetts, on April 7, 2016.
Colleen M. D'Alessandro,
Manager, Engine & Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 2016-09686 Filed 4-26-16; 8:45 am]
 BILLING CODE 4910-13-P