AD 2009-04-10 Airworthiness Directives; General Electric Company CF6-80A, CF6-80C2, and CF6-80E1 Series Turbofan Engines

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.

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. *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, and P/N 9362M58G11 72-53-02 Paragraph 7. Disk Dovetail Slot 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 Seal All Task 72-31-10-200-000-001 Fluorescent 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 One All Task 72-53-02-200-000-001 (Inspection—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 2047M 32G01 thru G07 Task 72-53-02-250-801 (Inspection—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 (R88DT, No Rim Bolt Holes) All Task 72-53-16-200-000-001 Fluorescent-Penetrant Inspect, and   Task 72-53-16-200-000-005 Disk Bore Area Eddy Current Inspection. Disk, HPT Rotor, Stage Two (R88DT, No Rim Bolt Holes) All Task 72-53-18-200-000-002 Fluorescent-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. 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 (Pre SB 72-0150) All Sub Task 72-31-07-230-051 Fluorescent Penetrant Inspection. Compressor Rotor Spool/Shaft, Stage 11-14 (Pre SB 72-0150) All Sub Task 72-31-08-230-051 Fluorescent Penetrant Inspection. Compressor Rotor Spool/Shaft, Stage 10-14 (SB 72-0150) All Sub Task 72-31-23-230-052 Fluorescent Penetrant Inspection. Compressor Rotor No. 4 Bearing Rotating Air Seal (CDP Rotating Seal) All Sub Task 72-31-10-230-051 Fluorescent Penetrant Inspection. HPT Disk/Shaft, Stage 1 All Sub Task 72-53-02-230-051 Fluorescent-Penetrant Inspection, and   Sub Task 72-53-02-250-051 Eddy Current Inspection, Rim Bolt Holes, and   Sub Task 72-53-02-250-054 Eddy Current Inspection, Disk Bore. 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 (R88DT, No Rim Bolt Holes) All Sub Task 72-53-16-230-052 Fluorescent-Penetrant Inspect, and   Sub Task 72-53-16-250-051 Disk Bore Area Eddy Current Inspection. Disk, HPT Rotor, Stage 2 (R88DT, No Rim Bolt Holes) All Sub Task 72-53-18-230-051 Fluorescent-Penetrant Inspect, and   Sub Task 72-53-18-250-051 Disk Bore Area Eddy Current Inspection. ** HPT Rotor Rotating Interstage Seal (R88DT) All Sub Task 72-53-17-230-056 Fluorescent-Penetrant Inspect, and   Sub Task 72-53-17-250-051 Seal Bore Area Eddy Current. HPT Rotor Forward Outer Seal (R88DT) All Sub Task 72-53-21-230-051 Fluorescent-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: robert.green@faa.gov ; 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] BILLING CODE 4910-13-P

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.