[Federal Register: August 23, 2005 (Volume 70, Number 162)]
[Rules and Regulations]
[Page 49178-49182]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr23au05-9]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2004-19144; Directorate Identifier 2003-NE-18-AD;
Amendment 39-14226; AD 2005-17-05]
RIN 2120-AA64
Airworthiness Directives; General Electric Company (GE) CF6-80C2
and CF6-80E1 Turbofan Engines
AGENCY: Federal Aviation Administration (FAA), Department of
Transportation (DOT).
ACTION: Final rule.
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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for
certain GE CF6-80C2 and CF6-80E1 turbofan engines. This AD requires you
to inspect the high pressure compressor rotor (HPCR) stage 11-14 spool
shaft for circumferential repair cuts, and to repair or replace the
spool shaft if you find certain circumferential cuts. This AD results
from an updated stress analysis. We are issuing this AD to prevent
failure of the HPCR stage 11-14 spool shaft due to low-cycle fatigue
that could result in an uncontained engine failure.
DATES: This AD becomes effective September 27, 2005. The Director of
the Federal Register approved the incorporation by reference of certain
publications listed in the regulations as of September 27, 2005.
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.
You may examine the AD docket on the Internet at http://dms.dot.gov
or in Room PL-401 on the plaza level of the
[[Page 49179]]
Nassif Building, 400 Seventh Street, SW., Washington, DC.
FOR FURTHER INFORMATION CONTACT: Karen Curtis, Aerospace Engineer,
Engine Certification Office, FAA, Engine and Propeller Directorate, 12
New England Executive Park, Burlington, MA 01803; telephone (781) 238-
7192; fax (781) 238-7199.
SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39
with a proposed airworthiness directive (AD). The proposed AD applies
to certain GE CF6-80C2 and CF6-80E1 turbofan engines. We published the
proposed AD in the Federal Register on September 22, 2004 (69 FR
56730). That action proposed to require inspection of the spool shaft
for circumferential repair cuts at the next piece-part level exposure,
but not to exceed a specific service cap specified in this proposed AD,
and repair or replacement of certain spool shafts.
Examining the AD Docket
You may examine the docket that contains the AD, any comments
received, and any final disposition in person at the Docket Management
System (DMS) Docket Office between 9 a.m. and 5 p.m., Monday through
Friday, except Federal holidays. The Docket Office (telephone (800)
647-5227) is located on the plaza level of the Department of
Transportation Nassif Building at the street address stated in
ADDRESSES. Comments will be available in the AD docket shortly after
the DMS receives them.
Comments
We provided the public the opportunity to participate in the
development of this AD. We have considered the comments received.
Request To Add a Definition
One commenter requests that for clarity, we add a definition for
cycles-since-repair (CSR) to the AD. We agree and have added a
definition to the compliance section. That definition states that for
the purposes of this AD, CSR limit is the current cycles-since-new
(CSN) minus the CSN at the time of the repair.
Request To Add Instructions
One commenter requests that for clarity, we add instructions to the
compliance section if the CSR limit cannot be determined from the
engine records. We agree and have added a sentence to the compliance
section. That sentence states that if the CSR limit cannot be
determined from the engine records, then CSN must be used.
Request for Document or Procedure References
One commenter requests that we add document or procedure references
such as Repair Documents, Service Bulletin numbers, and Shop Manual
tasks for the circumferential repairs, to help the commenter determine
affected spools. We do not agree. The AD references the applicable GE
Service Bulletins, which include the lists of affected parts by serial
number (SN). The AD is only applicable to those parts. Additional
references are not needed to determine if the operator has an affected
part.
Request To Exclude Spools That Previously Complied
One commenter requests that the AD be modified to exclude spools
that have previously complied with GEAE Service Bulletin (SB) No. CF6-
80C2 S/B 72-1052, Revision 01, dated February 5, 2004, or certain
revisions of engine shop manual (ESM) section 72-31-08 or ESM section
72-00-31. We partially agree. We agree that no further action is
required for spools that have already complied with GEAE SB No. CF6-
80C2 S/B 72-1052, Revision 01, dated February 5, 2004. The AD clearly
states in paragraph (e) that the AD actions are only required if the
actions are not already done.
We do not agree that accomplishment of ESM section 72-31-08 or 72-
00-31 is equivalent to compliance with GEAE SB No. CF6-80C2 S/B 72-
1052, Revision 01, dated February 5, 2004. ESM section 72-31-08,
Revision 60 or later does contain the same repair procedure (Repair 12)
referenced in the accomplishment instructions of the SB and
incorporated by reference in this AD. Credit for repairs done before
the effective date of the AD using ESM section 72-31-08, Revision 60 or
later, should be requested using the alternative methods of compliance
procedure described in this AD. However, ESM 72-00-31 does not include
the necessary repair instructions. Therefore, we have not changed the
AD to incorporate this comment.
Request To Add a Reference to List of Affected SNs
One commenter requests that Applicability paragraph (c) of the AD
be modified to include a reference to the list of affected SNs of stage
11-14 spool shafts in the manufacturer's SBs. The commenter states that
this additional information would clarify that the AD is only intended
to apply to those specific spools and not the entire fleet. We
partially agree. We agree that Applicability paragraph (c) would be
clearer if it states that the list of affected SNs can be found in the
referenced service bulletins. We have added a sentence to Applicability
paragraph (c) that states the affected stage 11-14 spool shafts are
identified by SN in the GE service information described in paragraphs
(f) and (j) of this AD.
Request To Clarify Number of Affected Stage 11-14 Spool Shafts
One commenter requests that the number of affected stage 11-14
spool shafts be clarified, as the number in GEAE SB No. CF6-80C2 S/B
72-1052, Revision 01, dated February 5, 2004, and in the Supplementary
Information of the NPRM are not the same.
We do not agree. The statement the commenter is referring to in the
Supplementary Information of the NPRM states that GE reports that as
many as 135 CF6-80C2 and CF6-80E1 HPCR 11-14 spool shafts have had this
(circumferential cut) repair. This quantity is the combined number of
affected spool shafts listed in not one, but two SBs, which are the SB
for CF6-80C2 engines and the SB for CF6-80E1 engines. Since the
issuance of the NPRM, however, these SBs have been revised to correct a
few errors in the SN lists of affected spool shafts. The revised SBs
referenced in this AD are GEAE SB No. CF6-80C2 S/B 72-1052, Revision
02, dated May 25, 2005, and GEAE SB No. CF6-80E1 S/B 72-0232, Revision
01, dated February 5, 2004. Therefore, we have not changed the AD to
address this comment.
Request To Include List of Affected Stage 11-14 Spool Shafts in AD
One commenter requests that we include in the AD the list of
affected stage 11-14 spool shafts, instead of referring readers to the
SBs for the lists, to avoid the potential for confusion. The commenter
also requests that we delete the stage 11-14 spool shaft SN MPOAP580
from the list of affected spools in the AD, suggesting that only stage
11 of spool shaft SN MPOAP580 was reworked, and so the proposed AD is
inapplicable to that spool.
We do not agree that referring readers to the SBs for the lists is
confusing. We believe it would be confusing to maintain lists of
affected SNs in both the AD and the SBs. We agree that the AD doesn't
affect spools repaired on stage 11. We also verified through the
manufacturer that spool SN MPOAP580 was repaired in only stage 11. This
SN spool shaft has been deleted from the revised SBs.
[[Page 49180]]
Request To Clarify Paragraph (f)
One commenter requests that compliance section paragraph (f) be
clarified by adding the words ``not to exceed the life limits specified
in Table 2 in the column entitled Replace by (CSR) Limit'', to the end
of the sentence. We do not agree. Compliance section paragraphs (f)(1)
and (f)(2) already include this necessary ``not to exceed''
information.
Request for Additional Cycles-in-Service
One commenter requests that up to 420 additional cycles-in-service
(CIS) be granted for those affected spools that will have accumulated
more cycles than the ``Repair By Limit'' but are within 420 cycles of
the ``Replace By Limit'' on the effective date of the AD. The commenter
states that this would provide margin for those operators suffering
heavy impact from this AD. The commenter notes that paragraph (h) of
the proposed AD provides an allowance of 420 CIS if an affected spool
has already accumulated more cycles than the ``Replace by Limit'' on
the effective date of the AD. We agree, and revised the compliance
section based on this request.
Request To Include a Note
The same commenter requests that a note be included in the AD to
specify that execution of the Accomplishment Instructions of GEAE SB
No. CF6-80C2 S/B 72-1052, Revision 01, dated February 5, 2004, is
considered terminating action for the AD. The commenter is unclear
whether or not the SB is terminating action for the AD.
We do not agree. The AD requires that spools either be repaired or
replaced. Once a spool has been repaired or replaced, no further action
is required.
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
There are approximately 173 GE CF6-80C2 and CF6-80E1 turbofan
engines of the affected design in the worldwide fleet. We estimate that
24 engines installed on airplanes of U.S. registry will be affected by
this AD. We also estimate that it will take about one work hour per
engine to inspect for the location of previous circumferential cut
repairs and 5 work hours per engine to repair the spool shaft. We
estimate that 24 engines will be repaired and that three spool shafts
will be replaced. The average labor rate is $65 per work hour. Each
replacement spool shaft will cost approximately $447,400. Based on
these figures, we estimate the total cost of the AD to U.S. operators
to be $1,351,755.
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, 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:
2005-17-05 General Electric Company: Amendment 39-14226. Docket No.
FAA-2004-19144; Directorate Identifier. 2003-NE-18-AD.
Effective Date
(a) This airworthiness directive (AD) becomes effective
September 27, 2005.
Affected ADs
(b) None.
Applicability
(c) This AD applies to certain GE CF6-80C2 and CF6-80E1 turbofan
engines that have a high pressure compressor rotor (HPCR) stage 11-
14 spool shaft with a part number (P/N) listed in Table 1 of this AD
and that had a seal wire groove repaired using a circumferential cut
at a location specified in Table 2 of this AD. The affected stage
11-14 spool shafts are identified by serial number (SN) in the GE
service information described in paragraphs (f) and (j) of this AD.
These engines are installed on, but not limited to, Airbus Industrie
A300, A310, and A330 series airplanes and Boeing 747, 767, and MD-11
series airplanes.
Table 1.--Stage 11-14 Spool Shaft P/Ns by Engine Model and Forging Group Designations
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Engine model Stage 11-14 Spool Shaft P/Ns Forging group designations
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CF6-80C2................................ 9380M30G07, 9380M30G08, 9380M30G09, Group 1.
9380M30G10, 9380M30G12, 1509M71G02,
1509M71G03, 1509M71G04, and
1509M71G05.
[[Page 49181]]
CF6-80C2................................ 1531M21G01, 1531M21G02, 1531M21G04, Group 2.
1509M71G06, 1509M71G07, 1509M71G08,
1509M71G11, 1509M71G12, 1703M74G01,
and 1703M74G03.
CF6-80E1................................ 1509M71G11, 1509M71G12, 1509M71G13, Not Applicable.
1644M99G03, 1703M74G01, and
1703M74G03.
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Unsafe Condition
(d) This AD results from an updated stress analysis. We are
issuing this AD to prevent failure of the HPCR stage 11-14 spool
shaft due to low-cycle fatigue that could result in an uncontained
engine failure.
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.
CF6-80C2 Engines
(f) For CF6-80C2 series engines with HPCR stage 11-14 spool
shaft SNs listed in 1.A.(2) of GE Aircraft Engines (GEAE) Service
Bulletin (SB) No. CF6-80C2 S/B 72-1052, Revision 02, dated May 25,
2005, inspect the spool shaft for the location of the
circumferential cut repair at the next piece-part exposure.
(1) If the stage and location of the repair is specified in the
engine records, inspect prior to exceeding the cycles-since-repair
(CSR) limit specified in the column titled, Replace By (CSR), in
Table 2.
(2) For the purposes of this AD, CSR limit is defined as the
current cycles-since-new (CSN) minus the CSN at the time of the
repair.
(3) If the CSR limit cannot be determined from the engine
records, then CSN must be used.
(4) If the stage or location of the repair is not known from the
engine records, remove the spool shaft for inspection before
exceeding 4,200 CSR for the Group 1 or before exceeding 10,000 CSR
for Group 2. Use 3.A.(1) of the Accomplishment Instructions of GEAE
SB No. CF6-80C2 S/B 72-1052, Revision 02, dated May 25, 2005, for
the inspection. Table 2 follows:
Table 2.--Repair and Replacement Limits for Spool Shafts by Forging Group and Location of the Circumferential Cut Repair
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Location of
Engine model Forging group (from Table Stage circumferential cut Repair by (CSR) limit Replace by
1) repair (CSR) limit
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(1) CF6-80C2........................ Group 1................... 14 (i) Aft Seal Wire 3,600.............................. 4,200
Groove Not in Area X.
(ii) Aft Seal Wire None--Replace spool................ 4,200
Groove--In Area X.
(iii) Forward Seal Wire 7,100.............................. 7,100
Groove--Not in Area X.
(iv) Forward Seal Wire None--Replace spool................ 7,100
Groove--In Area X.
(2) CF6-80C2........................ Group 1................... 13 (i) Aft Seal Wire 7,100.............................. 7,100
Groove--Not in Area X.
(ii) Aft Seal Wire 2,740.............................. 7,100
Groove--In Area X.
(iii) Forward Seal Wire 7,100.............................. 7,100
Groove--Not in Area X.
(iv) Forward Seal Wire 7,100.............................. 7,100
Groove--In Area X.
(3) CF6-80C2........................ Group 1................... 12 Aft Seal Wire Groove-- 7,100.............................. 7,100
In Area X.
(4) CF6-80C2........................ Group 2................... 14 (i) Aft Seal Wire 13,700............................. 13,700
Groove--Not in Area X.
(ii) Aft Seal Wire None--Replace spool................ 13,700
Groove--In Area X.
(iii) Forward Seal Wire 9,830.............................. 10,000
Groove--In Area X.
(5) CF6-80C2........................ Group 2................... 13 (i) Aft Seal Wire 9,830.............................. 10,000
Groove--In Area X.
(ii) Forward Seal Wire 9,830............................. 10,000
Groove--In Area X.
(6) CF6-80C2........................ Group 2................... 12 Aft Seal Wire Groove-- 9,830.............................. 10,000
In Area X.
(7) CF6-80E1........................ Not Applicable............ 14 (i) Aft Seal Wire 11,600............................. 11,600
Groove--Not in Area X.
(ii) Aft Seal Wire None--Replace spool................ 11,600
Groove--In spool Area
X.
(iii) Forward Seal Wire 8,080.............................. 11,600
Groove--In Area X.
(8) CF6-80E1........................ Not Applicable............ 13 (i) Aft Seal Wire 8,080.............................. 11,600
Groove--In Area X.
(ii) Forward Seal Wire 8,080.............................. 11,600
Groove--In Area X.
(9) CF6-80E1........................ Not Applicable............ 12 Aft Seal Wire Groove-- 8,080.............................. 11,600
In Area X.
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(g) If you have a Group 2 spool shaft, and the circumferential
cut repair is in the Stage 14 forward location, and not in Area X,
no further action is required by this AD. However, GEAE recommends
that you repair these spools at the next exposure of the spool
shaft.
Replacement of the Spool Shaft
(h) After the effective date of this AD, replace spool shafts as
follows:
(1) If the spool shaft exceeds the CSR limit in the column
titled, Repair by (CSR), in Table 2 of this AD, replace the spool
shaft within 420 cycles-in-service (CIS) or prior to exceeding the
CSR limit in the column titled, Replace by (CSR), in Table 2 of this
AD, whichever occurs later.
(2) If the spool shaft exceeds the CSR limit in the column
titled, Replace by (CSR), in Table 2 of this AD, replace the spool
shaft within 420 CIS or within the published part life limit,
whichever occurs first.
[[Page 49182]]
Repair of the Spool Shaft
(i) You may repair the spool if the CSR on the spool shaft are
fewer than or equal to the limit in the column titled, Repair by
(CSR), in Table 2 of this AD. Use 3.B. of the Accomplishment
Instructions of GEAE SB No. CF6-80C2 S/B 72-1052, Revision 02, dated
May 25, 2005, for the repair.
CF6-80E1 Engines
(j) For CF6-80E1 series engines with HPCR stage 11-14 spool
shafts with SNs listed in 1.A.(2) of GEAE SB No. CF6-80E1 S/B 72-
0232, Revision 01, dated February 5, 2004, do the following:
(1) Inspect the spool shaft for the location of the cut
circumferential repair at the next piece-part exposure, but before
exceeding 11,600 CSR. Use 3.A.(1) of the Accomplishment Instructions
of GEAE SB No. CF6-80E1 S/B 72-0232, Revision 01, dated February 5,
2004 for the inspection.
(2) For the purposes of this AD, CSR limit is defined as the
current CSN minus the CSN at the time of the repair.
(3) If the CSR limit cannot be determined from the engine
records, then CSN must be used.
(4) If the circumferential cut repair is in the Stage 14 forward
location, and not in Area X, no further action is required by this
AD. However, GEAE recommends that you repair these spools at the
next exposure of the spool shaft.
Replacement of the Spool Shaft
(k) After the effective date of this AD, replace spool shafts as
follows:
(1) If the spool shaft exceeds the CSR limit in the column
titled, Repair by (CSR), in Table 2 of this AD, replace the spool
shaft within 420 CIS or prior to exceeding the CSR limit in the
column titled, Replace by (CSR), in Table 2 of this AD, whichever
occurs later.
(2) If the spool shaft exceeds the CSR limit in the column
titled, Replace by (CSR), in Table 2 of this AD, replace the spool
shaft within 420 CIS or within the published part life limit,
whichever occurs first.
Repair of the Spool Shaft
(l) You may repair the spool shaft if the CSR on the spool shaft
are fewer than or equal to the limit in the column titled, Repair by
(CSR), in Table 2 of this AD. Use 3.B. of the Accomplishment
Instructions of GEAE SB CF6-80E1 S/B 72-0232, Revision 01, dated
February 5, 2004, for the repair.
Alternative Methods of Compliance
(m) 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.
Material Incorporated by Reference
(n) You must use the service information specified in Table 3 of
this AD to perform the actions required by this AD.
Table 3.--Incorporation by Reference
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Service bulletin No. Page Revision Date
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CF6-80C2 S/B 72-1052................. ALL......................... 02 May 25, 2005.
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Total Pages: 11
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CF6-80E1 S/B 72-0232................. ALL......................... 01 February 5, 2004.
Total Pages: 9
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The Director of the Federal Register approved the incorporation
by reference of the documents listed in Table 3 of this AD 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 Docket Management Facility; U.S.
Department of Transportation, 400 Seventh Street, SW., Nassif
Building, Room PL-401, Washington, DC 20590-0001, on the internet at
http://dms.dot.gov, 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
.
Issued in Burlington, Massachusetts, on August 12, 2005.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft
Certification Service.
[FR Doc. 05-16454 Filed 8-22-05; 8:45 am]
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