[Federal Register Volume 63, Number 227 (Wednesday, November 25, 1998)]
[Proposed Rules]
[Pages 65136-65147]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 98-31437]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 95-ANE-39]
RIN 2120-AA64
Airworthiness Directives; General Electric Company CF6 Series
Turbofan Engines
AGENCY: Federal Aviation Administration, DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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SUMMARY: This document proposes the supersedure of an existing
airworthiness directive (AD), applicable to General Electric Company
(GE) CF6 series turbofan engines, that currently requires initial and
repetitive ultrasonic and eddy current inspections of high pressure
compressor rotor (HPCR) stage 3-9 spools for cracks. This action would
define more aggressive inspection intervals for certain HPCR stage 3-9
spools, add CF6-80E1 engines to the inspection program, add inspection
requirements for spools manufactured from 8 inch diameter billet, add a
one-time inspection of the stage 3-5 blade slot bottoms, and add a one-
time inspection of the web and hub-to-web transition areas. This
proposal is prompted by analysis of recent HPCR stage 3-9 spool
inspection results and separations, and assessment of the adequacy of
the existing program to prevent HPCR stage 3-9 spool cracking and
separation. As a result of that assessment, the FAA has determined
there is a need to make changes to the existing AD. The actions
specified by the proposed AD are intended to prevent HPCR stage 3-9
spool cracking and separation, which can result in an uncontained
engine failure and aircraft damage.
DATES: Comments must be received by January 25, 1999.
ADDRESSES: Submit comments in triplicate to the Federal Aviation
Administration (FAA), New England Region, Office of the Regional
Counsel, Attention: Rules Docket No. 95-ANE-39, 12 New England
Executive Park, Burlington, MA 01803-5299. Comments may also be sent
via the Internet using the following address: ``engineprop@faa.dot.gov''. Comments sent via the Internet must contain
the docket number in the subject line. Comments may be inspected at
this location between 8:00 a.m. and 4:30 p.m., Monday through Friday,
except Federal holidays.
The service information referenced in the proposed rule may be
obtained 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. This information may be
examined at the FAA, New England Region, Office of the Regional
Counsel, 12 New England Executive Park, Burlington, MA.
FOR FURTHER INFORMATION CONTACT: William S. Ricci, Aerospace Engineer,
Engine Certification Office, FAA, Engine and Propeller Directorate, 12
New England Executive Park, Burlington, MA 01803-5299; telephone (781)
238-7742, fax (781) 238-7199.
SUPPLEMENTARY INFORMATION:
Comments Invited
Interested persons are invited to participate in the making of the
proposed rule by submitting such written data, views, or arguments as
they may desire. Communications should identify the Rules Docket number
and be submitted in triplicate to the address specified above. All
communications received on or before the closing date for comments,
specified above, will be considered before taking action on the
proposed rule. The proposals contained in this notice may be changed in
light of the comments received.
Comments are specifically invited on the overall regulatory,
economic, environmental, and energy aspects of the proposed rule. All
comments submitted will be available, both before and after the closing
date for comments, in the Rules Docket for examination by interested
persons. A report summarizing each FAA-public contact concerned with
the substance of this proposal will be filed in the Rules Docket.
Commenters wishing the FAA to acknowledge receipt of their comments
submitted in response to this notice must submit a self-addressed,
stamped postcard on which the following statement is made: ``Comments
to Docket Number 95-ANE-39.'' The postcard will be date-stamped and
returned to the commenter.
Availability of NPRMs
Any person may obtain a copy of this NPRM by submitting a request
to the FAA, New England Region, Office of the Regional Counsel,
Attention: Rules Docket No. 95-ANE-39, 12 New
[[Page 65137]]
England Executive Park, Burlington, MA 01803-5299.
Discussion
On January 31, 1995, the Federal Aviation Administration (FAA)
issued airworthiness directive (AD) 95-03-01, Amendment 39-9138 (60 FR
8930, February 16, 1995), applicable to General Electric Company (GE)
CF6-45/-50/-80A series turbofan engines, to require initial and
repetitive ultrasonic and eddy current inspections of a certain
population of high pressure compressor rotor (HPCR) stage 3-9 spools
for cracks. That action was prompted by a finding of several cracked
parts in service.
Since the issuance of AD 95-03-01, the FAA received a report of an
in-service uncontained failure of an HPCR stage 3-9 spool. The
investigation revealed that the uncontained failure was caused by a
crack that developed from the same metallurgical condition which
prompted AD 95-03-01. However, that spool was not part of the
population required to be inspected by AD 95-03-01. Further
investigation indicated that the scope of AD 95-03-01 had to be
expanded to include other HPCR stage 3-9 spools installed on GE CF6-45/
-50/-80A engines, and also HPCR stage 3-9 spools installed on GE CF6-
80C2 series engines, and that the inspection schedule for the spools
affected by AD 95-03-01 needed to be accelerated. The FAA issued AD 95-
23-03, amendment 39-9423 on November 13, 1995 (60 FR 57803, November
21, 1995) that superseded AD 95-03-01 and incorporated these inspection
program changes and added a reporting requirement for operators to
advise the FAA of the results of the inspections.
Since issuing AD 95-23-03, the FAA has analyzed the inspection
reports submitted in accordance with AD 95-23-03, the results of an
investigation of an uncontained failure caused by a crack that
developed from a hard alpha inclusion material defect in the hub-to-web
transition area of CF6-50 stage 6 disk, and the results of an
investigation of an uncontained failure caused by a crack that
developed in a CF6-80C2 stage 3 blade slot bottom. The stage 3-9 spool
is one of the major structural elements of the fourteen-stage axial
flow HPCR installed in the CF6 engine. The CF6 HPCR is manufactured
from Ti 6-2-4-2 titanium alloy. Since 1974 there have been 9 events
where CF6 stage 3-9 spools have failed due to cracking. All of these
events have resulted in the release of engine fragments, and a majority
have resulted in an uncontained engine failure. The root cause of the
cracking and separation events has been attributed to two failure
mechanisms. The first failure mechanism is crack initiation from hard
alpha inclusions. Hard alpha inclusions are hard brittle areas within
the material which can crack under service loads and propagate in
fatigue. The second failure mechanism is dwell time fatigue (DTF). DTF
is a crack initiation mode associated with certain creep resistant
titanium alloys under sustained loading (dwell) at temperatures below
400 degrees Fahrenheit that results in internal crack initiations at
flat facets. The facets are associated with groups or colonies of
primary alpha grains having a common alpha phase crystal orientation.
Crack initiation by both of these failure mechanisms can occur at
relatively low cyclic exposures and result in HPCR stage 3-9 failure.
Based on this analysis, the FAA has determined that the inspection
program required by AD 95-23-03 must be accelerated and expanded to
include spools manufactured from 8 inch diameter billets. This
condition, if not corrected, could result in HPCR stage 3-9 spool
cracking and separation, which can result in an uncontained engine
failure and aircraft damage.
The FAA has reviewed and approved the technical contents of the
following GE Service Bulletins (SBs) and Alert Service Bulletins
(ASBs): CF6-50 SB No. 72-1108, Revision 1, dated July 29, 1996; CF6-80A
SB No. 72-678, Revision 1, dated July 29, 1996; CF6-80C2 SB No. 72-812,
Revision 1, dated January 30, 1998, CF6-80E1 ASB No. 72-A135, Original,
dated August 13, 1998, CF6-50 SB No. 72-1157, Original, dated June 10,
1998, CF6-80A SB No. 72-719, Revision 1, dated September 24, 1998, CF6-
80C2 SB No. 72-934, Original, dated June 10, 1998, CF6-80E1 SB No. 72-
137, Original, dated June 9, 1998, CF6-50 ASB No. 72-A1131, Revision 1,
dated March 12, 1998, CF6-80A ASB No. 72-A691, Revision 2, dated
September 23, 1998, CF6-80C2 ASB No. 72-A848, Revision 2, dated March
12, 1998, CF6-80E1 ASB No. 72-A126, Revision 1, dated March 31, 1998,
and Table 801 of GE CF6-50 Shop Manual GEK 50481, section 05-11-02 Time
Limits. These service documents describe procedures for eddy current
and ultrasonic inspections of HPCR stage 3-9 spools for cracks.
Since an unsafe condition has been identified that is likely to
exist or develop on other products of this same type design, the
proposed AD would supersede AD 95-23-03 to define more aggressive
inspection intervals for certain HPCR stage 3-9 spools, add CF6-80E1
engines to the inspection program, add inspection requirements for
spools manufactured from 8 inch diameter billet, add a one-time
inspection of the stage 3-5 blade slot bottoms, and add a one-time
inspection of the web and hub-to-web transition areas. The proposed
inspection program would also incorporated repetitive inspection
intervals that change based on the calendar time that has elapsed since
the effective date of this proposed AD. These calendar date triggers
have the effect of tightening the repetitive inspection intervals as
the affected population of engines ages through normal utilization. The
dates also reflect the risk analysis performed by the manufacturer
which took into consideration many factors including the shop capacity
to perform the required inspections. The FAA chose to use calendar
dates for these triggers rather than engine cycles or hours in order
not to unduly penalize high utilization users while providing some
definite ending point for each phase of the repetitive inspection
program.
The FAA is also considering additional rulemaking that would
require eddy current and ultrasonic inspections of the side fillet
radii of the stage 3-5 blade slot bottoms, the stage 6-9 blade slot
bottoms, and a module level inspection of the stage 3-5 bores.
There are approximately 4,506 engines of the affected design in the
worldwide fleet. The FAA estimates that 1,197 engines installed on
aircraft of U.S. registry would be affected by this proposed AD, that
it would take approximately 216 work hours per engine to accomplish the
proposed actions, and that the average labor rate is $60 per work hour.
Based on these figures, the total cost impact of the proposed AD on
U.S. operators is estimated to be $15,485,340.
The regulations proposed herein would not have substantial direct
effects 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. Therefore, in
accordance with Executive Order 12612, it is determined that this
proposal would not have sufficient federalism implications to warrant
the preparation of a Federalism Assessment.
For the reasons discussed above, I certify that this proposed
regulation (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
[[Page 65138]]
Flexibility Act. A copy of the draft regulatory evaluation prepared for
this action 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.
The Proposed Amendment
Accordingly, pursuant to the authority delegated to me by the
Administrator, the Federal Aviation Administration proposes to amend
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 39-9423 (60 FR
57803, November 21, 1995) and by adding a new airworthiness directive
to read as follows:
General Electric Company: Docket No. 95-ANE-39. Supersedes AD 95-23-
03, Amendment 39-9423.
Applicability: General Electric Company (GE) CF6-45, -50, -80A,
-80C2 and -80E1 series turbofan engines, with High Pressure
Compressor Rotor (HPCR) stage 3-9 spools, part numbers (P/Ns)
1333M66G01, 1333M66G03, 1333M66G07, 1333M66G09, 1333M66G10,
1669M22G01, 1781M52P01, 1781M53G01, 1782M22G01, 1782M22G02,
1782M22G04, 1854M95P01, 1854M95P02, 1854M95P03, 1854M95P04,
1854M96P05, 1854M95P06, 9136M89G02, 9136M89G03, 9136M89G06,
9187M89G07, 9136M89G08, 9136M89G09, 9136M89G10, 9136M89G11,
9136M89G17, 9136M89G18, 9136M89G19, 9136M89G20, 9136M89G21,
9136M89G22, 9136M89G27, 9136M89G28, 9136M89G29, 9253M85G01,
9253M85G02, 9273M14G01, 9331M29G01, and 9380M28P05 installed. These
engines are installed on but not limited to Airbus A300, A310, and
A330 series, Boeing 747 and 767 series, and McDonnell Douglas DC-10
and MD-11 series aircraft.
Note 1: This airworthiness directive (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 (k) 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 accomplished
previously.
To prevent HPCR stage 3-9 spool cracking and separation, which
can result in an uncontained engine failure and aircraft damage,
accomplish the following:
(a) For the purpose of this AD, the following abbreviations
apply:
(1) Cycles Since New (CSN).
(2) Cycles Since Last Inspection (CSLI).
(3) Cycles At Last Inspection (CALI).
(4) Engine Shop Visit (ESV).
Note 2: Paragraph (b) of this AD is only applicable to GE CF6-
45/50 series engines. Paragraph (c) of this AD is only applicable to
GE CF6-80A series engines. Paragraph (d) of this AD is only
applicable to GE CF6-80C2 series engines. Paragraph (e) of this AD
is only applicable to GE CF6-80E1 series engines.
(b) For HPCR stages 3-9 spools installed in CF6-45/50 series
engines, eddy current and ultrasonic inspect for cracks as follows:
(1) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 9136M89G02, 9136M89G03, 9136M89G06, 9136M89G07,
9136M89G08, 9136M89G09, 9136M89G17, 9136M89G18, 9136M89G19,
9136M89G21, 9136M89G22, 9136M89G27, 9136M89G29, 9253M85G01,
9253M85G02, 9273M14G01, and 9331M29G01, installed in GE CF6-45/-50
series engines, as follows:
(i) Perform eddy current and ultrasonic inspections in
accordance with GE CF6-50 Service Bulletin (SB) No. 72-1157,
Original, dated June 10, 1998, at the next piece-part exposure after
1,000 CSN.
(ii) Perform eddy current and ultrasonic inspections in
accordance with GE CF6-50 Alert Service Bulletin (ASB) No. 72-A1131,
Revision 1, dated March 12, 1998, at the next piece-part exposure
after 1,000 CSN.
(iii) Remove from service, prior to further flight, HPCR stage
3-9 spools that equal or exceed the reject criteria established by
SB No. 72-1157, Original, dated June 10, 1998, or ASB No. 72-A1131,
Revision 1, dated March 12, 1998, as applicable, and replace with a
serviceable part.
(2) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 9136M89G08, 9253M85G02, 9273M14G01, and
9331M29G01 and with Serial Numbers (S/Ns) listed in Table 801 of GE
CF6-50 Shop Manual GEK50481, section 05-11-02 Time Limits, and with
P/Ns 9136M89G02 and 9136M89G06 installed in GE CF6-45/-50 series
engines. Perform the inspections in accordance with GE CF6-50 SB No.
72-1108, Revision 1, dated July 29, 1996, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-888, Revision 6,
dated December 22, 1995; or SB No. 72-1000, Revision 2, dated
September 9, 1993; or SB No. 72-1108, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, inspect at the first
piece-part exposure after 1,000 CSN but prior to accumulating 3,500
CSN, or prior to exceeding 30 days from the effective date of this
AD, whichever occurs later.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-888, Revision 6,
dated December 22, 1995; or SB No. 72-1000, Revision 2, dated
September 9, 1993; or SB No. 72-1108, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, perform repeat
inspections at the earliest occurrence of the requirements of Table
1, 2, or 3 of this AD, as applicable, based on elapsed calendar time
from the effective date of this AD, as specified in paragraph
(b)(2)(v) of this AD.
Table 1
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First piece-part exposure after both 1,000 CSLI and 3,500 CSN, but not
later than the first ESV after both 2,000 CSLI and 3,500 CSN, and
before 3,500 CSLI.
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Table 2
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First piece-part exposure after both 1,000 CSLI and 3,500 CSN, but not
later than the first ESV after both 2,000 CSLI and 3,500 CSN, and
before:
3,500 CSLI, if spool CALI is 0-6,500, or
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
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[[Page 65139]]
Table 3
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First piece-part exposure after both 1,000 CSLI and 3,500 CSN, but not
later than the first ESV after both 2,000 CSLI and 3,500 CSN, and
before:
3,500 CSLI, if spool CALI is 0-5,000, or
8,500 CSN, if spool CALI is 5,001-5,500, or
3,000 CSLI, if spool CALI is 5,501-6,500, or
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
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(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the earliest occurrence shown in Table 1, Table 2, or
Table 3 of this AD, as applicable, based on the elapsed calendar
time from the effective date of this AD, as specified in paragraph
(b)(2)(v) of this AD.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-50 SB No. 72-1108, Revision 1, dated July 29, 1996, and replace
with a serviceable part.
(v) Use the Tables as follows:
(A) Use Table 1 from the effective date of this AD to 18 months
from the effective date of this AD.
(B) Use Table 2 after 18 months from the effective date of this
AD to 36 months from the effective date of this AD.
(C) Use Table 3 after 36 months from the effective date of this
AD.
(3) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 9136M89G08, 9253M85G02, 9273M14G01, and
9331M29G01, with S/Ns not listed in Table 801 of GE CF6-50 Shop
Manual GEK50481, section 05-11-02 Time Limits, and with P/Ns
9136M89G03, 9136M89G07, 9136M89G09, 9136M89G17, 9136M89G18, and
9253M85G01 installed in GE CF6-45/-50 series engines. Perform the
inspections in accordance with GE CF6-50 SB No. 72-1108, Revision 1,
dated July 29, 1996, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-888, Revision 6,
dated December 22, 1995; or SB No. 72-1000, Revision 2, dated
September 9, 1993; or SB No. 72-1108, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, inspect at the first
piece-part exposure after 1,000 CSN but not later than the first ESV
after 4,000 CSN.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-888, Revision 6,
dated December 22, 1995; or SB No. 72-1000, Revision 2, dated
September 9, 1993; or SB No. 72-1108, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, perform repeat
inspections at the first piece-part exposure after both 1,000 CSLI
and 4,000 CSN, but not later than the first ESV after both 2,000
CSLI and 4,000 CSN.
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the first piece-part exposure after both 1,000 CSLI and
4,000 CSN, but not later than the first ESV after both 2,000 CSLI
and 4,000 CSN.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-50 SB No. 72-1108, Revision 1, dated July 29, 1996, and replace
with a serviceable part.
(4) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 9136M89G19, 9136M89G21, 9136M89G22, and
9136M89G27 installed in GE CF6-45/-50 series engines. Perform the
inspections in accordance with GE CF6-50 SB No. 72-1108, Revision 1,
dated July 29, 1996, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-888, Revision 6,
dated December 22,1995; or SB No. 72-1000, Revision 2, dated
September 9, 1993; or SB No. 72-1108, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, inspect at the first
piece-part exposure after 1,000 CSN but not later than the first ESV
after 3,000 CSN, provided, however, from 18 to 36 months after the
effective date of this AD, inspect not later than 9,500 CSN, and
after 36 months after the effective date of this AD, inspect not
later than 3,500 CSN.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-888, Revision 6,
dated December 22,1995; or SB No. 72-1000, Revision 2, dated
September 9, 1993; or SB No. 72-1108, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, perform repeat
inspections at the earliest occurrence of the requirements of Table
4, 5, or 6 of this AD, as applicable, based on elapsed calendar time
from the effective date of this AD, as specified in paragraph
(b)(4)(vi) of this AD.
Table 4
------------------------------------------------------------------------
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First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 2,000 CSLI and 5,000 CSN.
------------------------------------------------------------------------
Table 5
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 2,000 CSLI and 5,000 CSN, and
before:
9,500 CSN, if spool CALI is 0-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
Table 6
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 2,000 CSLI and 5,000 CSN, and
before:
5,000 CSN, if spool CALI is 0-1,500, or
3,500 CSLI, if spool CALI is 1,501-5,000, or
8,500 CSN, if spool CALI is 5,001-5,500, or
3,000 CSLI, if spool CALI is 5,501-6,500, or
[[Page 65140]]
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the earliest occurrence shown in Table 4, Table 5, or
Table 6 of this AD, as applicable, based on the elapsed calendar
time from the effective date of this AD, as specified in paragraph
(b)(4)(vi) of this AD.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-50 SB No. 72-1108, Revision 1, dated July 29, 1996, and replace
with a serviceable part.
(v) HPCR stage 3-9 spools with a CSN of 10,500 or greater may
not be put back in service after an ESV.
(vi) Use the Tables as follows:
(A) Use Table 4 from the effective date of this AD to 18 months
from the effective date of this AD.
(B) Use Table 5 after 18 months from the effective date of this
AD to 36 months from the effective date of this AD.
(C) Use Table 6 after 36 months from the effective date of this
AD.
(5) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/N 9136M89G29 installed in GE CF6-45/-50 series
engines. Perform the inspections in accordance with GE CF6-50 SB No.
72-1108, Revision 1, dated July 29, 1996, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-888, Revision 6,
dated December 22,1995; or SB No. 72-1000, Revision 2, dated
September 9, 1993; or SB No. 72-1108, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, or any of the
combinations of service documents specified by Table 7 of this AD,
inspect at the next piece-part exposure after 1,000 CSN.
Table 7
------------------------------------------------------------------------
-------------------------------------------------------------------------
Either any one of the following:
CF6 Standard Practice Manual GEK9250 Procedures 70-32-09, Revision 71,
dated October 1, 1995,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-09, Revision 72,
dated November 15, 1996,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-09, Revision 74,
dated May 1, 1998,
and any one of the following:
CF6 Standard Practice Manual GEK9250 Procedures 70-32-10, Revision 71,
dated October 1, 1995,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-010, Revision 72,
dated November 15, 1996,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-010, Revision 74,
dated May 1, 1998;
or any one of the following:
CF6 Standard Practice Manual GEK9250 Procedures 70-32-13, Revision 70-
25, dated August 26, 1996,
CF6 Standard Practice Manual GEK9250 Procedure 70-32-13, Revision 72,
dated November 15, 1996,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-13, Revision 73,
dated November 1, 1997,
and any one of the following:
CF6 Standard Practice Manual GEK9250 Procedures 70-32-14, Revision 70-
26, dated August 26, 1996,
CF6 Standard Practice Manual GEK9250 Procedure 70-32-14, Revision 72,
dated November 15, 1996,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-14, Revision 73,
dated November 1, 1997.
------------------------------------------------------------------------
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-888, Revision 6,
dated December 22,1995; or SB No. 72-1000, Revision 2, dated
September 9, 1993; or SB No. 72-1108, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, or any of the
combinations of service documents specified by Table 7 of this AD,
inspect at first piece-part exposure after both 1,000 CSLI and 5,000
CSN.
(iii) Thereafter, inspect HPCR stage 3-9 spools at piece part
exposure after both 1,000 CSLI and 5,000 CSN.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-50 SB No. 72-1108, Revision 1, dated July 29, 1996, and replace
with a serviceable part.
(c) For HPCR stages 3-9 spools installed in GE CF6-80A/-80A1/-
80A2/-80A3 series engines, eddy current and ultrasonic inspect for
cracks as follows:
(1) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 9136M89G10, 9136M89G11, 9136M89G20, 9136M89G21,
9136M89G22, 9136M89G27, and 9136M89G28 installed in GE CF6-80A/-
80A1/-80A2/-80A3 series engines, as follows:
(i) Perform eddy current and ultrasonic inspections in
accordance with GE CF6-80A SB No. 72-719, Revision 1, dated
September 24, 1998, at the next piece-part exposure after 1,000 CSN.
(ii) Perform eddy current and ultrasonic inspections in
accordance with GE CF6-80A ASB No. 72-A691, Revision 2, dated
September 23, 1998, at the next piece-part exposure after 1,000 CSN.
(iii) Remove from service, prior to further flight, HPCR stage
3-9 spools that equal or exceed the reject criteria established by
the SB No. 72-719, Revision 1, dated September 24, 1998, or ASB No.
72-A691, Revision 2, dated September 23, 1998, as applicable, and
replace with a serviceable part.
(2) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/N 9136M89G10, with the following S/Ns: MPOM0054,
MPOM7090, MPOM8303, MPOM8304, MPOM9263, MPOM9264, MPON0054,
MPON0071, MPON0072, MPON1643, MPON4251, and MPON4253 installed in GE
CF6-80A/-80A1/-80A2/-80A3 series engines. Perform the inspections in
accordance with GE CF6-80A SB No. 72-678, Revision 1, dated August
8, 1996, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22,1995; or SB No. 72-583, Revision 5, dated December
22, 1995; or SB No. 72-678, Revision 1, dated July 29, 1996, or any
earlier versions of these SBs, inspect at the first piece-part
exposure after 1,000 CSN but before accumulating 3,500 CSN, or prior
to exceeding 30 days from the effective date of this AD, whichever
is later.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22, 1995; or SB No. 72-583, Revision 5, dated
December 22, 1995; or SB No. 72-678, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, perform repeat
inspections at the earliest occurrence of the requirements of Table
8, 9, or 10 of this AD, as applicable, based on elapsed calendar
time from the effective date of this AD, as specified in paragraph
(c)(2)(vi) of this AD.
[[Page 65141]]
Table 8
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 3,500
CSN, but not later than the first ESV after both 3,500 CSN and 2,000
CSLI (for GE CF6-80A1/A3 engines) or 1,500 CSLI (for GE CF6-80A/A2
engines), and before 3,500 CSLI.
------------------------------------------------------------------------
Table 9
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece part exposure after both 1,000 CSLI and 3,500 CSN, but not
later than the first ESV after both 3,500 CSN and 2,000 CSLI (for GE
CF6-80A1/A3 engines) or 1,500 CSLI (for GE CF6-80A/A2 engines), and
before:
3,500 CSLI, if spool CALI is 0--6,500, or
9,500 CSN, if spool CALI is 6,501--7,000, or
2,500 CSLI, if spool CALI is 7,001--8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
Table 10
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 3,500 CSN, but not
later than the first ESV after both 2,000 CSLI (for GE CF6-80A1/A3) or
1,500 CSLI (for GE CF6-80A/A2) and 3,500 CSN, and before:
3,500 CSLI, if spool CALI is 0--5,000, or
8,500 CSN, if spool CALI is 5,001--5,500, or
3,000 CSLI, if spool CALI is 5,501--6,500, or
9,500 CSN, if spool CALI is 6,501--7,000, or
2,500 CSLI, if spool CALI is 7,001--8,000, or
10,500 CSN, if spool CALI is 8,001--8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the earliest occurrence shown in Table 8, Table 9, or
Table 10 of this AD, as applicable, based on the elapsed calendar
time from the effective date of this AD, as specified in paragraph
(c)(2)(vi) of this AD.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80A SB No. 72-678, Revision 1, dated August 8, 1996, and replace
with a serviceable part.
(v) HPCR stage 3-9 spools with a CSN of 10,500 or greater may
not be put back in service after an ESV.
(vi) Use the Tables as follows:
(A) Use Table 8 from the effective date of this AD to 18 months
from the effective date of this AD.
(B) Use Table 9 after 18 months from the effective date of this
AD to 36 months from the effective date of this AD.
(C) Use Table 10 after 36 months from the effective date of this
AD.
(3) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/N 9136M89G10, with S/Ns other than those listed in
paragraph (c)(2) of this AD, and P/N 9136M89G11, installed in GE
CF6-80A/A2 series engines. Perform the inspections in accordance
with GE CF6-80A SB No. 72-678, Revision 1, dated August 8, 1996, as
follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22,1995; or SB No. 72-583, Revision 5, dated December
22, 1995; or SB No. 72-678, Revision 1, dated July 29, 1996, or any
earlier versions of these SBs, inspect at the first piece-part
exposure after 1,000 CSN, but not later than the first ESV after
5,000 CSN.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22, 1995; or SB No. 72-583, Revision 5, dated
December 22, 1995; or SB No. 72-678, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, perform repeat
inspections at the first piece-part exposure after both 1,000 CSLI
and 5,000 CSN, but not later than the first ESV after both 1,500
CSLI and 5,000 CSN.
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the first piece-part exposure after both 1,000 CSLI and
5,000 CSN, but not later than the first ESV after both 1,500 CSLI
and 5,000 CSN.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80A SB No. 72-678, Revision 1, dated August 8, 1996, and replace
with a serviceable part.
(4) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/N 9136M89G10, with S/Ns other than those listed in
paragraph (c)(2) of this AD, and P/N 9136M89G11, installed in GE
CF6-80A1/A3 series engines. Perform the inspections in accordance
with GE CF6-80A SB No. 72-678, Revision 1, dated August 8, 1996, as
follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22,1995; or SB No. 72-583, Revision 5, dated December
22, 1995; or SB No. 72-678, Revision 1, dated July 29, 1996, or any
earlier versions of these SBs, inspect at the first piece-part
exposure after 1,000 CSN but not later than the first ESV after
5,000 CSN.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22,1995; or SB No. 72-583, Revision 5, dated December
22, 1995; or SB No. 72-678, Revision 1, dated July 29, 1996, or any
earlier versions of these SBs, perform repeat inspections at the
first piece-part exposure after both 1,000 CSLI and 5,000 CSN, but
not later than the first ESV after both 2,000 CSLI and 5,000 CSN.
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the first piece-part exposure after both 1,000 CSLI and
5,000 CSN, but not later than the first ESV after both 2,000 CSLI
and 5,000 CSN.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80A SB No. 72-678, Revision 1, dated August 8, 1996, and replace
with a serviceable part.
(5) Eddy current and ultrasonic inspect for cracks HPCR stage 3-9
spools with P/Ns 9136M89G20, 9136M89G21, 9136M89G22 and 9136M89G27,
installed in GE CF6-80A1/A3 series engines. Perform the inspections in
accordance with GE CF6-80A SB No. 72-678, Revision 1, dated August 8,
1996, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22,1995; or SB No. 72-583, Revision 5, dated December
22, 1995; or SB No. 72-678, Revision 1, dated July 29, 1996, or any
earlier versions of these SBs, inspect at the first piece-part
exposure after 1,000 CSN but not later than the first ESV after
3,000 CSN, provided, however, from 18 to 36 months after the
effective date of this AD, inspect not later than 9,500 CSN, and
after 36 months after the effective date of this AD, inspect not
later than 3,500 CSN.
[[Page 65142]]
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22,1995; or SB No. 72-583, Revision 5, dated December
22, 1995; or SB No. 72-678, Revision 1, dated July 29, 1996, or any
earlier versions of these SBs, perform repeat inspections at the
earliest occurrence of the requirements of Table 11, 12, or 13 of
this AD, as applicable, based on elapsed calendar time from the
effective date of this AD, as specified in paragraph (c)(5)(vi) of
this AD.
Table 11
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 2,000 CSLI and 5,000 CSN.
------------------------------------------------------------------------
Table 12
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 2,000 CSLI and 5,000 CSN, and
before:
9,500 CSN, if spool CALI is 0-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
Table 13
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 2,000 CSLI and 5,000 CSN, and
before:
5,000 CSN, if spool CALI is 0-1,500, or
3,500 CSLI, if spool CALI is 1,501-5,000, or
8,500 CSN, if spool CALI is 5,001-5,500, or
3,000 CSLI, if spool CALI is 5,501-6,500, or
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the earliest occurrence shown in Table 11, Table 12, or
Table 13 of this AD, as applicable, based on the elapsed calendar
time from the effective date of this AD, as specified in paragraph
(c)(5)(vi) of this AD.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80A SB No. 72-678, Revision 1, dated August 8, 1996, and replace
with a serviceable part.
(v) HPCR stage 3-9 spools with a CSN of 10,500 or greater may
not be put back in service after an ESV.
(vi) Use the Tables as follows:
(A) Use Table 11 from the effective date of this AD to 18 months
from the effective date of this AD.
(B) Use Table 12 after 18 months from the effective date of this
AD to 36 months from the effective date of this AD.
(C) Use Table 13 after 36 months from the effective date of this
AD.
(6) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 9136M89G20, 9136M89G21, 9136M89G22, and
9136M89G27 installed in GE CF6-80A/A2 series engines. Perform the
inspections in accordance with GE CF6-80A SB No. 72-678, Revision 1,
dated August 8, 1996, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22, 1995; or SB No. 72-583, Revision 5, dated
December 22, 1995; or SB No. 72-678, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, inspect at the first
piece-part exposure after 1,000 CSN but not later than the first ESV
after 3,000 CSN, provided, however, from 18 to 36 months after the
effective date of this AD, inspect not later than 9,500 CSN, and
after 36 months after the effective date of this AD, inspect not
later than 3,500 CSN.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22, 1995; or SB No. 72-583, Revision 5, dated
December 22, 1995; or SB No. 72-678, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, perform repeat
inspections at the earliest occurrence of the requirements of Table
14, 15, or 16 of this AD, as applicable, based on elapsed calendar
time from the effective date of this AD, as specified in paragraph
(c)(6)(vi) of this AD.
Table 14
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 1,500 CSLI and 5,000 CSN.
------------------------------------------------------------------------
Table 15
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 1,500 CSLI and 5,000 CSN, and
before:
9,500 CSN, if spool CALI is 0-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
[[Page 65143]]
Table 16
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part exposure after both 1,000 CSLI and 5,000 CSN, but not
later than the first ESV after both 1,500 CSLI and 5,000 CSN, and
before:
5,000 CSN, if spool CALI is 0-1,500, or
3,500 CSLI, if spool CALI is 1,501-5,000, or
8,500 CSN, if spool CALI is 5,001-5,500, or
3,000 CSLI, if spool CALI is 5,501-6,500, or
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the earliest occurrence shown in Table 14, Table 15, or
Table 16 of this AD, as applicable, based on the elapsed calendar
time from the effective date of this AD, as specified in paragraph
(c)(6)(vi) of this AD.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80A SB No. 72-678, Revision 1, dated August 8, 1996, and replace
with a serviceable part.
(v) HPCR stage 3-9 spools with a CSN of 10,500 or greater may
not be put back in service after an ESV.
(vi) Use the Tables as follows:
(A) Use Table 14 from the effective date of this AD to 18 months
from the effective date of this AD.
(B) Use Table 15 after 18 months from the effective date of this
AD to 36 months from the effective date of this AD.
(C) Use Table 16 after 36 months from the effective date of this
AD.
(7) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/N 9136M89G28 installed in GE CF6-80A/A1/A2/A3 series
engines. Perform the inspections in accordance with GE CF6-80A SB
No. 72-678, Revision 1, dated August 8, 1996, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22,1995; or SB No. 72-583, Revision 5, dated December
22, 1995; or SB No. 72-678, Revision 1, dated July 29, 1996, or any
earlier versions of these SBs, or any of the combinations of service
documents specified by Table 7 of this AD, inspect at the first
piece-part exposure after both 1,000 CSN and the effective date of
this AD.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-500, Revision 6,
dated December 22, 1995; or SB No. 72-583, Revision 5, dated
December 22, 1995; or SB No. 72-678, Revision 1, dated July 29,
1996, or any earlier versions of these SBs, or any of the service
documents listed in Table 7 of this AD, inspect at first piece-part
exposure after both 1,000 CSLI and 5,000 CSN.
(iii) Thereafter, inspect HPCR stage 3-9 spools at piece-part
exposure after both 1,000 CSLI and 5,000 CSN.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80A SB No. 72-678, Revision 1, dated August 8, 1996, and replace
with a serviceable part.
(d) For HPCR stages 3-9 spools installed in GE CF6-80C2 series
engines, eddy current and ultrasonic inspect for cracks as follows:
(1) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 1333M66G01, 1333M66G03, 1333M66G07, 1333M66G09,
1333M66G10, 1781M52P01, 1781M53G01, 1854M95P01, 1854M95P02,
1854M95P03, 1854M95P04, 1854M95P05, 1854M95P06, and 9380M28P05
installed in GE CF6-80C2 series engines, as follows:
(i) Perform eddy current and ultrasonic inspections in
accordance with GE CF6-80C2 SB No. 72-934, Original, dated June
10,1998, at the next piece-part exposure after 1,000 CSN.
(ii) Perform eddy current and ultrasonic inspections in
accordance with GE CF6-80C2 ASB No. 72-A848, Revision 2, dated March
12, 1998, at the next piece-part exposure after 1,000 CSN.
(iii) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by the
SB No. 72-934, Original, dated June 10, 1998 or ASB No. 72-A848,
Revision 2, dated March 12, 1998, as applicable and replace with a
serviceable part.
(2) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 1781M52P01, 1854M95P02, 1854M95P05, and
9380M28P05 installed in GE CF6-80C2 series engines. Perform the
inspections in accordance with GE CF6-80C2 SB No. 72-812, Revision
1, dated January 30, 1998, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-418, Revision 4,
dated December 22, 1995; or SB No. 72-758, Revision 1, dated
December 22, 1995; or SB No. 72-812, Revision 1, dated January 30,
1998, or any earlier versions of these SBs, inspect at the first
piece-part exposure after 1,000 CSN but prior to accumulating 3,500
CSN, or prior to exceeding 30 days from the effective date of this
AD, whichever occurs later.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-418, Revision 4,
dated December 22, 1995; or SB No. 72-758, Revision 1, dated
December 22, 1995; or SB No. 72-812, Revision 1, dated January 30,
1998, or any earlier versions of these SBs, perform repeat
inspections at the earliest occurrence of the requirements of Table
17, 18, or 19 of this AD, as applicable, based on elapsed calendar
time from the effective date of this AD, as specified in paragraph
(d)(2)(vi) of this AD.
Table 17
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN, and before 3,500 CSLI.
------------------------------------------------------------------------
Table 18
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN, and before:
3,500 CSLI, if spool CALI is 0-6,500, or
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
[[Page 65144]]
Table 19
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN, and before:
3,500 CSLI, if spool CALI is 0-5,000, or
8,500 CSN, if spool CALI is 5,001-5,500, or
3,000 CSLI, if spool CALI is 5,501-6,500, or
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the earliest occurrence shown in Table 17, Table 18, or
Table 19 of this AD, as applicable, based on the elapsed calendar
time from the effective date of this AD, as specified in paragraph
(d)(2)(vi) of this AD.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80C2 SB No. 72-812, Revision 1, dated January 30, 1998, and
replace with a serviceable part.
(v) HPCR stage 3-9 spools with a CSN of 10,500 or greater may
not be put back in service after an ESV.
(vi) Use the Tables as follows:
(A) Use Table 17 from the effective date of this AD to 18 months
from the effective date of this AD.
(B) Use Table 18 after 18 months from the effective date of this
AD to 36 months from the effective date of this AD.
(C) Use Table 19 after 36 months from the effective date of this
AD.
(3) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 1333M66G01, 1333M66G03, 1333M66G07, 1333M66G09,
1781M53G01, 1854M95P01, 1854M95P03, 1854M95P04, and 1854M95P06
installed in GE CF6-80C2 series engines. Perform the inspections in
accordance with GE CF6-80C2 SB No. 72-812, Revision 1, dated January
30, 1998, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-418, Revision 4,
dated December 22, 1995; or SB No. 72-758, Revision 1, dated
December 22, 1995; or SB No. 72-812, Revision 1, dated January 30,
1998, or any earlier versions of these SBs, inspect at the first
piece-part exposure after 1,000 CSN but not later than the first ESV
after 3,000 CSN, provided, however, from 18 to 36 months after the
effective date of this AD, inspect not later than 9,500 CSN, and
after 36 months after the effective date of this AD, inspect not
later than 3,500 CSN.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-418, Revision 4,
dated December 22, 1995; or SB No. 72-758, Revision 1, dated
December 22, 1995; or SB No. 72-812, Revision 1, dated January 30,
1998, or any earlier versions of these SBs, perform repeat
inspections at the earliest occurrence of the requirements of Table
20, 21, or 22 of this AD, as applicable, based on elapsed calendar
time from the effective date of this AD, as specified in paragraph
(d)(3)(vi) of this AD.
Table 20
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN.
------------------------------------------------------------------------
Table 21
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN, and before:
9,500 CSN, if spool CALI is 0-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
Table 22
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN, and before:
3,500 CSLI, if spool CALI is 0-5,000, or
8,500 CSN, if spool CALI is 5,001-5,500, or
3,000 CSLI, if spool CALI is 5,501-6,500, or
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the earliest occurrence shown in Table 21, Table 22, or
Table 23 of this AD, as applicable, based on elapsed calendar time
from the effective date of this AD, as specified in paragraph
(d)(3)(vi) of this AD.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80C2 SB No. 72-812, Revision 1, dated January 30, 1998, and
replace with a serviceable part.
(v) HPCR stage 3-9 spools with a CSN of 10,500 or greater may
not be put back in service after an ESV.
(vi) Use the Tables as follows:
(A) Use Table 21 from the effective date of this AD to 18 months
from the effective date of this AD.
(B) Use Table 22 after 18 months from the effective date of this
AD to 36 months from the effective date of this AD.
(C) Use Table 23 after 36 months from the effective date of this
AD.
(4) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/N 1333M66G10 installed in GE CF6-80C2 series
engines. Perform the inspections in accordance with GE CF6-80C2 SB
No. 72-812, Revision 1, dated January 30, 1998, as follows:
[[Page 65145]]
(i) For HPCR stage 3-9 spools that have not been previously
inspected using the procedures in GE SB No. 72-418, Revision 4,
dated December 22, 1995; or SB No. 72-758, Revision 1, dated
December 22, 1995; or SB No. 72-812, Revision 1, dated January 30,
1998, or any earlier versions of these SBs, or any of the
combinations of service documents specified by Table 7 of this AD,
inspect at the first piece-part exposure after both 1,000 CSN and
the effective date of this AD.
(ii) For HPCR stage 3-9 spools that have been previously
inspected using the procedures in GE SB No. 72-418, Revision 4,
dated December 22, 1995; or SB No. 72-758, Revision 1, dated
December 22, 1995; or SB No. 72-812, Revision 1, dated January 30,
1998, or any earlier versions of these SBs, or any of the
combinations of service documents specified by Table 7 of this AD,
inspect at first piece part exposure after both 1,000 CSLI and 3,500
CSN.
(iii) Thereafter, inspect HPCR stage 3-9 spools at piece part
exposure after both 1,000 CSLI and 3,500 CSN.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80C2 SB No. 72-812, Revision 1, dated January 30, 1998, and
replace with a serviceable part.
(e) For HPCR stages 3-9 spools installed in GE CF6-80E1 series
engines, eddy current and ultrasonic inspect for cracks as follows:
(1) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 1669M22G01, 1669M22G03, 1782M22G01, 1782M22G02,
and 1782M22G04 installed in GE CF6-80E1 series engines, as follows:
(i) Perform eddy current and ultrasonic inspections in
accordance with GE CF6-80E1 SB No. 72-137, Original, dated June 9,
1998, at the next piece-part exposure after 1,000 CSN.
(ii) Perform eddy current and ultrasonic inspections in
accordance with GE CF6-80E1 ASB No. 72-A126, Revision 1, dated March
31, 1998, at the next piece-part exposure after 1,000 CSN.
(iii) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by SB
No. 72-137, Original, dated June 9, 1998 or ASB No. 72-A126,
Revision 1, dated March 31, 1998, as applicable, and replace with a
serviceable part.
(2) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/Ns 1669M22G01, 1669M22G03, 1782M22G01, and
1782M22G02 installed in GE CF6-80E1 series engines. Perform the
inspections in accordance with GE CF6-80E1 ASB No. 72-A135,
Original, dated August 13, 1998, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected in accordance with in accordance GE CF6-80E1 ASB No. 72-
A135, Original, dated August 13, 1998, or any of the combinations of
service documents specified by Table 7 of this AD, inspect HPCR
stage 3-9 spools at the first piece-part exposure after 1,000 CSN,
but not later than the first ESV after 3,000 CSN, provided, however,
from 18 to 36 months after the effective date of this AD, inspect
not later than 9,500 CSN, and after 36 months after the effective
date of this AD, inspect not later than 3,500 CSN.
(ii) For HPCR stage 3-9 spools that have been previously
inspected in accordance with GE CF6-80E1 ASB No. 72-A135, Original,
dated August 13, 1998, or any of the combinations of service
documents specified by Table 7 of this AD, perform repeat
inspections at the earliest occurrence of the requirements of Table
24, 25, or 26 of this AD, as applicable, based on elapsed calendar
time from the effective date of this AD, as specified in paragraph
(e)(2)(vi) of this AD.
Table 24
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN.
------------------------------------------------------------------------
Table 25
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN, and before:
9,500 CSN, if spool CALI is 0-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
Table 26
------------------------------------------------------------------------
-------------------------------------------------------------------------
First piece-part or module level exposure after both 1,000 CSLI and
3,500 CSN, but not later than the first ESV after both 1,500 CSLI and
3,500 CSN, and before:
3,500 CSLI, if spool CALI is 0-5,000, or
8,500 CSN, if spool CALI is 5,001-5,500, or
3,000 CSLI, if spool CALI is 5,501-6,500, or
9,500 CSN, if spool CALI is 6,501-7,000, or
2,500 CSLI, if spool CALI is 7,001-8,000, or
10,500 CSN, if spool CALI is 8,001-8,500, or
2,000 CSLI, if spool CALI is greater than 8,500.
------------------------------------------------------------------------
(iii) Thereafter, inspect HPCR stage 3-9 spools at intervals not
to exceed the earliest occurrence shown in Table 24, Table 25, or
Table 26 of this AD, as applicable, based on the elapsed calendar
time from the effective date of this AD, as specified in paragraph
(e)(2)(vi ) of this AD.
(iv) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80E1 ASB No. 72-A135, Original, dated August 13, 1998, and
replace with a serviceable part.
(v) HPCR stage 3-9 spools with a CSN of 10,500 or greater may
not be put back in service after an ESV.
(vi) Use the Tables as follows:
(A) Use Table 24 from the effective date of this AD to 18 months
from the effective date of this AD.
(B) Use Table 25 after 18 months from the effective date of this
AD to 36 months from the effective date of this AD.
(C) Use Table 26 after 36 months from the effective date of this
AD.
(3) Eddy current and ultrasonic inspect for cracks HPCR stage 3-
9 spools with P/N 1782M22G04 installed in GE CF6-80E1 series
engines. Perform the inspections in accordance GE CF6-80E1 ASB No.
72-A135, Original, dated August 13, 1998, as follows:
(i) For HPCR stage 3-9 spools that have not been previously
inspected in accordance with any of the service documents listed in
Table 24 of this AD, inspect at first piece-part exposure after both
1,000 CSN and the effective date of this AD.
(ii) Thereafter, inspect at first piece part exposure after both
1,000 CSLI and 3,500 CSN.
[[Page 65146]]
(iii) Remove from service prior to further flight HPCR stage 3-9
spools that equal or exceed the reject criteria established by GE
CF6-80E1 ASB No. 72-A135, Original, dated August 13, 1998, and
replace with a serviceable part.
(f) Report within 5 calendar days of inspection the results of
inspections that equal or exceed the reject criteria to: William
Ricci, Aerospace Engineer, Engine Certification Office, FAA, Engine
and Propeller Directorate, 12 New England Executive Park,
Burlington, MA 01803-5299; telephone (718) 238-7742, fax (781) 238-
7199, as follows:
(1) Engine model in which the HPCR stage 3-9 spool was
installed;
(2) P/N;
(3) S/N;
(4) Part CSN;
(5) Part CSLI;
(6) Date and location of inspection.
Reporting requirements have been approved by the Office of
Management and Budget and assigned OMB control number 2120-0056.
(g) For the purpose of this AD, a serviceable part for
installation in an engine is defined as an HPCR stage 3-9 spool with
less than 1,000 CSN or with less than 1,000 CSLI, in accordance with
the inspection and pass/fail criteria contained in the applicable
service documents or combinations of service documents provided by
Table 27 of this AD.
Table 27
------------------------------------------------------------------------
-------------------------------------------------------------------------
GE CF6-50 SB No. 72-888, Revision 3, dated January 31, 1991,
GE CF6-50 SB No. 72-888, Revision 4, dated March 28, 1991,
GE CF6-50 SB No. 72-888, Revision 5, dated November 7, 1994,
GE CF6-50 SB No. 72-888, Revision 6, dated December 22, 1995,
GE CF6-50 SB No. 72-1000, Original, dated December 14, 1990,
GE CF6-50 SB No. 72-1000, Revision 1, dated March 28, 1991,
GE CF6-50 SB No. 72-1000, Revision 2, dated September 9, 1993,
GE CF6-50 SB No. 72-1000, Revision 3, dated December 22, 1995,
GE CF6-50 SB No. 72-1108, Original, dated November 6, 1995,
GE CF6-50 SB No. 72-1108, Revision 1, dated July 29, 1996,
GE CF6-80A SB No. 72-500, Revision 3, dated March 19, 1991,
GE CF6-80A SB No. 72-500, Revision 4, dated July 1, 1991,
GE CF6-80A SB No. 72-500, Revision 5, dated November 7, 1994,
GE CF6-80A SB No. 72-500, Revision 6, dated December 22, 1995,
GE CF6-80A SB No. 72-583, Original, dated December 20, 1990,
GE CF6-80A SB No. 72-583, Revision 1, dated March 18, 1991,
GE CF6-80A SB No. 72-583, Revision 2, dated July 15, 1991,
GE CF6-80A SB No. 72-583, Revision 3, dated July 24, 1991,
GE CF6-80A SB No. 72-583, Revision 4, dated September 15, 1993,
GE CF6-80A SB No. 72-583, Revision 5, dated December 22, 1995,
GE CF6-80A SB No. 72-678, Original, dated November 6, 1995,
GE CF6-80A SB No. 72-678, Revision 1, dated July 29, 1996,
GE CF6-80C2 SB No. 72-418, Revision 2, May 14, 1991,
GE CF6-80C2 SB No. 72-418, Revision 3, November 7, 1994,
GE CF6-80C2 SB No. 72-418, Revision 4, December 22, 1995,
GE CF6-80C2 SB No. 72-758, Original, dated November 7, 1994,
GE CF6-80C2 SB No. 72-758, Revision 1, dated December 22, 1995,
GE CF6-80C2 SB No. 72-812, Original, dated November 6, 1995,
GE CF6-80C2 SB No. 72-812, Revision 1, dated January 30, 1998,
GE CF6-80E1 ASB No. 72-A135, Original, dated August 13, 1998,
Either any one of the following:
CF6 Standard Practice Manual GEK9250 Procedures 70-32-09, Revision 71,
dated October 1, 1995,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-09, Revision 72,
dated November 15, 1996,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-09, Revision 74,
dated May 1, 1998,
and any one of the following:
CF6 Standard Practice Manual GEK9250 Procedures 70-32-10, Revision 71,
dated October 1, 1995,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-10, Revision 72,
dated November 15, 1996,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-10, Revision 74,
dated May 1, 1998;
or any one of the following:
CF6 Standard Practice Manual GEK9250 Procedures 70-32-13, Revision 70-
25, dated August 26, 1996,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-13, Revision 72,
dated November 15, 1996,
CF6 Standard Practice Manual GEK9250 Procedures 70-32-13, Revision 73,
dated November 1, 1997,
and any one of the following:
CF6 Standard Practice Manual GEK9250 Procedures 70-32-14, Revision 70-
26, dated August 26, 1996,
CF6 Standard Practice Manual GEK9250 Procedure 70-32-14, Revision 72,
dated November 15, 1996,
CF6 Standard Practice Manual GEK9250 Procedure 70-32-14, Revision 73,
dated November 1, 1997.
------------------------------------------------------------------------
(h) For the purpose of this AD, core module exposure is defined
as separation of the fan module from the engine.
(i) For the purpose of this AD, piece-part exposure is defined
as disassembly and removal of the stage 3-9 spool from the HPC rotor
structure, regardless of any blades, locking lugs, bolts or balance
weights assembled to the spool.
(j) For the purpose of this AD, an ESV is defined as the
introduction of an engine into a shop where the separation of a
major engine flange will occur after the effective date of this AD.
The following maintenance actions are not considered ESVs for the
purpose of this AD:
(1) Introduction of an engine into a shop solely for removal of
the compressor top case for airfoil maintenance;
(2) Introduction of an engine into a shop solely for removal or
replacement of the Stage 1 Fan Disk;
(3) Introduction of an engine into a shop solely for replacement
of the Turbine Rear Frame;
(4) Introduction of an engine into a shop solely for replacement
of the Accessory and/or Transfer Gearboxes;
[[Page 65147]]
(5) Introduction of an engine into a shop for any combination of
the above specified exceptions.
(k) 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 Manager, Engine Certification Office.
Operators shall submit their requests through an appropriate FAA
Principal Maintenance Inspector, who may add comments and then send
it to the Manager, Engine Certification Office.
Note 3: Information concerning the existence of approved
alternative methods of compliance with this airworthiness directive,
if any, may be obtained from the Engine Certification Office.
(l) Special flight permits may be issued in accordance with
sections 21.197 and 21.199 of the Federal Aviation Regulations (14
CFR 21.197 and 21.199) to operate the aircraft to a location where
the requirements of this AD can be accomplished.
Issued in Burlington, Massachusetts, on November 17, 1998.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification
Service.
[FR Doc. 98-31437 Filed 11-24-98; 8:45 am]
BILLING CODE 4910-13-P
