AD/CF6/71 Life Limited Parts (Cth)

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AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (AD) under subregulation 39.001(1) of CASR 1998.  The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

General Electric Turbine Engines - CF6 Series

AD/CF6/71 Life Limited Parts 4/2009

Applicability:

General Electric Company CF6-80A, CF6-80C2, and CF6-80E1 series turbofan engines.

Note 1:  These engines are installed on, but not limited to, Airbus A300, A310, and A330 series, Boeing 747 and 767 series, and McDonnell Douglas MD-11 series aeroplanes.

Requirement:

1.    Revise the Airworthiness Limitations Section (ALS) of the manufacturer's Instructions for Continued Airworthiness (ICA), and for air carrier operations revise the approved continuous airworthiness maintenance program, by adding the following: ''MANDATORY INSPECTIONS'' as detailed in Table 1 of this AD.

Table 1

Part Nomenclature

Part Number (P/N)

Inspect per Engine Manual Inspection Chapter

For CF6-80A Engines:

Disk, Fan Rotor,
 Stage 1

All

72-21-03 Paragraph 3. Fluorescent-Penetrant Inspect, and 72-21-03 Paragraph 4. Eddy Current Inspect

Fan Forward Shaft

All

72-21-05 Paragraph 2. Magnetic Particle Inspect

Fan Mid Shaft

All

72-24-01 Paragraph 2. Magnetic Particle Inspect

Disk, HPC Rotor, 
 Stage One

All

72-31-04 Paragraph 3. Fluorescent-Penetrant Inspect

** Disk, HPC Rotor, Stage Two

All

72-31-05 Paragraph 4. Fluorescent-Penetrant Inspect

Spool, HPC Rotor, Stage3-9

All

72-31-06 Paragraph 3. Fluorescent-Penetrant Inspect

Disk, HPC Rotor,
Stage 10

All

72-31-07 Paragraph 3. Fluorescent-Penetrant Inspect

Spool, HPC Rotor,
Stage 11-14

All

72-31-08 Paragraph 3.A. Fluorescent-Penetrant Inspect

Rotating CDP Seal

All

72-31-10 Paragraph 3. Fluorescent-Penetrant Inspect

Disk Shaft, HPT Rotor Stage One

All

72-53-02 Paragraph 3. Fluorescent-Penetrant-Inspect per 70-32-02, and

72-53-02 Paragraph 6.C. Disk Rim Bolt Hole Eddy Current Inspection, and

72-53-02 Paragraph 6.D. Disk Bore Eddy Current Inspection

* Disk Shaft, HPT Rotor Stage One

All

72-53-02 Paragraph 6.E. Disk Dovetail Slot Bottom Eddy Current Inspection

* Disk Shaft, HPT Rotor, Stage One

P/Ns 2047M33G01 thru G10, and P/N 9362M58G11

72-53-02 Paragraph 7. Disk Dovetail Slot Bottom Aft Corner Chamfers Eddy Current Inspection

Disk, HPT Rotor,
Stage Two

All

72-53-06 Paragraph 3. Fluorescent-Penetrant Inspection, and

72-53-06 Paragraph 6. Eddy Current Inspection of Rim Bolt Holes for Cracks, and

72-53-06 Paragraph 7. Disk Bore Eddy Current Inspection

Disk, LPT Rotor
Stage 1-4

All

72-57-02 Paragraph 3. Fluorescent-Penetrant Inspection

Shaft, LPT Rotor

All

72-57-03 Paragraph 3. Fluorescent-Penetrant Inspection, and

72-57-03 Paragraph 6. Eddy Current Inspection

For All CF6-80C2 Engines:

Disk, Fan Rotor,
 Stage 1

All

Task 72-21-03-200-000-004 Fluorescent-Penetrant Inspection, and

Task 72-21-03-200-000-008 Eddy Current Inspect Fan Rotor Disk Stage 1 Bore, Forward and Aft Hub Faces, and Bore Radii

Shaft, Fan Forward

All

Task 72-21-05-200-000-001 Fluorescent Penetrant Inspection, and

Task 72-21-05-200-000-005 Vent Hole Eddy Current Inspection

Fan Mid Shaft

All

Task 72-24-01-200-000-003 Magnetic Particle Inspection

HPCR Stage 1 Disk

All

Task 72-31-04-200-000-002 Fluorescent Penetrant Inspection

HPCR Stage 2 Disk

All

Task 72-31-05-200-000-002 Fluorescent Penetrant Inspection

HPCR Stage 3-9 Spool

All

Task 72-31-06-200-000-001 Fluorescent Penetrant Inspection

HPCR Stage 10 Disk

All

Task 72-31-07-200-000-001 Fluorescent Penetrant Inspection

HPCR Stage 11-14 Spool/Shaft

All

Task 72-31-08-200-000-002 Fluorescent Penetrant Inspection

No. 4 Bearing Rotating (CDP) Air Seal

All

Task 72-31-10-200-000-001 Fluorescent Penetrant Inspection or

Task 72-31-10-200-000-A01 Fluorescent Penetrant Inspection

HPCR Stage 10-14 Spool/Shaft

All

Task 72-31-22-200-000-002 Fluorescent Penetrant Inspection

** Disk/Shaft, HPT Rotor, Stage One

All

Task 72-53-02-200-000-001 (Inspection - Configuration 1), or Task 72-53-02-230-801 (Inspection - Configuration 2), Fluorescent-Penetrant Inspect, and

Task 72-53-02-200-000-005 (Inspection - Configuration 1), or Task 72-53-02-250-802 (Inspection - Configuration 2), Disk Rim Bolt Hole Eddy Current Inspection, and

Task 72-53-02-200-000-006 (Inspection - Configuration 1), or Task 72-53-02-250-803 (Inspection - Configuration 2), Disk Bore Area Eddy Current Inspection, and

Task 72-53-02-200-000-007 (Inspection - Configuration 1), or Task 72-53-02-250-804 (Inspection - Configuration 2), Disk Dovetail Slot Bottom Eddy Current

* Disk/Shaft, HPT Rotor, Stage One

P/N 1531M84G12 and P/Ns 2047M32G01 thru G07

Task 72-53-02-250-801 (Inspection - Configuration 1), Disk Dovetail Slot Bottom Aft Corner Chamfers Eddy Current Inspection

Disk, HPT Rotor,
Stage Two

All

Task 72-53-06-200-000-002 Fluorescent-Penetrant Inspect, and

Task 72-53-06-200-000-006 Disk Rim Bolt Hole Eddy Current Inspection, and

Task 72-53-06-200-000-007 Disk Bore Eddy Current Inspection

LPTR Stage 1-5 Disks

All

Task 72-57-02-200-000-001 Fluorescent-Penetrant Inspection

LPTR Shaft

All

Task 72-57-03-200-000-002 Fluorescent-Penetrant Inspect, and

Task 72-57-03-200-000-006 Eddy Current Inspection

For CF6-80C2 Engines configured with the R88DT Turbine (Models
CF6-80C2B2F, 80C2B4F, 80C2B6F, 80C2B7F, 80C2B8F):

Disk/Shaft, HPT Rotor, Stage One (R88DT, No Rim Bolt Holes)

All

Task 72-53-16-200-000-001 Fluorescent-Penetrant Inspect, and

Task 72-53-16-200-000-005 Disk Bore Area Eddy Current Inspection

Disk, HPT Rotor, Stage Two (R88DT, No Rim Bolt Holes)

All

Task 72-53-18-200-000-002 Fluorescent-Penetrant Inspect, and

Task 72-53-18-200-000-005 Disk Bore Area Eddy Current Inspection

Rotating Interstage Seal (R88DT)

All

Task 72-53-17-200-000-001 Fluorescent-Penetrant Inspect, and

Task 72-53-17-200-000-005 Seal Bore Area Eddy Current

Forward Outer Seal (R88DT)

All

Task 72-53-21-200-000-001 Fluorescent-Penetrant Inspect, and

Task 72-53-21-200-000-004 Seal Bore Area Eddy Current

For CF6-80E1 Engines:

Disk, Fan Rotor, 
 Stage One

All

Sub Task 72-21-03-230-051 Fluorescent-Penetrant Inspection, and

Sub Task 72-21-03-250-051 or 72-21-03-250-052 Disk Bore Eddy Current Inspection

Shaft, Fan

All

Sub Task 72-21-05-230-051 Fluorescent Penetrant Inspection, and

Sub Task 72-21-05-250-051 Vent Hole Eddy Current Inspection

Compressor Rotor,
Stage 1 Disk

All

Sub Task 72-31-04-230-051 Fluorescent Penetrant Inspection,

Compressor Rotor,
Stage 2 Disk

All

Sub Task 72-31-05-230-051 Fluorescent Penetrant Inspection

Compressor Rotor,
Stage 3-9 Spool

All

Sub Task 72-31-06-230-051 Fluorescent Penetrant Inspection

Compressor Rotor,
Stage 10 Disk (Pre SB
72-0150)

All

Sub Task 72-31-07-230-051 Fluorescent Penetrant Inspection

Compressor Rotor Spool/Shaft, Stage 11-14 (Pre SB 72-0150)

All

Sub Task 72-31-08-230-051 Fluorescent Penetrant Inspection

Compressor Rotor Spool/Shaft, Stage 10-14 (SB 72-0150)

All

Sub Task 72-31-23-230-052 Fluorescent Penetrant Inspection

Compressor Rotor No. 4 Bearing Rotating Air Seal (CDP Rotating Seal)

All

Sub Task 72-31-10-230-051 Fluorescent Penetrant Inspection

HPT Disk/Shaft,
Stage 1

All

Sub Task 72-53-02-230-051 Fluorescent-Penetrant Inspection, and

Sub Task 72-53-02-250-051 Eddy Current Inspection, Rim Bolt Holes, and

Sub Task 72-53-02-250-054 Eddy Current Inspection, Disk Bore

HPT Disk, Stage 2

All

Sub Task 72-53-06-230-051 Fluorescent-Penetrant Inspection, and

Sub Task 72-53-06-250-051 Eddy Current Inspection, Rim Bolt Holes, and

Sub Task 72-53-06-250-054 Eddy Current Inspection, Disk Bore

LPT Rotor Shaft

All

Sub Task 72-55-01-240-051 Magnetic Particle Inspect

LPT Disks, Stages 1-5

All

Sub Task 72-57-02-230-051 Fluorescent-Penetrant Inspect

LPT Rotor Torque Cone

All

Sub Task 72-57-03-220-051 Fluorescent-Penetrant Inspect

For CF6-80E1 Engines configured with the R88DT Turbine:

Disk/Shaft, HPT Rotor, Stage 1 (R88DT, No Rim Bolt Holes)

All

Sub Task 72-53-16-230-052 Fluorescent-Penetrant Inspect, and

Sub Task 72-53-16-250-051 Disk Bore Area Eddy Current Inspection

Disk, HPT Rotor, Stage 2 (R88DT, No Rim Bolt Holes)

All

Sub Task 72-53-18-230-051 Fluorescent-Penetrant Inspect, and

Sub Task 72-53-18-250-051 Disk Bore Area Eddy Current Inspection

** HPT Rotor Rotating Interstage Seal (R88DT)

All

Sub Task 72-53-17-230-056 Fluorescent-Penetrant Inspect, and

Sub Task 72-53-17-250-051 Seal Bore Area Eddy Current

HPT Rotor Forward Outer Seal (R88DT)

All

Sub Task 72-53-21-230-051 Fluorescent-Penetrant Inspect, and

Sub Task 72-53-21-250-051 Seal Bore Area Eddy Current

2.    Perform inspections of the parts listed in Table 1 of this AD in accordance with the instructions provided in the applicable manual provisions.

Definition:

For the purposes of these mandatory inspections, piece-part opportunity means:

a)    The part is considered completely disassembled when accomplished in accordance with the disassembly instructions in the manufacturer's engine manual; and

b)    The part has accumulated more than 100 cycles-in-service since the last piece-part opportunity inspection, provided that the part was not damaged or related to the cause for its removal from the engine.

The parts added to the table of this AD are identified by an asterisk (*) that precedes the part nomenclature.  Also, parts that have an Engine Manual Inspection Task and or Sub Task Number reference updated in the table of this AD, are identified by two asterisks (**) that precede the part nomenclature.

AMOC’s:

AMOC’s previously approved for FAA AD 2002-07-12, are also approved for this AD.

Note 2:  FAA AD 2009-04-10 Amdt 39-15816 dated 5 February 2009 refers.

Note 3:  This AD supersedes AD/CF6/46.

Compliance:

Fro Requirement 1 - Within 180 days after the effective date of this AD.

For Requirement 2 - At each piece-part opportunity after Requirement 1 of this AD is completed.

This Airworthiness Directive becomes effective on 9 April 2009.

Background:

This AD is superseding an existing airworthiness directive (AD) for General Electric Company (GE) CF6-80A, CF6-80C2, and CF6-80E1 series turbofan engines.  That AD required revisions to the Airworthiness Limitations Section (ALS) of the manufacturer's Instructions for Continued Airworthiness (ICA) to include required inspection of selected critical life-limited parts at each piece-part exposure.

This AD requires revisions to the CF6-80A, CF6-80C2, and CF6-80E1 series engines ALS sections of the manufacturer's manuals and an air carrier's approved continuous airworthiness maintenance program to incorporate additional inspection requirements, and to update certain Engine Manual Inspection Task and Sub Task Number references.

This AD results from the need to require enhanced inspection of selected critical life-limited parts of CF6-80A, CF6-80C2, and CF6-80E1 series engines.  The issuing of this AD is intended to prevent critical life-limited rotating engine part failure, which could result in an uncontained engine failure and damage to the aeroplane.


James Coyne
Delegate of the Civil Aviation Safety Authority

27 February 2009

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