AIRWORTHINESS DIRECTIVE
On the effective date specified below, and for the reasons set out in the background section, the CASA delegate whose signature appears below revokes Airworthiness Directive (AD) AD/CF6/48 and issues the following AD under subregulation 39.1 (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/CF6/48
Amdt 1
Nozzle Guide Vanes 10/2004
Applicability: General Electric Company (GE) CF6-80E1 engine models with high-pressure turbine (HPT) stage 2 (S2) nozzle guide vanes (NGVs), part number (P/N) 1647M84G09 or 1647M84G10 installed.
Note 1: These engines are installed on, but not limited to, Airbus A330 aeroplanes.
Note 2: Engines configured with HPT S2 NGV P/Ns 1647M84G05, 1647M84G06, 2080M47G01, 2080M47G02, 2086M62G03, or 2086M62G04 are not affected by this Directive.
Requirement: 1. NGVs Previously Inspected by Flex Borescope before the effective date of this Directive:
Reinspect or remove from service the NGVs.
2. NGVs Not Previously Inspected by Flex Borescope:
Remove from service, or re-inspect using the Accomplishment Instructions of GE SB No. CF6-80E1 S/B 72-0217, Revision 2, dated 5 January 5 2004.
Note 3: FAA AD 2004-09-34 Amdt 39-13625 refers.
Compliance: For Requirement 1: Unless previously accomplished in accordance with the Conditions and Reinspection intervals listed in the "Inspection Table for Cracking in the Airfoil Outer Fillet," Figure 5, of GE Service Bulletin (SB) No. CF6-80E1 S/B 72-0217, Revision 2, or within 200 cycles-in-service-since-last inspection (CSLI), whichever is earlier.
For Requirement 2: For NGVs with more than 800 cycles-since-overhaul (CSO) on the effective date of this AD, within 50 cycles-in-service (CIS) after the effective date of this AD; thereafter in accordance with the Conditions and Reinspection intervals listed in the "Inspection Table for Cracking in the Airfoil Outer Fillet," Figure 5, of GE SB No. CF6-80E1 S/B 72-0217, Revision 2.
General Electric Turbine Engines - CF6 Series
AD/CF6/48 Amdt 1 (continued)
For NGVs with 800 or fewer CSO on the effective date of this AD, at the first regular HPT blade inspection after 800 CSO, but before reaching 900 CSO; thereafter in accordance with the Conditions and Reinspection intervals listed in the "Inspection Table for Cracking in the Airfoil Outer Fillet," Figure 5, of GE SB No. CF6-80E1 S/B 72-0217, Revision 2.
For the purposes of this AD, cycles-since-overhaul (CSO) is defined as cycles since repair as described in GE SB No. CF6-80E1 S/B 72-0164 dated 16 March 1999.
The original issue of this Directive became effective on 20 February 2003. This Amendment becomes effective on 30 September 2004.
Background: An uncontained failure has been attributed to high-pressure turbine stage two nozzle guide vane distress. This directive introduced an inspection program to identify early signs of distress.
This amendment reduces the inspection interval, because it has been determined that the cracks that develop could grow at a faster rate than originally expected.
The original issue of this Directive became effective on 20 February 2003.
Gary J Carr
Delegate of the Civil Aviation Safety Authority 13 August 2004
The above AD is notified in the Commonwealth of Australia Gazette on 8 September 2004.
Overview
The Airworthiness Directive AD/CF6/48 Amdt 1, issued by the Civil Aviation Safety Authority (CASA) under the Civil Aviation Safety Regulations 1998, was enacted in 2004 to address the issue of uncontained failures in General Electric Company (GE) CF6-80E1 engines due to distress in the high-pressure turbine stage two nozzle guide vanes (NGVs). This directive specifically targets the NGVs with part numbers 1647M84G09 or 1647M84G10, which are installed in aircraft such as the Airbus A330. The policy objective behind this directive is to ensure the airworthiness of these engines by mandating reinspections or removal from service to prevent the risk of catastrophic failures. The directive became effective on 30 September 2004, as an amendment to the original AD/CF6/48 issued on 20 February 2003, responding to findings that cracks in the NGVs could develop and propagate more rapidly than initially anticipated.
Scope and Application
The Airworthiness Directive (AD) AD/CF6/48 Amdt 1 applies to General Electric Company (GE) CF6-80E1 engine models with high-pressure turbine stage 2 nozzle guide vanes (NGVs) part numbers 1647M84G09 or 1647M84G10 installed. These engines are primarily used in Airbus A330 aeroplanes, though they may be installed in other aircraft as well. Notably, engines configured with specific other part numbers for the HPT S2 NGVs are not affected by this directive. The directive requires that the NGVs either be reinspected or removed from service, depending on whether they have been previously inspected by Flex Borescope before the effective date of this directive. For NGVs not previously inspected, they must either be removed from service or re-inspected using the instructions provided in GE Service Bulletin (SB) No. CF6-80E1 S/B 72-0217, Revision 2, dated 5 January 2004. The compliance schedule varies depending on the number of cycles since the last overhaul (CSO) and the cycles in service (CIS) at the effective date of the AD. This AD is issued under the authority of the Civil Aviation Safety Authority (CASA) and its delegate, Gary J Carr, and is applicable throughout the Commonwealth of Australia.
Key Provisions
The Airworthiness Directive (AD) AD/CF6/48 Amendment 1, issued under the Civil Aviation Safety Authority (CASA) regulations, specifically targets the General Electric (GE) CF6-80E1 engines equipped with high-pressure turbine (HPT) stage 2 nozzle guide vanes (NGVs) part numbers 1647M84G09 or 1647M84G10. The AD mandates certain inspections and actions to ensure the airworthiness of these engines, particularly focusing on the nozzle guide vanes. The directive applies to engines that have not been previously inspected by flex borescope before the effective date of this directive or those that have been inspected but require further checks to ensure safety (sections 1 and 2). The compliance section outlines the timing and conditions for these inspections, which vary based on the number of cycles since the last overhaul and the inspection history of the NGVs (section 3).
The obligations imposed by this AD require the reinspection or removal from service of NGVs that have been previously inspected by flex borescope before the effective date of this directive. For NGVs not previously inspected, they must be removed from service or re-inspected using the instructions provided in GE Service Bulletin No. CF6-80E1 S/B 72-0217, Revision 2. These inspections must adhere to specific intervals and conditions as outlined in the AD, which are detailed in the "Inspection Table for Cracking in the Airfoil Outer Fillet," Figure 5, of the referenced service bulletin (section 2). The directive provides a clear timeline for when these inspections or removals must occur, depending on the number of cycles since the last overhaul (section 3).
Failure to comply with the requirements of this Airworthiness Directive could result in significant safety risks, potentially leading to the uncontained failure of the turbine engine. The AD does not explicitly outline specific penalties for non-compliance; however, any breaches of airworthiness directives typically result in enforcement actions by CASA, which could include fines, operational restrictions, or other regulatory actions to ensure compliance. The consequences of non-compliance could also include the grounding of aircraft until the required inspections or repairs are completed, which could lead to substantial operational disruptions and financial costs for operators.