2009-05-02: Drainless fuel manifold assemblies

2009-05-02 General Electric Company: Amendment 39-15826. Docket No. FAA-2007-28413; Directorate Identifier 2007-NE-25-AD. Effective Date (a) This airworthiness directive (AD) becomes effective March 31, 2009. Affected ADs (b) None. Applicability (c) This AD applies to: (1) General Electric (GE) CF6-80C2A1, -80C2A2, -80C2A3, -80C2A5, -80C2A8, -80C2A5F, -80C2B1, -80C2B2, -80C2B4, -80C2B6, -80C2B1F, - 80C2B1F1, -80C2B1F2, -80C2B2F, -80C2B3F, -80C2B4F, -80C2B5F, - 80C2B6F, -80C2B6FA, -80C2B7F, -80C2B8F, -80C2D1F, -80C2L1F, -80C2K1F turbofan engine models with fuel manifold part numbers (P/Ns) 1303M31G12 and 1303M32G12, installed in drainless fuel manifold assemblies (introduced by GE Aircraft Engines (GEAE) Service Bulletin (SB) CF6-80C2 S/B 73-0253). These engines are installed on, but not limited to, Boeing 747, 767, MD11, and Airbus A300-600 and A310 airplanes. (2) This AD also applies to GE CF6-80E1A1, -80E1A2, -80E1A3, - 80E1A4, -80E1A4/B turbofan engine models with fuel manifold P/Ns 1303M31G12 and 1303M32G12, installed in drainless fuel manifold assemblies (introduced by GEAE SB CF6-80E1 S/B 73-0026). These engines are installed on Airbus A330 airplanes. Unsafe Condition (d) This AD results from reports of fuel leaks during engine operation. We are issuing this AD to prevent fuel leaks that could result in an under-cowl fire and damage to the airplane. 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. Removal and Replacement of Loop Clamps and Fuel Manifold Inspection Compliance Times (f) Using Table 1 of this AD, Schedule for Inspections and Replacements, accomplish the following actions in the intervals indicated in the table: remove and discard all loop clamps, P/N J1220G10, or part manufacturer approval (PMA) equivalent, that hold the fuel manifold to the compressor rear frame (CRF) friction damper brackets. Inspect the fuel manifold for wear at each clamp location as specified in paragraphs (g) and (h) of this AD. Replace the discarded loop clamps with new, zero-time clamps. Table 1--Schedule for Inspections and Replacements If: Then replace clamps and inspect within: (1) The engine was previously inspected using GEAE SB CF6 80C2 S/ B 73 0326, dated March 5, 2003, for CF6 80C2 engines; or GEAE SB CF6 80E1 S/B 73 0061, dated April 14, 2003, for CF6 80E1 engines. 1,750 flight hours (FH) time-since-last-inspection (TSLI) or within 4 months after the effective date of this AD. (2) Used loop clamps or clamps of unknown heritage were installed at last shop visit. 1,750 FH time-since-last-shop-visit or within 4 months after the effective date of this AD. (3) The engine is a first-run engine or is an engine with zero-time, new loop clamps previously installed on-wing or at shop visit. 7,500 FH time-since-new or since zero-time, new loop clamps were installed (regardless if previously inspected per GEAE SB CF6 80C2 S/B 73 0326 or GEAE SB CF6 80E1 S/B 73 0061). (4) The engine has already exceeded the 1,750 FH initial inspection threshold on the effective date of this AD, but has fewer than 4,500 flight hours TSLI. 4,500 FH TSLI, or 4 months after the effective date of this AD, whichever occurs first. (5) The engine has already exceeded the 4,500 FH initial inspection threshold on the effective date of this AD. 4 months after the effective date of this AD. Inspection of Fuel Manifold P/Ns 1303M31G12 and 1303M32G12 (g) Remove any tape at any clamp location. Visually inspect the full circumference of the manifold for wear at each clamp location. If any wear is found, follow paragraph (h) of this AD. (h) When the fuel manifold shows any signs of wear, determine the depth of the wear as follows: (1) Measure the outside diameter of the tube adjacent to the worn area. (2) Measure the worn area at the smallest diameter. (3) Subtract the measurement of the worn tube diameter from the unworn diameter measurement. Allowable wear is 0.0035 inch. (4) Replace fuel manifolds with wear greater than 0.010 inch before further flight. (5) Replace fuel manifolds with wear greater than 0.0035 inch but less than 0.010 inch, within 50 flight cycles. Revise Air Carrier's Continuous Airworthiness Maintenance Program (CAMP) and Airworthiness Limitation Section (ALS) (i) Within 30 days of the effective date of this AD, revise the air carrier's approved CAMP and Instructions for Continued Airworthiness (ICA) Chapter 5, Airworthiness Limitation Section for the CF6-80C2 and CF6-80E1 series engines to require: (1) Repetitive inspections of fuel manifolds, P/Ns 1303M31G12 and 1303M32G12, installed in drainless fuel manifold assemblies introduced by CF6-80C2 S/B 73-0253 and CF6-80E1 S/B 73-0026, as detailed in paragraphs (g) and (h) of this AD, at 7,500 FHintervals. (2) Mandatory removal of all loop clamps that hold the fuel manifold, P/Ns 1303M31G12 and 1303M32G12, to the CRF damper brackets, at each inspection. (3) Replacement of all loop clamps with new, zero-time loop clamps, at each inspection. Alternative Methods of Compliance (j) The Manager, Engine Certification Office, has the authority to approve alternative methods of compliance for this AD if requested using the procedures found in 14 CFR 39.19. Related Information (k) GEAE SB CF6-80C2 S/B 73-0326, dated March 5, 2003, and GEAE SB CF6-80E1 S/B 73-0061, dated April 14, 2003; and the following GE engine manuals pertain to the subject of this AD: (1) CF6-80C2 Engine Manual GEK 92451. (2) CF6-80C2L1F Engine Manual GEK 112213. (3) CF6-80C2K1F Engine Manual GEK 112721. (4) CF6-80E1 Engine Manual GEK 99376. (l) 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 the service information identified in this AD. (m) Contact Robert Green, Aerospace Engineer, Engine Certification Office, FAA, Engine and Propeller Directorate, 12 New England Executive Park, Burlington, MA 01803; e-mail: Robert.green@faa.gov; telephone (781) 238-7754; fax (781) 238-7199, for more information about this AD.