FAA orders replacement of high-pressure turbine seals on A380 engines

The US Federal Aviation Administration has issued an airworthiness directive covering certain Engine Alliance engines that power only the Airbus A380, after a seal failure caused one aircraft to abandon its takeoff run.

The directive covers the GP7270, GP7272 and GP7277 powerplants built by Engine Alliance, a joint venture between GE and Pratt & Whitney. The FAA said the action followed a report of an aborted takeoff caused by an uncontrolled failure of the high-pressure turbine interstage seal, which left a GP7270 engine inoperative. The cause remains under investigation.

Operators are required to remove the affected high-pressure turbine interstage seal and replace it with a part approved for installation. The FAA warned that leaving the unsafe condition unaddressed could lead to an engine fire and damage to the aircraft.

The agency said it opted to require removal of the 15 interstage seals with the highest cycle counts since their last overhaul, which it indicated likely means 15 seals in 15 different engines, though the directive does not state this explicitly. Deadlines vary by serial number. The shortest is 50 flight cycles or 30 days after the directive takes effect on 23 October, whichever comes first.

The FAA put the cost at USD 528,150 per unit, made up of USD 527,300 in parts and ten work hours at USD 85 each.

Four airlines operate the A380 with these engines.