[Federal Register: April 3, 2003 (Volume 68, Number 64)]
[Rules and Regulations]
[Page 16200-16203]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr03ap03-8]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 2002-NM-315-AD; Amendment 39-13104; AD 2003-07-08]
RIN 2120-AA64
Airworthiness Directives; Boeing Model 757-200, 757-200CB, and
757-200PF Series Airplanes
AGENCY: Federal Aviation Administration, DOT.
ACTION: Final rule; request for comments.
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SUMMARY: This amendment adopts a new airworthiness directive (AD) that
is applicable to certain Boeing Model 757-200, 757-200CB, and 757-200PF
series airplanes. This action requires repetitive detailed inspections
to detect horizontal or vertical movement of the shims at the joint of
the mid-bulkhead and the upper link fittings, and corrective action if
necessary; or certain alternative actions that will terminate the
requirement for the repetitive inspections. This action is necessary to
detect and correct migration of shims at the joint of the mid-bulkhead
and the upper link fittings, which could result in cracking of the
strut and consequent loss of the strut and engine.
DATES: Effective April 18, 2003. The incorporation by reference of
certain publications listed in the regulations is approved by the
Director of the Federal Register as of April 18, 2003.
Comments for inclusion in the Rules Docket must be received on or
before June 2, 2003.
ADDRESSES: Submit comments in triplicate to the Federal Aviation
Administration (FAA), Transport Airplane Directorate, ANM-114,
Attention: Rules Docket No. 2002-NM-315-AD, 1601 Lind Avenue, SW.,
Renton, Washington 98055-4056. Comments may be inspected at this
location between 9 a.m. and 3 p.m., Monday through Friday, except
Federal holidays. Comments may be submitted via fax to (425) 227-1232.
Comments may also be sent via the Internet using the following address:
9-anm-iarcomment@faa.gov. Comments sent via fax or the Internet must
contain ``Docket No. 2002-NM-315-AD'' in the subject line and need not
be submitted in triplicate. Comments sent via the Internet as attached
electronic files must be formatted in Microsoft Word 97 for Windows or
ASCII text.
The service information referenced in this AD may be obtained from
Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, Washington
98124-2207. This information may be examined at the FAA, Transport
Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at
the Office of the Federal Register, 800 North Capitol Street, NW.,
suite 700, Washington, DC.
FOR FURTHER INFORMATION CONTACT: Dennis Stremick, Aerospace Engineer,
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office,
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425)
917-6450; fax (425) 917-6590.
SUPPLEMENTARY INFORMATION: The FAA has received several reports of
cracking of the strut in the mid-bulkhead on certain Boeing Model 757-
200, 757-200CB, and 757-200PF series airplanes. Investigation revealed
that the shims at the joint of the mid-bulkhead and the upper link
fittings had migrated out of position. The investigation also revealed
that the shim's movement was possibly caused by movement of the
fittings and
[[Page 16201]]
the installation of thin laminated shims at the joint. The holes in the
fittings rely on the action of the sleevebolts for alignment. If
complete alignment does not occur, the joint could move and cause the
shim to delaminate, resulting in the shim migrating away from the
joint. Such migration of the shims, if not corrected, could result in
cracking of the strut and consequent loss of the strut and engine.
Explanation of Relevant Service Information
The FAA has reviewed and approved Boeing Alert Service Bulletin
(ASB) 757-54A0039, Revision 1, dated June 20, 2002. Part I of the
Accomplishment Instructions of that ASB describes procedures for
performing repetitive detailed inspections of the laminated shims at
the joint of the mid-bulkhead and upper link fittings to detect any
vertical or horizontal movement of the shims. Part II of the
Accomplishment Instructions of the ASB describes follow-on corrective
actions (Figure 3 of the ASB) for shims that have migrated within
certain limits (e.g., replacing the laminated shims with new solid
shims, replacing the existing sleevebolts with new oversized
sleevebolts, performing visual and high frequency eddy current
inspections (HFEC) to detect cracking and deformation in the sleevebolt
holes and in the fittings, and corrective actions if necessary). The
ASB recommends that operators contact Boeing if any shims cannot be
removed. Additionally, Part III of the Accomplishment Instructions of
the ASB describes procedures for performing a one-time HFEC inspection
of the bolt holes (Figure 9 of the ASB) in the mid-bulkhead, and
describes repair procedures for cracking.
Explanation of the Requirements of the Rule
Since an unsafe condition has been identified that is likely to
exist or develop on other airplanes of the same type design, this AD is
being issued to detect and correct migration of shims at the joint of
the mid-bulkhead and the upper link fittings, which could result in
cracking of the strut and consequent loss of the strut and engine. This
AD requires accomplishment of the actions specified in the service
bulletin described previously, except as discussed below.
Differences Between the ASB and This AD
Revision 1 of the ASB recommends that operators who have
accomplished the inspections and actions described in Boeing ASB 757-
54A0039, November 2, 2000, perform a one-time non-destructive testing
(NDT) and/or HFEC inspection to detect cracking of the mid-bulkhead as
shown in Figure 9 of the ASB, and repair if necessary. Operators should
note that this AD requires those operators to perform a detailed
inspection to detect cracking rather than an NDT and/or HFEC
inspection. We have determined that, for airplanes on which the
inspections specified in Parts I and II of Boeing ASB 757-54A0039,
dated November 2, 2000, have been previously accomplished, a detailed
inspection to detect cracks, and repair if necessary, within 90 days of
the effective date of this AD, are adequate to continue to provide an
acceptable level of safety for this interim action.
Operators also should note that Boeing ASB 757-54A0039, Revision 1,
dated June 20, 2002, does not specify procedures for operators to add
previously recorded measurements of the shim movement to the current
measurement of shim movement. However, this AD requires those actions
to ensure that the cumulative or progressive movement is measured and
recorded to encompass total movement of the shim.
Additionally, operators also should note that, although the ASB
specifies that the manufacturer may be contacted for further
instructions if a shim cannot be removed or for disposition of certain
repair conditions, this AD requires the repair of those conditions to
be accomplished per a method approved by the FAA, or per data meeting
the type certification basis of the airplane approved by a Boeing
Company Designated Engineering Representative who has been authorized
by the FAA to make such findings.
Interim Action
This is considered to be interim action. We are currently
considering requiring HFEC inspections for cracking in and around the
bolt holes of the left and right side of the mid-bulkhead strut, and
repair if necessary, which would constitute terminating action for the
repetitive inspections required by this AD. However, the planned
compliance time for the HFEC inspections is sufficiently long so that
notice and opportunity for prior public comment will be practicable.
Determination of Rule's Effective Date
Since a situation exists that requires the immediate adoption of
this regulation, it is found that notice and opportunity for prior
public comment hereon are impracticable, and that good cause exists for
making this amendment effective in less than 30 days.
Comments Invited
Although this action is in the form of a final rule that involves
requirements affecting flight safety and, thus, was not preceded by
notice and an opportunity for public comment, comments are invited on
this rule. Interested persons are invited to comment on this rule by
submitting such written data, views, or arguments as they may desire.
Communications shall identify the Rules Docket number and be submitted
in triplicate to the address specified under the caption ADDRESSES. All
communications received on or before the closing date for comments will
be considered, and this rule may be amended in light of the comments
received. Factual information that supports the commenter's ideas and
suggestions is extremely helpful in evaluating the effectiveness of the
AD action and determining whether additional rulemaking action would be
needed.
Submit comments using the following format:
[sbull] Organize comments issue-by-issue. For example, discuss a
request to change the compliance time and a request to change the
service bulletin reference as two separate issues.
[sbull] For each issue, state what specific change to the AD is
being requested.
[sbull] Include justification (e.g., reasons or data) for each
request.
Comments are specifically invited on the overall regulatory,
economic, environmental, and energy aspects of the rule that might
suggest a need to modify the 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 that
summarizes each FAA-public contact concerned with the substance of this
AD will be filed in the Rules Docket.
Commenters wishing the FAA to acknowledge receipt of their comments
submitted in response to this rule must submit a self-addressed,
stamped postcard on which the following statement is made: ``Comments
to Docket Number 2002-NM-315-AD.'' The postcard will be date stamped
and returned to the commenter.
Regulatory Impact
The regulations adopted herein will not have a substantial direct
effect 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, it
is determined that this final rule does not have federalism
implications under Executive Order 13132.
[[Page 16202]]
The FAA has determined that this regulation is an emergency
regulation that must be issued immediately to correct an unsafe
condition in aircraft, and that it is not a ``significant regulatory
action'' under Executive Order 12866. It has been determined further
that this action involves an emergency regulation under DOT Regulatory
Policies and Procedures (44 FR 11034, February 26, 1979). If it is
determined that this emergency regulation otherwise would be
significant under DOT Regulatory Policies and Procedures, a final
regulatory evaluation will be prepared and placed in the Rules Docket.
A copy of it, if filed, may be obtained from the Rules Docket at the
location provided under the caption ADDRESSES.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
Adoption of the Amendment
0
Accordingly, pursuant to the authority delegated to me by the
Administrator, the Federal Aviation Administration amends part 39 of
the Federal Aviation Regulations (14 CFR part 39) as follows:
PART 39--AIRWORTHINESS DIRECTIVES
0
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]
0
2. Section 39.13 is amended by adding the following new airworthiness
directive:
2003-07-08 Boeing: Amendment 39-13104. Docket 2002-NM-315-AD.
Applicability: Model 757-200, 757-200CB, and 757-200PF series
airplanes, line numbers 1 through 735 inclusive, equipped with Rolls
Royce Model RB211 engines, as listed in Boeing Alert Service
Bulletin 757-54A0039, Revision 1, dated June 20, 2002; certificated
in any category.
Note 1: This AD applies to each airplane 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 airplanes 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 (i) 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 detect and correct migration of shims at the joint of the
mid-bulkhead and the upper link fittings, which could result in
cracking of the strut and consequent loss of the strut and engine;
accomplish the following:
Inspection for Movement of Shims and Corrective Actions
(a) With the exception of the airplanes specified in paragraph
(e) of this AD: Within 90 days after the effective date of this AD,
perform a detailed inspection to detect horizontal or vertical
movement of the shims at the joint of the mid-bulkhead and the upper
link fittings, per Boeing Alert Service Bulletin (ASB) 757-54A0039,
Revision 1, dated June 20, 2002.
Note 2: For the purposes of this AD, a detailed inspection is
defined as: ``An intensive visual examination of a specific
structural area, system, installation, or assembly to detect damage,
failure, or irregularity. Available lighting is normally
supplemented with a direct source of good lighting at intensity
deemed appropriate by the inspector. Inspection aids such as mirror,
magnifying lenses, etc., may be used. Surface cleaning and elaborate
access procedures may be required.''
(b) If all laminated shims have not moved, or if all laminated
shims have moved less than 0.25 inch, before further flight, perform
the actions specified in either paragraph (b)(1) or (b)(2) of this
AD, per Boeing Alert Service Bulletin (ASB) 757-54A0039, Revision 1,
dated June 20, 2002.
(1) Perform the actions specified in paragraph 3.B.6 of the
Accomplishment Instructions of the ASB (e.g., measure and record
movement of the shim, cut the exposed plies, and seal adjacent
surfaces and edges), and repeat the detailed inspections at
intervals not to exceed 12,000 flight cycles or 72 months, whichever
occurs first. At each inspection interval, the previously recorded
measurement must be added to the current measurement so that the
cumulative total movement of the shim is recorded. If the cumulative
total movement exceeds 0.25 but is less than 0.90, before further
flight, perform the actions specified in paragraph (c) of this AD.
If the cumulative total movement measures 0.90 inch or more: Before
further flight, perform the actions specified in paragraph (d) of
this AD. Or,
(2) Perform the actions specified in paragraphs (g) and (h) of
this AD.
(c) If any laminated shim has moved 0.25 inch or more but less
than 0.90 inch: Before further flight, perform the actions specified
in paragraph (c)(1) or (c)(2) of this AD, per Boeing Alert Service
Bulletin (ASB) 757-54A0039, Revision 1, dated June 20, 2002.
(1) Before further flight, perform the actions specified in
paragraph 3.B.6 of the Accomplishment Instructions of the ASB (e.g.,
measure and record movement of the shim, cut the exposed plies and
seal adjacent surfaces and edges), and repeat the detailed
inspections at intervals not to exceed 3,000 flight cycles or 18
months, whichever occurs first. At each inspection interval, the
previously recorded measurement must be added to the current
measurement so that the cumulative total movement of the shim is
recorded. If the cumulative total movement measures 0.90 inch or
more, before further flight, perform the actions specified in
paragraph (d) of this AD. Or,
(2) Perform the actions specified in paragraphs (g) and (h) of
this AD.
(d) If any laminated shim has moved 0.90 inch or more, before
further flight, perform the actions specified in paragraphs (g) and
(h) of this AD.
Inspection of Lower Mid-Spar Bolts
(e) For airplanes on which the actions specified in Boeing Alert
Service Bulletin (ASB) 757-54A0039, dated November 2, 2000, have
been accomplished prior to the effective date of this AD: Within 90
days after the effective date of this AD, perform a detailed
inspection for cracking around the four bolt heads, nuts, washers,
and radius fillers specified in Figure 9 of Boeing Alert Service
Bulletin (ASB) 757-54A0039, Revision 1, dated June 20, 2002.
(1) If no cracking is found, repeat the detailed inspection at
intervals not to exceed 3,000 flight cycles.
(2) If any cracking is found, before further flight, repair per
a method approved by the Manager, Seattle Aircraft Certification
Office (ACO), FAA; or per data meeting the type certification basis
of the airplane approved by a Boeing Company Designated Engineering
Representative who has been authorized by the Manager, Seattle ACO,
to make such findings. For a repair method to be approved, the
approval must specifically reference this AD.
Optional Terminating Action
(f) Accomplishment of the actions specified in paragraphs (g)
and (h) of this AD constitutes terminating action for the repetitive
inspection requirements of this AD.
(g) Replace any laminated shim with a solid shim; replace
existing sleevebolts with new, oversized sleevebolts; and perform a
general visual and high-frequency eddy current (HFEC) inspection to
detect cracking and deformation in the sleevebolt holes and in the
fittings, as shown in Part II, Figure 3, of Boeing Alert Service
Bulletin 757-54A0039, Revision 1, dated June 20, 2002. If any shim
cannot be removed, or if any cracking or deformation is found:
Before further flight, repair per a method approved by the Manager,
Seattle Aircraft Certification Office (ACO), FAA; or per data
meeting the type certification basis of the airplane approved by a
Boeing Company Designated Engineering Representative who has been
authorized by the Manager, Seattle ACO, to make such findings. For a
repair to be approved, the approval must specifically reference this
AD. No further action is required by this paragraph.
(h) Perform a one-time HFEC inspection for cracking in and
around the bolt holes of the left and right side of the mid-bulkhead
strut as shown in Part III, Figure 9, of Boeing Alert Service
Bulletin (ASB) 757-54A0039, Revision 1, dated June 20, 2002.
(1) If no cracking is found during any inspection specified in
paragraph (h) of this AD, before further flight, install oversized
[[Page 16203]]
bolts per Figure 10 of the ASB. No further action is required by
this AD.
(2) If any cracking is found during any inspection specified in
paragraph (h) of this AD that is within the limits specified in the
ASB: Before further flight, repair per the ASB.
(3) If any cracking is found during any inspection specified in
paragraph (h) of this AD that is outside the limits specified by the
ASB, and the ASB specifies to contact Boeing for appropriate action:
Before further flight, repair per a method approved by the Manager,
Seattle Aircraft Certification Office (ACO), FAA; or per data
meeting the type certification basis of the airplane approved by a
Boeing Company Designated Engineering Representative who has been
authorized by the Manager, Seattle ACO, to make such findings. For a
repair method to be approved, the approval must specifically
reference this AD.
Alternative Methods of Compliance
(i) 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, Seattle ACO. Operators shall submit
their requests through an appropriate FAA Principal Maintenance
Inspector, who may add comments and then send it to the Manager,
Seattle ACO.
Note 3: Information concerning the existence of approved
alternative methods of compliance with this AD, if any, may be
obtained from the Seattle ACO.
Special Flight Permits
(j) Special flight permits may be issued in accordance with
Sec. Sec. 21.197 and 21.199 of the Federal Aviation Regulations (14
CFR 21.197 and 21.199) to operate the airplane to a location where
the requirements of this AD can be accomplished.
Incorporation by Reference
(k) Unless otherwise specified in this AD, the actions shall be
done in accordance with Boeing Alert Service Bulletin 757-54A0039,
Revision 1, dated June 20, 2002. This incorporation by reference was
approved by the Director of the Federal Register in accordance with
5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from
Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, Washington
98124-2207. Copies may be inspected at the FAA, Transport Airplane
Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the
Office of the Federal Register, 800 North Capitol Street, NW., suite
700, Washington, DC.
Effective Date
(l) This amendment becomes effective on April 18, 2003.
Issued in Renton, Washington, on March 26, 2003.
Michael J. Kaszycki,
Acting Manager, Transport Airplane Directorate, Aircraft Certification
Service.
[FR Doc. 03-7748 Filed 4-2-03; 8:45 am]
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