[Federal Register: July 13, 2004 (Volume 69, Number 133)]
[Proposed Rules]
[Page 41997-42000]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr13jy04-28]
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DEPARTMENT OF TRANSPORTATION (DOT)
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2004-18583; Directorate Identifier 2002-NM-285-AD]
RIN 2120-AA64
Airworthiness Directives; Boeing Model 747-100, -100B, -100B SUD,
-200B, -200C, -300, -400, and -400D Series Airplanes; and Model 747SR
Series Airplanes
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD)
for certain Boeing Model 747-100, -100B, -100B SUD, -200B, -200C, -300,
-400, and -400D series airplanes; and Model 747SR series airplanes.
This proposed AD would require repetitive inspections of the forward
corner reveals for the main entry door (MED) 3 for cracking, and
corrective actions if necessary. This proposed AD is prompted by
reports of cracking in the forward corner reveals for the MED 3. We are
proposing this AD to detect and correct misalignment of the girt bar
fitting due to fatigue failure of the forward corner reveals for MED 3,
which could lead to the door escape slide departing from the airplane
if the door is opened when the slide is deployed, and consequent
injuries to passengers and crew using the door escape slide during an
emergency evacuation.
DATES: We must receive comments on this proposed AD by August 27, 2004.
ADDRESSES: Use one of the following addresses to submit comments on
this proposed AD.
DOT Docket Web site: Go to http://dms.dot.gov and follow
the instructions for sending your comments electronically.
Government-wide rulemaking Web site: Go to http://www.regulations.gov
and follow the instructions for sending your
comments electronically.
Mail: Docket Management Facility, U.S. Department of
Transportation, 400 Seventh Street SW., Nassif Building, room PL-401,
Washington, DC 20590.
By fax: (202) 493-2251.
Hand Delivery: room PL-401 on the plaza level of the
Nassif Building, 400 Seventh Street SW., Washington, DC, between 9 a.m.
and 5 p.m., Monday through Friday, except Federal holidays.
You can get the service information identified in this proposed AD
from Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington
98124-2207.
You may examine the contents of this AD docket on the Internet at
http://dms.dot.gov, or at the Docket Management Facility, U.S.
Department of Transportation, 400 Seventh Street SW., room PL-401, on
the plaza level of the Nassif Building, Washington, DC.
FOR FURTHER INFORMATION CONTACT: Nick Kusz, Aerospace Engineer,
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office,
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425)
917-6432; fax (425) 917-6590.
SUPPLEMENTARY INFORMATION:
Docket Management System (DMS)
The FAA has implemented new procedures for maintaining AD dockets
electronically. As of May 17, 2004, new AD actions are posted on DMS
and assigned a docket number. We track each action and assign a
corresponding directorate identifier. The DMS AD docket number is in
the form ``Docket No. FAA-2004-99999.'' The Transport Airplane
Directorate identifier is in the form ``Directorate Identifier 2004-NM-
999-AD.'' Each DMS AD docket also lists the directorate identifier
(``Old Docket Number'') as a cross-reference for searching purposes.
Comments Invited
We invite you to submit any written relevant data, views, or
arguments regarding this proposed AD. Send your comments to an address
listed under ADDRESSES. Include ``Docket No. FAA-2004-18583;
Directorate Identifier 2002-NM-285-AD'' in the subject line of your
comments. We specifically invite comments on the overall regulatory,
economic, environmental, and energy aspects of the proposed AD. We will
consider all comments submitted by the closing date and may amend the
proposed AD in light of those comments.
We will post all comments we receive, without change, to http://dms.dot.gov
, including any personal information you provide. We will
also post a report summarizing each substantive verbal contact with FAA
personnel concerning this proposed AD. Using the search function of
that website, anyone can find and read the comments in any of our
dockets, including the name of the individual who sent the comment (or
signed the comment on behalf of an association, business, labor union,
etc.). You may review DOT's complete Privacy Act Statement in the
Federal Register published on April 11, 2000 (65 FR 19477-78), or you
may visit http://dms.dot.gov.
We are reviewing the writing style we currently use in regulatory
documents. We are interested in your comments on whether the style of
this document is clear, and your suggestions to improve the clarity of
our communications that affect you. You can get more information about
plain language at http://www.faa.gov/language and http://www.plainlanguage.gov.Examining
the Docket
You may examine the AD docket in person at the Docket Management
Facility office between 9 a.m. and 5 p.m., Monday through Friday,
except Federal holidays. The Docket Management Facility office
(telephone (800) 647-5227) is located on the plaza level of the Nassif
Building at the DOT street address stated in the ADDRESSES section.
Comments will be available in the AD docket shortly after the DMS
receives them.
Discussion
We have received reports from eight operators indicating that
cracking of the
[[Page 41998]]
lower forward corner reveals for main entry door (MED) 3 was found on
Model 747 series airplanes. Of the twelve forward corner reveals that
were cracked, eleven were made of cast 356 aluminum and one was made of
6061 aluminum. The cause of the cracking of the forward corner reveals
made of cast 356 aluminum is deflection of the airplane structure at
the MED 3 frame. The cause of the cracking of the forward corner reveal
made of 6061 aluminum was a manufacturing error during the
manufacturing process. This condition, if not detected and corrected,
could result in misalignment of the girt bar fitting due to fatigue
failure of the forward corner reveals for MED 3, which could lead to
the door escape slide departing from the airplane if the door is opened
when the slide is deployed, and consequent injuries to passengers and
crew using the door escape slide during an emergency evacuation.
Explanation of Related AD
We have previously issued AD 96-23-05, amendment 39-9810 (61 FR
58318, November 14, 1996), which applies to certain Boeing Model 747
series airplanes. That AD requires repetitive inspections to detect
cracks and/or corrosion of the girt bar support fitting at certain main
entry doors, and repair or replacement of the support fitting. That AD
also provides for various terminating actions for the repetitive
inspections. Inspections, repair, and replacement required by that AD
are done in accordance with Boeing Service Bulletin 747-53A2378,
Revision 1, dated March 10, 1994. Accomplishment of the applicable
repair in this proposed AD would constitute compliance with the
requirements of paragraph (k)(2)(ii) of AD 96-23-05 for the repair of
the corner casting (reveal) only.
Relevant Service Information
We have reviewed Boeing Special Attention Service Bulletin 747-53-
2460, dated June 27, 2002, which describes procedures for performing
repetitive detailed inspections of the forward corner reveals for MED 3
for cracking, and follow-on and corrective actions, if necessary. Those
actions include the following:
Performing a material type inspection of the forward
corner reveal to determine if it is made of cast 356 aluminum or 6061
aluminum;
Replacing forward corner reveals with forward corner
reveals made of 6061 aluminum;
Repairing the forward corner reveals (including inspecting
for material type and inspecting for cracks); and
Contacting the manufacturer for repair of forward corner
reveals made of 6061 aluminum.
We have determined that accomplishment of the actions specified in
the service bulletin will adequately address the unsafe condition.
FAA's Determination and Requirements of the Proposed AD
We have evaluated all pertinent information and identified an
unsafe condition that is likely to exist or develop on other airplanes
of this same type design. Therefore, we are proposing this AD, which
would require repetitive inspections of the forward corner reveals for
the MED 3 for cracking, and corrective actions if necessary. The
proposed AD would require you to use the service information described
previously to perform these actions, except as discussed under
``Differences Between the Proposed AD and the Service Bulletin.''
Differences Between the Proposed AD and the Service Bulletin
Operators should note that, although the service bulletin specifies
that, if the forward corner reveal is found to be made from 6061
aluminum or if a new 6061 aluminum corner reveal is installed, no
further action is necessary, this proposed AD would require repetitive
inspections if the forward corner reveal is made of 6061 aluminum. The
cracking that was found in a forward corner reveal made of 6061
aluminum, as discussed previously, was detected after the service
bulletin was issued. Therefore, we determined that all forward corner
reveals need to be repetitively inspected to adequately ensure
continued operational safety.
In addition, operators should note that, although the service
bulletin does not specify coordinating with the manufacturer if the
repair of a forward corner reveal consists of installing a new forward
corner reveal made of 6061 aluminum, operators must coordinate with the
manufacturer to ensure that the new forward corner reveal is free from
manufacturing defects before obtaining FAA approval for the repair.
Although Figure 1 of the service bulletin says to ``repeat
inspections every 3,000 flight-cycles'' and to ``perform the next
inspection prior to 3,000 flight-cycles,'' this proposed AD requires
repetitive inspections at intervals not to exceed 3,000 flight cycles
for forward corner reveals made of cast 356 aluminum and repetitive
inspections at intervals not to exceed 1,500 flight cycles for forward
corner reveals made of 6061 aluminum.
Operators should also note that, while Boeing Special Attention
Service Bulletin 747-53-2460, dated June 27, 2002, specifies the
effectivity to be ``all 747 airplanes line numbers 1 through 1037
except for 747-SP's, Freighters and airplanes converted to Special
Freighters,'' this proposed AD has an applicability of ``Model 747-100,
-100B, -100B SUD, -200B, -200C, -300, -400, and -400D series airplanes;
and Model 747SR series airplanes, line numbers 1 through 1,342
inclusive, except freighters and airplanes converted to Boeing special
freighters.'' The line numbers were changed to include airplanes with
forward corner reveals made of 6061 aluminum that may have a
manufacturing defect. It has been verified that airplanes with line
number 1343 and up have forward corner reveals installed that are made
from 6061 aluminum and do not have the manufacturing defect.
Also operators should note that Figure 1 of the service bulletin
specifies the initial inspection threshold to be ``At or prior to 7,000
flight-cycles, or within 2,000 flight-cycles of the issue date of this
service bulletin, or within 3,000 flight-cycles of the last inspection
of the door 3 corner reveal as given in Boeing Service Bulletin 747-
53A2378, whichever is later.'' However, this proposed AD would require
the initial inspection within 1,500 flight cycles after the effective
date of the AD. We have determined that the threshold listed in Figure
1 of the service bulletin would not address the identified unsafe
condition soon enough to ensure an adequate level of safety for the
affected fleet. In developing an appropriate compliance time for this
AD, we considered new reports since the service bulletin was issued,
the manufacturer's recommendation and the degree of urgency associated
with the subject unsafe condition. In light of all of these factors, we
find that requiring the initial inspection within 1,500 flight cycles
represents an appropriate interval of time for affected airplanes to
continue to operate without compromising safety.
In addition, although the service bulletin specifies that the
manufacturer may be contacted for disposition of certain repair
conditions, this proposal would require 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 those findings.
[[Page 41999]]
Furthermore, although step 5 of Figure 8 of the service bulletin
specifies that operators may accomplish the actions on forward corner
reveals made of cast 356 aluminum in accordance with ``an operator's
equivalent procedure,'' this proposed AD would require operators to
accomplish step 5 of Figure 8 only in accordance with the procedures
specified in Standard Overhaul Practices Manual (SOPM) 20-20-02. An
``operator's equivalent procedure'' may be used only if approved as an
alternative method of compliance in accordance with paragraph (m) of
this AD.
The differences described above have been coordinated with the
manufacturer.
Costs of Compliance
This proposed AD would affect about 146 airplanes of U.S. registry
and 926 airplanes worldwide. The proposed detailed inspection for
cracking would take about 1 work hour per airplane, at an average labor
rate of $65 per work hour. Based on these figures, the estimated cost
of the proposed AD for U.S. operators is $9,490, or $65 per airplane,
per inspection cycle.
Regulatory Findings
We have determined that this proposed AD would not have federalism
implications under Executive Order 13132. This proposed AD would 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.
For the reasons discussed above, I certify that the proposed
regulation:
1. Is not a ``significant regulatory action'' under Executive Order
12866;
2. Is not a ``significant rule'' under the DOT Regulatory Policies
and Procedures (44 FR 11034, February 26, 1979); and
3. Will not have a significant economic impact, positive or
negative, on a substantial number of small entities under the criteria
of the Regulatory Flexibility Act.
We prepared a regulatory evaluation of the estimated costs to
comply with this proposed AD. See the ADDRESSES section for a location
to examine the regulatory evaluation.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Safety.
The Proposed Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA proposes to amend 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
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]
2. The FAA amends Sec. 39.13 by adding the following new
airworthiness directive (AD):
Boeing: Docket No. FAA-2004-18583; Directorate Identifier 2002-NM-
285-AD. Comments Due Date.
(a) The Federal Aviation Administration (FAA) must receive
comments on this AD action by August 27, 2004.
Affected ADs
(b) None.
Applicability
(c) This AD applies to Boeing Model 747-100, -100B, -100B SUD, -
200B, -200C, -300, -400, and -400D series airplanes; and Model 747SR
series airplanes, line numbers 1 through 1,342 inclusive, except
freighters and airplanes converted to Boeing special freighters;
certificated in any category.
Unsafe Condition
(d) This AD was prompted by reports of cracking in the forward
corner reveals for the main entry door (MED) 3. We are issuing this
AD to detect and correct misalignment of the girt bar fitting due to
fatigue failure of the forward corner reveals for MED 3, which could
lead to the door escape slide departing from the airplane if the
door is opened when the slide is deployed, and consequent injuries
to passengers and crew using the door escape slide during an
emergency evacuation.
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.
Service Bulletin References
(f) The term ``service bulletin,'' as used in this AD, means the
Accomplishment Instructions of Boeing Special Attention Service
Bulletin 747-53-2460, dated June 27, 2002.
Initial Inspections
(g) Within 1,500 flight cycles after the effective date of this
AD, perform a detailed inspection of the forward corner reveals for
MED 3 for cracking, in accordance with the service bulletin.
Note 1: 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.''
No Cracking Found--Repetitive Inspections
(h) If no crack is found during the detailed inspection required
by paragraph (g) of this AD, before further flight, perform the
material type inspection of the forward corner reveal to determine
if it is made of cast 356 aluminum or 6061 aluminum, in accordance
with the service bulletin.
(1) If the forward corner reveal is made of cast 356 aluminum,
repeat the detailed inspection required by paragraph (g) of this AD
thereafter at intervals not to exceed 3,000 flight cycles.
(2) If the forward corner reveal is made of 6061 aluminum,
repeat the detailed inspection required by paragraph (g) of this AD
thereafter at intervals not to exceed 1,500 flight cycles.
Cracking Found--Repair/Contact the FAA
(i) If any crack is found during the detailed inspection
required by paragraph (g) of this AD, before further flight, perform
the material type inspection of the forward corner reveal to
determine if it is made of cast 356 aluminum or 6061 aluminum, in
accordance with the service bulletin.
(1) If the forward corner reveal is made of cast 356 aluminum,
before further flight, repair the forward corner reveal in
accordance with the service bulletin or 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 those
findings. For a repair method to be approved, the approval must
specifically refer to this AD. Repeat the detailed inspection
required by paragraph (g) of this AD thereafter at intervals not to
exceed 3,000 flight cycles.
(2) If the forward corner reveal is made of 6061 aluminum,
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 those findings. For
a repair method to be approved, the approval must specifically refer
to this AD.
Operator's Equivalent Procedure
(j) Although step 5 of Figure 8 of the service bulletin
specifies that operators may accomplish the actions in accordance
with ``an operator's equivalent procedure,'' this AD requires
operators to accomplish step 5 of Figure 8 in accordance with only
the procedures specified in Standard Overhaul Practices Manual
(SOPM) 20-20-02. An ``operator's equivalent procedure'' may be used
only if approved as an alternative method of compliance in
accordance with paragraph (m) of this AD.
[[Page 42000]]
Parts Installation
(k) As of the effective date of this AD, no person may install a
door corner reveal made of cast 356 aluminum on any airplane in the
location specified by this AD, except as provided by paragraph
(i)(1) of this AD.
Compliance With AD 96-23-05 for MED 3 Only
(l) Accomplishment of the applicable repair required by this AD
constitutes compliance with the repair of the MED 3, lower forward
corner casting (reveal) only, as required by paragraph (k)(2)(ii) of
AD 96-23-05, amendment 39-9810 (which specifies the actions be done
in accordance with Boeing Service Bulletin 747-53A2378, Revision 1,
dated March 10, 1994). Accomplishment of the actions of this AD does
not terminate the remaining requirements of AD 96-23-05.
Alternative Methods of Compliance
(m) The Manager, Seattle Aircraft Certification Office, FAA, has
the authority to approve AMOCs for this AD, if requested in
accordance with the procedures found in 14 CFR 39.19.
Issued in Renton, Washington, on June 30, 2004.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification
Service.
[FR Doc. 04-15791 Filed 7-12-04; 8:45 am]
BILLING CODE 4910-13-P