[Federal Register: November 24, 2004 (Volume 69, Number 226)]
[Proposed Rules]
[Page 68274-68277]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr24no04-18]
[[Page 68274]]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2004-19679; Directorate Identifier 2003-NM-132-AD]
RIN 2120-AA64
Airworthiness Directives; Boeing Model 727, 727C, 727-100, 727-
100C, 727-200, and 727-200F 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 727, 727C, 727-100, 727-100C, 727-200, and
727-200F series airplanes. This proposed AD would require repetitive
inspections of the carriage attach fittings on the foreflaps of each
wing for cracking and other discrepancies, and corrective actions if
necessary. For certain airplanes, the proposed AD would also
concurrently require various other actions related to the subject area.
This proposed AD also provides for an optional terminating action for
the repetitive inspection requirements and for an optional replacement
that would defer the repetitive inspections. This proposed AD is
prompted by reports of damaged or failed outboard foreflaps with a
cracked or failed carriage attach fitting of the foreflap sequencing
carriage. We are proposing this AD to detect and correct fatigue
cracking of the attach fittings of the foreflap carriage of the wings,
which could result in partial or complete loss of the foreflap and
consequent loss of controllability of the airplane.
DATES: We must receive comments on this proposed AD by January 10,
2005.
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.
For service information identified in this proposed AD, contact
Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-
2207.
You can examine the contents of this AD docket on the Internet at
http://dms.dot.gov, or in person 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. This docket
number is FAA-2004-19679; the directorate identifier for this docket is
2003-NM-132-AD.
FOR FURTHER INFORMATION CONTACT: Technical information: Daniel F. Kutz;
Aerospace Engineer, Airframe Branch, ANM-120S, FAA, Seattle Aircraft
Certification Office, 1601 Lind Avenue, SW., Renton, Washington 98055-
4056; telephone (425) 917-6456; fax (425) 917-6590..
Plain language information: Marcia Walters, marcia.walters@faa.gov.
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 relevant written data, views, or
arguments regarding this proposed AD. Send your comments to an address
listed under ADDRESSES. Include ``Docket No. FAA-2004-19679;
Directorate Identifier 2003-NM-132-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 can review DOT's complete Privacy Act Statement in the
Federal Register published on April 11, 2000 (65 FR 19477-78), or you
can 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 can examine the AD docket on the Internet at http://dms.dot.gov
, or 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 several reports of damaged or failed outboard
foreflaps with a cracked or failed carriage attach fitting of the
foreflap sequencing carriage on certain Boeing Model 727, 727C, 727-
100, 727-100C, 727-200, and 727-200F series airplanes. Investigation
revealed that fatigue cracking of the fitting is possible due to high
fit-up stress combined with airloads. Such fatigue cracking, if not
detected and corrected, could result in partial or complete loss of the
foreflap and consequent loss of controllability of the airplane.
Relevant Service Information
We have reviewed Boeing Alert Service Bulletin 727-57A0135,
Revision 3, dated June 27, 2002. The service bulletin describes the
following inspection and corrective procedures for the two carriage
attach fittings on the inboard and outboard foreflaps of each wing:
Repetitive detailed inspections to detect cracks and
surface deviations on all edges, surfaces, and lug attachment fastener
holes;
[[Page 68275]]
Repetitive high frequency eddy current inspections (HFEC)
to detect cracks at the lug attachment fastener holes; and
For cases where any crack is detected at a lug attachment
fastener hole or any surface deviation beyond certain limits is
detected on any edge, surface, or lug attachment fastener hole:
Replacement of that carriage attach fitting with a new, improved
fitting or a new fitting having the same part number as the existing
fitting.
The service bulletin also describes the following two optional
procedures:
Replacing the two carriage attach fittings on the inboard
and outboard foreflaps of each wing with a new, improved fitting.
Accomplishment of this replacement and the applicable procedures
specified in Boeing Service Bulletin 57-59, Revision 1, dated September
27, 1965; Boeing Service Bulletin 727-27-133, Revision 1, dated May 9,
1972; and Boeing Service Bulletin 57-72, dated September 21, 1966 (all
three described below); as applicable; would eliminate the need for the
repetitive inspections described above.
Replacing the two carriage attach fittings on the inboard
and outboard foreflaps of each wing with new fittings having the same
part number as the existing fittings. Accomplishment of this
replacement and the applicable procedures specified in Boeing Service
Bulletins 57-59, 727-27-133, and 57-72 would defer the next inspections
described above for an additional 10,000 flight cycles.
In addition, the service bulletin also describes procedures for
inspecting for interference between the carriage attach fitting and the
carriage lug fitting, and other related investigative/corrective
actions if necessary. The related investigative actions include
measuring the radius for minimum permitted radius and inspecting
surface finish for maximum permitted finish. The corrective actions
include adding a shim; reworking the carriage attach lug; and
contacting the airplane manufacturer if rework of the improved fitting
is required; as applicable.
We have also reviewed Boeing Service Bulletin 57-59, Revision 1,
dated September 27, 1965. The service bulletin describes procedures for
installation of guide blocks and bushings in the midflap ribs.
In addition, we have reviewed Boeing Service Bulletin 727-27-133,
Revision 1, dated May 9, 1972. The service bulletin describes
procedures for performing a one-time inspection for foreflap airload
roller travel on the foreflap track; repair if necessary; and modifying
the control drum of the inboard flap and inboard jackscrews of the
outboard flap; as applicable. The modification includes installing a
stop plate on the control drum of the inboard flap, and replacing the
down stop at the inboard jackscrews of the outboard flap; as
applicable.
In addition, we have reviewed Boeing Service Bulletin 57-72, dated
September 21, 1966. The service bulletin describes procedures for
chamfering the upper and lower flanges at the aft end of the foreflap
tracks; performing a standard magnetic particle inspection of the
entire foreflap tracks for cracks; performing a one-time general
inspection of the track rib faces to verify if the opening in the spars
is flush with or clear of the plane of the track rib faces; and rework
if necessary. This rework includes trimming the midflap front and rear
spar webs. The service bulletin also describes procedures for a one-
time general visual inspection of the head or shank of bolts by
securing the foreflap links to the foreflap tracks to verify if they
protrude beyond the edge of the track flange, and rework if necessary.
This rework includes installing a laminated washer under the bolt head.
Accomplishing the actions specified in the service information
described above is intended to 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 carriage attach fittings on
the foreflaps of each wing for cracking and other discrepancies, and
corrective actions if necessary. For certain airplanes, the proposed AD
would also concurrently require various other actions related to the
subject area. This AD also provides for an optional terminating action
for the repetitive inspection requirements and for an optional
replacement that would defer the repetitive inspections. The actions,
if accomplished, would be required to be accomplished in accordance
with the service bulletins described previously, except as discussed
under ``Difference Between the Proposed AD and Service Bulletins.''
Difference Between the Proposed AD and Service Bulletins
Boeing Alert Service Bulletin 727-57A0135 and Boeing Service
Bulletin 727-27-133 specify that the manufacturer may be contacted for
disposition of certain rework and repair conditions. In addition,
Boeing Service Bulletin 57-72 does not specify what to do for cases of
crack findings during a standard magnetic particle inspection of the
entire foreflap tracks. However, unlike those service bulletins, this
proposal would require the rework and repair of those conditions to be
accomplished in accordance with a method approved by the FAA, or in
accordance with 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.
Costs of Compliance
There are about 1,292 airplanes of the affected design in the
worldwide fleet. We estimate that 855 airplanes of U.S. registry would
be affected by this proposed AD. The average labor rate is $65 per work
hour. The following table provides the estimated costs for U.S.
operators to comply with this proposed AD.
Estimated Costs
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For Action Work hours Parts cost Cost
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All airplanes.................... Inspections of the 4 None................. $222,300, $260 per
carriage attach airplane, per
fittings. inspection cycle.
Certain airplanes................ Installation of 32 Free................. $2,080 per
guide blocks. airplane.
Certain airplanes................ Inspection of 4 None................. $260 per airplane.
foreflap airload
roller travel.
Certain airplanes................ Modification of the 4 Free................. $260 per airplane.
inboard jackscrews
on the outboard
flap.
Certain airplanes................ Inspection of the 12 None................. $780 per airplane.
entire track and of
the track rib faces.
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[[Page 68276]]
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-2004-19679; Directorate Identifier 2003-NM-
132-AD.
Comments Due Date
(a) The Federal Aviation Administration (FAA) must receive
comments on this AD action by January 10, 2005.
Affected ADs
(b) None.
Applicability
(c) This AD applies to Boeing Model 727, 727C, 727-100, 727-
100C, 727-200, and 727-200F series airplanes, as listed in Boeing
Alert Service Bulletin 727-57A0135, Revision 3, dated June 27, 2002;
certificated in any category.
Unsafe Condition
(d) This AD was prompted by reports of damaged or failed
outboard foreflaps with a cracked or failed carriage attach fitting
of the foreflap sequencing carriage. We are issuing this AD to
detect and correct fatigue cracking of the attach fittings of the
foreflap carriage of the wings, which could result in partial or
complete loss of the foreflap and consequent loss of controllability
of 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.
Inspections
(f) Except as provided by paragraph (o) of this AD: Within 1,000
flight cycles after the effective date of this AD, and thereafter at
intervals not to exceed 1,000 flight cycles, inspect as specified in
paragraphs (f)(1) and (f)(2) of Table 1 of this AD in accordance
with the Accomplishment Instructions of Boeing Alert Service
Bulletin 727-57A0135, Revision 3, dated June 27, 2002. Table 1 is as
follows:
Table 1.--Inspection Requirements
------------------------------------------------------------------------
Requirements-- Description--
------------------------------------------------------------------------
(1) Area to inspect.................... The two carriage attach
fittings on the inboard and
outboard foreflaps of each
wing.
(2) Type of inspections................ (i) A detailed inspection to
detect cracks and surface
deviations on all edges,
surfaces, and lug attachment
fastener holes.
(ii) A high frequency eddy
current (HFEC) inspection to
detect cracks at the lug
attachment fastener holes.
------------------------------------------------------------------------
Crack or Surface Deviation Findings: Replacement
(g) If any crack is detected or if any surface deviation beyond
the limits specified in the service bulletin is detected during any
inspection required by paragraph (f) of this AD, before further
flight, replace the carriage attach fitting with a new, improved
fitting or a new fitting having the same part number as the existing
fitting, in accordance with the Accomplishment Instructions of
Boeing Alert Service Bulletin 727-57A0135, Revision 3, dated June
27, 2002.
Measurement and Associated Corrective Action(s)
(h) Within 3,500 flight cycles after the effective date of this
AD, inspect for interference between the carriage attach fitting and
the carriage lug fitting, and do other related investigative actions
by accomplishing all the actions specified in paragraph 3.C. and
Figure 2 of the Accomplishment Instructions of Boeing Alert Service
Bulletin 727-57A0135, Revision 3, dated June 27, 2002. Do the
actions in accordance with the service bulletin.
(i) If any discrepancy is found during any action required by
paragraph (h) of this AD, before further flight, accomplish
applicable corrective action(s) (e.g., adding a shim or reworking
the carriage attachment lug assembly) in accordance with paragraph
3.C. and Figure 2 of the Accomplishment Instructions of Boeing Alert
Service Bulletin 727-57A0135, Revision 3, dated June 27, 2002. Where
the service bulletin specifies to contact the manufacturer if rework
of the improved fitting is required: Before further flight, rework
in accordance with a method approved by the Manager, Seattle
Aircraft Certification Office (ACO), FAA, or in accordance with data
meeting the type certification basis of the airplane approved by a
Boeing Company Designated Engineering Representative (DER) who has
been authorized by the FAA to make such findings. For a repair
method to be approved, the approval must specifically reference this
AD.
Concurrent Requirements
(j) For Model 727 airplanes listed in Boeing Service Bulletin
57-59, Revision 1, dated September 27, 1965: Before or at the same
time with the requirements of paragraph (h) of this AD, install
guide blocks and bushings in the midflap ribs in accordance with the
Accomplishment Instructions of the service bulletin.
(k) For Model 727 airplanes listed in Boeing Service Bulletin
727-27-133, Revision 1, dated May 9, 1972: Before or at the same
time with the requirements of paragraph (h) of this AD, do the
actions specified in paragraphs (k)(1) and (k)(2) of this AD, as
applicable.
(1) For Groups I and II airplanes identified in the service
bulletin: Do a one-time inspection of the airload support roller for
travel on the foreflap track in accordance with Part I of the
Accomplishment Instructions of the service bulletin.
(i) If the airload support roller travels within the limits
specified in the service bulletin, modify the control drum of the
inboard flap and inboard jackscrews of the outboard flap, in
accordance with Part II of the Accomplishment Instructions of the
service bulletin.
[[Page 68277]]
(ii) If the airload support roller travels beyond the limits
specified in the service bulletin, repair in accordance with a
method approved by the Manager, Seattle ACO, FAA or in accordance
with data meeting the type certification basis of the airplane
approved by a Boeing Company DER who has been authorized by the FAA
to make such findings.
(2) For Group III airplanes identified in the service bulletin:
Modify the inboard jackscrews of the outboard flap (i.e., replacing
the down stop at the inboard jackscrews of the outboard flap) in
accordance with Part II of the Accomplishment Instructions of the
service bulletin.
(l) For Model 727 airplanes listed in Boeing Service Bulletin
57-72, dated September 21, 1966: Before or at the same time with the
requirements of paragraph (h) of this AD, do the actions specified
in paragraphs (l)(1) through (l)(4) of this AD.
(1) Chamfer the upper and lower flanges at the aft end of the
foreflap tracks in accordance with the Accomplishment Instructions
of the service bulletin.
(2) Do a standard magnetic particle inspection of the entire
foreflap tracks for cracks in accordance with the Accomplishment
Instructions of the service bulletin. If any crack is detected,
before further flight, repair in accordance with a method approved
by the Manager, Seattle ACO, FAA or in accordance with data meeting
the type certification basis of the airplane approved by a Boeing
Company DER who has been authorized by the FAA to make such
findings. For a repair method to be approved, the approval must
specifically reference this AD.
(3) Do a general visual inspection of the track rib faces at the
front and rear spars to verify if the opening in the spars is flush
with or clear of the plane of the rib faces, in accordance with the
Accomplishment Instructions of the service bulletin. If the opening
is not flush or clear with the plane, before further flight, rework
the spar opening in accordance with the Accomplishment Instructions
of the service bulletin.
(4) Do a general visual inspection of the head or shank of bolts
by securing the foreflap links to the foreflap tracks to verify if
they protrude beyond the edge of the track flange in accordance with
the Accomplishment Instructions of the service bulletin. If the head
or shank of the bolts protrude beyond the edge of the track flange,
before further flight, rework in accordance with the Accomplishment
Instructions of the service bulletin.
Note 1: For the purposes of this AD, a general visual inspection
is defined as: ``A visual examination of an interior or exterior
area, installation, or assembly to detect obvious damage, failure,
or irregularity. This level of inspection is made from within
touching distance unless otherwise specified. A mirror may be
necessary to enhance visual access to all exposed surfaces in the
inspection area. This level of inspection is made under normally
available lighting conditions such as daylight, hangar lighting,
flashlight, or droplight and may require removal or opening of
access panels or doors. Stands, ladders, or platforms may be
required to gain proximity to the area being checked.''
(m) For airplanes other than those identified in the service
bulletins specified in paragraphs (j) through (l) of this AD: Before
or at the same time with the requirements of paragraph (h) of this
AD, do an inspection to verify if any of the parts listed in the
``Spares Affected'' paragraph of each service bulletin referenced in
paragraphs (j) through (l) of this AD are installed on the airplane.
If any part identified in that paragraph is found installed, before
further flight, do the applicable corrective and investigative
action(s) specified in paragraphs (j) through (l) of this AD.
Optional Terminating Actions
(n) Replacement of the two carriage attach fittings on the
inboard and outboard foreflaps of each wing with new, improved
fittings, in accordance with the Accomplishment Instructions of
Boeing Alert Service Bulletin 727-57A0135, Revision 3, dated June
27, 2002; and accomplishment of the actions specified in paragraphs
(j) through (m) of this AD, as applicable, before or concurrently
with the replacement; constitutes terminating action for the
requirements of this AD.
Optional Deferral of Inspection
(o) Replacement of the two carriage attach fittings on the
inboard and outboard foreflaps of each wing with new fittings having
the same part number as the existing fittings, in accordance with
the Accomplishment Instructions of Boeing Alert Service Bulletin
727-57A0135, Revision 3, dated June 27, 2002; and accomplishment of
the actions specified in paragraphs (j) through (m) of this AD, as
applicable, before or concurrently with the replacement; defers the
next inspection required by paragraph (f) of this AD for 10,000
flight cycles after the replacement. Thereafter, repeat the
inspections required by paragraph (f) of this AD at intervals not to
exceed 1,000 flight cycles.
Credit for Previously Accomplished Service Bulletins
(p) Installations accomplished before the effective date of this
AD in accordance with Boeing Service Bulletin 57-59, dated September
2, 1965; are acceptable for compliance with the requirements of
paragraph (j) of this AD.
(q) Inspections and modifications accomplished before the
effective date of this AD in accordance with Boeing Service Bulletin
727-27-133, dated October 7, 1971; are acceptable for compliance
with the requirements of paragraph (k) of this AD.
Alternative Methods of Compliance (AMOCs)
(r)(1) In accordance with 14 CFR 39.19, the Manager, Seattle
ACO, FAA, is authorized to approve alternative methods of compliance
for this AD.
(2) An AMOC that provides an acceptable level of safety may be
used for any repair required by this AD, if it is 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.
Issued in Renton, Washington, on November 19, 2004.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification
Service.
[FR Doc. 04-26028 Filed 11-23-04; 8:45 am]
BILLING CODE 4910-13-P