[Federal Register Volume 76, Number 13 (Thursday, January 20, 2011)]
[Proposed Rules]
[Pages 3561-3564]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2011-1121]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2011-0027; Directorate Identifier 2010-NM-127-AD]
RIN 2120-AA64
Airworthiness Directives; The Boeing Company Model 777-200 and -
300 Series Airplanes Equipped with Rolls-Royce RB211 Trent 800 Engines
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Notice of proposed rulemaking (NPRM).
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SUMMARY: We propose to adopt a new airworthiness directive (AD) for
certain Model 777-200 and -300 series airplanes. This proposed AD would
require repetitive inspections of all thrust reverser (T/R) structure
and sealant for degradation, and related investigative and corrective
actions if necessary. This proposed AD results from reports of thrust
reverser events related to thermal damage of the thrust reverser inner
wall. We are proposing this AD to detect and correct a degraded T/R
inner wall panel, which could lead to failure of a T/R and adjacent
components and their consequent separation from the airplane, which
could result in a rejected takeoff (RTO) and cause asymmetric thrust
and consequent loss of control of the airplane during reverse thrust
operation. If a T/R inner wall overheats, separated components could
cause structural damage to the airplane, damage to other airplanes, or
possible injury to people on the ground.
DATES: We must receive comments on this proposed AD by March 7, 2011.
ADDRESSES: You may send comments by any of the following methods:
Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
Fax: 202-493-2251.
Mail: U.S. Department of Transportation, Docket
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New
Jersey Avenue, SE., Washington, DC 20590.
Hand Delivery: U.S. Department of Transportation, Docket
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New
Jersey Avenue, SE., Washington, DC 20590, 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, Attention: Data & Services Management,
P.O. Box 3707, MC 2H-65, Seattle, Washington 98124-2207; telephone 206-
544-5000, extension 1; fax 206-766-5680; e-mail [email protected];
Internet https://www.myboeingfleet.com. You may review copies of the
referenced service information at the FAA, Transport Airplane
Directorate, 1601 Lind Avenue, SW., Renton, Washington. For information
on the availability of this material at the FAA, call 425-227-1221.
Examining the AD Docket
You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Management Facility
between 9 a.m. and 5 p.m., Monday through Friday, except Federal
holidays. The AD docket contains this proposed AD, the regulatory
evaluation, any comments received, and other information. The street
address for the Docket Office (telephone 800-647-5527) is in the
ADDRESSES section. Comments will be available in the AD docket shortly
after receipt.
FOR FURTHER INFORMATION CONTACT: Margaret Langsted, Aerospace Engineer,
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification
Office, 1601 Lind Avenue, SW., Renton, Washington 98057-3356; telephone
(425) 917-6500; fax (425) 917-6590.
SUPPLEMENTARY INFORMATION:
Comments Invited
We invite you to send any written relevant data, views, or
arguments about this proposed AD. Send your comments to an address
listed under the ADDRESSES section. Include ``Docket No. FAA-2011-0027;
Directorate Identifier 2010-NM-127-AD'' at the beginning of your
comments. We specifically invite comments on the overall regulatory,
economic, environmental, and energy aspects of this proposed AD. We
will consider all comments received by the closing date and may amend
this proposed AD because of those comments.
We will post all comments we receive, without change, to http://www.regulations.gov, including any personal information you provide. We
will also post a report summarizing each substantive verbal contact we
receive about this proposed AD.
Discussion
We have received reports of eleven events related to thermal damage
of the thrust reverser (T/R) inner wall on Rolls Royce RB211 Trent 800
engines. The events have included air turnbacks, in-flight shutdowns,
T/R inner wall panel sections and parts being separated from the
airplane, collapse of the T/R inner wall panel, and engine fire loop
fault messages. No hull loss or personal injury has occurred from these
events. Boeing issued Alert Service Bulletin 777-78A0059, dated
February 24, 2005; and Alert Service Bulletin 777-78-0060, dated
February 24, 2005; to provide instructions for inspecting the T/R inner
wall panel structure and sealing the insulation blankets to prevent hot
under-cowl air from contact with the T/R inner wall panel. Since those
service bulletins were released, there have been seven events on thrust
reversers, four T/Rs on which those service bulletins had not been
fully accomplished, and three on which those service bulletins had been
fully accomplished. A separated T/R piece could result in a rejected
takeoff and cause asymmetric thrust and consequent loss of control of
the airplane during reverse thrust operation. If a thrust reverser
inner wall overheats, separated components could cause structural
damage to the airplane, damage to other airplanes, or injury to people
on the ground.
Relevant Service Information
We have reviewed Boeing Alert Service Bulletin 777-78A0065,
Revision 2, dated May 6, 2010. This service bulletin describes
procedures for doing actions specified in Work Packages 1 through 6 (as
necessary) of the
[[Page 3562]]
Accomplishment Instructions. This service bulletin states that
operators may choose between doing Work Package 2 (doing a full non-
destructive test (NDT)), or Work Package 6 (doing a limited NDT with
more restrictive repetitive intervals).
Work Package 1
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6,
2010, describes procedures for reviewing the airplane maintenance
records to determine whether sealant was added; repetitive detailed
inspections of all thrust reverser (T/R) inner wall insulation blanket
edges, grommet holes, penetrations, and seams for sealant that is
cracked, has gaps, is loose, or is missing; repetitive general visual
inspections of click bond studs, blanket studs, and temporary
fasteners; replacement of sealant if necessary; and related
investigative and corrective actions if necessary. The related
investigative actions include:
Measuring the distance between the overlapped blanket face
sheets adjacent to the damaged or missing sealant, or measuring the
distance between the inner wall and the insulation blanket adjacent to
the damaged or missing sealant
Doing an NDT and general visual inspection for thermal
degradation of the exposed T/R inner wall panel area within 12 inches
of cracks, gaps, or loose or missing sealant
Doing an NDT of an uncovered compression pad if it is
within 12 inches of the crack, gap, loose, or missing sealant
Doing a general visual inspection for areas of thermal
degradation
Doing an NDT of the T/R inner wall panel where the fitting
was installed
Doing a detailed inspection of the T/R panel wall inner
bolt holes for elongation
Doing a general visual inspection and NDT inspection for
thermal degradation of the inner wall panel area where a damaged click
bond stud, blanket stud, and temporary fastener is loose, damaged, or
missing
Doing an NDT (eddy current conductivity test) of the
number 1 upper, or numbers 1 and 2 lower, compression pad fittings if
they are exposed by blanket removal and within 12 inches of the loose,
damaged, or missing click bond studs, blanket studs, or temporary
fasteners
Doing a Barcol hardness test of the area of thermal
degradation
Doing a general visual inspection of bushings for
migration or looseness
The corrective actions include:
Replacing damaged or missing sealant
Repairing or replacing T/R inner wall panel areas
Contacting Boeing for repair instructions and doing the
repair
Installing compression pad fittings
Installing replacement click bonds, blanket studs, or
temporary fasteners
Installing the removed replacement blankets and fittings
Removing the bushing and repairing the inner wall panel
bolt hole
Work Package 2
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6,
2010, describes procedures for either a repetitive full inner wall
panel NDT of each T/R half and repetitive general visual inspections
for areas of thermal degradation, or a partial inner wall panel NDT,
and related investigative and corrective actions. The related
investigative actions include an NDT of the area of different color,
and a Barcol hardness inspection of the inner wall panel for areas of
thermal degradation. The corrective actions are repairing or replacing
unsatisfactory T/R inner wall panel areas, installing insulation
blankets, and contacting Boeing for repair instructions and doing the
repair. This service bulletin states that Work Package 6 may be done as
an alternative to Work Package 2, provided that the shorter interval
for the repetitive inspections specified in Work Package 6 are
followed.
Work Package 3
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6,
2010, describes procedures for repetitive detailed inspections of the
powered door opening system (PDOS) lug bushings on the upper number 1
compression pad fittings for hole elongation, deformation, and contact
with the PDOS actuator, and related investigative and corrective
actions. Related investigative actions include a detailed inspection of
the PDOS lug. Corrective actions include replacing unserviceable upper
number 1 compression pad fittings and replacing unserviceable bushings
with serviceable parts, and installing PDOS actuator rods and sealant.
Work Package 4
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6,
2010, describes procedures for repetitive NDTs of the number 1 upper
and numbers 1 and 2 lower compression pad fittings, and related
investigative and corrective actions. The related investigative actions
include doing an NDT of the T/R inner wall panel, a general visual
inspection for areas of thermal degradation, a detailed inspection of
the T/R inner wall panel bolt holes for elongation, a Barcol hardness
test of the area, and a general visual inspection of the bushing for
migration or looseness. Corrective actions include repairing the T/R
inner wall panel with a serviceable panel, installing removed
installation blankets, installing serviceable compression pad fittings,
contacting Boeing for repair instructions and doing the repair,
replacing the T/R inner wall panel with a new or serviceable T/R inner
wall panel, and removing bushings and repairing the inner wall panel
bolt hole.
Work Package 5
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6,
2010, describes procedures for repetitive general visual inspections of
the perforated side of the T/R wall aft of the intermediate pressure
compressor 8th stage (IP8) duct and high pressure compressor 3rd stage
(HP3) bleed port exits for a color that is different from that of the
general area, and related investigative and corrective actions. The
related investigative action is an NDT inspection of discolored areas
for delamination and disbonding on the perforated side of the inner
wall. The corrective actions are contacting Boeing for repair
instructions and doing the repair.
Work Package 6
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6,
2010, describes procedures for a limited area NDT inspection of the
inner wall panel of each T/R half for delaminating and disbonding, a
general visual inspection for areas of thermal degradation, and related
investigative and corrective actions. Related investigative actions
include a Barcol hardness test of the area. Corrective actions include
repairing or replacing the T/R inner wall panel with a new or
serviceable one. Work Package 6 may be done as an option to Work
Package 2 provided that the shorter repeat inspection intervals
specified in Work Package 2 are followed.
Compliance Times
The compliance times for Work Package 1 are as follows. The
compliance time for the initial inspections and replacement of sealant
(if necessary) is within 1,500 flight hours after the date on the
original issue of the service bulletin. The interval for the repetitive
inspections is 1,500 flight hours.
[[Page 3563]]
The compliance times for doing the initial and repetitive NDT
inspections on the T/R wall depend on which work packages are done--
either the full NDT option (Work Packages 2 and 5) or limited NDT
option (Work Packages 5 and 6). For the initial full NDT and limited
NDT options, the compliance time is between 600 and 2,000 flight
cycles, depending on the number of total airplane flight cycles and
whether a previous inspection has been conducted. The interval for the
repetitive inspections for the full NDT is 2,000 flight cycles. The
interval for the repetitive inspections for the limited NDT is 700
flight cycles.
The compliance times for Work Package 3 are as follows. The
compliance time for the detailed inspection of the PDOS lug bushings on
the upper number 1 compression pad fittings ranges from within 600 to
1,700 flight cycles after the date on the original issue of the service
bulletin. The interval for the repetitive inspections is 2,000 flight
cycles.
The compliance times for Work Package 4 are as follows. The
compliance time for the initial NDT inspection of the number 1 upper,
and number 1 and 2 lower, compression pad fittings are within 2,000
flight cycles after the date on the original issue of this service
bulletin. The interval for the repetitive inspections is 2,000 flight
cycles.
FAA's Determination and Requirements of This Proposed AD
We are proposing this AD because we evaluated all relevant
information and determined the unsafe condition described previously is
likely to exist or develop in other products of the same type design.
This proposed AD would require accomplishing the actions specified in
the service information described previously, except as discussed under
``Differences Between the Proposed AD and Service Information.''
Differences Between the Proposed AD and Service Information
Although Boeing Alert Service Bulletin 777-78A0065, Revision 2,
dated May 6, 2010, specifies that operators may contact the
manufacturer for disposition of certain repair conditions, this
proposed AD would require operators to repair those conditions using a
method approved by the FAA.
Interim Action
We consider this proposed AD interim action. The manufacturer is
currently developing a modification that will address the unsafe
condition identified in this AD. Once this modification is developed,
approved, and available, we might consider additional rulemaking.
Costs of Compliance
We estimate that this proposed AD would affect 54 airplanes of U.S.
registry. The following table provides the estimated costs for U.S.
operators to comply with this proposed AD.
Table--Estimated costs
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Number of U.S.-
Action Work hours Average labor Cost per registered Fleet cost
rate per hour product airplanes
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Records check................... 1 $85 $85 54 $4,590
Inspections..................... 73 85 6,205 54 335,070
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Authority for This Rulemaking
Title 49 of the United States Code specifies the FAA's authority to
issue rules on aviation safety. Subtitle I, section 106, describes the
authority of the FAA Administrator. ``Subtitle VII: Aviation
Programs,'' describes in more detail the scope of the Agency's
authority.
We are issuing this rulemaking under the authority described in
``Subtitle VII, Part A, Subpart III, Section 44701: General
requirements.'' Under that section, Congress charges the FAA with
promoting safe flight of civil aircraft in air commerce by prescribing
regulations for practices, methods, and procedures the Administrator
finds necessary for safety in air commerce. This regulation is within
the scope of that authority because it addresses an unsafe condition
that is likely to exist or develop on products identified in this
rulemaking action.
Regulatory Findings
We 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 this 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.
You can find our regulatory evaluation and the estimated costs of
compliance in the AD Docket.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, 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 AD:
The Boeing Company: Docket No. FAA-2011-0027; Directorate Identifier
2010-NM-127-AD.
Comments Due Date
(a) We must receive comments by March 7, 2011.
Affected ADs
(b) None.
Applicability
(c) This AD applies to The Boeing Company Model 777-200 and -300
series airplanes, certificated in any category, equipped with Rolls-
Royce RB211 Trent 800
[[Page 3564]]
engines; as identified in Boeing Alert Service Bulletin 777-78A0065,
Revision 2, dated May 6, 2010.
Subject
(d) Air Transport Association (ATA) of America Code 78: Engine
exhaust.
Unsafe Condition
(e) This AD results from reports of thrust reverser events
related to thermal damage of the thrust reverser (T/R) inner wall.
The Federal Aviation Administration is issuing this AD to detect and
correct a degraded T/R inner wall panel, which could lead to failure
of a T/R and adjacent components and their consequent separation
from the airplane, which could result in a rejected takeoff (RTO)
and cause asymmetric thrust and consequent loss of control of the
airplane during reverse thrust operation. If a T/R inner wall
overheats, separated components could cause structural damage to the
airplane, damage to other airplanes, or possible injury to people on
the ground.
Compliance
(f) You are responsible for having the actions required by this
AD performed within the compliance times specified, unless the
actions have already been done.
Records Review, Inspections, and Related Investigative and Corrective
Actions
(g) Except as required by paragraphs (h), (i), (j), and (k) of
this AD, at the applicable times in paragraph 1.E., ``Compliance,''
of Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May
6, 2010 (``this service bulletin''), review the airplane maintenance
records to determine whether sealant was added, do the actions
specified in paragraphs (g)(1), (g)(2), (g)(3), (g)(4), and (g)(5)
of this AD, and do all applicable related investigative and
corrective actions, in accordance with the Accomplishment
Instructions of this service bulletin, except as required by
paragraph (l) of this AD. Do all applicable related investigative
and corrective actions before further flight. Repeat the inspections
required by paragraphs (g)(1), (g)(2), (g)(3), (g)(4), and (g)(5) of
this AD thereafter at the applicable intervals specified in
paragraph 1.E., ``Compliance,'' of the service bulletin.
(1) Do a detailed inspection of all T/R inner wall insulation
blanket edges, grommet holes, penetrations, and seams for sealant
that is cracked, has gaps, is loose, or is missing; do a general
visual inspection of click bond studs, blanket studs, and temporary
fasteners; and replace sealant as applicable; in accordance with
Work Package 1 of the Accomplishment Instructions of this service
bulletin.
(2) Do the actions required by paragraph (g)(2)(i) or (g)(2)(ii)
of this AD.
(i) Do a full inner wall panel non-destructive test (NDT) for
delamination and disbonding of each T/R half, and do a general
visual inspection for areas of thermal degradation, in accordance
with Work Package 2 of the Accomplishment Instructions of this
service bulletin.
(ii) Do a limited area NDT of the inner wall panel of each T/R
half for delamination and disbonding, and do a general visual
inspection for areas of thermal degradation, in accordance with Work
Package 6 of the Accomplishment Instructions of this service
bulletin.
(3) Do a general visual inspection of the T/R perforated wall
aft of the intermediate pressure compressor 8th stage (IP8) and the
high pressure compressor 3rd stage (HP3) bleed port exits for a
color that is different from that of the general area, in accordance
with Work Package 5 of the Accomplishment Instructions of this
service bulletin.
(4) Do a detailed inspection of the powered door opening system
(PDOS) lug bushings on the upper number 1 compression pad fittings
for hole elongation, deformation, and contact with the PDOS
actuator, in accordance with Work Package 3 of the Accomplishment
Instructions of this service bulletin.
(5) Do an NDT of the number 1 upper and numbers 1 and 2 lower
compression pad fittings, in accordance with Work Package 4 of the
Accomplishment Instructions of this service bulletin.
Exceptions to the Service Bulletin
(h) Where Boeing Alert Service Bulletin 777-78A0065, Revision 2,
dated May 6, 2010, specifies a compliance time after the date on the
original issue of that service bulletin, this AD requires compliance
within the specified compliance time after the effective date of
this AD.
(i) Where paragraph 1.E., ``Compliance,'' in Boeing Alert
Service Bulletin 777-78A0065, Revision 2, dated May 6, 2010,
specifies a compliance time of ``2,000 flight cycles after the date
of the operator's own inspections,'' for doing Work Packages 2 and
5, or Work Packages 2 and 6, this AD requires compliance within
2,000 flight cycles after the date of the operator's own inspections
or within 12 months after the effective date of this AD, whichever
occurs later.
(j) Where the Condition columns in Table 2 of paragraph 1.E.,
``Compliance,'' of Boeing Alert Service Bulletin 777-78A0065,
Revision 2, dated May 6, 2010, refer to ``All airplanes, each T/R
half'' that has or has not ``been inspected before the date on this
service bulletin,'' this AD applies to all airplanes, each T/R half
that has or has not been inspected before the effective date of this
AD.
(k) Where the Condition columns in the Tables of paragraph 1.E.,
``Compliance,'' of Boeing Alert Service Bulletin 777-78A0065,
Revision 2, dated May 6, 2010, refer to total flight cycles, this AD
applies to the airplanes with the specified total flight cycles as
of the effective date of this AD.
(l) Where Boeing Alert Service Bulletin 777-78A0065, Revision 2,
dated May 6, 2010, specifies to contact Boeing for appropriate
action: Before further flight, repair in accordance with a method
approved by the Manager, Seattle Aircraft Certification Office
(ACO), FAA. For a repair method to be approved, the repair must meet
the certification basis of the airplane, and the approval must
specifically refer to this AD.
Credit for Actions Accomplished in Accordance With Previous Service
Information
(m) Actions done before the effective date of this AD in
accordance with Boeing Alert Service Bulletin 777-78A0065, dated
June 23, 2008; or Revision 1, dated January 29, 2009; are acceptable
for compliance with the corresponding requirements of this AD.
Alternative Methods of Compliance (AMOCs)
(n)(1) The Manager, Seattle ACO, FAA, has the authority to
approve AMOCs for this AD, if requested using the procedures found
in 14 CFR 39.19. Send information to Attn: Margaret Langsted,
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle
Aircraft Certification Office, 1601 Lind Avenue, SW., Renton,
Washington 98057-3356; telephone (425) 917-6500; fax (425) 917-6590.
Or, e-mail information to [email protected].
(2) Before using any approved AMOC, notify your appropriate
principal inspector, or lacking a principal inspector, the manager
of the local flight standards district office/certificate holding
district office.
Issued in Renton, Washington, on January 12, 2011.
Jeffrey E. Duven,
Acting Manager, Transport Airplane Directorate, Aircraft Certification
Service.
[FR Doc. 2011-1121 Filed 1-19-11; 8:45 am]
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