[Federal Register Volume 69, Number 214 (Friday, November 5, 2004)]
[Proposed Rules]
[Pages 64506-64510]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-24730]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2004-19530; Directorate Identifier 2002-NM-274-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 727 Series Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) for certain Boeing Model 727 series airplanes. That AD 
currently requires repetitive detailed inspections to detect cracking, 
corrosion, and existing stop-drilled repairs of cracking in the upper 
chord of the rear spar of the wing, and repair if necessary. This 
proposed AD would require new repetitive inspections to detect cracks, 
corrosion, minor surface defects, and existing stop-drilled repairs of 
cracks in the upper and lower chords of the front and rear spars of the 
wing; and repair if

[[Page 64507]]

necessary. This proposed AD is prompted by our determination that 
further rulemaking action is necessary to require additional actions 
specified in the referenced service bulletin. We are proposing this AD 
to prevent structural failure of the wing and fuel leaks in the 
airplane due to stress corrosion cracking of the wing spar chords.

DATES: We must receive comments on this proposed AD by December 20, 
2004.

ADDRESSES: Use one of the following addresses to submit comments on 
this proposed AD.
    <bullet> DOT Docket Web Site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
    <bullet> Government-wide Rulemaking Web Site: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
    <bullet> Mail: Docket Management Facility; U.S. Department of 
Transportation, 400 Seventh Street SW., Nassif Building, room PL-401, 
Washington, DC 20590.
    <bullet<ls-thn-eq> Fax: (202) 493-2251.
    <bullet> 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: 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.

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-2004-19530; 
Directorate Identifier 2002-NM-274-AD'' at the beginning 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 received 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 our 
docket Web site, 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 the 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

    On November 20, 2002, we issued AD 2002-24-05, amendment 39-12970 
(67 FR 71808, December 3, 2002) (a final rule correction was published 
in the Federal Register on January 2, 2003 (68 FR 10)), for certain 
Boeing Model 727 series airplanes. That AD requires repetitive detailed 
inspections to detect cracking, corrosion, and existing stop-drilled 
repair of cracking in the upper chord of the rear spar of the wing, and 
repair if necessary. That AD was prompted by reports of spanwise stress 
corrosion cracking of the upper chord of the rear spar of the wing 
between wing buttock line (WBL) 70.5 and the wing tip. Investigation 
revealed that some cracks were up to 14 inches long. Furthermore, one 
of the cracks was almost long enough to jeopardize the residual 
strength capability of the upper chord of the rear spar. We issued that 
AD to prevent structural failure of the wing and fuel leaks in the 
airplane due to stress corrosion cracking of the wing spar chords.

Actions Since Existing AD Was Issued

    In the preamble of AD 2002-24-05, we indicated that the actions 
required by that AD were considered ``interim action,'' and that 
further rulemaking action was being considered to require additional 
actions specified in the referenced service bulletin (i.e., Boeing 
Alert Service Bulletin 727-57A0145, Revision 2, dated October 24, 
2002). We have now determined that further rulemaking action is indeed 
necessary, and this proposed AD follows from that determination.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 727-57A0145, 
Revision 2, dated October 24, 2002. The service bulletin describes 
procedures for performing various inspections to detect cracks, 
corrosion, minor surface defects, and previously stop-drilled repairs 
in the upper and lower chords of the front and rear spars of the wings; 
and repair if necessary. The service bulletin also describes procedures 
for applying a wet layer of BMS 3-23 organic corrosion inhibiting 
compound or Boeing equivalent after any inspection or repair. We have 
determined that accomplishment of the actions specified in the service 
information 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 products 
of this same type design. Therefore, we are proposing this AD, which 
would supersede AD 2002-24-05 to require accomplishment of all actions 
specified

[[Page 64508]]

in the service bulletin described previously, except as described 
below.

Differences Between the Service Bulletin and the Proposed AD

    Operators should note that, although the service bulletin specifies 
that the manufacturer may be contacted for disposition of certain 
repair conditions, this proposed AD would require that those conditions 
be done 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.

Clarification of Inspection Terminology

    In this proposed AD, the ``detailed visual inspection'' specified 
in the Boeing service bulletin is referred to as a ``detailed 
inspection.'' We have included the definition for a detailed inspection 
in a note in the proposed AD.

Change to Existing AD

    This proposed AD would retain certain requirements of AD 2002-24-
05. Since that AD was issued, the AD format has been revised, and 
certain paragraphs have been rearranged. As a result, the corresponding 
paragraph identifiers have changed in this proposed AD, as listed in 
the following table:

                      Revised Paragraph Identifiers
------------------------------------------------------------------------
                                             Corresponding  requirement
       Requirement in AD 2002-24-05             in this  proposed AD
------------------------------------------------------------------------
Paragraph (a).............................  Paragraph (g).
Paragraph (a)(1)..........................  Paragraph (g).
Paragraph (a)(2)..........................  Paragraph (k).
Paragraph (a)(3)..........................  Paragraph (i).
Paragraph (a)(4)..........................  Paragraph (j).
------------------------------------------------------------------------

Costs of Compliance

    This Proposed AD would affect about 1,426 Model 727 series 
airplanes worldwide. This Proposed AD would affect about 946 airplanes 
of U.S. registry.
    For Group 1 airplanes identified in the service bulletin, the 
actions (Part 1 of the Accomplishment Instructions of the service 
bulletin) that are required by AD 2002-24-05 and retained in this 
Proposed AD take about 8 work hours per airplane, at an average labor 
rate of $65 per work hour. Based on these figures, the estimated cost 
of the currently required actions is $520 per airplane.
    The following table provides the estimated costs for U.S. operators 
to comply with the new actions proposed by this AD. The average labor 
rate is $65 per work hour.

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                   Per airplane
  For airplanes identified in the service                                                            cost, per
               bulletin as--                             Actions in--              Work hours--     inspection
                                                                                                      cycle--
----------------------------------------------------------------------------------------------------------------
Group 1....................................  Part 2 of the Accomplishment                     30          $1,950
                                              Instructions of the service
                                              bulletin.
Group 1....................................  Part 3 of the Accomplishment                     21           1,365
                                              Instructions of the service
                                              bulletin.
Group 1....................................  Part 4 of the Accomplishment                     68           4,420
                                              Instructions of the service
                                              bulletin.
Group 1....................................  Part 8 of the Accomplishment                      8             520
                                              Instructions of the service
                                              bulletin.
Group 1....................................  Part 9 of the Accomplishment                     30           1,950
                                              Instructions of the service
                                              bulletin.
Group 2....................................  Part 5 of the Accomplishment                     52           3,380
                                              Instructions of the service
                                              bulletin.
Group 2....................................  Part 6 of the Accomplishment                    110           7,150
                                              Instructions of the service
                                              bulletin.
----------------------------------------------------------------------------------------------------------------

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 removing amendment 39-12970 (67 FR 
71808, December 3, 2002) and adding the following new airworthiness 
directive (AD):

Boeing: Docket No. FAA-2004-19530; Directorate Identifier 2002-NM-
274-AD.

Comments Due Date

    (a) The Federal Aviation Administration must receive comments on 
this airworthiness directive (AD) action by December 20, 2004.

Affected ADs

    (b) This AD supersedes AD 2002-24-05, amendment 39-12970.
    Applicability: (c) This AD applies to Boeing Model 727, 727C, 
727-100, -100C, -200, and -200F series airplanes, line numbers 1 
through 1832 inclusive; certificated in any category.

Unsafe Condition

    (d) This AD was prompted by our determination that further 
rulemaking action is necessary to require additional actions 
specified in the referenced service bulletin. We are issuing this AD 
to prevent structural failure of the wing and fuel leaks in the 
airplane due to stress corrosion cracking of the wing spar chords.
    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 ``the service bulletin,'' as used in this AD, means 
Boeing Alert Service

[[Page 64509]]

Bulletin 727-57A0145, Revision 2, dated October 24, 2002.

Inspection Requirements of AD 2002-24-05, Amendment 39-12970

Inspection

    (g) For airplanes specified as ``Group 1'' airplanes in the 
service bulletin: Within 20 years after the date of manufacture or 
within 90 days after December 18, 2002 (the effective date of AD 
2002-24-05, amendment 39-12970), whichever occurs later, perform an 
external detailed inspection for cracking, corrosion, and existing 
stop-drilled repairs of cracking in the upper chord on the rear spar 
from Wing Butt Line (WBL) 70.5 through WBL 249.3, per the service 
bulletin, Paragraph 3.B, ``Work Instructions,'' Part 1. Thereafter, 
repeat the inspection at intervals not to exceed 2 years.

    Note 1: For the purposes of this AD, a detailed inspection is 
``an intensive examination of a specific item, installation, or 
assembly to detect damage, failure, or irregularity. Available 
lighting is normally supplemented with a direct source of good 
lighting at an intensity deemed appropriate. Inspection aids such as 
mirrors, magnifying lenses, etc., may be necessary. Surface cleaning 
and elaborate procedures may be required.''

New Actions Required by This AD

Inspections Specified in Parts 2 Through 6, and 8 and 9 of the 
Service Bulletin

    (h) Accomplish the applicable inspection(s) specified in 
paragraphs (h)(1) through (h)(7) of this AD at the later of the 
applicable times specified in the ``Threshold'' and ``Grace Period'' 
columns in Table 1 of this AD, and repeat the inspection(s) at the 
time specified in the ``Repetitive Interval'' column of Table 1 of 
this AD. Accomplishment of the inspection required by paragraph 
(h)(1) of this AD terminates the repetitive inspection requirements 
of paragraph (g) of this AD.

   Table 1.--Compliance Times for Inspections Specified in Parts 2 Through 6, and 8 and 9 of Service Bulletin
----------------------------------------------------------------------------------------------------------------
  For airplanes identified in                                               Repetitive
   the service bulletin as--         Threshold--        Grace period--      interval--              Do--
----------------------------------------------------------------------------------------------------------------
(1) Group 1...................  Before 20 years since  Within 1 year     None............  A high frequency eddy
                                 the date of issuance   after the                           current (HFEC)
                                 of the original        effective date                      inspection and
                                 Airworthiness          of this AD.                         detailed inspection
                                 Certificate or the                                         of the upper chord
                                 date of issuance of                                        of the rear spar
                                 the original Export                                        from WBL 70.5 to
                                 Certificate of                                             wing tip for cracks,
                                 Airworthiness,                                             corrosion, minor
                                 whichever occurs                                           surface defects, and
                                 first.                                                     existing stop-
                                                                                            drilled repairs of
                                                                                            cracking, in
                                                                                            accordance with
                                                                                            paragraph 3.B., Work
                                                                                            Instructions, Part
                                                                                            2, of the
                                                                                            Accomplishment
                                                                                            Instructions of the
                                                                                            service bulletin.
(2) Group 1...................  Before 20 years since  Within 2 years    At intervals not  A detailed inspection
                                 the date of issuance   after the         to exceed 2       of the upper and
                                 of the original        effective date    years.            lower chords of the
                                 Airworthiness          of this AD.                         front spar and the
                                 Certificate or the                                         lower chord of the
                                 date of issuance of                                        rear spar from WBL
                                 the original Export                                        70.5 to the wing tip
                                 Certificate of                                             for cracks,
                                 Airworthiness,                                             corrosion, minor
                                 whichever occurs                                           surface defects, and
                                 first.                                                     existing stop-
                                                                                            drilled repairs of
                                                                                            cracking (initial
                                                                                            inspection only), in
                                                                                            accordance with
                                                                                            paragraph 3.B., Work
                                                                                            Instructions, Part
                                                                                            3, of the
                                                                                            Accomplishment
                                                                                            Instructions of the
                                                                                            service bulletin.
(3) Group 1...................  Before 20 years since  Within 4 years    At intervals not  An HFEC inspection of
                                 the date of issuance   after the         to exceed 4       the upper and lower
                                 of the original        effective date    years.            chords of the front
                                 Airworthiness          of this AD.                         spar and the lower
                                 Certificate or the                                         chord of the rear
                                 date of issuance of                                        spar from WBL 70.5
                                 the original Export                                        to the wing tip for
                                 Certificate of                                             cracks, corrosion,
                                 Airworthiness,                                             minor surface
                                 whichever occurs                                           defects, and
                                 first.                                                     existing stop-
                                                                                            drilled repairs of
                                                                                            cracking (initial
                                                                                            inspection only), in
                                                                                            accordance with
                                                                                            paragraph 3.B., Work
                                                                                            Instructions, Part
                                                                                            4, of the
                                                                                            Accomplishment
                                                                                            Instructions of the
                                                                                            service bulletin.
(4) Group 1...................  Within 2 years after   None............  At intervals not  A detailed inspection
                                 doing the actions                        to exceed 2       of the upper chord
                                 required by                              years.            of the rear spar
                                 paragraph (h)(1) of                                        from WBL 70.5 to the
                                 this AD.                                                   wing tip for cracks,
                                                                                            corrosion, minor
                                                                                            surface defects, and
                                                                                            existing stop-
                                                                                            drilled repairs of
                                                                                            cracking (initial
                                                                                            inspection only), in
                                                                                            accordance with
                                                                                            paragraph 3.B., Work
                                                                                            Instructions, Part
                                                                                            8, of the
                                                                                            Accomplishment
                                                                                            Instructions of the
                                                                                            service bulletin.
(5) Group 1...................  Within 4 years after   None............  At intervals not  An HFEC inspection of
                                 doing the actions                        to exceed 4       the upper chord of
                                 required by                              years.            the rear spar from
                                 paragraph (h)(1) of                                        WBL 70.5 to the wing
                                 this AD.                                                   tip for cracks,
                                                                                            corrosion, minor
                                                                                            surface defects, and
                                                                                            existing stop-
                                                                                            drilled repairs of
                                                                                            cracking (initial
                                                                                            inspection only), in
                                                                                            accordance with
                                                                                            paragraph 3.B., Work
                                                                                            Instructions, Part
                                                                                            9, of the
                                                                                            Accomplishment
                                                                                            Instructions of the
                                                                                            service bulletin.

[[Page 64510]]

 
(6) Group 2...................  Before 20 years since  Within 2 years    At intervals not  An exterior detailed
                                 the date of issuance   after the         to exceed 2       inspection of the
                                 of the original        effective date    years.            upper and lower
                                 Airworthiness          of this AD.                         chords of the front
                                 Certificate or the                                         and rear spars from
                                 date of issuance of                                        WBL 70.5 to the wing
                                 the original Export                                        tip for cracks,
                                 Certificate of                                             corrosion, minor
                                 Airworthiness,                                             surface defects, and
                                 whichever occurs                                           existing stop-
                                 first.                                                     drilled repairs of
                                                                                            cracking (initial
                                                                                            inspection only), in
                                                                                            accordance with
                                                                                            paragraph 3.B., Work
                                                                                            Instructions, Part
                                                                                            5, of the
                                                                                            Accomplishment
                                                                                            Instructions of the
                                                                                            service bulletin.
(7) Group 2...................  Before 20 years since  Within 4 years    At intervals not  An HFEC inspection of
                                 the date of issuance   after the         to exceed 4       the upper and lower
                                 of the original        effective date    years.            chords of the front
                                 Airworthiness          of this AD.                         and rear spars from
                                 Certificate or the                                         WBL 70.5 to the wing
                                 date of issuance of                                        tip for cracks,
                                 the original Export                                        corrosion, minor
                                 Certificate of                                             surface defects, and
                                 Airworthiness,                                             existing stop-
                                 whichever occurs                                           drilled repairs of
                                 first.                                                     cracking (initial
                                                                                            inspection only), in
                                                                                            accordance with
                                                                                            paragraph 3.B., Work
                                                                                            Instructions, Part
                                                                                            6, of the
                                                                                            Accomplishment
                                                                                            Instructions of the
                                                                                            service bulletin.
----------------------------------------------------------------------------------------------------------------

Corrective Actions

    (i) If any crack, corrosion, or minor surface defect is detected 
during any inspection required by this AD, before further flight, do 
the applicable corrective actions in accordance with Part 7 of the 
Accomplishment Instructions of the service bulletin, except as 
provided by paragraph (j) of this AD.
    (j) If any crack or corrosion is detected during any inspection 
required by this AD that exceeds the limits specified in the service 
bulletin, and the bulletin 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; 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 
Manager, Seattle ACO, to make such findings. For a repair method to 
be approved, the approval must specifically reference this AD.
    (k) If any existing stop-drilled repair of previous cracking is 
detected during any inspection required by this AD, before further 
flight, permanently repair crack in accordance with paragraph 3.B., 
Work Instructions, Part 7, paragraph 2., ``Crack Repair'' of the 
Accomplishment Instructions of the service bulletin.
    (l) Before further flight following any inspection or repair 
required by this AD, apply a wet layer of BMS 3-23 organic corrosion 
inhibiting compound or Boeing equivalent, in accordance with the 
Accomplishment Instructions of the service bulletin.

Alternative Methods of Compliance (AMOCs)

    (m)(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.
    (2) Alternative methods of compliance, approved previously in 
accordance with AD 2002-24-05, amendment 39-12970, are approved as 
alternative methods of compliance with this AD.
    (3) 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 such findings. For a 
repair method to be approved, the approval must specifically 
reference this AD.

    Issued in Renton, Washington, on October 26, 2004.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 04-24730 Filed 11-4-04; 8:45 am]
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