[Federal Register Volume 60, Number 94 (Tuesday, May 16, 1995)]
[Rules and Regulations]
[Pages 25983-25985]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 95-11906]



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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 94-NM-188-AD; Amendment 39-9230; AD 95-10-13]


Airworthiness Directives; Boeing Model 757 Series Airplanes 
Equipped With Rolls Royce Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD), applicable to certain Boeing Model 757 series airplanes, that 
currently requires inspections to detect fatigue-related cracking or 
breakage of the hydraulic tubing support brackets located on the upper 
spar web in the engine struts; further inspection to detect related 
damage of the upper spar web, the fuel lines, and the hydraulic lines, 
as necessary; and repair or replacement of cracked or damaged parts. 
That AD was prompted by reports of fatigue-related cracks in the 
hydraulic tubing support brackets located on the upper spar web in the 
engine struts. The actions specified by that AD are intended to prevent 
such fatigue-related cracking, which could result in fuel or hydraulic 
fluid leakage into the interior of the engine strut and cause a fire. 
This amendment requires installation of a previously optional 
terminating action.

DATES: Effective June 15, 1995.
    The incorporation by reference of Boeing Alert Service Bulletin 
757-54A0030, Revision 1, dated December 20, 1993, as listed in the 
regulations was approved previously by the Director of the Federal 
Register as of February 28, 1994 (59 FR 6542).

ADDRESSES: The service information referenced in this AD may be 
obtained from Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, 
Washington 98124-2207. This information may be examined at the Federal 
Aviation Administration (FAA), Transport Airplane Directorate, Rules 
Docket, 1601 Lind Avenue, SW., Renton, Washington; or at the Office of 
the Federal Register, 800 North Capitol Street, NW., suite 700, 
Washington, DC.

FOR FURTHER INFORMATION CONTACT: Sheila Kirkwood, Aerospace Engineer, 
[[Page 25984]] Systems and Equipment Branch, ANM-130S, FAA, Transport 
Airplane Directorate, Seattle Aircraft Certification Office, 1601 Lind 
Avenue, SW., Renton, Washington 98055-4056; telephone (206) 227-2675; 
fax (206) 227-1181.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) by superseding AD 94-04-04, 
amendment 39-8822 (59 FR 11182, March 10, 1994), which is applicable to 
certain Boeing Model 757 series airplanes, was published in the Federal 
Register on December 29, 1994 (59 FR 67240). The action proposed to 
supersede AD 94-04-04 to continue to require inspections to detect 
fatigue-related cracking or breakage of the hydraulic tubing support 
brackets located on the upper spar web in the engine struts; further 
inspection to detect related damage of the upper spar web, the fuel 
lines, and the hydraulic lines, as necessary; and removal, and either 
repair or replacement of cracked or damaged parts. That action also 
proposed to require replacement of all existing support brackets 
manufactured from 2219 aluminum, 2024-T42 aluminum alloy, or 301 
stainless steel with new nickel alloy support brackets; this 
replacement would constitute terminating action for the repetitive 
inspection requirements.
    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. Due consideration has been given to 
the comments received.
    One commenter supports the proposed rule.
    One commenter requests that the FAA revise the proposal to allow 
support brackets manufactured from 2219 aluminum, 2024-T42 aluminum 
alloy, or 301 stainless steel to be replaced with either new brackets 
made of 17-7PH steel or new brackets made of nickel alloy. The 
commenter states that it previously received FAA approval of an 
alternative method of compliance with AD 94-04-04 for installation of 
new brackets made of 17-7PH steel. This commenter notes that it would 
be burdensome to have to request FAA approval for another alternative 
method of compliance with this AD for an action already accomplished. 
The FAA concurs and has revised paragraph (f) of the final rule 
accordingly.
    One commenter requests that references in the proposed rule to 
``nickel alloy brackets'' be changed to read ``nickel alloy 625 
brackets'' in order to avoid confusion with other nickel alloy 
possibilities. The FAA concurs and revised all references accordingly 
throughout this final rule.
    After careful review of the available data, including the comments 
noted above, the FAA has determined that air safety and the public 
interest require the adoption of the rule with the changes previously 
described. The FAA has determined that these changes will neither 
increase the economic burden on any operator nor increase the scope of 
the AD.
    There are approximately 132 Boeing Model 757 series airplanes 
equipped with Rolls Royce engines of the affected design in the 
worldwide fleet. The FAA estimates that 102 airplanes of U.S. registry 
will be affected by this AD.
    The actions currently required by AD 94-04-04 take approximately 4 
work hours per airplane to accomplish, at an average labor rate of $60 
per work hour. Based on these figures, the total cost impact of the 
currently required actions on U.S. operators is estimated to be 
$24,480, or $240 per airplane.
    The replacement actions take approximately 40 work hours per 
airplane to accomplish, at an average labor rate of $60 per work hour. 
Required parts will cost approximately $1,044 per airplane. Based on 
these figures, the total cost impact of the required replacement 
actions on U.S. operators is estimated to be $351,288, or $3,444 per 
airplane.
    The total cost impact figure discussed above is based on 
assumptions that no operator has yet accomplished any of the 
requirements of this AD action, and that no operator would accomplish 
those actions in the future if this AD were not adopted.
    The regulations adopted herein will not have substantial direct 
effects on the States, on the relationship between the national 
government and the States, or on the distribution of power and 
responsibilities among the various levels of government. Therefore, in 
accordance with Executive Order 12612, it is determined that this final 
rule does not have sufficient federalism implications to warrant the 
preparation of a Federalism Assessment.
    For the reasons discussed above, I certify that this action (1) is 
not a ``significant regulatory action'' under Executive Order 12866; 
(2) is not a ``significant rule'' under 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. A final evaluation has been prepared for this action 
and it is contained in the Rules Docket. A copy of it may be obtained 
from the Rules Docket at the location provided under the caption 
ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:
PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. App. 1354(a), 1421 and 1423; 49 U.S.C. 
106(g); and 14 CFR 11.89.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by removing amendment 39-8822 (59 FR 
11182, March 10, 1994), and by adding a new airworthiness directive 
(AD), amendment 39-9230, to read as follows:

95-10-13  Boeing: Amendment 39-9230. Docket 94-NM-188-AD. Supersedes 
AD 94-04-04, Amendment 39-8822.

    Applicability: Model 757 series airplanes equipped with Rolls 
Royce engines; as listed in Boeing Alert Service Bulletin 757-
54A0030, Revision 1, dated December 20, 1993; certificated in any 
category.

    Note 1: This AD applies to each airplane identified in the 
preceding applicability provision, regardless of whether it has been 
modified, altered, or repaired in the area subject to the 
requirements of this AD. For airplanes that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must use the authority 
provided in paragraph (h) to request approval from the FAA. This 
approval may address either no action, if the current configuration 
eliminates the unsafe condition; or different actions necessary to 
address the unsafe condition described in this AD. Such a request 
should include an assessment of the effect of the changed 
configuration on the unsafe condition addressed by this AD. In no 
case does the presence of any modification, alteration, or repair 
remove any airplane from the applicability of this AD.

    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent fuel or hydraulic fluid leakage into the interior of 
the engine strut, which could cause a fire, accomplish the 
following:
    (a) For Group 2 Airplanes: Within 60 days after February 28, 
1994 (the effective date of AD 94-04-04, amendment 39-8822), perform 
an inspection using a magnet to determine whether the forward 
support bracket for the hydraulic tubing on the upper spar web of 
each engine strut is manufactured from 17-7PH steel, in accordance 
with Boeing Alert [[Page 25985]] Service Bulletin 757-54A0030, 
Revision 1, dated December 20, 1993. If any forward support bracket 
is manufactured from 17-7PH steel, no further action is required by 
this AD for that forward bracket.

    Note 2: The brackets positioned after the forward bracket should 
be manufactured from 17-7PH steel, as shown below:

------------------------------------------------------------------------
                                                                (Power  
                                                                 plant  
                 Bracket                        Part No.        station 
                                                                 No.)   
------------------------------------------------------------------------
First Bracket............................  312N5817-13......  PPS 102   
                                           (or equivalent)..            
Second Bracket...........................  312N5817-19......  PPS 120   
                                           (or equivalent)..            
Third Bracket............................  312N5817-23......  PPS 129   
                                           (or equivalent)..            
Fourth Bracket...........................  312N5817-25......  PPS 145   
                                           (or equivalent)..            
------------------------------------------------------------------------

    (b) For Groups 1 and 2 Airplanes: Within 60 days after February 
28, 1994 (the effective date of AD 94-04-04, amendment 39-8822) (for 
Group 1 airplanes), and prior to further flight following the 
inspection required by paragraph (a) of this AD (for Group 2 
airplanes), perform an initial visual inspection to detect fatigue-
related cracks or breakage on the hydraulic tubing support brackets 
not manufactured of 17-7PH steel on the upper spar web of each 
engine strut, in accordance with Boeing Alert Service Bulletin 757-
54A0030, Revision 1, dated December 20, 1993. If any discrepancy is 
detected, prior to further flight, accomplish the following in 
accordance with the alert service bulletin:
    (1) For any support bracket that is completely broken: Perform a 
further visual inspection to detect worn areas or other damage of 
the upper spar web, the fuel lines, and the hydraulic lines; and 
prior to further flight, accomplish paragraphs (b)(1)(i), 
(b)(1)(ii), (b)(1)(iii), and (b)(1)(iv) of this AD in accordance 
with the alert service bulletin:
    (i) Repair any damaged upper spar web.
    (ii) Repair or replace any damaged fuel line with new or 
serviceable parts, as necessary.
    (iii) Replace any damaged hydraulic line with new or serviceable 
parts.
    (iv) Remove any broken support bracket; and, except as provided 
by paragraph (c) of this AD, replace it with a new nickel alloy 625 
bracket.
    (2) For any support bracket that is cracked, but not completely 
broken: Perform a further visual inspection to detect damage of the 
hydraulic pressure line only; and prior to further flight, 
accomplish paragraphs (b)(2)(i) and (b)(2)(ii) of this AD in 
accordance with the alert service bulletin:
    (i) Replace any damaged hydraulic pressure line with new or 
serviceable parts, as necessary.
    (ii) Remove any cracked support bracket; and, except as provided 
by paragraph (c) of this AD, replace it with a new nickel alloy 625 
bracket.
    (c) For any airplane having a support bracket that is removed 
during accomplishment of paragraph (b)(1)(iv) or (b)(2)(ii) of this 
AD: The following number of flights are permitted prior to 
replacement of any removed support bracket with a new nickel alloy 
625 bracket (in accordance with Boeing Alert Service Bulletin 757-
54A0030, Revision 1, dated December 20, 1993), provided that, prior 
to further flight, the cracked or broken brackets are removed 
completely, damaged spar webs are repaired, and fuel lines and 
hydraulic lines are repaired or replaced, in accordance with 
paragraph (b) of this AD:

----------------------------------------------------------------------------------------------------------------
                                                       Part No. (power plant station                            
                      Bracket                                       No.)                    Flights permitted   
----------------------------------------------------------------------------------------------------------------
First Bracket Removed..............................  312N5817-55 (PPS 102)............  No Flights.             
Second Bracket Removed.............................  312N5817-69 (PPS 120)............  Ten Flights.            
Third Bracket Removed..............................  312N5817-73 (PPS 129)............  Ten Flights.            
Fourth Bracket Removed.............................  312N5817-75 (PPS 145)............  Three Flights.          
Second and Third Brackets Removed..................  .................................  One Flight.             
Multiple Brackets, other than Second and Third.....  .................................  No Flights.             
----------------------------------------------------------------------------------------------------------------

    (d) For any airplane having a support bracket that is 
manufactured from 2024-T42 aluminum alloy or 301 stainless steel: 
Repeat the initial inspection required by paragraph (b) of this AD 
thereafter at intervals not to exceed 2,000 flight hours, in 
accordance with the procedures described in Boeing Alert Service 
Bulletin 757-54A0030, Revision 1, dated December 20, 1993.
    (e) For any airplane having a support bracket that is 
manufactured from 2219 aluminum: Repeat the initial inspection 
required by paragraph (b) of this AD thereafter at intervals not to 
exceed 1,000 flight hours, in accordance with the procedures 
described in Boeing Alert Service Bulletin 757-54A0030, Revision 1, 
dated December 20, 1993.
    (f) Within 18 months after the effective date of this AD: 
Replace all support brackets manufactured from 2219 aluminum, 2024-
T42 aluminum alloy, or 301 stainless steel, with either new 17-7PH 
steel brackets or new nickel alloy 625 support brackets for the 
hydraulic tubing on the upper spar web of the engine struts at all 
locations, in accordance with Boeing Alert Service Bulletin 757-
54A0030, Revision 1, dated December 20, 1993. Accomplishment of this 
modification constitutes terminating action for the requirements of 
this AD.
    (g) As of February 28, 1994 (the effective date of AD 94-04-04, 
amendment 39-8822), no person shall install any hydraulic tubing 
support bracket on the upper spar web of the engine struts that is 
manufactured from 2219 aluminum, 2024-T42 aluminum alloy, or 301 
stainless steel on any airplane.
    (h) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Seattle Aircraft Certification 
Office (ACO), FAA, Transport Airplane Directorate. Operators shall 
submit their requests through an appropriate FAA Principal 
Maintenance Inspector, who may add comments and then send it to the 
Manager, Seattle ACO.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Seattle ACO.

    (i) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the airplane to a location where 
the requirements of this AD can be accomplished.
    (j) The inspections, repair, replacement, and removal shall be 
done in accordance with Boeing Alert Service Bulletin 757-54A0030, 
Revision 1, dated December 20, 1993. The incorporation by reference 
of this document was approved previously by the Director of the 
Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 
51 as of February 28, 1994 (59 FR 65420). Copies may be obtained 
from Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, 
Washington 98124-2207. Copies may be inspected at the FAA, Transport 
Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or 
at the Office of the Federal Register, 800 North Capitol Street, 
NW., suite 700, Washington, DC.
    (k) This amendment becomes effective on June 15, 1995.

    Issued in Renton, Washington, on May 9, 1995.
Darrell M. Pederson,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 95-11906 Filed 5-15-95; 8:45 am]
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