[Federal Register Volume 70, Number 192 (Wednesday, October 5, 2005)]
[Rules and Regulations]
[Pages 58002-58005]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-19842]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-21085; Directorate Identifier 2004-NM-252-AD; 
Amendment 39-14307; AD 2005-20-13]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 727 Airplanes

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for all 
Boeing Model 727 airplanes. This AD requires a one-time inspection of 
the lower lobe frames of body section 43 to find open holes between 
stringers 17L and 17R and to record their location; repetitive high 
frequency eddy current (HFEC) inspections for cracks of all open holes; 
and related investigative and corrective actions if necessary. This AD 
also includes an optional terminating action of installing rivets in 
all open tooling holes and all unused lining holes, which would 
terminate the repetitive open-hole HFEC inspections once a hole is 
plugged with a rivet. This AD results from reports of cracks at open 
tooling holes in the lower lobe frames of body section 43. We are 
issuing this AD to detect and correct cracks in the frames, which could 
result in cracks in the skin panels and rapid decompression of the 
airplane.

DATES: This AD becomes effective November 9, 2005.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in the AD as of November 9, 
2005.

ADDRESSES: You may examine the 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., Nassif Building, 
room PL-401, Washington, DC.
    Contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, 
Washington 98124-2207, for service information identified in this AD.

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:

Examining the Docket

    You may examine the airworthiness directive (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 street address stated in the ADDRESSES section.

Discussion

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 to include an AD that would apply to all Boeing Model 727 
airplanes. That NPRM was published in the Federal Register on May 2, 
2005 (70 FR 22618). That NPRM proposed to require a one-time inspection 
of the lower lobe frames of body section 43 to find open holes between 
stringers 17L and 17R and to record their location; repetitive high 
frequency eddy current (HFEC) inspections for cracks of all open holes; 
and related investigative and corrective actions if necessary. That 
NPRM also

[[Page 58003]]

proposed to include an optional terminating action of installing rivets 
in all open tooling holes and all unused lining holes, which would 
terminate repetitive open-hole HFEC inspections once a hole is plugged 
with a rivet.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comments received.

Request To Clarify the Frequency of the General Visual Inspection

    Two commenters request that we clarify the frequency of the general 
visual inspection. The commenters point out that the summary of the 
NPRM specifies a one-time inspection, but this inspection is not 
clearly explained in either the preamble or the body of the NPRM. The 
commenters state that the general visual inspection of all body section 
43 frames between stringers 17L and 17R is needed only one time to 
identify and record all locations of open holes, including liner 
attachment holes. If repeat inspections are needed, the record of the 
hole locations will indicate exactly where open holes are located.
    We agree with the commenters. Both the NPRM and Boeing Alert 
Service Bulletin 727-53A0227, dated September 16, 2004 (which was cited 
as the applicable source of service information for the actions in the 
NPRM), are unclear about the frequency of the general visual 
inspection. The compliance table in paragraph 2.E. ``Compliance'' of 
the service bulletin states that the general visual inspection is to be 
repetitive. Figures 1 through 5 of the service bulletin instruct 
operators to record the locations of all open holes and to keep this 
information. We understood that, once all the open hole locations were 
identified and recorded, repeating the general visual inspection would 
not be necessary. This is not clear in the NPRM. Therefore, we have 
revised paragraph (g) of the final rule to clarify that the general 
visual inspection is a one-time inspection, and the HFEC inspection is 
repetitive. We have also clarified the Summary section to reflect this 
change. These changes do not increase the scope of the NPRM since these 
actions were already specified in the service bulletin and the NPRM 
specified to do all inspections in accordance with the service 
bulletin.

Request To Remove Requirement To Inspect Certain Open Holes Previously 
Modified

    The commenter, the airplane manufacturer, requests that we specify 
that open holes used for lining attachments (liner attach holes) are 
not subject to the repetitive inspection requirements proposed in the 
NPRM if the terminating modification of AD 90-20-14, amendment 39-6730 
(55 FR 37864, September 14, 1990), was accomplished for that hole. The 
commenter states that the proposed actions in the NPRM and the 
requirements of AD 90-20-14 conflict. AD 90-20-14 provides for the 
installation of a reinforcement angle and strap along the inner flange 
of the lower lobe frames in body section 43, which is terminating 
action for the repetitive inspections of in-use liner attach holes in 
that AD. The commenter states that the NPRM, as written, would require 
repeat inspections of all open liner attach holes, regardless of 
whether or not these reinforcement angles and straps are installed. The 
manufacturer has not received any reports of cracking at in-use liner 
attach holes in frames that have the reinforcements installed in 
accordance with AD 90-20-14, and the commenter contends that HFEC 
repetitive inspections are not necessary if these reinforcements are 
installed. The commenter also notes that the HFEC inspections specified 
in Boeing Alert Service Bulletin 727-53A0227 are an alternative method 
of compliance (AMOC) with the inspections required by paragraph A. of 
AD 90-20-14 and are the preferred method of inspection.
    We partially agree with the commenter. We agree that it is not 
necessary to accomplish the repetitive inspections specified in 
paragraph (g) of the NPRM for in-use liner attach holes where the frame 
has been reinforced in accordance with AD 90-20-14. We agree with the 
commenter's technical justification. We disagree with completely 
eliminating all inspections of in-use liner attach holes. Boeing 
Service Bulletin 727-53-0068, Revision 4, dated September 14, 1989, 
which is cited as the applicable source of service information for the 
actions in AD 90-20-14, specifies post-modification inspections of the 
in-use liner attach holes with the frame reinforcement modification 
installed. We have added a new paragraph (j) and Table 1 to the final 
rule to specify that repetitive inspection intervals for in-use liner 
attach holes are extended where the frame has been reinforced in 
accordance with AD 90-20-14. We have re-identified subsequent 
paragraphs accordingly.

Explanation of Additional Changes

    We have simplified paragraph (h)(2) of the final rule by referring 
to paragraph (k) of the final rule for repair methods.
    We have revised the applicability to identify model designations as 
published in the most recent type certificate data sheet for the 
affected models.
    We have revised this action to clarify the appropriate procedure 
for notifying the principal inspector before using any approved AMOC on 
any airplane to which the AMOC applies.

Conclusion

    We have carefully reviewed the available data, including the 
comments received, and determined that air safety and the public 
interest require adopting the AD with the changes described previously. 
We have determined that these changes will neither increase the 
economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

    There are about 1,038 airplanes of the affected design in the 
worldwide fleet. This AD affects about 616 airplanes of U.S. registry. 
The inspection takes between 8 and 15 work hours per airplane per 
inspection cycle, depending on the configuration of the airplane. The 
average labor rate is $65 per work hour. Based on these figures, the 
estimated cost of this AD for U.S. operators is between $320,320 and 
$600,600, or between $520 and $975 per airplane, per inspection cycle.
    For operators that choose to do the optional terminating action of 
installing rivets in all open tooling holes and all unused lining 
holes, the actions take between 13 and 23 work hours per airplane, 
depending on the configuration of the airplane. The average labor rate 
is $65 per work hour. Based on these figures, the estimated cost of the 
optional terminating action is between $845 and $1,495 per airplane.

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

[[Page 58004]]

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 have determined that this AD will not have federalism 
implications under Executive Order 13132. This AD will 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 this AD:
    (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.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this AD and placed it in the AD docket. 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, Incorporation by 
reference, Safety.

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the FAA amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
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]

0
2. The Federal Aviation Administration (FAA) amends Sec.  39.13 by 
adding the following new airworthiness directive (AD):

2005-20-13 Boeing: Amendment 39-14307. Docket No. FAA-2005-21085; 
Directorate Identifier 2004-NM-252-AD.

Effective Date

    (a) This AD becomes effective November 9, 2005.

Affected ADs

    (b) Accomplishing the inspections in paragraph (g) of this AD is 
an alternative method of compliance (AMOC) for the inspections 
required by paragraph A. of AD 90-20-14, amendment 39-6730, if 
accomplished in accordance with the requirements of paragraph (k)(2) 
of this AD.

Applicability

    (c) This AD applies to all Boeing Model 727, 727C, 727-100, 727-
100C, 727-200, and 727-200F series airplanes, certificated in any 
category.

Unsafe Condition

    (d) This AD was prompted by reports of cracks at open tooling 
holes in the lower lobe frames of body section 43. We are issuing 
this AD to detect and correct cracks in the frames, which could 
result in cracks in the skin panels and rapid decompression 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.

Service Bulletin Reference

    (f) The term ``service bulletin,'' as used in this AD, means the 
Accomplishment Instructions of Boeing Alert Service Bulletin 727-
53A0227, dated September 16, 2004.

Inspections

    (g) Before the accumulation of 40,000 total flight cycles, or 
within 3,500 flight cycles after the effective date of this AD, 
whichever occurs later: Do a one-time general visual inspection of 
the lower lobe frames to find open holes between stringer 17L and 
stringer 17R of body section 43, record their locations, and keep 
these records for future reference when accomplishing the actions in 
this AD; and do a high-frequency eddy current (HFEC) inspection for 
cracks of all open holes, including lining holes. Repeat the HFEC 
inspection at intervals not to exceed 3,500 flight cycles until the 
optional terminating action in paragraph (i) of this AD is 
accomplished. Do all inspections in accordance with the service 
bulletin.

Corrective Action

    (h) If any crack is found during any inspection required by 
paragraph (g) or (j) of this AD: Before further flight, do the 
applicable corrective action in paragraph (h)(1) or (h)(2) of this 
AD.
    (1) If the crack is less than 0.063 inch in length, do the 
corrective action and related investigative action in Figure 6 of 
the service bulletin.
    (2) If the crack is 0.063 inch in length or greater, repair the 
crack using a method approved in accordance with paragraph (k) of 
this AD. Chapters 51-40-3 and 53-10-4 of the Boeing 727 Structural 
Repair Manual (SRM) are approved methods. Except for these SRMs, for 
a repair method to be approved, the approval must specifically 
reference this AD.

Optional Terminating Action

    (i) Installing rivets in all open tooling holes, and all unused 
lining holes, according to Part 2 of the Work Instructions of the 
service bulletin terminates the repetitive inspection requirements 
of paragraph (g) of this AD only for those holes plugged with 
rivets. Terminating action for the repetitive inspection 
requirements of paragraph (g) of this AD is not permitted for all 
lining holes without installed rivets, except as provided by 
paragraph (j) of this AD.

Extended Intervals for Repetitive HFEC Inspections

    (j) For open holes that are in use for lining installation only: 
Doing the applicable actions in Table 1 of this AD extends the 
intervals of the repetitive HFEC inspections required by paragraph 
(g) of this AD.

      Table 1.--Extended Intervals for Repetitive HFEC Inspections
------------------------------------------------------------------------
If the modification specified
 in paragraph C. of AD 90-20-                    Then--
             14--
------------------------------------------------------------------------
(1) Was done before the        Do the initial HFEC inspection required
 effective date of this AD.     by paragraph (g) of this AD at the time
                                specified in that paragraph. Do the
                                repetitive HFEC inspections required by
                                paragraph (g) of this AD thereafter at
                                intervals not to exceed 20,000 flight
                                cycles.
(2) Has not been done before   Do the modification specified in
 the effective date of this     paragraph C. of AD 90-20-14 at the same
 AD.                            time as the initial HFEC inspection
                                required by paragraph (g) of this AD,
                                and repeat the HFEC inspection
                                thereafter at intervals not to exceed
                                20,000 flight cycles.
------------------------------------------------------------------------

AMOCs

    (k)(1) The Manager, Seattle Aircraft Certification Office (ACO), 
has the authority to approve AMOCs for this AD, if requested in 
accordance with the procedures found in 14 CFR 39.19.
    (2) The inspection methods specified in paragraph (g) of this AD 
are AMOCs to the inspection methods required by paragraph A. of AD 
90-20-14, amendment 39-6730. Inspection thresholds and repetitive 
intervals are not included in or affected by this AMOC. All other 
provisions of AD 90-20-14 that are not specifically mentioned above 
remain fully applicable and must be met.
    (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 an

[[Page 58005]]

Authorized Representative for the Boeing Commercial Airplanes 
Delegation Option Authorization Organization who has been authorized 
by the Manager, Seattle ACO, to make those findings. 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.
    (4) Before using any AMOC approved in accordance with Sec.  
39.19 on any airplane to which the AMOC applies, notify the 
appropriate principal inspector in the FAA Flight Standards 
Certificate Holding District Office.

Material Incorporated by Reference

    (l) You must use Boeing Alert Service Bulletin 727-53A0227, 
dated September 16, 2004, to perform the actions that are required 
by this AD, unless the AD specifies otherwise. The Director of the 
Federal Register approved the incorporation by reference of this 
document in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. 
Contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, 
Washington 98124-2207, for a copy of this service information. You 
may review copies at the Docket Management Facility, U.S. Department 
of Transportation, 400 Seventh Street SW., room PL-401, Nassif 
Building, Washington, DC; on the Internet at http://dms.dot.gov; or 
at the National Archives and Records Administration (NARA). For 
information on the availability of this material at the NARA, call 
(202) 741-6030, or go to http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.

    Issued in Renton, Washington, on September 26, 2005.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-19842 Filed 10-4-05; 8:45 am]
BILLING CODE 4910-13-P