Document ID: FAA-2011-0027-0008
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: The Boeing Company Airplanes
Posted Date: 2015-09-25T04:00Z

[Federal Register Volume 80, Number 186 (Friday, September 25, 2015)]
[Proposed Rules]
[Pages 57744-57751]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2015-24344]

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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 Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Supplemental notice of proposed rulemaking (SNPRM); reopening 
of comment period.

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SUMMARY: We are revising an earlier proposed airworthiness directive 
(AD) for The Boeing Company Model 777-200 and -300 series airplanes, 
equipped with Rolls-Royce Model RB211-Trent 800 engines. The notice of 
proposed rulemaking (NPRM) proposed to require repetitive inspections 
of the thrust reverser (T/R) structure and sealant, and related 
investigative and corrective actions if necessary. The NPRM was 
prompted by reports of T/R events related to thermal damage of the T/R 
inner wall. This action revises the NPRM by proposing to add different 
repetitive inspections requirements for T/R halves with a thermal 
protective system installed. This action also revises the NPRM by 
proposing to require installation of serviceable T/R halves, which 
would terminate the repetitive inspections in this SNPRM. This SNPRM 
also proposes to revise the inspection or maintenance program by 
incorporating new airworthiness limitations. We are proposing this 
SNPRM to detect and correct a degraded T/R inner wall panel, which 
could lead to failure of the T/R and adjacent components and their 
consequent separation from the airplane, and 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. Since these actions impose an additional 
burden over that proposed in the NPRM, we are reopening the comment 
period to allow the public the chance to comment on these proposed 
changes.

DATES: We must receive comments on this SNPRM by November 9, 2015.

ADDRESSES: You may send comments, using the procedures found in 14 CFR

[[Page 57745]]

11.43 and 11.45, 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 AD, contact Boeing 
Commercial Airplanes, Attention: Data & Services Management, P.O. Box 
3707, MC 2H-65, Seattle, WA 98124-2207; telephone 206-544-5000, 
extension 1; fax 206-766-5680; Internet https://www.myboeingfleet.com. 
You may view this referenced service information at the FAA, Transport 
Airplane Directorate, 1601 Lind Avenue SW., Renton, WA. For information 
on the availability of this material at the FAA, call 425-227-1221. It 
is also available on the Internet at http://www.regulations.gov by 
searching for and locating Docket No. FAA-2011-0027.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2011-
0027; 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 (phone: 800-647-5527) is in the ADDRESSES section. Comments will 
be available in the AD docket shortly after receipt.

FOR FURTHER INFORMATION CONTACT: Kevin Nguyen, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification Office 
(ACO), 1601 Lind Avenue SW., Renton, Washington 98057-3356; phone: 425-
917-6501; fax: 425-917-6590; email: kevin.nguyen@faa.gov.

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 issued an NPRM to amend 14 CFR part 39 by adding an AD that 
would apply to certain Model 777-200 and -300 series airplanes. The 
NPRM published in the Federal Register on January 20, 2011 (76 FR 
3561). The NPRM proposed to require repetitive inspections for 
degradation of T/R structure and sealant, and related investigative and 
corrective actions if necessary.

Actions Since NPRM (76 FR 3561, January 20, 2011) Was Issued

    Since we issued the NPRM (76 FR 3561, January 20, 2011), we have 
received additional reports of thermal damage of the T/R inner wall on 
Rolls-Royce Model RB211-Trent 800 engines.
    The preamble to the NPRM (76 FR 3561, January 20, 2011) specified 
that we considered those proposed requirements ``interim action,'' and 
that the manufacturer was developing a modification to address the 
unsafe condition. That NPRM explained that we might consider further 
rulemaking if a modification were developed, approved, and available. 
The manufacturer now has developed a thermal protection system (TPS) 
and inner wall. We have determined that further rulemaking is indeed 
necessary. This proposed AD also would require a revision to the 
maintenance or inspection program to incorporate new airworthiness 
limitations. We have determined the following actions are necessary to 
address the identified unsafe condition:
     For airplanes with pre-TPS insulation blankets, part 
number P/N 315W5113-(XX) and 315W5010-(XX): The interim actions and 
repetitive inspections are specified Boeing Alert Service Bulletin 777-
78A0065, Revision 2, dated May 6, 2010.
     For airplanes with TPS insulation blankets, P/N 315W5115-
(XX): The interim repetitive inspections (non-destructive test (NDT) 
and electronic engine control (EEC) repetitive inspections only) are 
specified in Boeing Service Bulletin 777-78-0082, Revision 1, dated 
June 15, 2015; and Boeing Special Attention Service Bulletin 777-78-
0071, Revision 2, dated July 23, 2013.
     For all airplanes: The final terminating action, 
installing serviceable T/R halves, is specified in Boeing Alert Service 
Bulletin 777-78A0094, dated July 29, 2014.
     For all airplanes: New airworthiness limitations, 
Airworthiness Limitations 78-AWL-01 and 78-AWL-02, that need to be 
incorporated in the maintenance or inspection program are specified in 
Boeing 777 Maintenance Planning Data (MPD) Document, Section 9, 
Airworthiness Limitations (AWLs) and Certification Maintenance 
Requirements (CMRs), D622W001-9, Revision dated October 2014.

Related Service Information Under 1 CFR Part 51

    We reviewed the following service information. This service 
information is reasonably available because the interested parties have 
access to it through their normal course of business or by the means 
identified in the ADDRESSES section of this SNPRM.
     Boeing Alert Service Bulletin 777-78A0065, Revision 2, 
dated May 6, 2010. This service information describes procedures for a 
review of the airplane maintenance records to determine whether sealant 
was added to insulation blankets around compression pad fittings and 
powered door opening system (PDOS) fittings; inspections of the T/R 
structure; and related investigative and corrective actions.
     Boeing Alert Service Bulletin 777-78A0094, dated July 29, 
2014. This service information describes procedures for installing 
serviceable T/R halves.
     Boeing Service Bulletin 777-78-0082, Revision 1, dated 
June 15, 2015; and Boeing Special Attention Service Bulletin 777-78-
0071, Revision 2, dated July 23, 2013. This service information 
describes, among other actions, procedures for inspections of the T/R 
structure, and related investigative and corrective actions. Boeing 
Special Attention Service Bulletin 777-78-0071, Revision 2, dated July 
23, 2013, also describes, for airplanes on which the actions specified 
Boeing Special Attention Service Bulletin 777-78-0071, dated November 
29, 2009, have been done, procedures for installation of

[[Page 57746]]

click bond covers and bracket, a general visual inspection of the 
compression fitting for incorrect pin orientation, and related 
investigative and corrective actions.
     Airworthiness Limitations 78-AWL-01, Thrust Reverser 
Thermal Protection System; and 78-AWL-02, Thrust Reverser Inner Wall; 
as specified in Boeing 777 Maintenance Planning Data (MPD) Document, 
Section 9, Airworthiness Limitations (AWLs) and Certification 
Maintenance Requirements (CMRs), D622W001-9, Revision dated October 
2014. Airworthiness Limitation 78-AWL-01 describes an inspection of the 
T/R TPS on both engines. Airworthiness Limitation 78-AWL-02 describes 
an inspection of the T/R inner wall.

Comments

    We gave the public the opportunity to comment on the NPRM (76 FR 
3561, January 20, 2011). The following presents the comments received 
on the NPRM and the FAA's response to each comment.

Support for the NPRM (76 FR 3561, January 20, 2011)

    Boeing concurred with the contents of the NPRM (76 FR 3561, January 
20, 2011).

Requests To Include Terminating Action

    American Airlines (AAL), Delta Air Lines, and Air New Zealand 
requested that we revise the NPRM (76 FR 3561, January 20, 2011) to 
allow installation of a TPS, which is described in Boeing Special 
Attention Service Bulletin 777-78-0071, Revision 2, dated July 23, 
2013. The commenters proposed that the TPS installation terminate the 
proposed repetitive inspections of Boeing Alert Service Bulletin 777-
78A0065, Revision 2, dated May 6, 2010, which are specified in the 
NPRM.
    We partially agree with the request. We agree to provide a 
terminating action for the inspections specified in this proposed AD. 
However, we do not agree that installation of a TPS as described in 
Boeing Special Attention Service Bulletin 777-78-0071, Revision 2, 
dated July 23, 2013, would provide an adequate level of safety to 
completely address the identified unsafe condition. Instead, we have 
determined that installing serviceable T/R halves as specified in 
Boeing Alert Service Bulletin 777-78A0094, dated July 29, 2014, is 
terminating action for the inspections specified in this proposed AD. 
We have also determined that installing serviceable T/R halves (see 
Boeing Alert Service Bulletin 777-78A0094, dated July 29, 2014, for 
definition of serviceable) and revising the maintenance or inspection 
program to incorporate new airworthiness limitations addresses the 
identified unsafe condition. We have added the proposed requirement to 
install serviceable T/R halves to paragraph (l) of this AD and we have 
added the proposed requirement to revise the maintenance or inspection 
program to paragraph (n) of this AD.

Request To Correct Work Package Reference

    AAL requested that we revise paragraph (i) of the proposed AD, 
which incorrectly referred to the compliance time for Work Packages 2 
and 5 ``or Work Packages 2 and 6.'' The correct reference is to the 
compliance time for Work Packages 2 and 5 ``or Work Packages 5 and 6.''
    We agree with this request, and have changed the references 
accordingly in paragraph (h)(2) in this proposed AD, which was 
paragraph (i) in the original proposed AD.
    We also note a similar typographical error in the preamble of the 
NPRM (76 FR 3561, January 20, 2011), in the ``Relevant Service 
Information'' section, under the subsection titled ``Work Package 6'' 
for Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010. That subsection incorrectly specified that Work Package 6 may be 
done as an option to Work Package 2, if the shorter repetitive 
inspection intervals specified in ``Work Package 2'' are followed. The 
correct intervals are specified in ``Work Package 6.'' The ``Relevant 
Service Information'' section is not repeated in this proposed AD, 
however, so we have not changed this proposed AD regarding this issue. 
We have provided a general description of Boeing Alert Service Bulletin 
777-78A0065, Revision 2, dated May 6, 2010 in the ``Related Service 
Information under 1 CFR part 51'' section of this proposed AD.

Request To Remove Certain Service Bulletin Exception

    AAL requested that we remove paragraph (k) from the proposed AD, 
which explained that where the Condition column in paragraph 1.E., 
``Compliance,'' of Boeing Alert Service Bulletin 777-78A0065, Revision 
2, dated May 6, 2010, referred to ``total flight cycles,'' it means 
``total flight cycles as of the effective date of this AD.'' AAL was 
concerned that total flight cycles are stated to be total flight cycles 
on the airplane rather than total flight cycles on the T/R half. AAL 
reported that it is not uncommon for the total flight cycles of the T/R 
half to differ from the total flight cycles of the airframe, because T/
Rs are line-replacement units.
    We partially agree. We agree that those compliance times, in terms 
of total flight cycles, should apply to each T/R half, although we had 
inadvertently specified total flight cycles on the airplane. We 
disagree, however, to remove paragraph (k) of the original proposed AD, 
which is paragraph (h)(4) in this proposed AD. The intent of paragraph 
(h)(4) of this proposed AD is to provide a relative starting date from 
which to establish the compliance time; no such starting point was 
provided in the service information. We have retained the exception in 
paragraph (h)(4) in this proposed AD, but changed ``airplanes with the 
specified total flight cycles'' to ``each T/R half with the specified 
total flight cycles as of the effective date of this AD.''

Requests To Allow Future Aircraft Maintenance Manual (AMM) Revisions

    AAL stated that Boeing intends to revise AMM 78-31-06, which is 
referenced in Work Package 1 of the Accomplishment Instructions of 
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010. AAL recommended that we revise paragraph (g)(1) of the proposed 
AD to allow the use of any revision of that AMM during the inspection 
specified in Work Package 1. AAL stated that the AD does not specify 
which revision levels of AMM 78-31-06 are acceptable for this 
inspection.
    We disagree that it is necessary to revise the NPRM (76 FR 3561, 
January 20, 2011) in response to this request. Use of a specific 
revision level of an AMM is not required during the accomplishment of 
the actions specified in Boeing Alert Service Bulletin 777-78A0065, 
Revision 2, dated May 6, 2010. An operator can therefore use a new AMM 
revision during that inspection without requesting FAA approval of an 
alternative method of compliance (AMOC). We have not changed this 
proposed AD regarding this issue.

Request To Allow Organization Designation Authorization (ODA) Approval 
of Repairs

    AAL was concerned about the effect on its operation of the proposed 
requirement for FAA approval of certain repairs. AAL recommended that 
we revise the NPRM (76 FR 3561, January 20, 2011) to provide Boeing 
repair approval authority. AAL added that Boeing's technical and 
engineering

[[Page 57747]]

support can support any situation and avoid grounding an airplane.
    We partially agree with the request. We agree to allow Boeing 
repair approval authority for structural aspects of the repair, but the 
FAA must approve non-structural aspects of any repair. We have added 
new paragraph (r)(3) in this proposed AD to delegate the authority to 
the Boeing Commercial Airplanes ODA to approve AMOCs for structural 
repairs that may be conditionally required by this AD.

Request To Allow Flexibility in Work Accomplishment

    AAL requested that we revise the NPRM (76 FR 3561, January 20, 
2011) to allow airlines the flexibility to reorganize the proposed 
actions in such a way as to meet the work requirements and more easily 
fit the work into airline practices. AAL stated that forcing all 
airlines to do the actions strictly in alignment with the work package 
sequence in the service information could lead to confusion and the 
increased potential for noncompliance.
    We agree with the intent of the request. Paragraph (g) of this 
proposed AD refers to Boeing Alert Service Bulletin 777-78A0065, 
Revision 2, dated May 6, 2010, as the appropriate source of service 
information for doing the actions in that paragraph. Note 2 of 
paragraph 3.A., ``General Information,'' of Boeing Alert Service 
Bulletin 777-78A0065, Revision 2, dated May 6, 2010, states, ``You can 
do each Work Package independently or at the same time. Refer to 
Service Bulletin Paragraph 1.E, Compliance, for when to do the work 
packages.'' Therefore, for paragraph (g) of this proposed AD, operators 
are already allowed to combine work packages or otherwise adjust the 
procedure sequence as necessary to fit their work plan, provided the 
configuration meets the type design of the airplane before it is 
returned to service and the work package is done within the compliance 
time specified in Boeing Alert Service Bulletin 777-78A0065, Revision 
2, dated May 6, 2010. We have not revised this proposed AD regarding 
this issue.

Request To Allow Alternative Sealant Curing

    AAL reported that Boeing has agreed to develop alternative methods 
for sealant curing that would reduce the time to achieve an adequate 
cure. AAL therefore requested that we revise paragraph (g) of the 
proposed AD to allow use of this alternative sealant curing method.
    We disagree with the request. While acceptable alternative cure 
methods might exist, the commenter did not supply sufficient 
information on the proposed cure process to allow the FAA to approve 
that process as part of the AD. Operators may propose alternative cure 
methods via the AMOC process as specified in paragraph (r) of this 
proposed AD. We have not changed this proposed AD regarding this issue.

FAA's Determination

    We are proposing this SNPRM because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design. 
Certain changes described above expand the scope of the NPRM (76 FR 
3561, January 20, 2011). As a result, we have determined that it is 
necessary to reopen the comment period to provide additional 
opportunity for the public to comment on this SNPRM.

Proposed Requirements of This SNPRM

    This SNPRM would require accomplishing the actions specified in the 
service information described previously, except as discussed under 
``Difference Between this SNPRM and the Service Information.'' Refer to 
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010; Boeing Alert Service Bulletin 777-78A0094, dated July 29, 2014; 
Boeing Service Bulletin 777-78-0082, Revision 1, dated June 15, 2015; 
and Boeing Special Attention Service Bulletin 777-78-0071, Revision 2, 
dated July 23, 2013; for details on the procedures and compliance 
times.
    The phrase ``related investigative actions'' is used in this SNPRM. 
``Related investigative actions'' are follow-on actions that (1) are 
related to the primary action, and (2) further investigate the nature 
of any condition found. Related investigative actions in an AD could 
include, for example, inspections.
    The phrase ``corrective actions'' is used in this SNPRM. 
``Corrective actions'' are actions that correct or address any 
condition found. Corrective actions in an AD could include, for 
example, repairs.

Differences Between This SNPRM and the Service Information

    Boeing Special Attention Service Bulletin 777-78-0071, Revision 2, 
dated July 23, 2013, describe procedures for a general visual 
inspection of the perforated side of the T/R inner wall aft of the IP8 
and the HP3 bleed port exits for color that is different than the 
normal T/R perforated wall color; a general visual inspection of the 
compression fitting for incorrect pin orientation; and a general visual 
inspection of the EEC wire bundles and clips for damage. However, this 
SNPRM would require detailed inspections instead of general visual 
inspections. Detailed inspections are necessary in order to adequately 
determine if the specified condition exists. This difference has been 
coordinated with Boeing.
    Boeing Alert Service Bulletin 777-78A0094, dated July 29, 2014, 
specifies a compliance time of 5 years for doing the installation, but 
this SNPRM would require a compliance time of 48 months to ensure the 
safety of the fleet in light of the identified unsafe condition. This 
difference has been coordinated with Boeing.
    Boeing Special Attention Service Bulletin 777-78-0071, Revision 2, 
dated July 23, 2013, specifies a compliance time of 4 years for 
installation of click bond covers and bracket, and washer replacement; 
and for the general visual inspection of the compression fitting for 
incorrect pin orientation, a compliance time of 2,000 flight-cycles 
after accomplishing a certain work package (these actions are for 
airplanes on which the actions specified Boeing Special Attention 
Service Bulletin 777-78-0071, dated November 29, 2009, have been done). 
This SNPRM would require these actions to be done prior to or 
concurrently with the inspection specified in paragraph (i) of this 
SNPRM. These actions must be done first in order to accomplish the 
inspections specified in paragraph (i) of this SNPRM. We have 
coordinated this difference with Boeing.
    Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010; Boeing Special Attention Service Bulletin 777-78-0071, Revision 
2, dated July 23, 2013; Boeing Service Bulletin 777-78-0082, Revision 
1, dated June 15, 2015; and Boeing Alert Service Bulletin 777-78A0094, 
dated July 29, 2014; specify contacting the manufacturer for 
instructions on how to repair certain conditions. Instead, this SNPRM 
would require repairing those conditions in one of the following ways:
     In accordance with a method that we approve; or
     Using data that meet the certification basis of the 
airplane, and that have been approved by the Boeing Commercial 
Airplanes ODA whom we have authorized to make those findings.

Other Related Rulemaking

    On March 31, 2005, we issued AD 2005-07-24, Amendment 39-14049 (70 
FR 18285, April 11, 2005), for certain Boeing Model 777-200 and -300 
series

[[Page 57748]]

airplanes. AD 2005-07-24 requires inspecting the T/Rs for damage of the 
insulation blankets, the inner wall, and the compression and drag link 
fittings; and repair if necessary. AD 2005-07-24 also requires applying 
sealant to certain areas of the T/R. AD 2005-07-24 was prompted by two 
reports of T/R failure. Investigation revealed that the inner wall of 
the T/Rs had collapsed from exposure to hot engine core compartment 
air. We issued AD 2005-07-24 to prevent 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 an RTO does not occur, these separated components could 
cause structural damage to the airplane or damage to other airplanes 
and possible injury to people on the ground.
    This SNPRM would terminate the actions required by paragraphs (f), 
(g), and (h) of AD 2005-07-24, Amendment 39-14049 (70 FR 18285, April 
11, 2005), by accomplishment of any of the following actions specified 
in this SNPRM:
     The actions specified in Boeing Alert Service Bulletin 
777-78A0065, Revision 2, dated May 6, 2010 (paragraph (g) of this 
SNPRM).
     Certain inspections and actions specified in Boeing 
Service Bulletin 777-78-0082, Revision 1, dated June 15, 2015; and 
Boeing Special Attention Service Bulletin 777-78-0071, Revision 2, 
dated July 23, 2013 (paragraphs (i), (j), and (k) of this SNPRM).
     The installation specified in Boeing Alert Service 
Bulletin 777-78A0094, dated July 29, 2014 (paragraph (l) of this 
SNPRM).

Costs of Compliance

    We estimate that this proposed AD affects 55 of U.S. registry. We 
estimate the following costs to comply with this proposed AD:

                                                                     Estimated Costs
--------------------------------------------------------------------------------------------------------------------------------------------------------
                                                              Average labor
               Action                      Work hours         rate per hour        Parts cost           Cost per product              Fleet cost
--------------------------------------------------------------------------------------------------------------------------------------------------------
Actions per Boeing Alert Service     Up to 79 work-hours,                85  $0....................  Up to $6,715 per T/R    $0 (No airplanes on the
 Bulletin 777[dash]78A0065,           per T/R half.                                                   half.                   U.S. Register are in the
 Revision 2, dated May 6, 2010.                                                                                               configuration specified in
                                                                                                                              Boeing Alert Service
                                                                                                                              Bulletin 777[dash]78A0065,
                                                                                                                              Revision 2, dated May 6,
                                                                                                                              2010.)
Actions per Boeing Special           Up to 48 work-hours,                85  $0....................  Up to $4,080 per T/R    Up to $897,600 (4 T/R
 Attention Service Bulletin           per T/R half.                                                   half.                   halves per airplane).
 777[dash]78[dash]0071, Revision 2,
 dated July 23, 2013.
Inspections per Boeing Service       Up to 39 work-hours,                85  $0....................  Up to $3,315 per T/R    $0 (No airplanes on the
 Bulletin 777[dash]78[dash]0082,      per T/R half.                                                   half.                   U.S. Register are in the
 Revision 1, dated June 15, 2015.                                                                                             configuration specified in
                                                                                                                              Boeing Service Bulletin
                                                                                                                              777[dash]78[dash]0082,
                                                                                                                              Revision 1, dated June 15,
                                                                                                                              2015.)
Maintenance or Inspection Program    1 work-hour...........              85  $0....................  $85...................  $4,675.
 Revision.
T/R half installation per Boeing     Up to 206 work-hours,               85  Up to $400,651 per T/R  Up to $418,161 per T/R  Up to $91,995,420 (4 T/R
 Alert Service Bulletin               per T/R half.                           half. \1\               half.                   halves per airplane).\2\
 777[dash]78A0094, dated July 29,
 2014.
--------------------------------------------------------------------------------------------------------------------------------------------------------
\1\ The cost of parts is split into two major parts: (1) TPS blankets and (2) inner wall structure. The vast majority of the cost associated with the
  TPS upgrade has already been completed. In addition, nearly half of the inner wall structure modification has already been done.
\2\ The fleet cost estimate above is based on just a general estimate for a given airplane with two engines having two T/R halves for each engine. Not
  all tasks required by this SNPRM and specified in the service information would need to be done for a given T/R half. For a given TR half, it may only
  be necessary to accomplish certain actions or none for compliance, depending on its configuration status. We have no data to determine any given T/R
  half configuration to determine the cost for each T/R half to do the applicable actions for that T/R half. The majority of this cost has already been
  incurred.

    We have received no definitive data that would enable us to provide 
cost estimates for the on-condition actions specified in this SNPRM.
    According to the manufacturer, some of the costs of this proposed 
AD may be covered under warranty, thereby reducing the cost impact on 
affected individuals. We do not control warranty coverage for affected 
individuals. As a result, we have included all costs in our cost 
estimate.

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,

[[Page 57749]]

    (2) Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979),
    (3) Will not affect intrastate aviation in Alaska, and
    (4) 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.

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

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 FAA amends Sec.  39.13 by adding the following new airworthiness 
directive (AD):

The Boeing Company: Docket No. FAA-2011-0027; Directorate Identifier 
2010-NM-127-AD.

(a) Comments Due Date

    We must receive comments by November 9, 2015.

(b) Affected ADs

    This AD affects AD 2005-07-24, Amendment 39-14049 (70 FR 18285, 
April 11, 2005).

(c) Applicability

    This AD applies to The Boeing Company Model 777-200 and -300 
series airplanes, certificated in any category, equipped with Rolls-
Royce Model RB211-Trent 800 engines.

(d) Subject

    Air Transport Association (ATA) of America Code 78, Engine 
exhaust.

(e) Unsafe Condition

    This AD was prompted by reports of thrust reverser (T/R) events 
related to thermal damage of the T/R inner wall. We are issuing this 
AD to detect and correct a degraded T/R inner wall panel, which 
could lead to failure of the T/R and adjacent components and their 
consequent separation from the airplane, and 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.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Records Review, Inspections, and Related Investigative and 
Corrective Actions for Airplanes With Pre-Thermal Protection System 
(TPS) Insulation Blankets (Part Numbers (P/Ns) 315W5113-(XX) and 
315W5010-(XX)) Installed

    For airplanes with pre-TPS insulation blankets, P/Ns 315W5113-
(XX) and 315W5010-(XX): Except as required by paragraphs (h)(1), 
(h)(2), (h)(3), and (h)(4) of this AD, at the applicable time in 
paragraph 1.E., ``Compliance,'' of Boeing Alert Service Bulletin 
777-78A0065, Revision 2, dated May 6, 2010, review the airplane 
maintenance records to determine whether sealant was added to 
insulation blankets around the compression pad fittings and the 
powered door opening system (PDOS) fitting; do the applicable 
actions specified in paragraphs (g)(1), (g)(2), (g)(3), (g)(4), 
(g)(5), and (g)(6) of this AD; and do all applicable related 
investigative and corrective actions; in accordance with the 
applicable work packages of the Accomplishment Instructions of 
Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010, except as required by paragraph (h)(5) of this AD. Do all 
applicable related investigative and corrective actions before 
further flight. Repeat the applicable inspections, replacement, and 
installations required by paragraphs (g)(1), (g)(2), (g)(3), (g)(4), 
(g)(5), and (g)(6) of this AD thereafter at the applicable intervals 
specified in paragraph 1.E., ``Compliance,'' of Boeing Alert Service 
Bulletin 777-78A0065, Revision 2, dated May 6, 2010.
    (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.
    (2) Do the actions specified by either paragraph (g)(2)(i) or 
(g)(2)(ii) of this AD.
    (i) Do a full inner wall panel non-destructive test (NDT) 
inspection for delamination and disbonding of each T/R half, and do 
a general visual inspection for areas of thermal degradation.
    (ii) Do a limited area NDT inspection 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.
    (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.
    (4) Do a detailed inspection of the PDOS lug bushings on the 
upper number 1 compression pad fittings to detect hole elongation, 
deformation, and contact with the PDOS actuator; and install a PDOS 
actuator rod and sealant.
    (5) Do an NDT inspection for unsatisfactory number 1 upper and 
numbers 1 and 2 lower compression pad fittings.
    (6) Install and seal insulation blankets.

(h) Exceptions to Specifications of Boeing Alert Service Bulletin 777-
78A0065, Revision 2, Dated May 6, 2010

    (1) Where paragraph 1.E., ``Compliance,'' of Boeing Alert 
Service Bulletin 777-78A0065, Revision 2, dated May 6, 2010, 
specifies a compliance time ``after the date on the original issue 
of this service bulletin,'' this AD requires compliance within the 
specified compliance time after the effective date of this AD.
    (2) Where table 2 of 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 5 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.
    (3) Where the Condition column in table 2 of paragraph 1.E., 
``Compliance,'' of Boeing Alert Service Bulletin 777-78A0065, 
Revision 2, dated May 6, 2010, refers to a T/R half that has or has 
not been inspected before ``the date on this service bulletin,'' 
this AD requires compliance for each corresponding T/R half that has 
or has not been inspected before the effective date of this AD.
    (4) Where the Condition column in tables 2 and 3 of paragraph 
1.E., ``Compliance,'' of Boeing Alert Service Bulletin 777-78A0065, 
Revision 2, dated May 6, 2010, refers to ``total flight cycles,'' 
this AD applies to each T/R half with the specified total flight 
cycles as of the effective date of this AD.
    (5) Where Boeing Alert Service Bulletin 777-78A0065, Revision 2, 
dated May 6, 2010, specifies to contact Boeing for appropriate 
action: Before further flight, repair using a method approved in 
accordance with the procedures specified in paragraph (r) of this 
AD.

(i) Repetitive NDT and Additional Inspections for Airplanes With TPS 
Insulation Blankets (P/N 315W5115-(XX)) Installed

    For airplanes with TPS insulation blankets, P/N 315W5115-(XX): 
Within 2,000 flight cycles after doing any NDT inspection specified 
in Boeing Special Attention Service Bulletin 777-78-0071; or within 
2,000 flight cycles after doing any NDT inspection specified in 
Boeing Service Bulletin 777-78-0082; or within 30 days after the 
effective date of this AD; whichever occurs latest; do the 
inspections specified in paragraphs (i)(1) and (i)(2) of this AD, 
and do all applicable related investigative and corrective actions, 
in accordance with the Accomplishment Instructions of Boeing Special 
Attention Service Bulletin 777-78-0071, Revision 2, dated July 23, 
2013, or in accordance with the Accomplishment Instructions of 
Boeing Service Bulletin 777-78-0082, Revision 1, dated June 15, 
2015, as applicable; except as required by paragraph (m) of this AD. 
Do all applicable related investigative and corrective actions 
before further flight.

[[Page 57750]]

Repeat the inspections specified in paragraphs (i)(1) and (i)(2) of 
this AD thereafter at the applicable time specified in paragraph 
1.E., ``Compliance,'' of Boeing Special Attention Service Bulletin 
777-78-0071, Revision 2, dated July 23, 2013; or Boeing Service 
Bulletin 777-78-0082, Revision 1, dated June 15, 2015; as 
applicable.
    (1) Do an NDT inspection of the full T/R inner wall panel for 
delaminations and disbonds.
    (2) Do a detailed inspection of the perforated side of the T/R 
inner wall aft of the IP8 and the HP3 bleed port exits for color 
that is different from the normal T/R perforated wall color.

(j) Concurrent Requirements for Paragraph (i) of This AD

    For airplanes with TPS insulation blankets, part number P/N 
315W5115-(XX) on which any action specified in Boeing Special 
Attention Service Bulletin 777-78-0071 have been done but the 
actions specified paragraphs (j)(1) and (j)(2) of this AD have not 
been done: Prior to or concurrently with doing the inspection 
required by paragraph (i) of this AD, do the actions specified in 
paragraphs (j)(1) and (j)(2) of this AD, in accordance with the 
Accomplishment Instructions of Boeing Special Attention Service 
Bulletin 777-78-0071, Revision 2, dated July 23, 2013, except as 
required by paragraph (m) of this AD.
    (1) Install click bond covers and bracket and replace the 
washers.
    (2) Do a detailed inspection of the compression fitting for 
incorrect pin orientation, and do all applicable related 
investigative and corrective actions. Do all applicable related 
investigative and corrective actions before further flight.

(k) Repetitive Electronic Engine Control (EEC) Wire Bundle Inspections 
for Airplanes With TPS Insulation Blankets (P/N 315W5115-(XX)) 
Installed

    For airplanes with TPS insulation blankets, part number P/N 
315W5115-(XX): Do the inspections specified in paragraph (k)(1) or 
(k)(2) of this AD, as applicable.
    (1) For airplanes on which any inspection specified in Boeing 
Special Attention Service Bulletin 777-78-0071 has been done: Within 
2,000 flight hours after doing a detailed inspection of the EEC wire 
bundles and clips specified in Boeing Special Attention Service 
Bulletin 777-78-0071, or within 500 flight hours after the effective 
date of this AD, whichever occurs later; do a detailed inspection of 
the EEC wire bundles and clips for damage, and do all applicable 
corrective actions, in accordance with the Accomplishment 
Instructions of Boeing Special Attention Service Bulletin 777-78-
0071, Revision 2, dated July 23, 2013, except as required by 
paragraph (m) of this AD. Do all applicable corrective actions 
before further flight. Repeat the inspection thereafter at the 
applicable time specified in table 5 of paragraph 1.E., 
``Compliance,'' of Boeing Special Attention Service Bulletin 777-78-
0071, Revision 2, dated July 23, 2013.
    (2) For airplanes on which any inspection specified in Boeing 
Service Bulletin 777-78-0082 has been done: Within 2,000 flight 
hours after doing a detailed inspection of the EEC wire bundles and 
clips specified in Boeing Special Attention Service Bulletin 777-78-
0082, or within 500 flight hours after the effective date of this 
AD, whichever occurs later; do a detailed inspection for damage of 
the EEC wire bundles and clips, and do all applicable corrective 
actions, in accordance with the Accomplishment Instructions of 
Boeing Service Bulletin 777-78-0082, Revision 1, dated June 15, 
2015, except as required by paragraph (m) of this AD. Do all 
applicable corrective actions before further flight. Repeat the 
inspection thereafter at the applicable time specified in paragraph 
1.E., ``Compliance,'' of Boeing Service Bulletin 777-78-0082, 
Revision 1, dated June 15, 2015.

(l) T/R Inner Wall Installation

    Within 48 months after the effective date of this AD: Install 
serviceable T/R halves, in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 777-78A0094, dated 
July 29, 2014, except as required by paragraph (m) of this AD. The 
definition of a serviceable T/R half is specified in Boeing Alert 
Service Bulletin 777-78A0094, dated July 29, 2014. Accomplishing the 
installation specified in this paragraph and the revision to the 
maintenance or inspection program required by paragraph (n) of this 
AD terminates the actions required by paragraphs (g), (i), (j), and 
(k) of this AD.

(m) Exceptions to Service Information Specified in Paragraphs (i), (j), 
(k), and (l) of This AD

    Where Boeing Alert Service Bulletin 777-78A0094, dated July 29, 
2014; Boeing Service Bulletin 777-78-0082, Revision 1, dated June 
15, 2015; and Boeing Special Attention Service Bulletin 777-78-0071, 
Revision 2, dated July 23, 2013; specify to contact Boeing for 
appropriate action: Before further flight, repair using a method 
approved in accordance with the procedures specified in paragraph 
(r) of this AD.

(n) Revise the Maintenance or Inspection Program

    Within 30 days after the effective date of this AD, revise the 
maintenance or inspection program, as applicable, to incorporate 
Airworthiness Limitations 78-AWL-01, Thrust Reverser Thermal 
Protection System; and 78-AWL-02, Thrust Reverser Inner Wall; as 
specified in Boeing 777 Maintenance Planning Data (MPD) Document, 
Section 9, Airworthiness Limitations (AWLs) and Certification 
Maintenance Requirements (CMRs), D622W001-9, Revision dated October 
2014.
    (1) The initial compliance time for Airworthiness Limitation 78-
AWL-01, Thrust Reverser Thermal Protection System, as specified in 
Boeing 777 Maintenance Planning Data (MPD) Document, Section 9, 
Airworthiness Limitations (AWLs) and Certification Maintenance 
Requirements (CMRs), D622W001-9, Revision dated October 2014, is 
concurrent with the next inspection required by paragraph (i) of 
this AD, or within 30 days after the effective date of this AD, 
whichever occurs later.
    (2) The initial compliance time for Airworthiness Limitation 78-
AWL-02, Thrust Reverser Inner Wall, as specified in Boeing 777 
Maintenance Planning Data (MPD) Document, Section 9, Airworthiness 
Limitations (AWLs) and Certification Maintenance Requirements 
(CMRs), D622W001-9, Revision dated October 2014, is at the 
applicable time specified in paragraph (n)(2)(i) or (n)(2)(ii) of 
this AD.
    (i) For airplanes on which any inspections required by paragraph 
(i) of this AD are done: Concurrent with the next inspection 
required by paragraph (i) of this AD; or within 30 days after the 
effective date of this AD; whichever occurs later.
    (ii) For airplanes on which the installation required by 
paragraph (l) of this AD is done: The later of the times specified 
in paragraph (n)(2)(ii)(A) and (n)(2)(ii)(B) of this AD.
    (A) Within 1,125 days or 6,000 flight cycles, whichever occurs 
first after accomplishing the installation required by paragraph (l) 
of this AD.
    (B) Within 30 days after the effective date of this AD.

(o) No Alternative Actions or Intervals

    After the the maintenance or inspection program, as applicable, 
has been revised as required by paragraph (n) of this AD, no 
alternative actions (e.g., inspections) or intervals may be used 
unless the actions or intervals are approved as an alternative 
method of compliance (AMOC) in accordance with the procedures 
specified in paragraph (r) of this AD.

(p) Credit for Previous Actions

    (1) This paragraph provides credit for the actions specified in 
paragraph (g) of this AD, if those actions were performed before the 
effective date of this AD using Boeing Alert Service Bulletin 777-
78A0065, dated June 23, 2008; or Boeing Alert Service Bulletin 777-
78A0065, Revision 1, dated January 29, 2009. This service 
information is not incorporated by reference in this AD.
    (2) This paragraph provides credit for the actions specified in 
paragraph (i) of this AD, if those actions were performed before the 
effective date of this AD using any service information specified in 
paragraphs (p)(2)(i), (p)(2)(ii), and (p)(2)(iii) of this AD. This 
service information is not incorporated by reference in this AD.
    (i) Boeing Service Bulletin 777-78-0082, dated November 9, 2011.
    (ii) Boeing Special Attention Service Bulletin 777-78-0071, 
dated November 25, 2009.
    (iii) Boeing Special Attention Service Bulletin 777-78-0071, 
Revision 1, dated September 8, 2010.
    (3) This paragraph provides credit for the actions specified in 
paragraph (j) of this AD, if those actions were performed before the 
effective date of this AD using Boeing Special Attention Service 
Bulletin 777-78-0071, Revision 1, dated September 8, 2010. This 
service information is not incorporated by reference in this AD.
    (4) This paragraph provides credit for the actions specified in 
paragraph (k)(2) of this AD, if those actions were performed before 
the effective date of this AD using Boeing

[[Page 57751]]

Service Bulletin 777-78-0082, dated November 9, 2011. This service 
information is not incorporated by reference in this AD

(q) Terminating Action for AD 2005-07-24, Amendment 39-14049 (70 FR 
18285, April 11, 2005)

    Accomplishing the actions specified in paragraph (q)(1), (q)(2), 
or (q)(3) of this AD terminates the actions required by paragraphs 
(f), (g), and (h) of AD 2005-07-24, Amendment 39-14049 (70 FR 18285, 
April 11, 2005).
    (1) The actions required by paragraph (g) of this AD.
    (2) The inspections required by paragraphs (i) and (k) of this 
AD, and, as applicable, the actions required by paragraph (j) of 
this AD.
    (3) The installation specified in paragraph (l) of this AD.

(r) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle Aircraft Certification Office (ACO), 
FAA, has the authority to approve AMOCs for this AD, if requested 
using the procedures found in 14 CFR 39.19. In accordance with 14 
CFR 39.19, send your request to your principal inspector or local 
Flight Standards District Office, as appropriate. If sending 
information directly to the manager of the ACO, send it to the 
attention of the person identified in paragraph (s)(1) of this AD. 
Information may be emailed to: 9-ANM-Seattle-ACO-AMOC-Requests@faa.gov.
    (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.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any structural repair required by this AD if it is approved 
by the Boeing Commercial Airplanes Organization Designation 
Authorization (ODA) that 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.

(s) Related Information

    (1) For more information about this AD, contact Kevin Nguyen, 
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle 
Aircraft Certification Office (ACO), 1601 Lind Avenue SW., Renton, 
Washington 98057-3356; phone: 425-917-6501; fax: 425-917-6590; 
email: kevin.nguyen@faa.gov.
    (2) For service information identified in this AD, contact 
Boeing Commercial Airplanes, Attention: Data & Services Management, 
P.O. Box 3707, MC 2H-65, Seattle, WA 98124-2207; telephone 206-544-
5000, extension 1; fax 206-766-5680; Internet https://www.myboeingfleet.com. You may view this referenced service 
information at the FAA, at the FAA, Transport Airplane Directorate, 
1601 Lind Avenue SW., Renton, WA. For information on the 
availability of this material at the FAA, call 425-227-1221.

    Issued in Renton, Washington, on September 16, 2015.
Michael Kaszycki,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2015-24344 Filed 9-24-15; 8:45 am]
 BILLING CODE 4910-13-P