Document ID: FAA-2009-1069-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Boeing Model 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D,747-400F, and 747SR Series Airplanes
Posted Date: 2009-11-20T05:00Z

[Federal Register: November 20, 2009 (Volume 74, Number 223)]
[Proposed Rules]               
[Page 60215-60218]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr20no09-30]                         

========================================================================
Proposed Rules
                                                Federal Register
________________________________________________________________________

This section of the FEDERAL REGISTER contains notices to the public of 
the proposed issuance of rules and regulations. The purpose of these 
notices is to give interested persons an opportunity to participate in 
the rule making prior to the adoption of the final rules.

========================================================================

[[Page 60215]]

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-1069; Directorate Identifier 2009-NM-036-AD]
RIN 2120-AA64

 
Airworthiness Directives; Boeing Model 747-100, 747-100B, 747-
100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 
747-400F, and 747SR Series Airplanes

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

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: The FAA proposes to supersede an existing airworthiness 
directive (AD) that applies to all Boeing Model 747-100, 747-100B, 747-
100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 
747-400F, and 747SR series airplanes. The existing AD currently 
requires repetitive inspections to find cracking of the web, strap, 
inner chords, and inner chord angle of the forward edge frame of the 
number 5 main entry door cutouts, and repair, if necessary. This 
proposed AD would expand the inspection areas to include the frame 
segment between stringers 16 and 23. This proposed AD would reinstate 
the repetitive inspections specified above for certain airplanes. This 
proposed AD would also require repetitive inspections for cracking of 
repairs. This proposed AD results from additional reports of cracks 
that have been found in the strap and inner chord of the forward edge 
frame of the number 5 main entry door cutouts, between stringers 16 and 
23. We are proposing this AD to detect and correct such cracks. This 
condition, if not corrected, could cause damage to the adjacent body 
structure, which could result in depressurization of the airplane in 
flight.

DATES: We must receive comments on this proposed AD by January 4, 2010.

ADDRESSES: You may send comments by any of the following methods:
     Federal eRulemaking Portal: Go to http://
www.regulations.gov. Follow the instructions for submitting comments.
     Fax: 202-493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue, SE., Washington, DC 20590.
     Hand Delivery: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue, SE., Washington, DC 20590, between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays.
    For service information identified in this proposed AD, contact 
Boeing Commercial Airplanes, Attention: Data & Services Management, 
P.O. Box 3707, MC 2H-65, Seattle, Washington 98124-2207; telephone 206-
544-5000, extension 1; fax 206-766-5680; e-mail me.boecom@boeing.com; 
Internet https://www.myboeingfleet.com. You may review copies of the 
referenced service information at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington. For information 
on the availability of this material at the FAA, call 425-227-1221 or 
425-227-1152.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://
www.regulations.gov; or in person at the Docket Management Facility 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this proposed AD, the regulatory 
evaluation, any comments received, and other information. The street 
address for the Docket Office (telephone 800-647-5527) is in the 
ADDRESSES section. Comments will be available in the AD docket shortly 
after receipt.

FOR FURTHER INFORMATION CONTACT: Ivan Li, Aerospace Engineer, Airframe 
Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 1601 Lind 
Avenue, SW., Renton, Washington 98057-3356; telephone (425) 917-6437; 
fax (425) 917-6590.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposed AD. Send your comments to an address 
listed under the ADDRESSES section. Include ``Docket No. FAA-2009-1069; 
Directorate Identifier 2009-NM-036-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

    On July 26, 2001, we issued AD 2001-16-02, amendment 39-12370 (66 
FR 41440, August 8, 2001), for certain Boeing Model 747 series 
airplanes. That AD requires repetitive inspections to find cracking of 
the web, strap, inner chords, and inner chord angle of the forward edge 
frame of the number 5 main entry door cutouts, and repair, if 
necessary. That AD resulted from reports of cracks in the web, strap, 
inner chords, and inner chord angle of the forward edge frame of the 
number 5 main entry door cutouts. We issued that AD to detect and 
correct such cracks, which could result in severing of the frame, 
inability of the frame to react loads from the door stops, and 
consequent rapid depressurization of the airplane in flight.

Actions Since Existing AD Was Issued

    Since we issued AD 2001-16-02, Boeing stated that production line 
numbers 1305 and on have an improved frame design and issued Boeing 
Service Bulletin 747-53A2450, Revision 3, dated July 24, 2003, which 
removed those line numbers from the effectivity. We referred to Boeing 
Alert Service Bulletin 747-53A2450, Revision 2, including Appendix A, 
dated January 4, 2001, as the appropriate source of service information 
for accomplishing the required actions of AD 2001-16-02. Based on 
Revision 3 of the service bulletin, we approved an alternative

[[Page 60216]]

method of compliance (AMOC), dated September 22, 2003, which allowed an 
alternative applicability to AD 2001-16-02. AD 2001-16-02 is applicable 
to all Model 747 airplanes except Model 747SP series airplanes; the 
AMOC allowed an alternative applicability of Model 747 airplanes, 
production line numbers 1 through 1304, excluding Model 747SP 
airplanes.
    After approving the AMOC, we have since received reports of cracks 
in the left and right Station 2231 frame inner chord and strap between 
stringers 16 and 23. Subsequently, we have determined that line numbers 
1305 and on are again subject to the unsafe condition.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 747-53A2450, 
Revision 5, dated January 29, 2009. Revision 5 of the service bulletin 
also adds airplanes having production line numbers 1305 and on to the 
effectivity. Revision 5 describes the same repetitive inspections as 
those specified in Revision 2 of the service bulletin but it also 
identifies expanded inspection areas that include the frame segment 
between stringers 16 and 23.
    Revision 5 also specifies repetitive post-repair inspections of the 
repaired frame segments for cracks and repair if necessary. The post-
repair inspections include a detailed inspection, an open hole high 
frequency eddy current (HFEC) inspection, a surface HFEC inspection, 
and a subsurface low frequency eddy current inspection, and corrective 
actions if necessary.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to develop on other airplanes of the 
same type design. For this reason, we are proposing this AD, which 
would supersede AD 2001-16-02 and would retain the requirements of the 
existing AD. This proposed AD would also require accomplishing the 
actions specified in Relevant Service Information described previously, 
except as discussed under ``Differences Between the Proposed AD and 
Relevant Service Information.''

Difference Between the Proposed AD and Relevant Service Information

    The service bulletin specifies to contact the manufacturer for 
instructions on how to repair certain conditions, but this proposed AD 
would require repairing those conditions in one of the following ways:
     Using a method that we approve; or
     Using data that meet the certification basis of the 
airplane, and that have been approved by an Authorized Representative 
for the Boeing Commercial Airplanes Delegation Option Authorization 
Organization whom we have authorized to make those findings.

Change to Existing AD

    This proposed AD would retain all requirements of AD 2001-16-02. 
Since AD 2001-16-02 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 in this
   Requirement in  AD 2001-16-02                 proposed AD
------------------------------------------------------------------------
             paragraph (a)                        paragraph (g)
             paragraph (b)                        paragraph (h)
             paragraph (c)                        paragraph (i)
------------------------------------------------------------------------

    Boeing Commercial Airplanes has received a Delegation Option 
Authorization (DOA). In paragraph (l) of this AD, we have referred to 
paragraph (m) of this AD to delegate the authority to approve an 
alternative method of compliance for any repair required by this AD to 
an Authorized Representative for the Boeing Commercial Airplanes DOA 
rather than a Designated Engineering Representative (DER).

Costs of Compliance

    There are about 163 airplanes of the affected design in the 
worldwide fleet. The following table provides the estimated costs for 
U.S. operators to comply with this proposed AD.

                                                                     Estimated Costs
--------------------------------------------------------------------------------------------------------------------------------------------------------
                                                                                                                    Number of U.S.-
              Action                     Work hours        Average labor         Parts          Cost per airplane     registered         Fleet cost
                                                           rate per hour                                               airplanes
--------------------------------------------------------------------------------------------------------------------------------------------------------
Inspections (required by AD 2001-   16..................             $80  None..............  $1,280, per                      163  $208,640, per
 16-02).                                                                                       inspection cycle.                     inspection cycle.
Inspections (new proposed action).  28 depending on                   80  None..............  Up to $2,240, per                163  Up to $365,120, per
                                     airplane                                                  inspection cycle;                     inspection cycle;
                                     configuration.                                            depending on                          depending on
                                                                                               airplane                              airplane
                                                                                               configuration.                        configuration.
--------------------------------------------------------------------------------------------------------------------------------------------------------

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 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

[[Page 60217]]

under the criteria of the Regulatory Flexibility Act.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this proposed 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.

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 39-12370 (66 FR 
41440, August 8, 2001) and adding the following new AD:

Boeing: Docket No. FAA-2009-1069; Directorate Identifier 2009-NM-
036-AD.

Comments Due Date

    (a) The FAA must receive comments on this AD action by January 
4, 2010.

Affected ADs

    (b) This AD supersedes AD 2001-16-02.

Applicability

    (c) This AD applies to Boeing Model 747-100, 747-100B, 747-100B 
SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-
400F, and 747SR series airplanes, certificated in any category, as 
identified in Boeing Alert Service Bulletin 747-53A2450, Revision 5, 
dated January 29, 2009.

Subject

    (d) Air Transport Association (ATA) of America Code 53: 
Fuselage.

Unsafe Condition

    (e) This AD results from additional reports of cracks that have 
been found in the strap and inner chord of the forward edge frame of 
the number 5 main entry door cutouts, between stringers 16 and 23. 
Based on these reports, we have determined that the frame segment 
between stringers 16 and 23 is also susceptible to the unsafe 
condition. The Federal Aviation Administration is issuing this AD to 
detect and correct such cracks. This condition, if not corrected, 
could cause damage to the adjacent body structure, which could 
result in depressurization of the airplane in flight.

Compliance

    (f) You are responsible for having the actions required by this 
AD performed within the compliance times specified, unless the 
actions have already been done.

Restatement of AD 2001-16-02, With New Service Information

Repetitive Inspections for Frame Segment Between Stringers 23 and 31 
(No Terminating Action)

    (g) For airplanes having line numbers 1 through 1304 inclusive: 
Inspect the airplane for cracks between stringers 23 and 31 per 
Boeing Alert Service Bulletin 747-53A2450, Revision 2, including 
Appendix A, dated January 4, 2001; or Boeing Alert Service Bulletin 
747-53A2450, Revision 5, dated January 29, 2009; at the later of the 
times specified in either paragraph (h) or (i) of this AD, per Table 
1, as follows. After the effective date of this AD, use only 
Revision 5 of Boeing Service Bulletin 747-53A2450.

                    Table 1--Inspection Requirements
------------------------------------------------------------------------
      Type of inspection                    Area to inspect
------------------------------------------------------------------------
(1) Detailed Visual..........  Strap inner chords forward and aft of the
                                web, and exposed web adjacent to the
                                inner chords on station 2231 frame from
                                stringer 23 through 31 per Figure 5 or
                                Figure 6 of the service bulletin, as
                                applicable.
(2) Surface High Frequency     Station 2231 inner chord angles at lower
 Eddy Current (HFEC).           main sill interface per Figure 5 or
                                Figure 6 of the service bulletin, as
                                applicable.
(3) Open Hole HFEC...........  Station 2231 frame fastener locations per
                                Figures 4 and 7, and either Figure 5 or
                                6 of the service bulletin, as
                                applicable.
(4) Surface HFEC.............  Around fastener locations on station 2231
                                inner chords from stringer 23 through 31
                                per Figure 5 or Figure 6 of the service
                                bulletin, as applicable.
(5) Low Frequency Eddy         Station 2231 frame strap in areas covered
 Current.                       by the reveal per Figure 5 or Figure 6
                                of the service bulletin, as applicable.
------------------------------------------------------------------------

     (h) Do the inspections specified in paragraph (g) of this AD at 
the applicable times specified in paragraph (h)(1) or (h)(2) of this 
AD. Repeat the inspections at intervals not to exceed 3,000 flight 
cycles.
    (1) Do the inspections per Table 1 of this AD at the applicable 
time specified in the logic diagram in Figure 1 of Boeing Alert 
Service Bulletin 747-53A2450, Revision 2, including Appendix A, 
dated January 4, 2001. Where the compliance time in the logic 
diagram specifies a compliance time beginning, ``from receipt of 
this service bulletin,'' this AD requires that the compliance time 
begin ``after September 12, 2001 (the effective date of AD 2001-16-
02).''
    (2) After the effective date of this AD, do the inspections per 
Table 1 of this AD at the applicable compliance time specified in 
paragraph 1.E., ``Compliance'' of the Boeing Alert Service Bulletin 
747-53A2450, Revision 5, dated January 29, 2009. Where the 
compliance time in the service bulletin specifies a compliance time 
beginning, ``after the date on Revision 2 of this service 
bulletin,'' this AD requires that the compliance time begin ``after 
September 12, 2001 (the effective date of AD 2001-16-02).''
    (i) Within 3,000 flight cycles after accomplishment of the 
inspections specified in Figure 1 of Boeing Alert Service Bulletin 
747-53A2450, dated May 4, 2000, or Revision 1, dated July 6, 2000, 
repeat the inspections at intervals not to exceed 3,000 flight 
cycles.

    Note 1:  There is no terminating action currently available for 
the inspections required by paragraph (g) of this AD.

    Note 2:  Where there are differences between the AD and the 
alert service bulletin, the AD prevails.

New Requirements of This AD

Additional Repetitive Inspections (For Frame Segment Between Stringers 
16 and 23)

    (j) For all airplanes: Before the accumulation of 16,000 total 
flight cycles, or within 1,500 flight cycles after the effective 
date of this AD, whichever occurs later, do a detailed inspection, 
an open hole high frequency eddy current (HFEC) inspection, a 
surface HFEC inspection, and a subsurface low frequency eddy current 
(LFEC) inspection for cracking of the forward edge frame of the 
number 5 main entry door cutouts, at station 2231, between stringers 
16 and 23; in accordance with the Accomplishment Instructions of 
Boeing Alert Service Bulletin 747-53A2450, Revision 5, dated January 
29, 2009. Repeat the inspections thereafter at intervals not to 
exceed 3,000 flight cycles.

Repetitive Inspections for Line Numbers 1305 and On (For Frame Segment 
Between Stringers 23 and 31)

    (k) For airplanes having line numbers 1305 and on: Before 16,000 
total flight cycles or within 1,500 flight cycles after the 
effective date of this AD, whichever occurs later, do a detailed 
inspection, an open hole HFEC inspection, a surface HFEC inspection, 
and a

[[Page 60218]]

subsurface LFEC inspection for cracking of the forward edge frame of 
the number 5 main entry door cutouts, at station 2231, between 
stringers 23 and 31; in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 747-53A2450, Revision 
5, dated January 29, 2009. Repeat the inspections thereafter at 
intervals not to exceed 3,000 flight cycles.

Corrective Action

    (l) If any crack is found during any inspection required this 
AD, before further flight repair the crack per a method approved by 
the Manager, Seattle Aircraft Certification Office (SACO), FAA; Per 
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; 
or in accordance with Boeing Alert Service Bulletin 747-53A2450, 
Revision 5, dated January 29, 2009. For a repair method to be 
approved by the Manager, Seattle ACO, as required by this paragraph, 
the approval letter must specifically reference this AD. As of the 
effective date of this AD, repair the crack using a method approved 
in accordance with the procedures specified in paragraph (o) of this 
AD.

Post-Repair Inspections

    (m) Except as required by paragraph (n) of this AD, for 
airplanes on which the forward edge frame of the number 5 main entry 
door cutouts, at station 2231, between stringers 16 and 31, is 
repaired in accordance with Boeing Alert Service Bulletin 747-
53A2450: Within 3,000 flight cycles after doing the repair or within 
1,500 flight cycles after the effective date of this AD, whichever 
occurs later, do the detailed, LFEC, and HFEC inspections of the 
repaired area for cracks in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 747-53A2450, Revision 
5, dated January 29, 2009. If no cracking is found, repeat the 
inspections thereafter at intervals not to exceed 3,000 flight 
cycles. If any crack is found, before further flight, repair using a 
method approved in accordance with the procedures specified in 
paragraph (o) of this AD. Doing the inspections specified in 
paragraph (m) of this AD terminates the repetitive inspections 
required by paragraphs (g), (h), (i), (j), and (k) of this AD for 
the repaired area.
    (n) For any frame that is repaired in accordance with a method 
other than the Accomplishment Instructions of Boeing Alert Service 
Bulletin 747-53A2450, Revision 5, dated January 29, 2009, do the 
inspection in accordance with a method approved in accordance with 
the procedures specified in paragraph (o) of this AD.

Alternative Methods of Compliance (AMOCs)

    (o)(1) The Manager, Seattle Aircraft Certification Office 
(SACO), FAA, has the authority to approve AMOCs for this AD, if 
requested using the procedures found in 14 CFR 39.19. Send 
information to ATTN: Ivan Li, Aerospace Engineer, Airframe Branch, 
ANM-120S, FAA, Seattle Aircraft Certification Office, 1601 Lind 
Avenue, SW., Renton, Washington 98057-3356; telephone (425) 917-
6437; fax (425) 917-6590; Or, e-mail information to 9-ANM-Seattle-
ACO-AMOC-Requests@faa.gov.
    (2) To request a different method of compliance or a different 
compliance time for this AD, follow the procedures in 14 CFR 39.19. 
Before using any approved AMOC on any airplane to which the AMOC 
applies, notify your principal maintenance inspector (PMI) or 
principal avionics inspector (PAI), as appropriate, or lacking a 
principal inspector, your local Flight Standards District Office. 
The AMOC approval letter must specifically reference 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 an 
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) AMOCs approved previously in accordance with AD 2001-16-02, 
amendment 39-12370, are approved as AMOCs for the corresponding 
provisions of paragraphs (g), (h), (i), and (l) of this AD.

    Issued in Renton, Washington, on November 6, 2009.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. E9-27963 Filed 11-19-09; 8:45 am]

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