Document ID: FAA-2011-1068-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Boeing Co. Model 737-100, -200, -200C, -300, -400, and -500 Series Airplanes
Posted Date: 2011-10-12T04:00Z

[Federal Register Volume 76, Number 197 (Wednesday, October 12, 2011)]
[Proposed Rules]
[Pages 63229-63235]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2011-26242]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2011-1068; Directorate Identifier 2010-NM-189-AD]
RIN 2120-AA64

Airworthiness Directives; The Boeing Company Model 737-100, -200, 
-200C, -300, -400, and -500 Series Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to adopt a new airworthiness directive (AD) for the 
products listed above. This proposed AD would require installing an 
automatic shutoff system for the center and auxiliary tank fuel boost 
pumps, as applicable, and installing a placard in the airplane flight 
deck if necessary; replacing the P5-2 fuel system module assembly; and 
installing the un-commanded on (UCO) protection system for the center 
and auxiliary tank fuel boost pumps, as applicable. This proposed AD 
would also require revisions to the Limitations and Normal Procedures 
sections of the airplane flight manual to advise the flightcrew of 
certain operating restrictions for airplanes equipped with an automatic 
shutoff system. This proposed AD would also require revising the 
maintenance program by incorporating new airworthiness limitations for 
fuel tank systems to satisfy Special Federal Aviation Regulation No. 88 
requirements. This proposed AD was prompted by fuel system reviews 
conducted by the manufacturer. We are proposing this AD to prevent 
operation of the center and auxiliary tank fuel boost pumps with 
continuous low pressure, which could lead to friction sparks or 
overheating in the fuel pump inlet that could create a potential 
ignition source inside the center and auxiliary fuel tanks. These 
conditions, in combination with flammable fuel vapors, could result in 
a fuel tank explosion and consequent loss of the airplane.

DATES: We must receive comments on this proposed AD by November 28, 
2011.

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: Deliver to Mail address above 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.

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 (phone: 800-647-5527) is in the ADDRESSES 
section. Comments will be available in the AD docket shortly after 
receipt.

FOR FURTHER INFORMATION CONTACT: Tak Kobayashi, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification 
Office, 1601 Lind Avenue SW., Renton, Washington 98057-3356; telephone: 
425-917-6499; fax: 425-917-6590; e-mail: Takahisa.Kobayashi@faa.gov.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to

[[Page 63230]]

an address listed under the ADDRESSES section. Include ``Docket No. 
FAA-2011-1068; Directorate Identifier 2010-NM-189-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

    The FAA has examined the underlying safety issues involved in fuel 
tank explosions on several large transport airplanes, including the 
adequacy of existing regulations, the service history of airplanes 
subject to those regulations, and existing maintenance practices for 
fuel tank systems. As a result of those findings, we issued a 
regulation titled ``Transport Airplane Fuel Tank System Design Review, 
Flammability Reduction and Maintenance and Inspection Requirements'' 
(66 FR 23086, May 7, 2001). In addition to new airworthiness standards 
for transport airplanes and new maintenance requirements, this rule 
included Special Federal Aviation Regulation No. 88 (``SFAR 88,'' 
Amendment 21-78, and subsequent Amendments 21-82 and 21-83).
    Among other actions, SFAR 88 requires certain type design (i.e., 
type certificate (TC) and supplemental type certificate (STC)) holders 
to substantiate that their fuel tank systems can prevent ignition 
sources in the fuel tanks. This requirement applies to type design 
holders for large turbine-powered transport airplanes and for 
subsequent modifications to those airplanes. It requires them to 
perform design reviews and to develop design changes and maintenance 
procedures if their designs do not meet the new fuel tank safety 
standards. As explained in the preamble to the rule, we intended to 
adopt airworthiness directives to mandate any changes found necessary 
to address unsafe conditions identified as a result of these reviews.
    In evaluating these design reviews, we have established four 
criteria intended to define the unsafe conditions associated with fuel 
tank systems that require corrective actions. The percentage of 
operating time during which fuel tanks are exposed to flammable 
conditions is one of these criteria. The other three criteria address 
the failure types under evaluation: single failures, single failures in 
combination with a latent condition(s), and in-service failure 
experience. For all four criteria, the evaluations included 
consideration of previous actions taken that may mitigate the need for 
further action.
    We have determined that the actions identified in this AD are 
necessary to reduce the potential of ignition sources inside fuel 
tanks, which, in combination with flammable fuel vapors, could result 
in fuel tank explosions and consequent loss of the airplane.
    The manufacturer has found that certain failures will result in the 
center and auxiliary tank fuel boost pumps continuing to run after the 
tank has been depleted. Depending on the failure, pump low pressure may 
not be annunciated, or power may not be removed from the pump when the 
pump has been commanded ``OFF.'' Operation of the center and auxiliary 
tank fuel boost pumps with continuous low pressure could lead to 
friction sparks or overheating in the fuel pump inlet. This condition, 
if not corrected, could result in a fuel tank explosion and consequent 
loss of the airplane.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 737-28A1216, 
Original Issue, dated July 29, 2010, which describes procedures for 
installing the automatic shutoff system for the center and auxiliary 
fuel tank boost pumps, as applicable, on Model 737-300, -400, and -500 
series airplanes; and refers to Airworthiness Limitation (AWL) No. 28-
AWL-20 and No. 28-AWL-21 that are related to the modifications 
specified in that service bulletin.
    We have also reviewed Boeing Alert Service Bulletin 737-28A1228, 
Original Issue, dated August 2, 2010, which describes procedures for 
installing the automatic shutoff system for the center and auxiliary 
fuel tank boost pumps, as applicable, on Model 737-100, -200, and -200C 
series airplanes; and refers to AWL No. 28-AWL-21 and AWL No. 28-AWL-22 
that are related to the modifications specified in that service 
bulletin.
    Boeing Alert Service Bulletins 737-28A1216, Original Issue, dated 
July 29, 2010; and 737-28A1228, Original Issue, dated August 2, 2010; 
specify prior or concurrent accomplishment of Boeing Service Bulletin 
737-28A1210, Original Issue, dated August 2, 2010, which describes 
procedures for replacing the P5-2 fuel system module assembly with a 
new or modified P5-2 fuel system module assembly having a new part 
number, for Model 737-100, -200, -200C, -300, -400, and -500 series 
airplanes.
    Boeing Service Bulletin 737-28A1210, Original Issue, dated August 
2, 2010, refers to BAE Systems Service Bulletin 69-37335-28-04, 
Revision 2, dated February 10, 2010, as an additional source of 
guidance for modifying and updating the existing P5-2 fuel system 
module assembly part numbers to new part numbers.
    We have also reviewed Boeing Alert Service Bulletin 737-28A1227, 
Revision 1, dated July 18, 2011. The service information describes 
procedures for installing the ``un-commanded ON'' protection system for 
the center and auxiliary fuel boost pumps, as applicable, on airplanes. 
The installation includes installing new relays and toggle switches in 
the J2802 box assembly located in the electronic equipment bay (E/E 
bay), and changing and adding new wire bundles that route from the 
J2802 box assembly to the P5 forward overhead panel and the P6 
disconnect panels. This service bulletin also refers to AWL No. 28-AWL-
24 and No. 28-AWL-25 that are related to the modifications specified in 
that service bulletin for Model 737-100, -200, and -200C series 
airplanes; and AWL No. 28-AWL-23 and No. 28-AWL-24 that are related to 
the modifications specified in that service bulletin for Model 737-300, 
-400, and -500 airplanes.
    We have also reviewed Section C, ``Fuel Systems Airworthiness 
Limitations,'' of Section 9 of the Boeing 737-100/200/200C/300/400/500 
Airworthiness Limitations (AWLs) and Certification Maintenance 
Requirements (CMRs), Document D6-38278-CMR, Revision July 2011, which 
contains the following airworthiness limitations:
     For Model 737-300, -400, and -500 series airplanes that 
have incorporated Boeing Alert Service Bulletin 737-28A1216, AWLs No. 
28-AWL-20 and No. 28-AWL-21 are airworthiness limitation instructions 
(ALIs) for an operational check of the installed automatic shutoff 
system.
     For Model 737-100, -200, and -200C series airplanes that 
have incorporated Boeing Alert Service Bulletin 737-28A1228, AWLs No. 
28-AWL-21 and No. 28-AWL-22 are ALIs for an operational check of the 
installed automatic shutoff system.
     For Model 737-300, -400, and -500 series airplanes that 
have incorporated Boeing Alert Service Bulletin 737-28A1227, AWLs No. 
28-AWL-23 and No. 28-AWL-24 are ALIs for an operational check of the 
installed

[[Page 63231]]

power-failed-on (un-commanded ON) protection system.
     For Model 737-100, -200, and -200C series airplanes that 
have incorporated Boeing Alert Service Bulletin 737-28A1227, AWL No. 
28-AWL-24 and No. 28-AWL-25 are ALIs for an operational check of the 
installed power-failed-on (un-commanded ON) protection system.

Other Relevant Rulemaking

    On April 18, 2001, we issued AD 2001-08-24, Amendment 39-12201 (66 
FR 20733, April 25, 2001), for all Model 737 series airplanes. That AD 
requires revising the airplane flight manual to prohibit extended dry 
operation of the center tank fuel pumps (with no fuel passing through 
the pumps). We issued that AD to prevent ignition of fuel vapors due to 
the generation of sparks and a potential ignition source inside the 
center tank caused by metal-to-metal contact during dry fuel pump 
operation, which could result in a fire or explosion of the fuel tank. 
Accomplishment of the actions required by paragraphs (g), (h), (i), and 
(l) of this AD, and paragraph (j) or (k) of this AD, as applicable, is 
acceptable for compliance with the requirements of paragraph (a) of AD 
2001-08-24.
    On December 16, 2009, we issued AD 2008-10-09 R1, Amendment 39-
16148 (74 FR 69264, December 31, 2009), for all Model 737-100, -200, -
200C, -300, -400, and -500 series airplanes. That AD requires revising 
the maintenance program to incorporate new airworthiness limitations 
(AWLs) for fuel tank systems to satisfy Special Federal Aviation 
Regulation No. 88 requirements. That AD also requires an initial 
inspection to phase in certain repetitive AWL inspections, and repair 
if necessary. We issued that AD to prevent the potential for ignition 
sources inside fuel tanks caused by latent failures, alterations, 
repairs, or maintenance actions, which, in combination with flammable 
fuel vapors, could result in a fuel tank explosion and consequent loss 
of the airplane. Incorporation of AWLs No. 28-AWL-21 and No. 28-AWL-22 
for Model 737-100, -200, and 200C series airplanes; and AWLs No. 28-
AWL-20 and No. 28-AWL-21 for Model 737-300, -400, and -500 series 
airplanes; in accordance with paragraphs (g)(1) and (g)(2) of AD 2008-
10-09 R1, terminates the requirements of the corresponding AWLs 
incorporation required by paragraph (l) of this AD.

FAA's Determination

    We are proposing this AD because we evaluated all the relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of these same type 
designs.

Proposed AD Requirements

    This proposed AD would require accomplishing the actions specified 
in the service information described previously, except as discussed 
under ``Differences Between the Proposed AD and the Service 
Information.''
    This proposed AD would also require installing a placard adjacent 
to the pilot's primary flight display on all airplanes not equipped 
with an automatic shutoff system for the center tank fuel boost pumps 
and auxiliary fuel boost pumps, to specify that fuel usage restrictions 
given in AD 2001-08-24 (66 FR 20733, April 25, 2001) are required. 
Installing an automatic shutoff system on an airplane would end the 
need for the placard installation for only that airplane.
    This proposed AD would also require revisions to the Limitations 
and Normal Procedures sections of the applicable Boeing 737 Airplane 
Flight Manual (AFM) to advise the flightcrew of certain operating 
restrictions related to the automatic shutoff system for the center and 
auxiliary tank fuel boost pumps.

Differences Between the Proposed AD and the Service Information

    Although Boeing Service Bulletin 737-28A1210, Revision 1, dated May 
13, 2011; and Boeing Alert Service Bulletins 737-28A1227, Revision 1, 
dated July 18, 2011; and 737-28A1228, Original Issue, dated August 2, 
2010; specify that certain operators may contact the manufacturer for 
modification instructions, this proposed AD would require those 
operators to do the modification using a method approved by the FAA.
    We received a copy of Boeing Information Notice 737-28A1216 IN 01, 
dated March 25, 2011; and Boeing Information Notice 737-28A1228 IN 01, 
dated March 25, 2011, which describe an issue pertaining to 
installation of the J2802 box on airplanes with airstairs. When the 
J2802 box is installed in accordance with Boeing Alert Service Bulletin 
737-28A1216, Original Issue, dated July 29, 2010; or 737-28A1228, 
Original Issue, dated August 2, 2010; the forward face of the box will 
interfere with the airstairs and the airstairs support structure. 
Boeing is currently designing a new J2802 box for airplanes with 
airstairs. Installation of the automatic shutoff system required by 
paragraph (g) of this AD only applies to the affected airplanes without 
airstairs. In addition, installation of the `un-commanded ON' 
protection system required by paragraph (m) of this AD only applies to 
the affected airplanes without airstairs. We may consider further 
rulemaking for installations of the automatic shutoff system and the 
`un-commanded ON' protection system on those affected airplanes with 
airstairs. Installation of a placard required by paragraph (i) of this 
AD applies to all affected airplanes regardless of airstairs. Once the 
automatic shutoff system is installed on any airplanes in an operator's 
fleet, a placard must be installed on all affected airplanes not 
equipped with an automatic shutoff system.
    Although Boeing Alert Service Bulletins 737-28A1216, Original 
Issue, dated July 29, 2010; and 737-28A1228, Original Issue, dated 
August 2, 2010; refer to Boeing Alert Service Bulletin 737-28A1210, 
Original Issue, dated August 2, 2010, as a concurrent requirement, this 
AD refers to Boeing Service Bulletin 737-28A1210, Revision 1, dated May 
13, 2011. Since the P5-2 fuel system module assembly part numbers and 
the associated airplane group numbers, as shown in the figures of 
Boeing Alert Service Bulletin 737-28A1210, Original Issue, dated August 
2, 2010, may be incorrect for certain airplanes due to 
interchangeability of certain part numbers, this AD requires Revision 1 
of that service bulletin.

Costs of Compliance

    We estimate that this proposed AD will affect 701 airplanes of U.S. 
registry. Of those 701 airplanes, 554 airplanes are without airstairs.
    We estimate the following costs to comply with this proposed AD:

[[Page 63232]]

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                  Cost on U.S.
             Action                    Labor cost            Parts cost      Cost per product      operators
----------------------------------------------------------------------------------------------------------------
Install auto shutoff protection  Between 92 and 152      Between $10,127    Between $17,947    Between
 for Model 737-100, -200, -200C   work-hours x $85 per    and $15,123 \1\.   and $28,043 \1\.   $1,758,806 and
 airplanes (98 airplanes).        hour = Between $7,820                                         $2,748,214 \1\.
                                  and $12,920 \1\.
Install auto shutoff protection  Between 92 and 152      Between $9,869     Between $17,689    Between
 for Model 737-300, -400, and -   work-hours x $85 per    and $14,265 \1\.   and $27,185 \1\.   $8,066,184 and
 500 airplanes (456 airplanes).   hour = Between $7,820                                         $12,396,360 \1\.
                                  and $12,920 \1\.
Install P5-2 module............  1 work-hour x $85 per   $0...............  $85..............  $47,090.
                                  hour = $85.
Install `un-commanded ON'        Between 38 and 63 work- Between $3,440     Between $6,670     Between
 protection.                      hours x $85 per hour    and $5,699 \1\.    and $11,054 \1\.   $3,695,180 and
                                  = Between $3,230 and                                          $6,123,916 \1\.
                                  $5,355 \1\.
Revise aircraft flight manual..  1 work-hour x $85 per   $0...............  $85..............  $47,090.
                                  hour = $85.
Revise Maintenance Program.....  1 work-hour x $85 per   $0...............  $85..............  $47,090.
                                  hour = $85.
----------------------------------------------------------------------------------------------------------------
\1\ Depending on group.

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,
    (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

    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 adding the following new 
airworthiness directive (AD):

The Boeing Company: Docket No. FAA-2011-1068; Directorate Identifier 
2010-NM-189-AD.

Comments Due Date

    (a) We must receive comments by November 28, 2011.

Affected ADs

    (b) This AD affects AD 2001-08-24, Amendment 39-12201 (66 FR 
20733, April 25, 2001). Also, AD 2008-10-09 R1, Amendment 39-16148 
(74 FR 69264, December 31, 2009), affects this AD.

Applicability

    (c) The Boeing Company Model 737-100, -200, -200C, -300, -400, 
and -500 series airplanes; certificated in any category.

    Note 1:  This AD requires revisions to certain operator 
maintenance documents to include new inspections. Compliance with 
these inspections is required by 14 CFR 91.403(c). For airplanes 
that have been previously modified, altered, or repaired in the 
areas addressed by these inspections, the operator may not be able 
to accomplish the inspections described in the revisions. In this 
situation, to comply with 14 CFR 91.403(c), the operator must 
request approval for an alternative method of compliance according 
to paragraph (t) of this AD. The request should include a 
description of changes to the required inspections that will ensure 
the continued operational safety of the airplane.

Subject

    (d) Joint Aircraft System Component (JASC)/Air Transport 
Association (ATA) of America Code 28, Fuel.

Unsafe Condition

    (e) This AD was prompted by fuel system reviews conducted by the 
manufacturer. We are issuing this AD to prevent operation of the 
center and auxiliary tank fuel boost pumps with continuous low 
pressure, which could lead to friction sparks or overheating in the 
fuel pump inlet that could create a potential ignition source inside 
the center and auxiliary fuel tanks. These conditions, in 
combination with flammable fuel vapors, could result in a fuel tank 
explosion and consequent loss of the airplane.

Compliance

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

Installation of Automatic Shutoff System for the Center and Auxiliary 
Tank Fuel Boost Pumps

    (g) Within 36 months after the effective date of this AD, do the 
actions required by paragraph (g)(1), (g)(2), or (g)(3) of this AD, 
as applicable. If a placard has been previously installed on an 
airplane, in accordance with the requirements of paragraph (i) of 
this AD, the placard may be removed from the flight deck of only 
that airplane after the automatic shutoff system has been installed, 
as specified in paragraph (g)(1), (g)(2), or (g)(3) of this AD, as 
applicable. Installing automatic shutoff systems on all airplanes in 
an operator's fleet, in accordance with this paragraph, terminates 
the placard installation required by paragraph (i) of this AD, for 
all airplanes in an operator's fleet.
    (1) For Model 737-100, -200, and -200C series airplanes without 
airstairs, in Groups 2 through 16, as identified in Boeing Alert 
Service Bulletin 737-28A1228, Original

[[Page 63233]]

Issue, dated August 2, 2010: Install the automatic shutoff system 
for the center and auxiliary fuel tank boost pumps, as applicable, 
in accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 737-28A1228, Original Issue, dated August 2, 2010.
    (2) For Model 737-100, -200, and -200C series airplanes in Group 
1, as identified in Boeing Alert Service Bulletin 737-28A1228, 
Original Issue, dated August 2, 2010: Install the automatic shutoff 
system for the center and auxiliary fuel tank boost pumps, as 
applicable, in accordance with a method approved by the Manager, 
Seattle Aircraft Certification Office (ACO). For a modification 
method to be approved by the Manager, Seattle ACO, as required by 
this paragraph, the Manager's approval letter must specifically 
refer to this AD.
    (3) For Model 737-300, -400, and -500 series airplanes without 
airstairs, as identified in Boeing Alert Service Bulletin 737-
28A1216, Original Issue, dated July 29, 2010: Install the automatic 
shutoff system for the center and auxiliary fuel tank boost pumps, 
as applicable, in accordance with the Accomplishment Instructions of 
Boeing Alert Service Bulletin 737-28A1216, Original Issue, dated 
July 29, 2010.

Concurrent Installation of the P5-2 Fuel System Module Assembly

    (h) Before or concurrently with accomplishing the actions 
required by paragraph (g) of this AD, do the actions required by 
paragraph (h)(1) or (h)(2) of this AD, as applicable.
    (1) For airplanes in Group 2, as identified in Boeing Service 
Bulletin 737-28A1210, Revision 1, dated May 13, 2011: Replace the 
P5-2 fuel system module assembly with a modified or new P5-2 fuel 
system module assembly having a new part number, in accordance with 
Boeing Service Bulletin 737-28A1210, Revision 1, dated May 13, 2011.

    Note 2:  Boeing Service Bulletin 737-28A1210, Revision 1, dated 
May 13, 2011, refers to BAE Systems Service Bulletin 69-37335-28-04, 
Revision 2, dated February 10, 2010, as an additional source of 
guidance for modifying and updating the existing P5-2 fuel system 
module assembly part numbers to new part numbers.

    (2) For airplanes in Group 1 as identified in Boeing Service 
Bulletin 737-28A1210, Revision 1, dated May 13, 2011: Replace the 
P5-2 fuel system module assembly, in accordance with a method 
approved by the Manager, Seattle ACO. For a modification method to 
be approved by the Manager, Seattle ACO, as required by this 
paragraph, the Manager's approval letter must specifically refer to 
this AD.

Concurrent Installation of a Placard for Mixed Fleet Operation

    (i) Concurrently with installing the automatic shutoff system on 
any airplane in an operator's fleet, as required by paragraph (g) of 
this AD, install a placard adjacent to the pilot's primary flight 
display on all airplanes in the operator's fleet not equipped with 
an automatic shutoff system for the center and auxiliary tank fuel 
boost pumps, as applicable. The placard reads as follows 
(alternative placard wording may be used if approved by an 
appropriate FAA Principal Operations Inspector):

``AD 2001-08-24 fuel usage restrictions required.''

    Installing an automatic shutoff system on an airplane, in 
accordance with the requirements of paragraph (g) of this AD, 
terminates the placard installation required by this paragraph for 
only that airplane. Installing automatic shutoff systems on all 
affected airplanes in an operator's fleet, in accordance with the 
requirements of paragraph (g) of this AD, terminates the placard 
installation required by this paragraph for all affected airplanes 
in an operator's fleet.

Airplane Flight Manual (AFM) Revisions for Airplanes Without Boeing 
Auxiliary Fuel Tanks

    (j) For airplanes without Boeing auxiliary fuel tanks: 
Concurrently with accomplishing the actions required by paragraph 
(g) of this AD, do the actions specified in paragraphs (j)(1) and 
(j)(2) of this AD.
    (1) Revise Section 1 of the Limitations section of the 
applicable Boeing 737 AFM to include the following statement. This 
may be done by inserting a copy of this AD into the AFM.

``CENTER TANK FUEL PUMPS

    Intentional dry running of a center tank fuel pump (low pressure 
light illuminated) is prohibited.''

    Note 3:  When a statement identical to that in paragraph (j)(1) 
of this AD has been included in the general revisions of the 
applicable Boeing 737 AFM, the general revisions may be inserted 
into the AFM, and the copy of this AD may be removed from the AFM.

    (2) Revise Section 3 of the Normal Procedures section of the 
applicable Boeing 737 AFM to include the following statements. This 
may be done by inserting a copy of this AD into the AFM. Alternative 
statements that meet the intent of the following requirements may be 
used if approved by an appropriate FAA Principal Operations 
Inspector.

``NORMAL FUEL USAGE

    Center tank fuel pumps must not be ``ON'' unless personnel are 
available in the flight deck to monitor low pressure lights.
    For ground operation, center tank fuel pump switches must not be 
positioned ``ON'' unless the center tank fuel quantity exceeds 1,000 
pounds (453 kilograms), except when defueling or transferring fuel. 
Upon positioning the center tank fuel pump switches ``ON,'' verify 
momentary illumination of each center tank fuel pump low pressure 
light.
    For ground and flight operations, the corresponding center tank 
fuel pump switch must be positioned ``OFF'' when a center tank fuel 
pump low pressure light illuminates [1]. Both center tank fuel pump 
switches must be positioned ``OFF'' when the first center tank fuel 
pump low pressure light illuminates if the center tank is empty. [1] 
When established in a level flight attitude, both center tank pump 
switches should be positioned ``ON'' again if the center tank 
contains usable fuel.

DEFUELING AND FUEL TRANSFER

    When transferring fuel or defueling center or main tanks, the 
fuel pump low pressure lights must be monitored and the fuel pumps 
positioned to ``OFF'' at the first indication of the fuel pump low 
pressure [1].
    Defueling the main tanks with passengers on board is prohibited 
if the main tank fuel pumps are powered [2].
    Defueling the center tank with passengers on board is prohibited 
if the center tank fuel pumps are powered and the auto-shutoff 
system is inhibited [2].
    [1] Prior to transferring fuel or defueling, conduct a lamp test 
of the respective fuel pump low pressure lights.
    [2] Fuel may be transferred from tank to tank or the aircraft 
may be defueled with passengers on board, provided fuel quantity in 
the tank from which fuel is being taken is maintained at or above 
2,000 pounds (907 kilograms).''

AFM Revisions for Airplanes With Boeing Auxiliary Fuel Tanks

    (k) For airplanes with Boeing auxiliary fuel tanks: Concurrently 
with accomplishing the actions required by paragraph (g) of this AD, 
do the actions specified in paragraphs (k)(1) and (k)(2) of this AD.
    (1) Revise Section 1 of the Limitations section of the 
applicable Boeing 737 AFM to include the following statements. This 
may be done by inserting a copy of this AD into the AFM.

``CENTER WING (AND BOEING AUXILIARY) TANK FUEL PUMPS

    Intentional dry running of a center wing or auxiliary tank fuel 
pump (low pressure light illuminated) is prohibited.''

    Note 4:  When a statement identical to that in paragraph (k)(1) 
of this AD has been included in the general revisions of the 
applicable Boeing 737 AFM, the general revisions may be inserted 
into the AFM, and the copy of this AD may be removed from the AFM.

    (2) Revise Section 3 of the Normal Procedures section of the 
applicable Boeing 737 AFM to include the following statements. This 
may be done by inserting a copy of this AD into the AFM. Alternative 
statements that meet the intent of the following requirements may be 
used if approved by an appropriate FAA Principal Operations 
Inspector.

``CENTER WING (AND BOEING AUXILIARY) TANK FUEL PUMPS

    Center wing or auxiliary tank fuel pumps must not be ``ON'' 
unless personnel are available in the flight deck to monitor low 
pressure lights.
    For ground operation, center wing (or auxiliary) tank fuel pump 
switches must not be positioned ``ON'' unless the center wing (or 
auxiliary) tank fuel quantity exceeds 1,000 pounds (453 kilograms), 
except when defueling or transferring fuel. Upon positioning the 
center wing (or auxiliary) tank fuel pump switches ``ON,'' verify 
momentary illumination of each center wing

[[Page 63234]]

(or auxiliary) tank fuel pump low pressure light.
    For ground and flight operations, the corresponding center wing 
(or auxiliary) tank fuel pump switch must be positioned ``OFF'' when 
a center wing (or auxiliary) tank fuel pump low pressure light 
illuminates [1]. Both center wing (or auxiliary) tank fuel pump 
switches must be positioned ``OFF'' when the first center wing (or 
auxiliary) tank fuel pump low pressure light illuminates if the 
center wing (or auxiliary) tank is empty.
    [1] When established in a level flight attitude, both center 
wing (or auxiliary) tank pump switches should be positioned ``ON'' 
again if the center wing (or auxiliary) tank contains usable fuel.

DEFUELING AND FUEL TRANSFER

    When transferring fuel or defueling center wing, auxiliary or 
main tanks, the fuel pump low pressure lights must be monitored and 
the fuel pumps positioned to ``OFF'' at the first indication of the 
fuel pump low pressure [1].
    Defueling the main tanks with passengers on board is prohibited 
if the main tank fuel pumps are powered [2].
    Defueling the center wing (or auxiliary) tank with passengers on 
board is prohibited if the center wing (or auxiliary) tank fuel 
pumps are powered and the auto-shutoff system is inhibited [2].
    [1] Prior to transferring fuel or defueling, conduct a lamp test 
of the respective fuel pump low pressure lights.
    [2] Fuel may be transferred from tank to tank or the aircraft 
may be defueled with passengers on board, provided fuel quantity in 
the tank from which fuel is being taken is maintained at or above 
2,000 pounds (907 kilograms).''

Airworthiness Limitations (AWLs) Revision for Automatic Shutoff System

    (l) Concurrently with accomplishing the actions required by 
paragraph (g) of this AD, or within 30 days after the effective date 
of this AD, whichever occurs later: Revise the maintenance program 
by incorporating the AWLs specified in paragraphs (l)(1), (l)(2), 
(l)(3), and (l)(4) of this AD, as applicable. The initial compliance 
time for the actions specified in the applicable AWLs is within 1 
year after accomplishing the installation required by paragraph (g) 
of this AD, or within 1 year after the effective date of this AD, 
whichever occurs later.
    (1) For Model 737-100, -200, and -200C series airplanes without 
Boeing auxiliary fuel tanks installed: AWL No. 28-AWL-21 of Section 
C, ``Fuel Systems Airworthiness Limitations,'' of Section 9 of the 
Boeing 737-100/200/200C/300/400/500 Airworthiness Limitations (AWLs) 
and Certification Maintenance Requirements (CMRs), Document D6-
38278-CMR, Revision July 2011.
    (2) For Model 737-100, -200, and -200C series airplanes with 
Boeing auxiliary fuel tanks installed: AWL No. 28-AWL-21 and AWL No. 
28-AWL-22 of Section C, ``Fuel Systems Airworthiness Limitations,'' 
of Section 9 of the Boeing 737-100/200/200C/300/400/500 
Airworthiness Limitations (AWLs) and Certification Maintenance 
Requirements (CMRs), Document D6-38278-CMR, Revision July 2011. (3) 
For Model 737-300, -400, and -500 series airplanes without Boeing 
auxiliary fuel tanks installed: AWL No. 28-AWL-20 of Section C, 
``Fuel Systems Airworthiness Limitations,'' of Section 9 of the 
Boeing 737-100/200/200C/300/400/500 Airworthiness Limitations (AWLs) 
and Certification Maintenance Requirements (CMRs), Document D6-
38278-CMR, Revision July 2011.
    (4) For Model 737-300, -400, and -500 series airplanes with 
Boeing auxiliary fuel tanks installed: AWL No. 28-AWL-20 and AWL No. 
28-AWL-21 of Section C, ``Fuel Systems Airworthiness Limitations,'' 
of Section 9 of the Boeing 737-100/200/200C/300/400/500 
Airworthiness Limitations (AWLs) and Certification Maintenance 
Requirements (CMRs), Document D6-38278-CMR, Revision July 2011.

Installation of `Un-Commanded ON' Protection System

    (m) Within 60 months after the effective date of this AD, do the 
actions required by paragraph (m)(1) or (m)(2) of this AD, as 
applicable.
    (1) For airplanes without airstairs in Groups 2 through 8, as 
identified in Boeing Alert Service Bulletin 737-28A1227, Revision 1, 
dated July 18, 2011: Install the `un-commanded ON' protection system 
for the center and auxiliary tank fuel boost pumps, as applicable, 
in accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 737-28A1227, Revision 1, dated July 18, 2011.
    (2) For airplanes in Group 1, as identified in Boeing Alert 
Service Bulletin 737-28A1227, Revision 1, dated July 18, 2011: 
Install the `un-commanded ON' protection system for the center and 
auxiliary tank fuel boost pumps, as applicable, in accordance with a 
method approved by the Manager, Seattle ACO. For an installation 
method to be approved by the Manager, Seattle ACO, as required by 
this paragraph, the manager's approval letter must specifically 
refer to this AD.

AWLs Revision for `Un-Commanded ON' Protection System

    (n) Concurrently with accomplishing the actions required by 
paragraph (m) of this AD, or within 30 days after the effective date 
of this AD, whichever occurs later: Revise the maintenance program 
by incorporating the AWLs specified in paragraphs (n)(1), (n)(2), 
(n)(3), and (n)(4) of this AD, as applicable. The initial compliance 
time for the actions specified in applicable AWLs is within 1 year 
after accomplishing the installation required by paragraph (m) of 
this AD, or within 1 year after the effective date of this AD, 
whichever occurs later.
    (1) For Model 737-100, -200, and -200C series airplanes without 
Boeing auxiliary fuel tanks: AWL No. 28-AWL-24 of Section C, ``Fuel 
Systems Airworthiness Limitations,'' of Section 9 of the Boeing 737-
100/200/200C/300/400/500 Airworthiness Limitations (AWLs) and 
Certification Maintenance Requirements (CMRs), Document D6-38278-
CMR, Revision July 2011.
    (2) For Model 737-100, -200, and -200C series airplanes with 
Boeing auxiliary fuel tanks: AWL No. 28-AWL-24 and AWL No. 28-AWL-25 
of Section C, ``Fuel Systems Airworthiness Limitations,'' of Section 
9 of the Boeing 737-100/200/200C/300/400/500 Airworthiness 
Limitations (AWLs) and Certification Maintenance Requirements 
(CMRs), Document D6-38278-CMR, Revision July 2011.
    (3) For Model 737-300, -400, and -500 series airplanes without 
Boeing auxiliary fuel tanks: AWL No. 28-AWL-23 of Section C, ``Fuel 
Systems Airworthiness Limitations,'' of Section 9 of the Boeing 737-
100/200/200C/300/400/500 Airworthiness Limitations (AWLs) and 
Certification Maintenance Requirements (CMRs), Document D6-38278-
CMR, Revision July 2011.
    (4) For Model 737-300, -400, and -500 series airplanes with 
Boeing auxiliary fuel tanks: AWL No. 28-AWL-23 and AWL No. 28-AWL-24 
of Section C, ``Fuel Systems Airworthiness Limitations,'' of Section 
9 of the Boeing 737-100/200/200C/300/400/500 Airworthiness 
Limitations (AWLs) and Certification Maintenance Requirements 
(CMRs), Document D6-38278-CMR, Revision July 2011.

No Alternative Inspections or Inspection Intervals

    (o) After accomplishing the applicable actions specified in 
paragraphs (l) and (n) of this AD, no alternative inspections or 
inspection intervals may be used unless the inspections or 
inspection intervals are approved as an alternative method of 
compliance (AMOC) in accordance with the procedures specified in 
paragraph (t) of this AD.

Credit for Actions Accomplished in Accordance With Previous Service 
Information

    (p) Replacement of the P5-2 fuel system module assembly done 
before the effective date of this AD in accordance with Boeing Alert 
Service Bulletin 737-28A1210, Original Issue, dated August 2, 2010, 
is acceptable for compliance with the requirements of paragraph (h) 
of this AD.
    (q) Actions accomplished before the effective date of this AD in 
accordance with the Boeing 737-100/200/200C/300/400/500 
Airworthiness Limitations (AWLs) and Certification Maintenance 
Requirements (CMRs), D6-38278-CMR, Revision May 2009; or Revision 
August 2010; are acceptable for compliance with the corresponding 
requirements of paragraphs (l) and (n) of this AD.

Method of Compliance for Paragraph (l) of This AD

    (r) Incorporating AWLs No. 28-AWL-21 and No. 28-AWL-22 for Model 
737-100, -200, and -200C series airplanes; and AWLs No. 28-AWL-20 
and No. 28-AWL-21 for Model 737-300, -400, and -500 series 
airplanes; in accordance with paragraphs (g)(1) and (g)(2) of AD 
2008-10-09 R1 (74 FR 69264, December 31, 2009), is acceptable for 
compliance with the corresponding AWL incorporation required by 
paragraph (l) of this AD.

[[Page 63235]]

Method of Compliance for Paragraph (a) of AD 2001-08-24

    (s) Accomplishing the actions required by paragraphs (g), (h), 
(i), and (l) of this AD, and paragraph (j) or (k) of this AD, as 
applicable, is an acceptable method of compliance with the 
requirements of paragraph (a) of AD 2001-08-24, Amendment 39-12201 
(66 FR 20733, April 25, 2001).

Alternative Methods of Compliance (AMOCs)

    (t)(1) The Manager, Seattle ACO, 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 the 
Related Information section of this AD. Information may be e-mailed 
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.

Related Information

    (u) For more information about this AD, contact Tak Kobayashi, 
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle 
Aircraft Certification Office, 1601 Lind Avenue, SW., Renton, 
Washington 98057-3356; telephone: 425-917-6499; fax: 425-917-6590; 
e-mail: Takahisa.Kobayashi@faa.gov.
    (v) For service information identified in this 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, the FAA, 1601 Lind Avenue, SW., 
Renton, Washington. For information on the availability of this 
material at the FAA, call 425-227-1221.

    Issued in Renton, Washington, on October 3, 2011.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2011-26242 Filed 10-11-11; 8:45 am]
BILLING CODE 4910-13-P