Document ID: FAA-2007-0225-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Boeing Model 757 Airplanes Equipped with Rolls Royce RB211-535E Engines
Posted Date: 2007-11-26T05:00Z

[Federal Register: November 26, 2007 (Volume 72, Number 226)]
[Proposed Rules]               
[Page 65903-65905]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr26no07-7]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2007-0225; Directorate Identifier 2007-NM-210-AD]
RIN 2120-AA64

 
Airworthiness Directives; Boeing Model 757 Airplanes Equipped 
with Rolls Royce RB211-535E Engines

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

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for certain Boeing Model 757 airplanes equipped with Rolls Royce RB211-
535E engines. This proposed AD would require repetitive inspections for 
signs of damage of the aft hinge fittings and attachment bolts of the 
thrust reversers, and related investigative and corrective actions if 
necessary. This proposed AD results from reports of several incidents 
of bolt failure at the aft hinge fittings of the thrust reversers due 
to, among other things, high operational loads. We are proposing this 
AD to prevent failure of the attachment bolts and consequent separation 
of a thrust reverser from the airplane during flight, which could 
result in structural damage to the airplane.

DATES: We must receive comments on this proposed AD by January 10, 
2008.

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

[[Page 65904]]

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, P.O. Box 3707, Seattle, Washington 98124-2207.

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: Jason Deutschman, Aerospace Engineer, 
Airframe Branch, ANM-120S, Seattle Aircraft Certification Office, FAA, 
1601 Lind Avenue, SW., Renton, Washington 98057-3356; telephone (425) 
917-6449; 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-2007-0225; 
Directorate Identifier 2007-NM-210-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 have received reports indicating that several incidents of bolt 
failure at the aft hinge fittings of the thrust reversers have occurred 
on certain Boeing Model 757 airplanes equipped with Rolls Royce RB211-
535E engines. Of these incidents, there were nine hinges with failure 
of one out of four bolts, two hinges with failure of two out of four 
bolts, and three hinges with failure of three out of four bolts. The 
possible causes of the bolt failures can be high operational loads, 
contact loads caused by possible interference between the thrust 
reverser hinge and the hinge beam, or installation of the four 
attachment bolts with washers that could rub against the radius of the 
hinge fitting spotface. The hinge has integral fail safe features, but 
loss of the entire four-bolt pattern constitutes complete loss of the 
load path. Failure of the attachment bolts could result in separation 
of a thrust reverser from the airplane during flight and consequent 
structural damage to the airplane.

Relevant Service Information

    We have reviewed Boeing Special Attention Service Bulletins 757-54-
0049 and 757-54-0050, both dated July 16, 2007. The service information 
describes procedures for doing a detailed inspection of the aft hinge 
fittings and the eight attachment bolts of the thrust reversers for 
signs of damage (includes, but is not limited to, cracked or broken 
hinge fittings or contact damage to the base metal), and related 
investigative and corrective actions if necessary. The compliance time 
for the initial inspection is within 3,000 flight cycles after the date 
on the service bulletin.
    The related investigative and corrective actions for the number 1 
and number 2 engines include the following:
     For airplanes on which any aft hinge fitting is cracked or 
broken: Accomplish the preventive modification specified in Part III of 
the Accomplishment Instructions and install a new fitting.
     For airplanes on which any contact damage to the base 
metal is found that is less than .005 inch deep: Accomplish the 
preventive modification specified in Part III of the Accomplishment 
Instructions before further flight; or reapply the surface finish as 
specified in Part II of the Accomplishment Instructions (standard 
operating procedures manual 20-60-02), and accomplish the preventive 
modification within 3,000 flight cycles after the surface finish is 
applied.
     For airplanes on which any contact damage to the base 
metal is found that is equal to or more than .005 inches deep: 
Accomplish the preventive modification as specified in Part III of the 
Accomplishment Instructions.
     For airplanes on which any damage is found that is outside 
the limits specified in the service information, the service bulletins 
recommend contacting Boeing for repair instructions.
     For airplanes on which any attachment bolt is damaged: 
Accomplish the preventive modification specified in Part III of the 
Accomplishment Instructions, or remove the damaged bolt and accomplish 
a high frequency eddy current inspection of the bolt hole for cracking. 
If no crack is found in the bolt hole, replace the bolt with a new or 
serviceable bolt before further flight and accomplish the preventive 
modification within 3,000 flight cycles after the bolt is replaced. If 
any crack is found, accomplish the preventive modification.
    For airplanes on which no attachment bolt is found damaged, repeat 
the detailed inspection at intervals not to exceed 3,000 flight cycles. 
Accomplishing the preventive modification at any time would eliminate 
the need for the repetitive inspections.
    Accomplishing the actions specified in the service information is 
intended to adequately address the unsafe condition.

Concurrent Service Information

    Service Bulletin 757-54-0049 recommends prior or concurrent 
accomplishment of Boeing Service Bulletin 757-54-0015, Revision 3, 
dated September 19, 1996. Service Bulletin 757-54-0015 describes 
procedures for replacing a certain older hinge fitting and attachment 
on airplanes after line number 241.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other airplanes 
of this same type design. For this reason, we are proposing this AD, 
which would require accomplishing the actions specified in the service 
information described previously, except as discussed under 
``Difference Between the AD and the Service Information.''

Difference Between the AD and the Service Information

    Although Boeing Special Attention Service Bulletins 757-54-0049 and 
757-54-0050 specify that you may contact the manufacturer for repair 
instructions, this proposed AD requires you to repair in one of the 
following ways:
     Using a method that we approve; or
     Using data that meet the certification basis of the 
airplane that have been approved by an Authorized Representative for 
the Boeing Delegation

[[Page 65905]]

Option Authorization Organization who has been authorized by the FAA to 
make those findings.

Costs of Compliance

    There are about 606 airplanes of the affected design in the 
worldwide fleet. This proposed AD would affect about 295 airplanes of 
U.S. registry. The proposed inspections would take about 2 work hours 
per airplane, at an average labor rate of $80 per work hour. Based on 
these figures, the estimated cost of the proposed AD for U.S. operators 
is $47,200, or $160 per airplane, per inspection cycle.

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

Boeing: Docket No. FAA-2007-0225; Directorate Identifier 2007-NM-
210-AD.

Comments Due Date

    (a) The FAA must receive comments on this AD action by January 
10, 2008.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 757-200, -200CB, -200PF, and 
-300 series airplanes, certificated in any category; equipped with 
Rolls Royce RB211-535E engines.

Unsafe Condition

    (d) This AD results from reports of several incidents of bolt 
failure at the aft hinge fittings of the thrust reversers due to, 
among other things, high operational loads. We are issuing this AD 
to prevent failure of the attachment bolts and consequent separation 
of a thrust reverser from the airplane during flight, which could 
result in structural damage to the airplane.

Compliance

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

Repetitive Inspections/Investigative and Corrective Actions

    (f) At the time specified in paragraph 1.E. ``Compliance'' of 
Boeing Special Attention Service Bulletins 757-54-0049 or 757-54-
0050, both dated July 16, 2007, as applicable, except as provided by 
paragraph (g) of this AD: Do a detailed inspection for signs of 
damage of the aft hinge fittings and attachment bolts of the thrust 
reversers by doing all the actions, including all applicable related 
investigative and corrective actions, as specified in the 
Accomplishment Instructions of the applicable service bulletin. Do 
all applicable related investigative and corrective actions at the 
time specified in paragraph 1.E., ``Compliance'' of the applicable 
service bulletin. If any damage is found and the service bulletins 
specify to contact Boeing for appropriate action: Before further 
flight, repair using a method approved in accordance with the 
procedures specified in paragraph (j) of this AD.
    (g) Where Boeing Special Attention Service Bulletins 757-54-0049 
and 757-54-0050, both dated July 16, 2007, specify compliance times 
relative to the date on the service bulletin, this AD requires 
compliance within the specified compliance time after the effective 
date of this AD.

Concurrent Service Information

    (h) Prior to or concurrently with accomplishing the actions 
specified in Boeing Special Attention Service Bulletin 757-54-0049, 
dated July 16, 2007, accomplish the replacement specified in Boeing 
Service Bulletin 757-54-0015, Revision 3, dated September 19, 1996.
    (i) Actions accomplished before the effective date of this AD in 
accordance with Boeing Service Bulletin 757-54-0015, dated February 
16, 1989; Revision 1, dated December 20, 1990; or Revision 2, dated 
April 21, 1994; are considered acceptable for compliance with the 
corresponding actions specified in paragraph (h) of this AD.

Alternative Methods of Compliance (AMOCs)

    (j)(1) The Manager, Seattle Aircraft Certification Office (ACO), 
FAA, has the authority to approve AMOCs for this AD, if requested in 
accordance with the procedures found in 14 CFR 39.19.
    (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 appropriate principal inspector (PI) in the FAA 
Flight Standards District Office (FSDO), or lacking a PI, your local 
FSDO.
    (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.

    Issued in Renton, Washington, on November 13, 2007.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. E7-22924 Filed 11-23-07; 8:45 am]

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