Document ID: FAA-2007-0201-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; McDonnell Douglas Model DC-10-10 and DC-10-10F Airplanes, Model DC-10-15 Airplanes, Model DC-10-30 and DC- 10-30F (KC-10A and KDC-10) Airplanes, Model DC-10-40 and DC-10-40F Airplanes, Model MD-10-10F and MD-10-30F Airplanes, and Model MD-11 and MD-11F Airplanes
Posted Date: 2007-11-19T05:00Z

[Federal Register: November 19, 2007 (Volume 72, Number 222)]
[Proposed Rules]               
[Page 64957-64960]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr19no07-15]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2007-0201; Directorate Identifier 2007-NM-163-AD]
RIN 2120-AA64

 
Airworthiness Directives; McDonnell Douglas Model DC-10-10 and 
DC-10-10F Airplanes, Model DC-10-15 Airplanes, Model DC-10-30 and DC-
10-30F (KC-10A and KDC-10) Airplanes, Model DC-10-40 and DC-10-40F 
Airplanes, Model MD-10-10F and MD-10-30F Airplanes, and Model MD-11 and 
MD-11F Airplanes

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 all McDonnell Douglas airplane models identified above. This 
proposed AD would require revising the FAA-approved maintenance 
program, or the Airworthiness Limitations (AWLs) section of the 
Instructions for Continued Airworthiness, as applicable, to incorporate 
new AWLs for fuel tank systems to satisfy Special Federal Aviation 
Regulation No. 88 requirements. For certain airplanes, this proposed AD 
would also require the initial accomplishment of a certain repetitive 
AWL inspection to phase in that inspection, and repair if necessary. 
This proposed AD results from a design review of the fuel tank systems. 
We are proposing this 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.

DATES: We must receive comments on this proposed AD by January 3, 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 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, Long Beach Division, 3855 Lakewood Boulevard, 
Long Beach, California 90846, Attention: Data and Service Management, 
Dept. C1-L5A (D800-0024).

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: Philip C. Kush, Aerospace Engineer, 
Propulsion Branch, ANM-140L, FAA, Los Angeles Aircraft Certification 
Office, 3960 Paramount Boulevard, Lakewood, California 90712-4137; 
telephone (562) 627-5263; fax (562) 627-5210.

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-2007-0201; 
Directorate Identifier 2007-NM-163-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

[[Page 64958]]

flammable conditions is one of these criteria. The other three criteria 
address the failure types under evaluation: Single failures, single 
failures in combination with another 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 proposed AD 
are necessary to reduce the potential of ignition sources inside fuel 
tanks, which, in combination with flammable fuel vapors, could result 
in a fuel tank explosion and consequent loss of the airplane.

Relevant Service Information

    We have reviewed the following appendixes of the Boeing Trijet 
Special Compliance Item Report, MDC-02K1003, Revision C, dated July 24, 
2007 (hereafter referred to as ``Report MDC-02K1003''):
     Appendix B, Critical Design Configuration Control 
Limitations (CDCCLs)
     Appendix C, Airworthiness Limitation Instructions (ALIs)
     Appendix D, Short-Term Extensions
    Appendixes B and C of Report MDC-02K1003 describe new airworthiness 
limitations (AWLs) for fuel tank systems. The new AWLs include:
     CDCCLs, which are limitation requirements to preserve a 
critical ignition source prevention feature of the fuel tank system 
design that is necessary to prevent the occurrence of an unsafe 
condition. The purpose of a CDCCL is to provide instruction to retain 
the critical ignition source prevention feature during configuration 
change that may be caused by alterations, repairs, or maintenance 
actions. A CDCCL is not a periodic inspection, and
     AWL inspections, which are periodic inspections of certain 
features for latent failures that could contribute to an ignition 
source.
    Accomplishing the actions specified in the service information is 
intended to adequately address the unsafe condition.

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 revising the FAA-approved maintenance program, or 
the AWLs section of the Instructions for Continued Airworthiness, as 
applicable, by incorporating the information in Appendixes B, C, and D 
of Report MDC-02K1003. For certain airplanes, this proposed AD would 
also require the initial accomplishment of a certain repetitive AWL 
inspection to phase in that inspection, and repair if necessary.

Explanation of Compliance Time

    In most ADs, we adopt a compliance time allowing a specified amount 
of time after the AD's effective date. In this case, however, the FAA 
has already issued regulations that require operators to revise their 
maintenance/inspection programs to address fuel tank safety issues. The 
compliance date for these regulations is December 16, 2008. To provide 
for efficient and coordinated implementation of these regulations and 
this proposed AD, we are using this same compliance date in this 
proposed AD.

Rework Required When Implementing AWLs Into an Existing Fleet

    The maintenance program revision specified in paragraph (g) of this 
proposed AD, and the AWLs revision specified in paragraph (h) of this 
proposed AD, for the fuel tank systems, which involve incorporating the 
information specified in Report MDC-02K1003, would affect how operators 
maintain their airplanes. After doing the maintenance program revision 
or AWLs revision, as applicable, operators would need to do any 
maintenance on the fuel tank system as specified in the CDCCLs. 
Maintenance done before the maintenance program revision specified in 
paragraph (g), or the AWLs revision specified in paragraph (h), as 
applicable, would not need to be redone in order to comply with 
paragraph (g) or (h). For example, the AWL that requires fuel pumps to 
be repaired and overhauled per the FAA-approved component maintenance 
manual (CMM) applies to fuel pumps repaired after the maintenance 
programs are revised; spare or on-wing fuel pumps do not need to be 
reworked. For AWLs that require repetitive inspections, the initial 
inspection interval (threshold) starts from the date that the 
maintenance program revision specified in paragraph (g), or the AWLs 
revision specified in paragraph (h), as applicable, is done, except as 
provided by paragraph (i) of this proposed AD. This proposed AD would 
require only the applicable maintenance program revision or AWL 
revision specified in this proposed AD and the initial inspection 
specified in paragraph (i). No other fleet-wide inspections need to be 
done.

Changes to Fuel Tank System AWLs

    For certain airplanes, paragraph (g) of this proposed AD would 
require revising the FAA-approved maintenance program by incorporating 
certain information specified in Report MDC-02K1003. For certain other 
airplanes, paragraph (h) of this proposed AD would require revising the 
AWLs section of the Instructions for Continued Airworthiness by 
incorporating certain information specified in Report MDC-02K1003. 
Paragraphs (g) and (h) allow accomplishing the revision in accordance 
with later revisions of Report MDC-02K1003 as an acceptable method of 
compliance if they are approved by the Manager, Los Angeles Aircraft 
Certification Office (ACO), FAA. For certain airplanes, paragraph (i) 
of this AD allows accomplishing the initial inspection and repair in 
accordance with later revisions of Report MDC-02K1003 as an acceptable 
method of compliance if they are approved by the Manager, Los Angeles 
ACO. In addition, Appendixes B and C of Report MDC-02K1003 specify that 
any deviations from the published AWL instructions, including AWL 
intervals, must be approved by the Manager, Los Angeles ACO. Therefore, 
after the maintenance program or AWLs revision, any further revision to 
an AWL or AWL interval should be done as an AWL change, not as an 
alternative method of compliance (AMOC). For U.S.-registered airplanes, 
operators must make requests through an appropriate FAA Principal 
Maintenance Inspector (PMI) or Principal Avionics Inspector (PAI) for 
approval by the Manager, Los Angeles ACO. A non-U.S. operator should 
coordinate changes with its governing regulatory agency.

Exceptional Short-Term Extensions

    Appendix D of Report MDC-02K1003 has provisions for an exceptional 
short-term extension of 30 days. An exceptional short-term extension is 
an increase in an AWL interval that may be needed to cover an 
uncontrollable or unexpected situation. For U.S.-registered airplanes, 
the FAA PMI or PAI must concur with any exceptional short-term 
extension before it is used, unless the operator has identified another 
appropriate procedure with the local regulatory authority. The FAA PMI 
or PAI may grant the exceptional short-term extensions described in 
Appendix D without consultation with the Manager, Los Angeles ACO. A 
non-U.S. operator should coordinate changes with its governing 
regulatory agency. As explained in Appendix D, exceptional short-term 
extensions must not be used

[[Page 64959]]

for fleet AWL extensions. An exceptional short-term extension should 
not be confused with an operator's short-term escalation authorization 
approved in accordance with the Operations Specifications or the 
operator's reliability program.

Ensuring Compliance With Fuel Tank System AWLs

    Boeing has revised the applicable maintenance manuals and task 
cards to address AWLs and to include notes about CDCCLs. Operators that 
do not use Boeing's revision service should revise their maintenance 
manuals and task cards to highlight actions tied to CDCCLs to ensure 
that maintenance personnel are complying with the CDCCLs.

Recording Compliance With Fuel Tank System AWLs

    The applicable operating rules of the Federal Aviation Regulations 
(14 CFR parts 91, 121, 125, and 129) require operators to maintain 
records with the identification of the current inspection status of an 
airplane. The AWLs contained in Appendix C of Report MDC-02K1003 are 
inspections for which the applicable sections of the operating rules 
apply. The AWLs contained in Appendix B of Report MDC-02K1003 are 
CDCCLs, which are tied to conditional maintenance actions. An entry 
into an operator's existing maintenance record system for corrective 
action is sufficient for recording compliance with CDCCLs, as long as 
the applicable maintenance manual and task cards identify actions that 
are CDCCLs.

Changes to Component Maintenance Manuals (CMMs) Cited in Fuel Tank 
System AWLs

    Some of the AWLs in Appendix B of Report MDC-02K1003 refer to 
specific revision levels of the CMMs as additional sources of service 
information for doing the AWLs. Boeing is referring to the CMMs by 
revision level in the applicable AWL for certain components rather than 
including information directly in the AWL because of the volume of that 
information. As a result, the Manager, Los Angeles ACO, must approve 
the CMMs. Any later revision of those CMMs will be handled like a 
change to the AWL itself. Any use of parts (including the use of parts 
manufacturer approval (PMA) approved parts), methods, techniques, and 
practices not contained in the CMMs need to be approved by the Manager, 
Los Angeles ACO, or governing regulatory authority. For example, 
certain pump repair/overhaul manuals must be approved by the Manager, 
Los Angeles ACO.

Changes to Airplane Maintenance Manual Referenced in Fuel Tank System 
AWLs

    In other AWLs in Report MDC-02K1003, the AWLs contain all the 
necessary data. The applicable section of the maintenance manual is 
usually included in the AWLs. Boeing intended this information to 
assist operators in maintaining the maintenance manuals. A maintenance 
manual change to these tasks may be made without approval by the 
Manager, Los Angeles ACO, through an appropriate FAA PMI or PAI, by the 
governing regulatory authority, or by using the operator's standard 
process for revising maintenance manuals. An acceptable change would 
have to maintain the information specified in the AWL such as the pass/
fail criteria or special test equipment.

Difference Between the Proposed AD and Service Information

    Although Report MDC-02K1003 specifies to submit certain information 
to the manufacturer, this proposed AD does not include that 
requirement.

Costs of Compliance

    There are about 300 airplanes of the affected design in the 
worldwide fleet. This proposed AD would affect about 180 airplanes of 
U.S. registry. The proposed actions would take about 1 work hour 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 
$14,400, or $80 per airplane.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, Section 106, describes the 
authority of the FAA Administrator. Subtitle VII, Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    We are issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701, ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation 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):

McDonnell Douglas: Docket No. FAA-2007-0201; Directorate Identifier 
2007-NM-163-AD.

Comments Due Date

    (a) The FAA must receive comments on this AD action by January 
3, 2008.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to all McDonnell Douglas Model DC-10-10 and 
DC-10-10F airplanes, Model DC-10-15 airplanes, Model DC-10-30 and 
DC-10-30F (KC-10A and KDC-10) airplanes, Model DC-10-40 and DC-10-
40F airplanes, Model MD-10-10F and MD-10-30F airplanes, and Model 
MD-

[[Page 64960]]

11 and MD-11F airplanes, certificated in any category.

    Note 1: This AD requires revisions to certain operator 
maintenance documents to include new inspections and maintenance 
actions. Compliance with these limitations is required by 14 CFR 
43.16 and 91.403(c). For airplanes that have been previously 
modified, altered, or repaired in the areas addressed by these 
limitations, the operator may not be able to accomplish the actions 
described in the revisions. In this situation, to comply with 14 CFR 
43.16 and 91.403(c), the operator must request approval for revision 
to the airworthiness limitations (AWLs) in the Boeing Trijet Special 
Compliance Item Report, MDC-02K1003, according to paragraph (g), 
(h), or (k) of this AD, as applicable.

Unsafe Condition

    (d) This AD results from a design review of the fuel tank 
systems. We are issuing this 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.

Compliance

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

Service Information Reference

    (f) The term ``Report MDC-02K1003'' as used in this AD, means 
the Boeing Trijet Special Compliance Item Report, MDC-02K1003, 
Revision C, dated July 24, 2007.

Revise the FAA-Approved Maintenance Program

    (g) For Model DC-10-10 and DC-10-10F airplanes, Model DC-10-15 
airplanes, Model DC-10-30 and DC-10-30F (KC-10A and KDC-10) 
airplanes, and Model DC-10-40 and DC-10-40F airplanes: Before 
December 16, 2008, revise the FAA-approved maintenance program to 
incorporate the information specified in Appendixes B, C, and D of 
Report MDC-02K1003. Accomplishing the revision in accordance with a 
later revision of Report MDC-02K1003 is an acceptable method of 
compliance if the revision is approved by the Manager, Los Angeles 
Aircraft Certification Office (ACO), FAA.

Revise the AWLs Section

    (h) For Model MD-10-10F and MD-10-30F airplanes, and Model MD-11 
and MD-11F airplanes: Before December 16, 2008, revise the AWLs 
section of the Instructions for Continued Airworthiness to 
incorporate the information specified in Appendixes B, C, and D of 
Report MDC-02K1003, except that the initial inspection required by 
paragraph (i) of this AD must be done at the applicable compliance 
time specified in that paragraph. Accomplishing the revision in 
accordance with a later revision of Report MDC-02K1003 is an 
acceptable method of compliance if the revision is approved by the 
Manager, Los Angeles ACO.

Initial Inspection and Repair If Necessary

    (i) For Model MD-11 and MD-11F airplanes: Within 60 months after 
the effective date of this AD, do a detailed inspection of the 
metallic overbraiding and red-wrap tape installed on the tail tank 
fuel quantity indication system (FQIS) wiring to verify if the 
metallic overbraiding or red-wrap tape is damaged or shows signs of 
deterioration, in accordance with ALI 20-2 of Appendix C of Report 
MDC-02K1003. If any discrepancy is found during the inspection, 
repair the discrepancy before further flight in accordance with ALI 
20-2 of Appendix C of Report MDC-02K1003. Accomplishing the actions 
required by this paragraph in accordance with a later revision of 
Report MDC-02K1003 is an acceptable method of compliance if the 
revision is approved by the Manager, Los Angeles ACO.

    Note 2: For the purposes of this AD, a detailed inspection is: 
``An intensive examination of a specific item, installation, or 
assembly to detect damage, failure, or irregularity. Available 
lighting is normally supplemented with a direct source of good 
lighting at an intensity deemed appropriate. Inspection aids such as 
mirror, magnifying lenses, etc., may be necessary. Surface cleaning 
and elaborate procedures may be required.''

No Reporting Requirement

    (j) Although Report MDC-02K1003 specifies to submit certain 
information to the manufacturer, this AD does not require that 
action.

Alternative Methods of Compliance (AMOCs)

    (k)(1) The Manager, Los Angeles 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.

    Issued in Renton, Washington, on November 7, 2007.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. E7-22547 Filed 11-16-07; 8:45 am]

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