Document ID: FAA-2012-1103-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: The Boeing Company Airplanes
Posted Date: 2012-10-19T04:00Z

[Federal Register Volume 77, Number 203 (Friday, October 19, 2012)]
[Proposed Rules]
[Pages 64242-64244]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2012-25780]

[[Page 64242]]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2012-1103; Directorate Identifier 2012-NM-131-AD]
RIN 2120-AA64

Airworthiness Directives; The Boeing Company 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 
certain The Boeing Company Model 757-200, -200PF, -200CB, and -300 
series airplanes. This proposed AD was prompted by reports of cracking 
of the forward bulkhead web, web stiffeners, attachment angles, and 
thermal anti-ice (TAI) spray ring assemblies of the engine air intake 
cowl. This proposed AD would require replacing the forward bulkhead 
assembly, TAI spray ring assembly, and attachment fittings of the air 
intake cowl. We are proposing this AD to prevent the failure of air 
intake cowl components due to cracking, which could result in the air 
intake cowl separating from the engine and striking critical airplane 
control surfaces that could result in a loss of airplane control; 
severe engine damage and loss of thrust; or large parts striking a 
person or property on the ground.

DATES: We must receive comments on this proposed AD by December 3, 
2012.

ADDRESSES: You may send comments, using the procedures found in 14 CFR 
11.43 and 11.45, by any of the following methods:
     Federal eRulemaking Portal: Go to http://www.regulations.gov. Follow the instructions for submitting comments.
     Fax: 202-493-2251.
     Mail: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue SE., Washington, DC 20590.
     Hand Delivery: Deliver to Mail address above between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    For Rolls-Royce service information identified in this proposed AD, 
contact Rolls-Royce plc, P.O. Box 31, Derby, DE24 8BJ, United Kingdom; 
telephone 011 44 1332 242424; fax 011 44 1332 249936; email http://www.rolls-royce.com/contact/civil_team.jsp; Internet https://www.aeromanager.com. For Bombardier service information identified in 
this proposed AD, contact Short Brothers PLC, Airworthiness, P.O. Box 
241, Airport Road, Belfast, BT3 9DZ Northern Ireland; telephone 
+44(0)2890-462469; fax +44(0)2890-468444; Internet http://www.bombardier.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: Kevin Nguyen, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification Office 
(ACO), 1601 Lind Avenue SW., Renton, WA 98057-3356; phone: (425) 917-
6501; fax: (425) 917-6590; email: kevin.nguyen@faa.gov.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2012-1103; 
Directorate Identifier 2012-NM-131-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 of extensive cracking of the forward 
bulkhead web, web stiffeners, attachment angles, and TAI spray ring 
assemblies of the air intake cowl. We received another report of 
extensive cracking in the forward bulkhead inner and outer cap angles, 
stiffeners, and the bulkhead web. In addition, the TAI piccolo tube and 
supports were found cracked after the intake cowl was disassembled. 
Further investigation determined that the issue was related to metal 
fatigue during the service lifetime of the components; therefore, there 
is a need to remove and replace the affected components within a 
prescribed timescale. Cracked air intake cowl parts and assemblies, if 
not corrected, could result in the air intake cowl separating from the 
engine and striking critical airplane control surfaces that could 
result in a loss of airplane control; severe engine damage, and loss of 
thrust; or large parts striking a person or property on the ground.

Relevant Service Information

    We reviewed Rolls-Royce Service Bulletin RB.211-71-AG698, including 
Appendices 1, 2, 3, and 4, dated October 14, 2011 (for engines having 
Dyna-Rohr or Bombardier standard air intake cowls); and Bombardier 
Alert Service Bulletin RB211-E4-A1003, Revision 1, dated August 15, 
2012 (for engines with air intake cowls modified by Bombardier 
Aerospace Supplemental Type Certificate (STC) ST02102NY, http://
rgl.faa.gov/Regulatory--and--Guidance--Library/rgstc.nsf/0/
256325188c3b1f2f8625705f004dd977/$FILE/ST02102NY.pdf, commonly known as 
a 535EX cowls). The service information describes procedures for 
removing and replacing, with new parts, the forward bulkhead assembly, 
TAI spray ring assembly, and attachment fittings of the air intake 
cowl.

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 the same type design.

Proposed AD Requirements

    This proposed AD would require accomplishing the actions specified 
in the service information described previously.

Interim Action

    We consider this proposed AD interim action due to on-going 
investigation into the nature, cause, and extent of the cracking. If 
final action is later identified, based on the results of the 
investigation, we might consider further rulemaking then.

[[Page 64243]]

Costs of Compliance

    We estimate that this proposed AD affects 332 airplanes of U.S. 
registry.
    We estimate the following costs to comply with this proposed AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                  Cost on U.S.
             Action                    Labor cost            Parts cost      Cost per product      operators
----------------------------------------------------------------------------------------------------------------
Replace left-side air intake     Up to 252 work-hours x  Up to $158,760...  Up to $180,180     Up to
 cowl components.                 $85 per hour =                             per replacement.   $59,819,760.
                                  $21,420 per
                                  replacement.
Replace right-side air intake    Up to 252 work-hours x  Up to $158,760...  Up to $180,180     Up to
 cowl components.                 $85 per hour =                             per replacement.   $59,819,760.
                                  $21,420 per
                                  replacement.
----------------------------------------------------------------------------------------------------------------

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-2012-1103; Directorate Identifier 
2012-NM-131-AD.

(a) Comments Due Date

    We must receive comments by December 3, 2012.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to The Boeing Company Model 757-200, -200PF, -
200CB, and -300 series airplanes, certificated in any category, 
equipped with Rolls-Royce RB211-535E4, -535E4-B, -535E4-C, and -
535E4X engines; or with Rolls-Royce RB211-535E4, -535E4-B, and -
535E4-C engines that have air intake cowls that were modified by 
Bombardier Aerospace Supplemental Type Certificate (STC) ST02102NY, 
http://rgl.faa.gov/Regulatory_and_Guidance_Library/rgstc.nsf/0/
256325188c3b1f2f8625705f004dd977/$FILE/ST02102NY.pdf, commonly known 
as 535E4X cowls.

(d) Subject

    Joint Aircraft System Component (JASC)/Air Transport Association 
(ATA) of America Code 71, Powerplant.

(e) Unsafe Condition

    This AD was prompted by reports of cracking of the forward 
bulkhead web, web stiffeners, attachment angles, and thermal anti-
ice (TAI) spray ring assemblies of the engine air intake cowl. We 
are issuing this AD to prevent the failure of air intake cowl 
components due to cracking, which could result in the air intake 
cowl separating from the engine and striking critical airplane 
control surfaces that could result in a loss of airplane control; 
severe engine damage, and loss of thrust; or large parts striking a 
person or property on the ground.

(f) Compliance

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

(g) Replacement of Air Intake Cowl Complete Forward Bulkhead Assemblies 
Previously Disassembled

    For airplanes on which the air intake cowls were replaced before 
the effective date of this AD using a kit or parts identified in 
paragraph (g)(1), (g)(2), or (g)(3) of this AD: Within 144 months 
since replacement of the air intake cowl, or within 12 months after 
the effective date of this AD, whichever is later, replace the 
forward bulkhead assembly, TAI spray ring assembly, and associated 
attachment fittings of the air intake cowl with new parts, in 
accordance with the Accomplishment Instructions of Bombardier Alert 
Service Bulletin RB211-E4-A1003, Revision 1, dated August 15, 2012 
(for engines with air intake cowls modified by Bombardier Aerospace 
STC ST02102NY, http://rgl.faa.gov/Regulatory--and--Guidance--
Library/rgstc.nsf/0/256325188c3b1f2f8625705f004dd977/$FILE/
ST02102NY.pdf, commonly known as a 535EX cowls); or Rolls-Royce 
Service Bulletin RB.211-71-AG698, dated October 14, 2011 (for 
engines having Dyna-Rohr or Bombardier standard air intake cowls). 
Repeat the replacement thereafter at intervals not to exceed 144 
months.
    (1) RB211-E4A1003 KIT, or all the parts listed in Appendix 3 of 
Bombardier Alert Service Bulletin RB211-E4-A1003, Revision 1, dated 
August 15, 2012 (for engines with air intake cowls modified by STC 
ST02102NY, commonly known as a 535EX cowls).
    (2) RB-211-71-AG698-E4KIT, or all the parts listed in Appendix 3 
of Rolls-Royce Service Bulletin RB.211-71-AG698, dated October 14, 
2011 (for engines with Dyna-Rohr standard air intake cowls).
    (3) RB-211-71-AG698-E4BKIT, or all the parts listed in Appendix 
4 of Rolls-Royce

[[Page 64244]]

Service Bulletin RB.211-71-AG698, dated October 14, 2011 (for 
engines with Bombardier standard air intake cowls).

(h) Replacement of In-Service Air Intake Cowl Complete Forward Bulkhead 
Assemblies

    For airplanes other than those identified in paragraph (g) of 
this AD: At the applicable time specified in paragraphs (h)(1) 
through (h)(12) of this AD, replace the forward bulkhead assembly, 
TAI spray ring assembly, and associated attachment fittings of the 
air intake cowl with new parts, in accordance with the 
Accomplishment Instructions of Bombardier Alert Service Bulletin 
RB211-E4-A1003, Revision 1, dated August 15, 2012 (for engines with 
air intake cowls modified by Bombardier Aerospace STC ST02102NY 
http://rgl.faa.gov/Regulatory_and_Guidance_Library/rgstc.nsf/0/
256325188c3b1f2f8625705f004dd977/$FILE/ST02102NY.pdf, commonly known 
as a 535EX cowls); or Rolls-Royce Service Bulletin RB.211-71-AG698, 
dated October 14, 2011 (for engines with Dyna-Rohr or Bombardier 
standard air intake cowls.) Repeat the replacement thereafter at 
intervals not to exceed 144 months.
    (1) For airplanes with air intake cowls having serial numbers 
4001 through 4121 inclusive: Replace within 12 months after the 
effective date of this AD.
    (2) For airplanes with air intake cowls having serial numbers 
4122 through 4241 inclusive: Replace within 24 months after the 
effective date of this AD.
    (3) For airplanes with air intake cowls having serial numbers 
4242 through 4361 inclusive: Replace within 36 months after the 
effective date of this AD.
    (4) For airplanes with air intake cowls having serial numbers 
4362 through 4481 inclusive: Replace within 48 months after the 
effective date of this AD.
    (5) For airplanes with air intake cowls having serial numbers 
4482 through 4484 inclusive: Replace within 60 months after the 
effective date of this AD.
    (6) For airplanes with air intake cowls having serial numbers 
9001 through 9117 inclusive: Replace within 60 months after the 
effective date of this AD.
    (7) For airplanes with air intake cowls having serial numbers 
9118 through 9237 inclusive: Replace within 72 months after the 
effective date of this AD.
    (8) For airplanes with air intake cowls having serial numbers 
9238 through 9357 inclusive: Replace within 84 months after the 
effective date of this AD.
    (9) For airplanes with air intake cowls having serial numbers 
9358 through 9477 inclusive: Replace within 96 months after the 
effective date of this AD.
    (10) For airplanes with air intake cowls having serial numbers 
9478 through 9597 inclusive: Replace within 108 months after the 
effective date of this AD.
    (11) For airplanes with air intake cowls having serial numbers 
9598 through 9717 inclusive: Replace within 120 months after the 
effective date of this AD.
    (12) For airplanes with air intake cowls having serial numbers 
9718 through 9780 inclusive: Replace within 132 months after the 
effective date of this AD.

(i) Credit for Previous Actions

    For engines with air intake cowls modified by Bombardier 
Aerospace STC ST02102NY http://rgl.faa.gov/Regulatory--and--
Guidance--Library/rgstc.nsf/0/256325188c3b1f2f8625705f004dd977/
$FILE/ST02102NY.pdf, commonly known as a 535EX cowls): This 
paragraph provides credit for actions required by paragraphs (g) and 
(h) of this AD, if those actions were performed before the effective 
date of this AD using Bombardier Alert Service Bulletin RB211-E4-
A1003, dated June 27, 2012 (which is not incorporated by reference 
in this AD).

(j) No Reporting Requirement

    Although Bombardier Alert Service Bulletin RB211-E4-A1003, 
Revision 1, dated August 15, 2012; and Rolls-Royce Service Bulletin 
RB.211-71-AG698, excluding Appendix 1 and including Appendices 2, 3, 
and 4, dated October 14, 2011; specify to submit certain reporting 
information to the manufacturer, this AD does not include that 
requirement.

(k) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle Aircraft Certification Office (ACO), 
FAA, has the authority to approve AMOCs for this AD, if requested 
using the procedures found in 14 CFR 39.19. In accordance with 14 
CFR 39.19, send your request to your principal inspector or local 
Flight Standards District Office, as appropriate. If sending 
information directly to the manager of the ACO, send it to the 
attention of the person identified in the Related Information 
section of this AD. Information may be emailed to: 9-ANM-Seattle-ACO-AMOC-Requests@faa.gov.
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any repair required by this AD if it is approved by the 
Boeing Commercial Airplanes Organization Designation Authorization 
(ODA) that has been authorized by the Manager, Seattle ACO, to make 
those findings. For a repair method to be approved, the repair must 
meet the certification basis of the airplane, and the approval must 
specifically refer to this AD.

(l) Related Information

    (1) For more information about this AD, contact Kevin Nguyen, 
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle 
Aircraft Certification Office (ACO), 1601 Lind Avenue SW., Renton, 
WA 98057-3356; phone: (425) 917-6501; fax: (425) 917-6590; email: 
kevin.nguyen@faa.gov.
    (2) For Rolls-Royce service information identified in this AD, 
contact Rolls-Royce plc, P.O. Box 31, Derby, DE24 8BJ, United 
Kingdom; telephone 011 44 1332 242424; fax 011 44 1332 249936; email 
http://www.rolls-royce.com/contact/civil_team.jsp; Internet https://www.aeromanager.com. For Bombardier Service information identified 
in this AD, contact Short Brothers PLC, Airworthiness, P.O. Box 241, 
Airport Road, Belfast, BT3 9DZ Northern Ireland; telephone 
+44(0)2890-462469; fax +44(0)2890-468444; Internet http://www.bombardier.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.

    Issued in Renton, Washington, on October 12, 2012.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2012-25780 Filed 10-18-12; 8:45 am]
BILLING CODE 4910-13-P