Document ID: FAA-2011-0027-0001
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Boeing Co. Model 777 200 and  300 Series Airplanes Equipped with Rolls-Royce RB211 Trent 800 Engines
Posted Date: 2011-01-20T05:00Z

[Federal Register Volume 76, Number 13 (Thursday, January 20, 2011)]
[Proposed Rules]
[Pages 3561-3564]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2011-1121]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2011-0027; Directorate Identifier 2010-NM-127-AD]
RIN 2120-AA64

Airworthiness Directives; The Boeing Company Model 777-200 and -
300 Series Airplanes Equipped with Rolls-Royce RB211 Trent 800 Engines

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 Model 777-200 and -300 series airplanes. This proposed AD would 
require repetitive inspections of all thrust reverser (T/R) structure 
and sealant for degradation, and related investigative and corrective 
actions if necessary. This proposed AD results from reports of thrust 
reverser events related to thermal damage of the thrust reverser inner 
wall. We are proposing this AD to detect and correct a degraded T/R 
inner wall panel, which could lead to failure of a T/R and adjacent 
components and their consequent separation from the airplane, which 
could result in a rejected takeoff (RTO) and cause asymmetric thrust 
and consequent loss of control of the airplane during reverse thrust 
operation. If a T/R inner wall overheats, separated components could 
cause structural damage to the airplane, damage to other airplanes, or 
possible injury to people on the ground.

DATES: We must receive comments on this proposed AD by March 7, 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: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue, SE., Washington, DC 20590, between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays.
    For service information identified in this proposed AD, contact 
Boeing Commercial Airplanes, Attention: Data & Services Management, 
P.O. Box 3707, MC 2H-65, Seattle, Washington 98124-2207; telephone 206-
544-5000, extension 1; fax 206-766-5680; e-mail me.boecom@boeing.com; 
Internet https://www.myboeingfleet.com. You may review copies of the 
referenced service information at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington. For information 
on the availability of this material at the FAA, call 425-227-1221.

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: Margaret Langsted, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification 
Office, 1601 Lind Avenue, SW., Renton, Washington 98057-3356; telephone 
(425) 917-6500; 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-2011-0027; 
Directorate Identifier 2010-NM-127-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 eleven events related to thermal damage 
of the thrust reverser (T/R) inner wall on Rolls Royce RB211 Trent 800 
engines. The events have included air turnbacks, in-flight shutdowns, 
T/R inner wall panel sections and parts being separated from the 
airplane, collapse of the T/R inner wall panel, and engine fire loop 
fault messages. No hull loss or personal injury has occurred from these 
events. Boeing issued Alert Service Bulletin 777-78A0059, dated 
February 24, 2005; and Alert Service Bulletin 777-78-0060, dated 
February 24, 2005; to provide instructions for inspecting the T/R inner 
wall panel structure and sealing the insulation blankets to prevent hot 
under-cowl air from contact with the T/R inner wall panel. Since those 
service bulletins were released, there have been seven events on thrust 
reversers, four T/Rs on which those service bulletins had not been 
fully accomplished, and three on which those service bulletins had been 
fully accomplished. A separated T/R piece could result in a rejected 
takeoff and cause asymmetric thrust and consequent loss of control of 
the airplane during reverse thrust operation. If a thrust reverser 
inner wall overheats, separated components could cause structural 
damage to the airplane, damage to other airplanes, or injury to people 
on the ground.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 777-78A0065, 
Revision 2, dated May 6, 2010. This service bulletin describes 
procedures for doing actions specified in Work Packages 1 through 6 (as 
necessary) of the

[[Page 3562]]

Accomplishment Instructions. This service bulletin states that 
operators may choose between doing Work Package 2 (doing a full non-
destructive test (NDT)), or Work Package 6 (doing a limited NDT with 
more restrictive repetitive intervals).

Work Package 1

    Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010, describes procedures for reviewing the airplane maintenance 
records to determine whether sealant was added; repetitive detailed 
inspections of all thrust reverser (T/R) inner wall insulation blanket 
edges, grommet holes, penetrations, and seams for sealant that is 
cracked, has gaps, is loose, or is missing; repetitive general visual 
inspections of click bond studs, blanket studs, and temporary 
fasteners; replacement of sealant if necessary; and related 
investigative and corrective actions if necessary. The related 
investigative actions include:
     Measuring the distance between the overlapped blanket face 
sheets adjacent to the damaged or missing sealant, or measuring the 
distance between the inner wall and the insulation blanket adjacent to 
the damaged or missing sealant
     Doing an NDT and general visual inspection for thermal 
degradation of the exposed T/R inner wall panel area within 12 inches 
of cracks, gaps, or loose or missing sealant
     Doing an NDT of an uncovered compression pad if it is 
within 12 inches of the crack, gap, loose, or missing sealant
     Doing a general visual inspection for areas of thermal 
degradation
     Doing an NDT of the T/R inner wall panel where the fitting 
was installed
     Doing a detailed inspection of the T/R panel wall inner 
bolt holes for elongation
     Doing a general visual inspection and NDT inspection for 
thermal degradation of the inner wall panel area where a damaged click 
bond stud, blanket stud, and temporary fastener is loose, damaged, or 
missing
     Doing an NDT (eddy current conductivity test) of the 
number 1 upper, or numbers 1 and 2 lower, compression pad fittings if 
they are exposed by blanket removal and within 12 inches of the loose, 
damaged, or missing click bond studs, blanket studs, or temporary 
fasteners
     Doing a Barcol hardness test of the area of thermal 
degradation
     Doing a general visual inspection of bushings for 
migration or looseness
    The corrective actions include:
     Replacing damaged or missing sealant
     Repairing or replacing T/R inner wall panel areas
     Contacting Boeing for repair instructions and doing the 
repair
     Installing compression pad fittings
     Installing replacement click bonds, blanket studs, or 
temporary fasteners
     Installing the removed replacement blankets and fittings
     Removing the bushing and repairing the inner wall panel 
bolt hole

Work Package 2

    Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010, describes procedures for either a repetitive full inner wall 
panel NDT of each T/R half and repetitive general visual inspections 
for areas of thermal degradation, or a partial inner wall panel NDT, 
and related investigative and corrective actions. The related 
investigative actions include an NDT of the area of different color, 
and a Barcol hardness inspection of the inner wall panel for areas of 
thermal degradation. The corrective actions are repairing or replacing 
unsatisfactory T/R inner wall panel areas, installing insulation 
blankets, and contacting Boeing for repair instructions and doing the 
repair. This service bulletin states that Work Package 6 may be done as 
an alternative to Work Package 2, provided that the shorter interval 
for the repetitive inspections specified in Work Package 6 are 
followed.

Work Package 3

    Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010, describes procedures for repetitive detailed inspections of the 
powered door opening system (PDOS) lug bushings on the upper number 1 
compression pad fittings for hole elongation, deformation, and contact 
with the PDOS actuator, and related investigative and corrective 
actions. Related investigative actions include a detailed inspection of 
the PDOS lug. Corrective actions include replacing unserviceable upper 
number 1 compression pad fittings and replacing unserviceable bushings 
with serviceable parts, and installing PDOS actuator rods and sealant.

Work Package 4

    Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010, describes procedures for repetitive NDTs of the number 1 upper 
and numbers 1 and 2 lower compression pad fittings, and related 
investigative and corrective actions. The related investigative actions 
include doing an NDT of the T/R inner wall panel, a general visual 
inspection for areas of thermal degradation, a detailed inspection of 
the T/R inner wall panel bolt holes for elongation, a Barcol hardness 
test of the area, and a general visual inspection of the bushing for 
migration or looseness. Corrective actions include repairing the T/R 
inner wall panel with a serviceable panel, installing removed 
installation blankets, installing serviceable compression pad fittings, 
contacting Boeing for repair instructions and doing the repair, 
replacing the T/R inner wall panel with a new or serviceable T/R inner 
wall panel, and removing bushings and repairing the inner wall panel 
bolt hole.

Work Package 5

    Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010, describes procedures for repetitive general visual inspections of 
the perforated side of the T/R wall aft of the intermediate pressure 
compressor 8th stage (IP8) duct and high pressure compressor 3rd stage 
(HP3) bleed port exits for a color that is different from that of the 
general area, and related investigative and corrective actions. The 
related investigative action is an NDT inspection of discolored areas 
for delamination and disbonding on the perforated side of the inner 
wall. The corrective actions are contacting Boeing for repair 
instructions and doing the repair.

Work Package 6

    Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 6, 
2010, describes procedures for a limited area NDT inspection of the 
inner wall panel of each T/R half for delaminating and disbonding, a 
general visual inspection for areas of thermal degradation, and related 
investigative and corrective actions. Related investigative actions 
include a Barcol hardness test of the area. Corrective actions include 
repairing or replacing the T/R inner wall panel with a new or 
serviceable one. Work Package 6 may be done as an option to Work 
Package 2 provided that the shorter repeat inspection intervals 
specified in Work Package 2 are followed.

Compliance Times

    The compliance times for Work Package 1 are as follows. The 
compliance time for the initial inspections and replacement of sealant 
(if necessary) is within 1,500 flight hours after the date on the 
original issue of the service bulletin. The interval for the repetitive 
inspections is 1,500 flight hours.

[[Page 3563]]

    The compliance times for doing the initial and repetitive NDT 
inspections on the T/R wall depend on which work packages are done--
either the full NDT option (Work Packages 2 and 5) or limited NDT 
option (Work Packages 5 and 6). For the initial full NDT and limited 
NDT options, the compliance time is between 600 and 2,000 flight 
cycles, depending on the number of total airplane flight cycles and 
whether a previous inspection has been conducted. The interval for the 
repetitive inspections for the full NDT is 2,000 flight cycles. The 
interval for the repetitive inspections for the limited NDT is 700 
flight cycles.
    The compliance times for Work Package 3 are as follows. The 
compliance time for the detailed inspection of the PDOS lug bushings on 
the upper number 1 compression pad fittings ranges from within 600 to 
1,700 flight cycles after the date on the original issue of the service 
bulletin. The interval for the repetitive inspections is 2,000 flight 
cycles.
    The compliance times for Work Package 4 are as follows. The 
compliance time for the initial NDT inspection of the number 1 upper, 
and number 1 and 2 lower, compression pad fittings are within 2,000 
flight cycles after the date on the original issue of this service 
bulletin. The interval for the repetitive inspections is 2,000 flight 
cycles.

FAA's Determination and Requirements of This Proposed AD

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

Differences Between the Proposed AD and Service Information

    Although Boeing Alert Service Bulletin 777-78A0065, Revision 2, 
dated May 6, 2010, specifies that operators may contact the 
manufacturer for disposition of certain repair conditions, this 
proposed AD would require operators to repair those conditions using a 
method approved by the FAA.

Interim Action

    We consider this proposed AD interim action. The manufacturer is 
currently developing a modification that will address the unsafe 
condition identified in this AD. Once this modification is developed, 
approved, and available, we might consider additional rulemaking.

Costs of Compliance

    We estimate that this proposed AD would affect 54 airplanes of U.S. 
registry. The following table provides the estimated costs for U.S. 
operators to comply with this proposed AD.

                                             Table--Estimated costs
----------------------------------------------------------------------------------------------------------------
                                                                                  Number of U.S.-
             Action                 Work hours     Average labor     Cost per       registered      Fleet cost
                                                   rate per hour      product        airplanes
----------------------------------------------------------------------------------------------------------------
Records check...................               1             $85             $85              54          $4,590
Inspections.....................              73              85           6,205              54         335,070
----------------------------------------------------------------------------------------------------------------

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), 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.
    You can find our regulatory evaluation and the estimated costs of 
compliance in the AD Docket.

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 AD:
The Boeing Company: Docket No. FAA-2011-0027; Directorate Identifier 
2010-NM-127-AD.

Comments Due Date

    (a) We must receive comments by March 7, 2011.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to The Boeing Company Model 777-200 and -300 
series airplanes, certificated in any category, equipped with Rolls-
Royce RB211 Trent 800

[[Page 3564]]

engines; as identified in Boeing Alert Service Bulletin 777-78A0065, 
Revision 2, dated May 6, 2010.

Subject

    (d) Air Transport Association (ATA) of America Code 78: Engine 
exhaust.

Unsafe Condition

    (e) This AD results from reports of thrust reverser events 
related to thermal damage of the thrust reverser (T/R) inner wall. 
The Federal Aviation Administration is issuing this AD to detect and 
correct a degraded T/R inner wall panel, which could lead to failure 
of a T/R and adjacent components and their consequent separation 
from the airplane, which could result in a rejected takeoff (RTO) 
and cause asymmetric thrust and consequent loss of control of the 
airplane during reverse thrust operation. If a T/R inner wall 
overheats, separated components could cause structural damage to the 
airplane, damage to other airplanes, or possible injury to people on 
the ground.

Compliance

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

Records Review, Inspections, and Related Investigative and Corrective 
Actions

    (g) Except as required by paragraphs (h), (i), (j), and (k) of 
this AD, at the applicable times in paragraph 1.E., ``Compliance,'' 
of Boeing Alert Service Bulletin 777-78A0065, Revision 2, dated May 
6, 2010 (``this service bulletin''), review the airplane maintenance 
records to determine whether sealant was added, do the actions 
specified in paragraphs (g)(1), (g)(2), (g)(3), (g)(4), and (g)(5) 
of this AD, and do all applicable related investigative and 
corrective actions, in accordance with the Accomplishment 
Instructions of this service bulletin, except as required by 
paragraph (l) of this AD. Do all applicable related investigative 
and corrective actions before further flight. Repeat the inspections 
required by paragraphs (g)(1), (g)(2), (g)(3), (g)(4), and (g)(5) of 
this AD thereafter at the applicable intervals specified in 
paragraph 1.E., ``Compliance,'' of the service bulletin.
    (1) Do a detailed inspection of all T/R inner wall insulation 
blanket edges, grommet holes, penetrations, and seams for sealant 
that is cracked, has gaps, is loose, or is missing; do a general 
visual inspection of click bond studs, blanket studs, and temporary 
fasteners; and replace sealant as applicable; in accordance with 
Work Package 1 of the Accomplishment Instructions of this service 
bulletin.
    (2) Do the actions required by paragraph (g)(2)(i) or (g)(2)(ii) 
of this AD.
    (i) Do a full inner wall panel non-destructive test (NDT) for 
delamination and disbonding of each T/R half, and do a general 
visual inspection for areas of thermal degradation, in accordance 
with Work Package 2 of the Accomplishment Instructions of this 
service bulletin.
    (ii) Do a limited area NDT of the inner wall panel of each T/R 
half for delamination and disbonding, and do a general visual 
inspection for areas of thermal degradation, in accordance with Work 
Package 6 of the Accomplishment Instructions of this service 
bulletin.
    (3) Do a general visual inspection of the T/R perforated wall 
aft of the intermediate pressure compressor 8th stage (IP8) and the 
high pressure compressor 3rd stage (HP3) bleed port exits for a 
color that is different from that of the general area, in accordance 
with Work Package 5 of the Accomplishment Instructions of this 
service bulletin.
    (4) Do a detailed inspection of the powered door opening system 
(PDOS) lug bushings on the upper number 1 compression pad fittings 
for hole elongation, deformation, and contact with the PDOS 
actuator, in accordance with Work Package 3 of the Accomplishment 
Instructions of this service bulletin.
    (5) Do an NDT of the number 1 upper and numbers 1 and 2 lower 
compression pad fittings, in accordance with Work Package 4 of the 
Accomplishment Instructions of this service bulletin.

Exceptions to the Service Bulletin

    (h) Where Boeing Alert Service Bulletin 777-78A0065, Revision 2, 
dated May 6, 2010, specifies a compliance time after the date on the 
original issue of that service bulletin, this AD requires compliance 
within the specified compliance time after the effective date of 
this AD.
    (i) Where paragraph 1.E., ``Compliance,'' in Boeing Alert 
Service Bulletin 777-78A0065, Revision 2, dated May 6, 2010, 
specifies a compliance time of ``2,000 flight cycles after the date 
of the operator's own inspections,'' for doing Work Packages 2 and 
5, or Work Packages 2 and 6, this AD requires compliance within 
2,000 flight cycles after the date of the operator's own inspections 
or within 12 months after the effective date of this AD, whichever 
occurs later.
    (j) Where the Condition columns in Table 2 of paragraph 1.E., 
``Compliance,'' of Boeing Alert Service Bulletin 777-78A0065, 
Revision 2, dated May 6, 2010, refer to ``All airplanes, each T/R 
half'' that has or has not ``been inspected before the date on this 
service bulletin,'' this AD applies to all airplanes, each T/R half 
that has or has not been inspected before the effective date of this 
AD.
    (k) Where the Condition columns in the Tables of paragraph 1.E., 
``Compliance,'' of Boeing Alert Service Bulletin 777-78A0065, 
Revision 2, dated May 6, 2010, refer to total flight cycles, this AD 
applies to the airplanes with the specified total flight cycles as 
of the effective date of this AD.
    (l) Where Boeing Alert Service Bulletin 777-78A0065, Revision 2, 
dated May 6, 2010, specifies to contact Boeing for appropriate 
action: Before further flight, repair in accordance with a method 
approved by the Manager, Seattle Aircraft Certification Office 
(ACO), FAA. 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.

Credit for Actions Accomplished in Accordance With Previous Service 
Information

    (m) Actions done before the effective date of this AD in 
accordance with Boeing Alert Service Bulletin 777-78A0065, dated 
June 23, 2008; or Revision 1, dated January 29, 2009; are acceptable 
for compliance with the corresponding requirements of this AD.

Alternative Methods of Compliance (AMOCs)

    (n)(1) The Manager, Seattle ACO, FAA, has the authority to 
approve AMOCs for this AD, if requested using the procedures found 
in 14 CFR 39.19. Send information to Attn: Margaret Langsted, 
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle 
Aircraft Certification Office, 1601 Lind Avenue, SW., Renton, 
Washington 98057-3356; telephone (425) 917-6500; fax (425) 917-6590. 
Or, e-mail information 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.

    Issued in Renton, Washington, on January 12, 2011.
Jeffrey E. Duven,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2011-1121 Filed 1-19-11; 8:45 am]
BILLING CODE 4910-13-P