Document ID: FAA-2011-1326-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: The Boeing Company Airplanes
Posted Date: 2011-12-29T05:00Z

[Federal Register Volume 76, Number 250 (Thursday, December 29, 2011)]
[Proposed Rules]
[Pages 81890-81894]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2011-33355]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2011-1326; Directorate Identifier 2010-NM-177-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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[[Page 81891]]

SUMMARY: We propose to supersede an existing airworthiness directive 
(AD) that applies to The Boeing Company Model 757-200, -200CB, and -300 
series airplanes. The existing AD currently requires initial and 
repetitive inspections of the fuselage skin and bear strap at the 
forward, upper corner of the L1 entry door cutout for cracking, and 
repair if necessary. That action also provides an optional terminating 
action for the repetitive inspections. Since we issued that AD, we have 
received reports of additional cracking in the fuselage skin. This 
proposed AD would add inspections for airplanes having repairs or 
preventative modifications installed and supplemental inspections for 
certain airplanes. This proposed AD also would add airplanes to the 
applicability. We are proposing this AD to detect and correct cracking 
of the fuselage skin and bear strap at the forward, upper corner of the 
L1 entry door cutout, which could result in reduced structural 
integrity of the L1 entry door and consequent rapid decompression of 
the airplane.

DATES: We must receive comments on this proposed AD by February 13, 
2012.

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 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; email 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: Nancy Marsh, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue SW., Renton, Washington 98057-3356; phone: (425) 917-
6440; fax: (425) 917-6590; email: nancy.marsh@faa.gov.

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-2011-1326; 
Directorate Identifier 2010-NM-177-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

    On April 28, 2004, we issued AD 2004-09-32, Amendment 39-13622 (69 
FR 25481, May 7, 2004), for certain Model 757-200 series airplanes. 
That AD requires initial and repetitive inspections of the fuselage 
skin and bear strap at the forward, upper corner of the L1 entry door 
cutout for cracking, and repair if necessary. That AD also provides an 
optional terminating action for the repetitive inspections. That AD 
resulted from reports of cracking in the fuselage skin and bear strap 
at the forward, upper corner of the L1 entry door cutout. We issued 
that AD to detect and correct cracking of the fuselage skin and bear 
strap at the forward, upper corner of the L1 entry door cutout, which 
could result in reduced structural integrity of the L1 entry door and 
consequent rapid decompression of the airplane.

Actions Since Existing AD Was Issued

    Since we issued AD 2004-09-32, Amendment 39-13622 (69 FR 25481, May 
7, 2004), we have received reports of additional cracking in the 
fuselage skin. We also have determined that all Model 757-200, -200CB, 
and -300 series airplanes may be subject to the unsafe condition, and 
that the existing actions may not adequately address the unsafe 
condition.

Relevant Service Information

    We reviewed Boeing Special Attention Service Bulletin 757-53-0094, 
Revision 1, dated August 12, 2009. The service information describes 
procedures for the following repetitive inspections, depending on 
configuration:
     High frequency eddy current (HFEC) and low frequency eddy 
current (LFEC) inspections for cracking of the skin and bear strap at 
the forward upper corner of the L1 entry door cutout.
     Supplemental HFEC and LFEC inspections for cracking of the 
bear strap and inner chord strap on airplanes having a repair doubler, 
tripler, and quadrupler installed.
     Supplemental HFEC, LFEC, and detailed inspections for 
cracking of the skin, bear strap, doubler, tripler, and quadrupler on 
airplanes having a repair doubler, tripler, and quadrupler installed.
     Supplemental HFEC, LFEC, and detailed inspections for 
cracking of the skin, bear strap, inner chord strap, doubler, and 
tripler on airplanes having a repair doubler and tripler installed.
     Supplemental HFEC, LFEC, and detailed inspections for 
cracking of the skin, bear strap, and doubler on airplanes having a 
preventive modification doubler installed.
     Supplemental HFEC and LFEC inspections for cracking of the 
bear strap and inner chord strap on airplanes having a doubler 
installed.
    That service bulletin also provides procedures for corrective 
actions, which include repairing certain cracks, and contacting Boeing 
for certain other repair instructions.
    The compliance times for the initial inspections are either before 
22,000 total flight cycles or within 500 flight cycles after the issue 
date on Boeing Special Attention Service Bulletin 757-53-0094, dated 
January 16, 2008, whichever occurs later; or within 12,000 flight 
cycles after the modification, or within 500 flight cycles after the 
issue date on Boeing Special Attention Service Bulletin 757-53-0094, 
Revision 1, dated August 12, 2009, whichever occurs later; depending on 
configuration. The

[[Page 81892]]

repetitive inspection interval for these inspections is 1,400 flight 
cycles.
    The compliance times for the initial supplemental inspections are 
37,500 total flight cycles (for inspection of the skin, bear strap, 
doubler, and tripler), or 50,000 total flight cycles (for inspection of 
the bear strap and inner chord strap). The repetitive inspection 
interval for these inspections is either 4,000 flight cycles or 12,000 
flight cycles, depending on configuration.

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 retain all requirements of AD 2004-09-32, 
Amendment 39-13622 (69 FR 25481, May 7, 2004). This proposed AD would 
add inspections for airplanes having repairs or preventative 
modifications installed, and supplemental inspections for certain 
airplanes; and repair, if necessary. This proposed AD also would add 
airplanes to the applicability of the existing AD.

Exceptions to Certain Compliance Times

    The service bulletin specifies to do certain HFEC, LFEC, and 
detailed inspections before the accumulation of 37,500 total flight 
cycles. However, in order to address airplanes that might have already 
exceeded that threshold, this proposed AD would require the inspections 
to be accomplished at the latest of the times below:
     Before the accumulation of 37,500 total flight cycles.
     Within 4,000 flight cycles since installation of the 
modification.
     Within 24 months after the effective date of this AD.

Changes to Existing AD

    This proposed AD would retain all requirements of AD 2004-09-32, 
Amendment 39-13622 (69 FR 25481, May 7, 2004). Since AD 2004-09-32 was 
issued, the AD format has been revised, and certain paragraphs have 
been rearranged. As a result, the corresponding paragraph identifiers 
have changed in this proposed AD, as listed in the following table:

                      Revised Paragraph Identifiers
------------------------------------------------------------------------
                                      Corresponding requirement in this
    Requirement in AD 2004-09-32                 proposed AD
------------------------------------------------------------------------
             paragraph (a)                        paragraph (g)
             paragraph (b)                        paragraph (h)
             paragraph (c)                        paragraph (i)
             paragraph (d)                        paragraph (j)
------------------------------------------------------------------------

    Boeing Commercial Airplanes has received an Organization 
Designation Authorization (ODA). We have revised paragraph (i) of this 
proposed AD to delegate the authority to approve an alternative method 
of compliance for any repair required by this proposed AD to the Boeing 
Commercial Airplanes ODA rather than a Designated Engineering 
Representative (DER).

Costs of Compliance

    We estimate that this proposed AD affects 591 airplanes of U.S. 
registry.
    We estimate the following costs to comply with this proposed AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                 Number of U.S.-
            Action               Work-hours     Average labor      Cost per        registered       Fleet cost
                                                rate per hour      airplane         airplanes
----------------------------------------------------------------------------------------------------------------
Inspections (retained actions               2             $85  $170 per                      57  $9,690 per
 from existing AD).                                             inspection                        inspection
                                                                cycle.                            cycle.
Inspection (new proposed                    3              85  $255 per                     591  $150,705 per
 action).                                                       inspection                        inspection
                                                                cycle.                            cycle.
Supplemental inspection......              15              85  $1,275 per                   591  $753,525 per
                                                                inspection                        inspection
                                                                cycle.                            cycle.
----------------------------------------------------------------------------------------------------------------

    We estimate the following costs to do any necessary repairs that 
would be required based on the results of the proposed inspections. We 
have no way of determining the number of aircraft that might need these 
repairs:

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                Action                        Labor cost               Parts cost            Cost per product
----------------------------------------------------------------------------------------------------------------
Repair...............................  Up to 26 work-hours x    Up to $2,661...........  Up to $4,871 depending
                                        $85 = Up to $2,210                                on configuration.
Preventive modification..............  18 work-hours x $85 =    $1,338.................  $2,868.
                                        $1,530
----------------------------------------------------------------------------------------------------------------

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.

[[Page 81893]]

    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),
    (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 removing airworthiness directive 
(AD) 2004-09-32, Amendment 39-13622 (69 FR 25481, May 7, 2004), and 
adding the following new AD:

The Boeing Company: Docket No. FAA-2011-1326; Directorate Identifier 
2010-NM-177-AD.

(a) Comments Due Date

    The FAA must receive comments on this AD action by February 13, 
2012.

(b) Affected ADs

    This AD supersedes AD 2004-09-32, Amendment 39-13622 (69 FR 
25481, May 7, 2004).

(c) Applicability

    This AD applies to all The Boeing Company Model 757-200, -200CB, 
and -300 series airplanes; certificated in any category.

(d) Subject

    Joint Aircraft System Component (JASC)/Air Transport Association 
(ATA) of America Code 53: Fuselage.

(e) Unsafe Condition

    This AD was prompted by reports of cracks in the fuselage skin 
and bear strap at the forward upper corner of the L1 entry door 
cutout. We are issuing this AD to detect and correct cracking of the 
fuselage skin and bear strap at the forward, upper corner of the L1 
entry door cutout, which could result in reduced structural 
integrity of the L1 entry door and consequent rapid decompression of 
the airplane.

(f) Compliance

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

RESTATEMENT OF REQUIREMENTS OF AD 2004-09-32, AMENDMENT 39-13622 (69 FR 
25481, MAY 7, 2004), WITH NEW TERMINATING ACTION

(g) Initial Inspections

    For airplanes having line numbers 1 through 90 inclusive: Within 
500 flight cycles after May 24, 2004 (the effective date of AD 2004-
09-32 Amendment 39-13622 (69 FR 25481, May 7, 2004)), or within 90 
days after May 24, 2004, whichever occurs later, do the inspections 
of the forward, upper corner of the L1 entry door cutout specified 
in paragraphs (g)(1), (g)(2), and (g)(3) of this AD, per Part 1 of 
the Work Instructions of Boeing Special Attention Service Bulletin 
757-53-0089, dated March 18, 2004, until the initial inspection 
required by paragraph (k) of this AD has been done. Doing the repair 
specified in paragraph (i) or (l) of this AD, or doing the 
preventive modification specified in paragraph (j) of this AD, 
terminates the inspection required by this paragraph.
    (1) Do a high frequency eddy current (HFEC) inspection for 
cracking of the fuselage skin around the adjacent fasteners.
    (2) Do an HFEC inspection for cracking along the edge of the 
skin and bear strap.
    (3) Do a low frequency eddy current (LFEC) inspection of the 
bear strap.

(h) No Crack Detected: Repetitive Inspections and New Terminating 
Modification

    If no crack is detected during any inspection required by 
paragraph (g) of this AD: Repeat the inspections required by 
paragraph (g) of this AD at intervals not to exceed 1,400 flight 
cycles, until the requirements of paragraph (k) are done. Doing the 
repair specified in paragraph (l) of this AD, or doing the 
preventive modification specified in paragraph (j) of this AD, as 
applicable, terminates the repetitive inspections required by this 
paragraph.

(i) Any Crack Detected: Repair, With New Repair Option

    If any crack is detected during any inspection required by 
paragraph (g) or (h) of this AD, and Boeing Special Attention 
Service Bulletin 757-53-0089, dated March 18, 2004, 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; or in accordance with data 
meeting the type certification basis of the airplane approved by a 
Boeing Company Organization Designation Authorization who has been 
authorized by the Manager, Seattle ACO, to make such findings, or 
using a method approved in accordance with the procedures specified 
in paragraph (q) of this AD. For a repair method to be approved, the 
approval must specifically reference this AD. Doing the repair 
terminates the inspections required by paragraphs (g) and (h) of 
this AD.

(j) Optional Preventive Modification

    As an alternative to accomplishing the inspections required by 
paragraphs (g) and (h) of this AD, do the optional preventative 
modification of the forward, upper corner of the L1 entry door 
cutout, and do all applicable related investigative/corrective 
actions, by accomplishing all the actions specified in Part 2 of the 
Work Instructions of Boeing Special Attention Service Bulletin 757-
53-0089, dated March 18, 2004. Accomplishment of the modification 
constitutes terminating action for the inspections required by 
paragraphs (g) and (h) of this AD.

New Requirements of This AD

(k) Inspections

    For airplanes in Group 1, Configurations 1-2, and Group 2, 
Configuration 1, as identified in Boeing Special Attention Service 
Bulletin 757-53-0094, Revision 1, dated August 12, 2009: At the 
applicable times specified in paragraph 1.E, ``Compliance,'' of 
Boeing Special Attention Service Bulletin 757-53-0094, Revision 1, 
dated August 12, 2009, do HFEC and LFEC inspections for cracking of 
the skin and bear strap at the forward upper corner of the L1 entry 
door cutout, in accordance with the Accomplishment Instructions of 
Boeing Special Attention Service Bulletin 757-53-0094, Revision 1, 
dated August 12, 2009. Repeat the inspections thereafter at 
intervals not to exceed 1,400 flight cycles. Doing the initial 
inspection required by this paragraph terminates the inspections 
required by paragraphs (g) and (h) of this AD. Doing the repair 
specified in paragraph (l) of this AD, or doing the optional 
preventive modification specified in paragraph (m) of this AD, 
terminates the inspections required by this paragraph.

(l) Repair

    If any cracking is found during any inspection required by 
paragraph (k) of this AD, before further flight, repair, in 
accordance with the Accomplishment Instructions of Boeing Special 
Attention Service Bulletin 757-53-0094, Revision 1, dated August 12, 
2009; except as required by paragraph (p)(3) of this AD. Doing the 
repair terminates the repetitive inspections required by paragraph 
(k) of this AD.

(m) Optional Preventive Modification

    Accomplishment of the optional preventive modification, in 
accordance with the Accomplishment Instructions of Boeing Special 
Attention Service Bulletin 757-53-0094, Revision 1, dated August 12, 
2009, terminates the repetitive inspections required by paragraph 
(k) of this AD.

(n) Supplemental Inspections and Repair

    For airplanes in Group 1, Configurations 3-5, and Group 2, 
Configurations 2-4 as identified in Boeing Special Attention Service 
Bulletin 757-53-0094, Revision 1, dated August 12, 2009; on which a 
repair doubler, tripler, or quadrupler is installed, or on which a 
preventive modification doubler

[[Page 81894]]

is installed: At the applicable times in paragraph 1.E, 
``Compliance,'' of Boeing Special Attention Service Bulletin 757-53-
0094, Revision 1, dated August 12, 2009, except as required by 
paragraph (p)(2) of this AD, do LFEC, HFEC, and detailed 
inspections, as applicable, for cracking of the doubler, tripler, 
quadrupler, skin, bear strap, and inner chord strap, as applicable, 
in accordance with the Accomplishment Instructions of Boeing Special 
Attention Service Bulletin 757-53-0094, Revision 1, dated August 12, 
2009. Repeat the inspections thereafter at the applicable times 
specified in paragraph 1.E., ``Compliance,'' of Boeing Special 
Attention Service Bulletin 757-53-0094, Revision 1, dated August 12, 
2009.

(o) Supplemental Repair

    If any cracking is found during any inspection required by 
paragraph (n) of this AD, before further flight, repair the crack in 
accordance with the procedures specified in paragraph (q) of this 
AD.

(p) Exceptions to Service Bulletin Specifications

    The following exceptions apply to this AD.
    (1) Where Boeing Special Attention Service Bulletin 757-53-0094, 
Revision 1, dated August 12, 2009, specifies a compliance time after 
the ``original issue date'' or ``Revision 1 date of the service 
bulletin,'' this AD requires compliance after the effective date of 
this AD.
    (2) Where Boeing Special Attention Service Bulletin 757-53-0094, 
Revision 1, dated August 12, 2009, specifies doing the HFEC, LFEC, 
and detailed inspections required by paragraph (n) of this AD before 
the accumulation of 37,500 total flight cycles, this AD requires the 
inspections to be accomplished at the latest of the times specified 
in paragraphs (p)(2)(i) and (p)(2)(ii) of this AD.
    (i) Before the accumulation of 37,500 total flight cycles.
    (ii) Within 24 months after the effective date of this AD.
    (3) Where Boeing Special Attention Service Bulletin 757-53-0094, 
Revision 1, dated August 12, 2009, specifies contacting Boeing for 
repair instructions, this AD requires repairing in accordance with 
the procedures specified in paragraph (q) of this AD.

(q) Alternative Methods of Compliance (AMOCs)

    (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. 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 ACO, send it to 
ATTN: Nancy Marsh, Aerospace Engineer, Airframe Branch, ANM-120S, 
FAA, 1601 Lind Avenue SW., Renton, Washington 98057-3356; phone: 
(425) 917-6440; fax: (425) 917-6432; email: nancy.marsh@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.
    (4) AMOCs approved for AD 2004-09-32, Amendment 39-13622 (69 FR 
25481, May 7, 2004), are approved as AMOCs for the corresponding 
actions in paragraphs (g), (h), and (i) of this AD.

(r) Related Information

    (1) For more information about this AD, contact Nancy Marsh, 
Aerospace Engineer, Airframe Branch, ANM-120S, FAA, 1601 Lind Avenue 
SW., Renton, Washington 98057-3356; phone: (425) 917-6440; fax: 
(425) 917-6432; email: nancy.marsh@faa.gov.
    (2) 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; email 
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.

    Issued in Renton, Washington, on December 16, 2011.
Michael Kaszycki,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2011-33355 Filed 12-28-11; 8:45 am]
BILLING CODE 4910-13-P