Document ID: FAA-2013-0867-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: The Boeing Company Airplanes
Posted Date: 2013-10-25T04:00Z

[Federal Register Volume 78, Number 207 (Friday, October 25, 2013)]
[Proposed Rules]
[Pages 63903-63907]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2013-25134]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2013-0867; Directorate Identifier 2013-NM-115-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 777-200, -200LR, -300, and -300ER 
series airplanes. This proposed AD was prompted by reports of severe 
corrosion on bonding jumpers installed on the flight control surfaces. 
This proposed AD would require repetitive bonding jumper inspections 
for corrosion, sealant disbond, and insufficient sealant coverage, and 
corrective actions if necessary. This proposed AD also specifies an 
optional action of doing an inspection for corrosion damage of the 
bonding brackets, and corrective actions if necessary, which would 
terminate the repetitive inspections. For certain airplanes, this 
proposed AD would also require installing certain bonding jumpers and 
related ground clips and fasteners to the elevators, horizontal 
stabilizers, rudder, and vertical fin, removing certain bonding jumpers 
and installing new bonding jumpers, and replacing single-tabbed 
brackets with two-tabbed brackets. We are proposing this AD to detect 
and correct corrosion

[[Page 63904]]

on bonding jumpers installed on the flight control surfaces, which, in 
the event of a lighting strike, could damage the actuator control 
electronics (ACEs) and result in the loss of the ability to command 
individual flight control surfaces or cause uncommanded motion of 
individual flight control surfaces.

DATES: We must receive comments on this proposed AD by December 9, 
2013.

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 service information identified in this proposed AD, contact 
Boeing Commercial Airplanes, Attention: Data & Services Management, 
P.O. Box 3707, MC 2H-65, Seattle, WA 98124-2207; telephone 206-544-
5000, extension 1; fax 206-766-5680; 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: Georgios Roussos, Aerospace Engineer, 
Systems and Equipment Branch, ANM-130S, Seattle Aircraft Certification 
Office, FAA, 1601 Lind Avenue SW., Renton, Washington 98057-3356; 
phone: 425-917-6482; fax: 425-917-6590; email: 
Georgios.Roussos@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-2013-0867; 
Directorate Identifier 2013-NM-115-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 a report of severe corrosion on 15 bonding jumpers 
on the ailerons, horizontal stabilizers, and vertical fins of six 
airplanes that were approximately eight years old. We also received a 
similar report on an airplane that was approximately seven years old. 
The corrosion is caused by sealant voids, which allow moisture under 
the sealant and then trap it inside.
    The bonding jumpers are part of the lightning protection ground 
path for the flight control surfaces that prevent excessive lightning 
energy from traveling to the primary flight control actuators and then 
to one of the four ACEs. Corrosion damage on the bonding jumper 
connections creates high resistance bonding paths that could, in the 
event of a lightning strike, potentially expose multiple flight control 
system ACEs to high voltage transients. The excessive voltage could 
cause damage to the ACEs and result in the loss of the ability to 
command individual flight control surfaces or cause uncommanded motion 
of individual flight control surfaces.
    A new category 2 fay seal method has been developed to improve the 
integrity of the bonding jumper connections. This new method creates a 
continuous layer of sealant inside and outside of all mating surfaces 
to keep moisture away from the bonding surfaces and prevent corrosion.

Relevant Service Information

    We reviewed the following service bulletins:

 Boeing Service Bulletin 777-27A0078, Revision 1, dated April 
1, 2013
 Boeing Service Bulletin 777-55A0010, Revision 1, dated April 
17, 2001
 Boeing Service Bulletin 777-55A0014, Revision 1, dated April 
1, 2010

For information on the procedures and compliance times, see this 
service information at http://www.regulations.gov by searching for 
Docket No. FAA-2013-0867.

Other Relevant Rulemaking

    This proposed AD is related to AD 2012-08-13, Amendment 39-17030 
(77 FR 24357, April 24, 2012). AD 2012-08-13 requires replacing certain 
single-tabbed bonding brackets in the airplane empennage with two-
tabbed bonding brackets. AD 2012-08-13 also requires, for certain 
airplanes, installing new bonding jumpers, and measuring the resistance 
of the modified installation to verify resistance is within specified 
limits. AD 2012-08-13 refers to Boeing Service Bulletin 777-55A0010, 
Revision 1, dated April 17, 2001; and Boeing Service Bulletin 777-
55A0014, Revision 1, dated April 1, 2010; as the appropriate sources of 
service information for accomplishing the required actions.
    This proposed AD would require inspecting the installation of the 
bonding jumpers associated with AD 2012-08-13, Amendment 39-17030 (77 
FR 24357, April 24, 2012).

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 identified previously, except as discussed 
under ``Differences Between the Proposed Rule and the Service 
Information.''
    The phrase ``corrective actions'' might be used in this proposed 
AD. ``Corrective actions'' are actions that correct or address any 
condition found. Corrective actions in an AD could include, for 
example, repairs.

Difference Between the Proposed Rule and the Service Bulletin

    Boeing Service Bulletin 777-27A0078, Revision 1, dated April 1, 
2013, specifies to contact the manufacturer for instructions on how to 
repair certain conditions, but this proposed AD would require repairing

[[Page 63905]]

those conditions in one of the following ways:
     In accordance with a method that we approve; or
     Using data that meet the certification basis of the 
airplane, and that have been approved by the Boeing Commercial 
Airplanes Organization Designation Authorization (ODA) whom we have 
authorized to make those findings.

Costs of Compliance

    We estimate that this proposed AD affects 131 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
----------------------------------------------------------------------------------------------------------------
Inspection of bonding jumpers..  Up to 67 work-hours x                $0  Up to $5,695 per    Up to $746,045 per
                                  $85 per hour = Up to                     inspection cycle.   inspection cycle.
                                  $5,695 per inspection
                                  cycle.
Replacement of bonding brackets  Up to 158 work-hours x           37,928  Up to $51,358.....  Up to $6,727,898.
                                  $85 per hour = Up to
                                  $13,430.
Concurrent cost Boeing Service   66 work-hours x $85 per           2,668  $8,278............  $1,084,418.
 Bulletin 777-55A0010, Revision   hour = $5,610.
 1, dated April 17, 2001.
Concurrent cost Boeing Service   21 work-hours x $85 per           1,235  $3,020............  $395,620.
 Bulletin 777-55A0014, Revision   hour = $1,785.
 1, dated April 1, 2010.
----------------------------------------------------------------------------------------------------------------

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

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                Action                          Labor cost           Parts cost           Cost per product
----------------------------------------------------------------------------------------------------------------
Replacement of bonding brackets.......  Up to 158 work-hours x            $37,928  Up to $51,358.
                                         $85 per hour = Up to
                                         $13,430.
----------------------------------------------------------------------------------------------------------------

    We have received no definitive data that would enable us to provide 
cost estimates for certain on-condition repairs specified in this 
proposed AD.

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

0
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]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive (AD):

The Boeing Company: Docket No. FAA-2013-0867; Directorate Identifier 
2013-NM-115-AD.

(a) Comments Due Date

    We must receive comments by December 9, 2013.

(b) Affected ADs

    This AD affects AD 2012-08-13, Amendment 39-17030 (77 FR 24357, 
April 24, 2012).

(c) Applicability

    This AD applies to the Boeing Company Model 777-200, -200LR, -
300, and -300ER series airplanes, certificated in any category, as 
identified in Boeing Service Bulletin 777-27A0078, Revision 1, dated 
April 1, 2013.

 (d) Subject

    Joint Aircraft System Component (JASC)/Air Transport Association 
(ATA) of America Code 27, Flight Controls.

(e) Unsafe Condition

    This AD was prompted by reports of severe corrosion on bonding 
jumpers installed on the flight control surfaces. We are issuing 
this AD to detect and correct corrosion on bonding jumpers installed 
on the flight control surfaces, which, in the event of a lighting 
strike, could damage the actuator control electronics (ACEs) and 
result in the

[[Page 63906]]

loss of the ability to command individual flight control surfaces or 
cause uncommanded motion of individual flight control surfaces.

(f) Compliance

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

(g) Bonding Jumper or Bracket Inspection

    At the applicable compliance time specified in paragraph 1.E., 
``Compliance,'' of Boeing Service Bulletin 777-27A0078, Revision 1, 
dated April 1, 2013, except as specified in paragraphs (j)(1) and 
(j)(2) of this AD: Do a general visual inspection or a detailed 
inspection using a borescope, as applicable, for corrosion, sealant 
disbond, and insufficient sealant coverage of bonding jumpers; and 
do all applicable corrective actions; in accordance with Option 1, 
and Option 2, as applicable, of the Accomplishment Instructions of 
Boeing Service Bulletin 777-27A0078, Revision 1, dated April 1, 
2013, except as required by paragraph (j)(3) of this AD. Do a 
detailed inspection using a borescope if the horizontal stabilizer 
tips have not been removed. Do all applicable corrective actions 
before further flight. Repeat the inspection thereafter at intervals 
not to exceed 48 months. Doing the actions specified in paragraph 
(h)(1) of this AD on a bonding jumper terminates the repetitive 
inspections required by this paragraph. Doing the actions specified 
in paragraph (h)(2) of this AD terminates repetitive inspections 
required by this paragraph for that bonding jumper.

(h) Optional Terminating Action and Termination of Certain Repetitive 
Inspections

    (1) Doing a general visual inspection or a detailed inspection 
for corrosion damage of the bonding jumper brackets, and all 
applicable corrective actions; in accordance with Option 2 of the 
Accomplishment Instructions of Boeing Service Bulletin 777-27A0078, 
Revision 1, dated April 1, 2013; terminates the repetitive 
inspections required by paragraph (g) of this AD. Do all applicable 
corrective actions before further flight.
    (2) The repetitive inspections required by paragraph (g) of this 
AD are not required on the bonding jumpers that were removed, 
inspected, and replaced with new bonding jumpers and new fasteners 
using the new category 2 fay sealed direct standard ground stud 
installation method, in accordance with the Accomplishment 
Instructions of Boeing Service Bulletin 777-27A0078, Revision 1, 
dated April 1, 2013.

(i) Prior and Concurrent Requirements

    (1) For Group 1 airplanes, as identified in Boeing Service 
Bulletin 777-27A0078, Revision 1, dated April 1, 2013: Prior to or 
concurrently with accomplishing the actions required by paragraph 
(g) of this AD, install new bonding jumpers, and do resistance 
measurements of the modified installation to verify resistance is 
within the limits specified in the Accomplishment Instructions of 
Boeing Service Bulletin 777-55A0010, Revision 1, dated April 17, 
2001. Do the actions in accordance with the Accomplishment 
Instructions of Boeing Service Bulletin 777-55A0010, Revision 1, 
dated April 17, 2001.

    Note 1 to paragraph (i)(1) of this AD:  AD 2012-08-13, Amendment 
39-17030 (77 FR 24357, April 24, 2012), refers to Boeing Service 
Bulletin 777-55A0010, Revision 1, dated April 17, 2001, as the 
appropriate source of service information for accomplishing the 
actions specified in paragraph (h) of AD 2012-08-13.

    (2) For Group 1 and Group 2 airplanes, as identified in Boeing 
Service Bulletin 777-27A0078, Revision 1, dated April 1, 2013: Prior 
to or concurrently with accomplishing the actions required by 
paragraph (g) of this AD, replace certain single-tabbed bonding 
brackets in the airplane empennage with two-tabbed bonding brackets, 
in accordance with the Accomplishment Instructions of Boeing Service 
Bulletin 777-55A0014, Revision 1, dated April 1, 2010.

    Note 2 to paragraph (i)(2) of this AD: AD 2012-08-13, Amendment 
39-17030 (77 FR 24357, April 24, 2012), refers to Boeing Service 
Bulletin 777-55A0014, Revision 1, dated April 1, 2010, as the 
appropriate source of service information for accomplishing the 
actions specified in paragraph (g) of AD 2012-08-13.

(j) Exceptions to Service Information

    (1) Where Boeing Service Bulletin 777-27A0078, Revision 1, dated 
April 1, 2013, specifies a compliance time after the ``Original 
issue date of this service bulletin,'' this AD requires compliance 
within the specified compliance time after the effective date of 
this AD.
    (2) The ``Condition'' column in paragraph 1.E., ``Compliance,'' 
of Boeing Service Bulletin 777-27A0078, Revision 1, dated April 1, 
2013, refers to a condition as of the ``Original Issue date of this 
service bulletin.'' This AD applies to the corresponding condition 
as of the effective date of this AD.
    (3) If any corrosion damage is found during any inspection 
required by this AD, and Boeing Service Bulletin 777-27A0078, 
Revision 1, dated April 1, 2013, specifies to contact Boeing for 
appropriate action: Before further flight, repair the corrosion 
damage using a method approved in accordance with the procedures 
specified in paragraph (l) of this AD.

(k) Credit for Previous Actions

    (1) For Groups 1, 2, and 6 through 9, as identified in Boeing 
Alert Service Bulletin 777-27A0078, dated September 10, 2009: This 
paragraph provides credit for actions required by paragraph (g) of 
this AD and the actions specified in paragraph (h) of this AD, if 
those actions were performed before the effective date of this AD 
using Boeing Alert Service Bulletin 777-27A0078, dated September 10, 
2009, which is not incorporated by reference in this AD.
    (2) For Groups 3 through 5, as identified in Boeing Alert 
Service Bulletin 777-27A0078, dated September 10, 2009: This 
paragraph provides credit for actions required by paragraph (g) of 
this AD, except for the actions required for bonding jumpers 21 and 
22, if those actions were performed before the effective date of 
this AD using Boeing Alert Service Bulletin 777-27A0078, dated 
September 10, 2009, which is not incorporated by reference in this 
AD. If a check of the airplane's maintenance records positively 
determines that bonding jumpers 21 and 22 were inspected before the 
effective date of this AD in accordance with Option 1 of Work 
Package 3 of the Accomplishment Instructions of Boeing Alert Service 
Bulletin 777-27A0078, dated September 10, 2009, this paragraph 
provides credit for the actions required by paragraph (g) of this AD 
for the inspected bonding jumpers.
    (3) For Groups 3 through 5, as identified in Boeing Alert 
Service Bulletin 777-27A0078, dated September 10, 2009: This 
paragraph provides credit for actions specified in paragraph (h) of 
this AD, if those actions were performed before the effective date 
of this AD using Boeing Alert Service Bulletin 777-27A0078, dated 
September 10, 2009, which is not incorporated by reference in this 
AD; provided that a check of the airplane's maintenance records 
positively determines that bonding jumpers 21 and 22 were replaced 
in accordance with Option 2 of Work Package 3 of the Accomplishment 
Instructions of Boeing Alert Service Bulletin 777-27A0078, dated 
September 10, 2009, or were replaced using the new Category 2 fay 
sealed direct ground stud installation method.
    (4) This paragraph provides credit for actions required by 
paragraph (i)(1) of this AD if those actions were performed before 
the effective date of this AD using Boeing Alert Service Bulletin 
777-55A0010, dated October 26, 2000, which is not incorporated by 
reference in this AD.
    (5) This paragraph provides credit for actions required by 
paragraph (i)(2) of this AD if those actions were performed before 
the effective date of this AD using Boeing Alert Service Bulletin 
777-55A0014, dated May 8, 2008, which is not incorporated by 
reference in this AD.

(l) 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 paragraph (m) of this AD. 
Information may be emailed to: 9-ANM-Seattle-ACO-AMOC-Requests@faa.gov.
    (2) Before using any approved AMOC, notify your Principal 
Maintenance Inspector or Principal Avionics Inspector, as 
appropriate, or lacking a principal inspector, your local Flight 
Standards 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 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.

[[Page 63907]]

(m) Related Information

    (1) For more information about this AD, Georgios Roussos, 
Aerospace Engineer, Systems and Equipment Branch, ANM-130S, Seattle 
Aircraft Certification Office, FAA, 1601 Lind Avenue SW., Renton, 
Washington 98057-3356; phone: 425-917-6482; fax: 425-917-6590; 
email: Georgios.Roussos@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, WA 98124-2207; telephone 206-544-
5000, extension 1; fax 206-766-5680; 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 October 15, 2013.
Jeffrey E. Duven,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2013-25134 Filed 10-24-13; 8:45 am]
BILLING CODE 4910-13-P