Document ID: FAA-2012-0421-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: The Boeing Company Airplanes
Posted Date: 2012-04-25T04:00Z

[Federal Register Volume 77, Number 80 (Wednesday, April 25, 2012)]
[Proposed Rules]
[Pages 24643-24646]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2012-9916]

=======================================================================
-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2012-0421; Directorate Identifier 2012-NM-042-AD]
RIN 2120-AA64

Airworthiness Directives; The Boeing Company Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: We propose to adopt a new airworthiness directive (AD) for 
certain Boeing Company Model 757 airplanes. This proposed AD was 
prompted by a report of in-flight fracture of the right windshield 
(window 1) on the flight deck and multiple reports of electrical arcs 
at the terminal blocks of the flight deck windshields resulting in 
smoke and fire. This proposed AD would require repetitive inspections 
of electrical heat terminals on the left and right windshields for 
damage, and corrective actions if necessary. This proposed AD would 
also allow for replacing an affected windshield with a windshield 
equipped with different electrical connections, which would terminate 
the repetitive inspections for that windshield. We are proposing this 
AD to prevent smoke and fire in the flight deck, which can lead to loss 
of visibility, and injuries to or incapacitation of the flight crew.

DATES: We must receive comments on this proposed AD by June 11, 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 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; 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: Elias Natsiopoulos, Aerospace 
Engineer, Systems and Equipment Branch, ANM-130S, FAA, Seattle Aircraft 
Certification Office (ACO), 1601 Lind Avenue SW., Renton, Washington 
98057-3356; phone: 425-917-6478; fax: 425-917-6590; email: 
Elias.Natsiopoulos@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-2012-0421; 
Directorate Identifier 2012-NM-042-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

[[Page 24644]]

substantive verbal contact we receive about this proposed AD.

Discussion

    We have received nine reports from eight operators that electrical 
arcs occurred at the lower terminal blocks of the flight deck 
windshields. AD 2010-15-01, Amendment 39-16367 (75 FR 39804, July 13, 
2010), addresses the lower electrical connections. We have also 
received reports of four failures of upper terminal blocks on Model 757 
airplanes. In more than one incident, the arcs resulted in open flames. 
While in flight, one Model 757-200 series airplane experienced smoke in 
the cockpit, followed by the fracture of the inner pane of the first 
officer's windshield (right window 1). This windshield fracture 
resulted in total loss of the first officer's outside visibility and 
small shards of glass striking the first officer. Examination of the 
fractured windshield revealed evidence of arcing at the upper outboard 
(J1) and the upper inboard (J4) windshield electrical heat terminal 
connections. The inner pane fracture initiated beneath the J4 terminal 
block.
    The electrical connections on the windshields are made with lugs 
that attach with screws to the terminal block. A loose connection 
increases the heat at the terminal, which can cause damage to the 
internal joints (including solder, if present). Damaged solder joints 
are the primary cause of the electrical arcs. The primary cause of 
loose connections is the incorrectly torqued or incorrectly installed 
screw. This condition, if not corrected, could result in smoke and fire 
in the flight deck, which can result in the loss of visibility, and 
injuries to or incapacitation of the flightcrew.

Other Related Rulemaking

    On July 6, 2010, the FAA issued AD 2010-15-01, Amendment 39-16367 
(75 FR 39804, July 13, 2010), applicable to certain Boeing Model 757, 
767, and 777 series airplanes, which requires repetitive inspections 
for damage of the electrical terminal (J5 terminal) at the left and 
right flight deck window 1 windshield, and corrective actions if 
necessary. The most forward flight deck windows are referred to as 
windshields and named left and right window 1 respectively. The actions 
required by that AD are intended to prevent smoke and fire in the 
cockpit, which could lead to loss of visibility, and injuries to or 
incapacitation of the flight crew. Accomplishing the actions in this 
proposed AD would terminate the requirements of AD 2010-15-01 for Model 
757 airplanes.

Relevant Service Information

    We reviewed Boeing Special Attention Service Bulletin 757-30-0019, 
Revision 3, dated December 16, 2011 (for Model 757-200, -200PF, and -
200CB series airplanes); and Boeing Special Attention Service Bulletin 
757-30-0020, Revision 3, dated December 16, 2011 (for Model 757-300 
series airplanes). This service information describes procedures for 
repetitive detailed inspections for damage (including, but not limited 
to, arcing, loose terminals, heat damage, cross-threaded connections, 
and cracking) of the wiring and electrical terminals J1, J4, and J5 at 
the left and right flight deck windshields; and corrective actions if 
necessary.
    The corrective actions include applying correct torque to a loose 
electrical connection, replacing any damaged terminal lug with a new 
lug, repairing damaged wiring, and replacing an unserviceable 
windshield with a new or serviceable windshield. Boeing Special 
Attention Service Bulletin 757-30-0019, Revision 3, dated December 16, 
2011 (for Model 757-200, -200PF, and -200CB series airplanes); and 
Boeing Special Attention Service Bulletin 757-30-0020, Revision 3, 
dated December 16, 2011 (for Model 757-300 series airplanes); specify 
that the replacement windshield can be either a new or serviceable 
windshield that uses screws and lugs for the electrical connection, or 
a new or serviceable windshield that uses pins and sockets for the 
electrical connections.
    For airplanes on which a new windshield that uses pins and sockets 
is installed, Boeing Special Attention Service Bulletin 757-30-0019, 
Revision 3, dated December 16, 2011 (for Model 757-200, -200PF, and -
200CB series airplanes); and Boeing Special Attention Service Bulletin 
757-30-0020, Revision 3, dated December 16, 2011 (for Model 757-300 
series airplanes); also specify changing the related wire bundle and 
cutting the bulb seal to give clearance for terminals on the 
replacement windshield. This service information specifies that 
installing a windshield that uses pins and sockets for the electrical 
connections eliminates the need for the repetitive detailed inspections 
for that windshield.
    Boeing Special Attention Service Bulletin 757-30-0019, Revision 3, 
dated December 16, 2011 (for Model 757-200, -200PF, and -200CB series 
airplanes); and Boeing Special Attention Service Bulletin 757-30-0020, 
Revision 3, dated December 16, 2011 (for Model 757-300 series 
airplanes); also specify repetitive detailed inspections for damage of 
any windshield that is replaced with a windshield that uses screws and 
lugs for the heat connection, or if a windshield heat power connection 
is reassembled on windshields that use screws and lugs for the heat 
connection.

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, except as discussed 
under ``Differences Between the Proposed AD and the Service 
Information.''

Differences Between the Proposed AD and the Service Information

    Although Boeing Special Attention Service Bulletin 757-30-0019, 
Revision 3, dated December 16, 2011 (for Model 757-200, -200PF, and -
200CB series airplanes); and Boeing Special Attention Service Bulletin 
757-30-0020, Revision 3, dated December 16, 2011 (for Model 757-300 
series airplanes); recommend accomplishing certain inspections, window 
replacement, and reassembly of the electrical connections within 500 
flight hours or 150 days, whichever occurs first, we have determined 
that a compliance time of within 500 flight hours after the effective 
date of this AD addresses the identified unsafe condition soon enough 
to ensure an adequate level of safety for the affected fleet. This 
difference has been coordinated with The Boeing Company.

Costs of Compliance

    We estimate that this proposed AD affects 664 airplanes of U.S. 
registry.
    We estimate the following costs to comply with this proposed AD:

[[Page 24645]]

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                  Cost on U.S.
             Action                     Labor cost           Parts cost     Cost per product       operators
----------------------------------------------------------------------------------------------------------------
Detailed inspection of           3 work-hours x $85 per               $0   $255 per            $169,320 per
 windshields.                     hour = $255 per                           inspection cycle.   inspection
                                  inspection cycle.                                             cycle.
----------------------------------------------------------------------------------------------------------------

    We estimate the following costs to do any necessary corrective 
actions 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 corrective actions.

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                Action                        Labor cost               Parts cost            Cost per product
----------------------------------------------------------------------------------------------------------------
Windshield replacement and changes to  9 work-hours x $85 per   $19,687 per windshield.  $20,452 per windshield.
 related wiring including lug           hour = $765 per
 replacement.                           windshield.
----------------------------------------------------------------------------------------------------------------

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-2012-0421; Directorate Identifier 
2012-NM-042-AD.

(a) Comments Due Date

    We must receive comments by June 11, 2012.

(b) Affected ADs

    This AD affects AD 2010-15-01, Amendment 39-16367 (75 FR 39804, 
July 13, 2010).

(c) Applicability

    This AD applies to The Boeing Company airplanes, certificated in 
any category, as identified in paragraphs (c)(1) and (c)(2) of this 
AD.
    (1) Model 757-200, -200PF, and -200CB airplanes identified in 
Boeing Special Attention Service Bulletin 757-30-0019, Revision 3, 
dated December 16, 2011.
    (2) Model 757-300 airplanes identified in Boeing Special 
Attention Service Bulletin 757-30-0020, Revision 3, dated December 
16, 2011.

(d) Subject

    Joint Aircraft System Component (JASC)/Air Transport Association 
(ATA) of America Code 30, Ice and Rain Protection.

(e) Unsafe Condition

    This AD was prompted by a report of in-flight fracture of the 
right windshield (window 1) on the flightdeck and multiple reports 
of electrical arcs at the terminal blocks of the flight deck 
windshields resulting in smoke and fire. We are issuing this AD to 
prevent smoke and fire in the flight deck, which can lead to loss of 
visibility, and injuries to or incapacitation of the flight crew.

(f) Compliance

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

(g) Inspection and Repair

    Within 500 flight hours after the effective date of this AD, 
except as required by paragraph (h) of this AD: Do a detailed 
inspection for damage of the wiring and electrical terminal blocks 
(J1, J4, and J5 terminals) at the left and right flight deck window 
1 windshield, and do all applicable corrective actions, by 
accomplishing all the applicable actions specified in the 
Accomplishment Instructions of Boeing Special Attention Service 
Bulletin 757-30-0019, Revision 3, dated December 16, 2011 (for Model 
757-200, -200PF, and -200CB series airplanes); or Boeing Special 
Attention Service Bulletin 757-30-0020, Revision 3, dated December 
16, 2011 (for Model 757-300 series airplanes). Except as provided by 
paragraph (j) of this AD, do all applicable corrective actions 
before further flight. Repeat the detailed inspection thereafter at 
the applicable interval specified in paragraph (g)(1) or (g)(2) of 
this AD. Doing the replacement specified in paragraph (k) of this AD 
terminates the repetitive inspection

[[Page 24646]]

requirements of this paragraph for that replaced flight deck 
windshield.
    (1) For flight deck windshields manufactured by GKN Aerospace 
(GKN) with screw/lug electrical connections, repeat the detailed 
inspection thereafter at intervals not to exceed 12,000 flight hours 
or 48 months, whichever occurs later.
    (2) For flight deck windshields manufactured by PPG Aerospace 
(PPG) with screw/lug electrical connections, repeat the detailed 
inspection thereafter at intervals not to exceed 6,000 flight hours 
or 24 months, whichever occurs later.

(h) Compliance Time Exception for Previous Inspection

    For airplanes on which inspections of the J1, J4, and J5 
terminals, as specified in the Accomplishment Instructions of Boeing 
Special Attention Service Bulletin 757-30-0019, Revision 2, dated 
April 19, 2010 (for Model 757-200, -200PF, and -200CB series 
airplanes); or Boeing Special Attention Service Bulletin 757-30-
0020, Revision 2, dated March 31, 2010 (for Model 757-300 series 
airplanes); were accomplished before the effective date of this AD: 
Do the actions required by paragraph (g) of this AD at the 
applicable compliance time specified in paragraphs (h)(1) and (h)(2) 
of this AD. Repeat the inspection thereafter at the applicable 
intervals specified in paragraphs (g)(1) or (g)(2) of this AD.
    (1) For flight deck windshields manufactured by GKN with screw/
lug electrical connections: At the later of the times specified in 
paragraphs (h)(1)(i) and (h)(1)(ii) of this AD.
    (i) Within 12,000 flight hours or 48 months, whichever occurs 
later, after accomplishing the inspection.
    (ii) Within 500 flight hours after the effective date of this 
AD.
    (2) For flight deck windshields manufactured by PPG with screw/
lug electrical connections: At the later of the times specified in 
paragraphs (h)(2)(i) and (h)(2)(ii) of this AD.
    (i) Within 6,000 flight hours or 24 months, whichever occurs 
later, after accomplishing the inspection.
    (ii) Within 500 flight hours after the effective date of this 
AD.

(i) Inspection for Replaced Windshield or Reassembled Heat Power 
Connection

    For any windshield replaced after the effective date of this AD 
with a windshield that uses screws and lugs for electrical heat 
connection, or if a windshield heat power connection is reassembled 
on windshields that use screws and lugs for windshield heat 
connections: Do the actions required in paragraph (g) of this AD 
within 500 flight hours after the windshield replacement or 
connection reassembly, and thereafter at the applicable interval 
specified in paragraph (g)(1) or (g)(2) of this AD, as applicable.

(j) Exception to Compliance Time for Certain Windshield Replacement

    If, during the inspection required by paragraph (g) or (i) of 
this AD, the screw is found cross threaded: Do the applicable 
actions specified in paragraph (j)(1) or (j)(2) of this AD.
    (1) If the terminal lug is loose and cannot be tightened: Before 
further flight, replace that windshield, in accordance with the 
Accomplishment Instructions of Boeing Special Attention Service 
Bulletin 757-30-0019, Revision 3, dated December 16, 2011 (for Model 
757-200, -200PF, and -200CB series airplanes); or Boeing Special 
Attention Service Bulletin 757-30-0020, Revision 3, dated December 
16, 2011 (for Model 757-300 series airplanes).
    (2) If the terminal lug is tight or can be tightened: Replace 
that windshield within 500 flight hours after the inspection, in 
accordance with the Accomplishment Instructions Boeing Special 
Attention Service Bulletin 757-30-0019, Revision 3, dated December 
16, 2011 (for Model 757-200, -200PF, and -200CB series airplanes); 
or Boeing Special Attention Service Bulletin 757-30-0020, Revision 
3, dated December 16, 2011 (for Model 757-300 series airplanes).

(k) Optional Terminating Action

    Replacing a flight deck windshield that uses screws and lugs for 
the electrical connections with a flight deck windshield that uses 
pins and sockets for the electrical connections, in accordance with 
the Accomplishment Instructions of Boeing Special Attention Service 
Bulletin 757-30-0019, Revision 3, dated December 16, 2011 (for Model 
757-200, -200PF, and -200CB series airplanes); or Boeing Special 
Attention Service Bulletin 757-30-0020, Revision 3, dated December 
16, 2011 (for Model 757-300 series airplanes); ends the repetitive 
inspection requirements of paragraph (g) of this AD for that 
windshield.

(l) Related AD Termination

    Accomplishing the actions required by this AD terminates the 
requirements of AD 2010-15-01, Amendment 39-16367 (75 FR 39804, July 
13, 2010), paragraphs (g), (j), and (k), for that airplane only.

 (m) Credit for Previous Actions

    This paragraph provides credit for the actions required by this 
AD, if those actions were performed before the effective date of 
this AD using Boeing Special Attention Service Bulletin 757-30-0019, 
Revision 2, dated April 19, 2010 (for Model 757-200, -200PF, and -
200CB series airplanes); or Boeing Special Attention Service 
Bulletin 757-30-0020, Revision 2, dated March 31, 2010 (for Model 
757-300 series airplanes).

(n) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle Aircraft Certification Office, 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.

 (o) Related Information

    (1) For more information about this AD, contact Elias 
Natsiopoulos, Aerospace Engineer, Systems and Equipment Branch, ANM-
130S, FAA, Seattle Aircraft Certification Office (ACO), 1601 Lind 
Avenue SW., Renton, Washington 98057-3356; phone: 425-917-6478; fax: 
425-917-6590; email: Elias.Natsiopoulos@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 April 5, 2012.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2012-9916 Filed 4-24-12; 8:45 am]
BILLING CODE 4910-13-P