Document ID: FAA-2011-1094-0001
Agency: faa
Document Type: Proposed Rule
Title: Airworthiness Directives: Boeing Co. Airplanes
Posted Date: 2011-10-26T04:00Z

[Federal Register: October 26, 2011 (Volume 76, Number 207)]
[Proposed Rules]               
[Page 66200-66203]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr26oc11-16]                         

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

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2011-1094; Directorate Identifier 2011-NM-070-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 The Boeing Company Model 757 airplanes. This proposed AD would 
require inspecting for discrepancies and insufficient coverage of the 
secondary fuel barrier, determining the thickness of the secondary fuel 
barrier, and corrective actions if necessary. This proposed AD was 
prompted by reports that inspections of the wing center section 
revealed defective, misapplied, or missing secondary fuel vapor barrier 
on the center fuel tank. We are proposing this AD to detect and correct 
defective surfaces and insufficient thickness of secondary fuel 
barrier, which could allow fuel leaks or fumes into the pressurized 
cabin, and allow fuel or fuel vapors to come in contact with an 
ignition source, which could result in a fire or an explosion.

DATES: We must receive comments on this proposed AD by December 12, 
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: 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; 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 (phone: 800-647-5527) is in the ADDRESSES 
section. Comments will be available in the AD docket shortly after 
receipt.

FOR FURTHER INFORMATION CONTACT: Kevin Nguyen, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification Office 
(ACO), 1601 Lind Avenue, SW., Renton, Washington 98057-3356; phone: 
425-917-6501; fax: 425-917-6590; e-mail: kevin.nguyen@faa.gov.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposal. Send your comments to an address listed 
under the ADDRESSES section. Include ``Docket No. FAA-2011-1094; 
Directorate Identifier 2011-NM-070-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 received reports that inspections of the wing center section 
revealed

[[Page 66201]]

defective, misapplied, or missing secondary fuel vapor barrier on the 
center fuel tank. The secondary fuel barrier is applied external to the 
fuel tank walls, which are subject to cabin pressure to provide a 
secondary means to contain fuel and fuel vapors. When the secondary 
fuel barrier is applied satisfactorily, it protects the pressurized 
cabin areas from fuel leaks and fumes. If the secondary fuel barrier is 
defective, fuel or fumes can leak through fastener holes or cracks in 
the structure and pass into the passenger compartment. There have been 
no reports from operators of fuel leaks or fumes in the passenger 
compartment. We are proposing this AD to detect and correct defective 
surfaces and insufficient thickness of secondary fuel barrier, which 
could allow fuel leaks or fumes into the pressurized cabin, and allow 
fuel or fuel vapors to come in contact with an ignition source, which 
could result in a fire or an explosion.

Related Rulemaking

    On June 10, 2005, the FAA issued AD 2005-13-15, Amendment 39-14152 
(70 FR 36486, June 24, 2005), applicable to certain Boeing Model 737-
200, -200C, -300, -400, -500, -600, -700, -700C, -800, and -900 series 
airplanes, which requires a one-time detailed inspection for 
discrepancies of the secondary fuel vapor barrier of the wing center 
section, and related investigative and corrective actions if necessary. 
That AD was prompted by reports that the secondary fuel vapor barrier 
was not applied correctly to, or was missing from, certain areas of the 
wing center section. The actions required by that AD are intended to 
prevent fuel or fuel vapors from leaking into the cargo or passenger 
compartments and coming into contact with a possible ignition source, 
which could result in fire or explosion.

Relevant Service Information

    We reviewed Boeing Service Bulletins 757-57-0060, Revision 2, dated 
May 24, 2007 (for Model 757-200, 757-200PF, and 757-200CB series 
airplanes); and 757-57-0061, Revision 1, dated May 24, 2007 (for Model 
757-300 series airplanes). These service bulletins describe procedures 
for, depending on airplane configuration, inspecting for discrepancies 
and insufficient coverage of the secondary fuel barrier, determining 
the thickness of the secondary fuel barrier, and corrective actions if 
necessary. Discrepancies include missing, peeled, non-continuous, or 
non-transparent secondary fuel barrier; small air bubbles, air pockets, 
blister-like areas, or solid particles in the secondary fuel barrier; 
fillet sealant, primer, corrosion-inhibiting compound or other finishes 
applied to the top of the secondary fuel barrier; missing fillet (cap) 
seals; or areas of secondary fuel barrier whose thickness is less than 
or greater than specified limits; or areas not having a transparent 
quality that makes it possible to see a crack in the structure; or 
areas not having a minimum application coverage area. Corrective 
actions include repairing the secondary fuel barrier, including removal 
and reapplication, if needed; or applying more secondary fuel barrier, 
as needed.

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 these same type 
designs.

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 Service Bulletin 757-57-0060, Revision 2, and 
Boeing Service Bulletin 757-57-0061, Revision 1, both dated May 24, 
2007, specify to send the inspection results to the manufacturer, this 
proposed AD would not require any report. Boeing Service Bulletin 757-
57-0060, Revision 2, and Boeing Service Bulletin 757-57-0061, Revision 
1, both dated May 24, 2007, refer to a ``detailed visual inspection'' 
for discrepancies and insufficient coverage of the secondary fuel 
barrier. We have determined that the procedures in the service bulletin 
should be described as a ``detailed inspection.'' Note 1 has been 
included in this AD to define this type of inspection.

Costs of Compliance

    We estimate that this proposed AD affects 619 airplanes of U.S. 
registry. We estimate the following costs to comply with this proposed 
AD:

                                                                     Estimated Costs
--------------------------------------------------------------------------------------------------------------------------------------------------------
                                                                                                             Cost per       Cost on U.S.
                    Action                                    Labor cost                   Parts cost        product         operators
-----------------------------------------------------------------------------------------------------------------------------------------
Access and inspect secondary fuel barrier.....  42 work-hours x $85 per hour = $3,570               $0           $3,570       $2,209,830
                                                 per inspection.
--------------------------------------------------------------------------------------------------------------------------------------------------------

    We estimate the following costs to do any necessary repairs 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 
repairs:

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                  Action                                Labor cost                 Parts cost        product
----------------------------------------------------------------------------------------------------------------
Apply secondary fuel barrier..............  7 work-hours x $85 per hour = $595              $0             $595
                                             per secondary fuel barrier
                                             application.
----------------------------------------------------------------------------------------------------------------

    According to the manufacturer, some of the costs of this proposed 
AD may be covered under warranty, thereby reducing the cost impact on 
affected individuals. We do not control warranty coverage for affected 
individuals. As a result, we have included all costs in our cost 
estimate.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I,

[[Page 66202]]

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-2011-1094; Directorate Identifier 
2011-NM-070-AD.

Comments Due Date

    (a) We must receive comments by December 12, 2011.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to The Boeing Company Model 757-200, 757-
200PF, and 757-200CB series airplanes, certificated in any category, 
as identified in Boeing Service Bulletin 757-57-0060, Revision 2, 
dated May 24, 2007; and Model 757-300 series airplanes, certificated 
in any category, as identified in Boeing Service Bulletin 757-57-
0061, Revision 1, dated May 24, 2007.

Subject

    (d) Joint Aircraft System Component (JASC)/Air Transport 
Association (ATA) of America Code 57: Wings.

Unsafe Condition

    (e) This proposed AD was prompted by reports that inspections of 
the wing center section revealed defective, misapplied, or missing 
secondary fuel vapor barrier on the center fuel tank. We are issuing 
this AD to detect and correct defective surfaces and insufficient 
thickness of secondary fuel barrier, which could allow fuel leaks or 
fumes into the pressurized cabin, and allow fuel or fuel vapors to 
come in contact with an ignition source, which could result in a 
fire or an explosion.

Compliance

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

Detailed Inspection

    (g) For airplanes identified in Boeing Service Bulletin 757-57-
0060, Revision 2, dated May 24, 2007, as Group 1, Group 2, and Group 
4 Configuration 1; and airplanes identified in Boeing Service 
Bulletin 757-57-0061, Revision 1, dated May 24, 2007, as Group 1, 
Group 2, and Group 3 Configuration 1: Within 60 months after the 
effective date of this AD, do a detailed inspection to detect 
discrepancies of the secondary fuel barrier at the front spar and 
the upper panel of the wing center section, and if discrepancies 
exist, repair before further flight, in accordance with the 
Accomplishment Instructions of Boeing Service Bulletin 757-57-0060, 
Revision 2, dated May 24, 2007; or Boeing Service Bulletin 757-57-
0061, Revision 1, dated May 24, 2007; as applicable.

    Note 1: For the purposes of this AD, a detailed inspection is: 
``An intensive examination of a specific item, installation, or 
assembly to detect damage, failure, or irregularity. Available 
lighting is normally supplemented with a direct source of good 
lighting at intensity deemed appropriate. Inspection aids such as 
mirror, magnifying lenses, etc., may be necessary. Surface cleaning 
and elaborate access procedures may be required.''

Inspection of Minimum Application Coverage Area

    (h) For Group 3 airplanes identified in Boeing Service Bulletin 
757-57-0060, Revision 2, dated May 24, 2007; and Group 2 airplanes 
identified in Boeing Service Bulletin 757-57-0061, Revision 1, dated 
May 24, 2007: Within 60 months after the effective date of this AD, 
do a detailed inspection of the front spar and the upper panel to 
ensure the secondary fuel barrier application covers the minimum 
area specified in Boeing Service Bulletin 757-57-0060, Revision 2, 
dated May 24, 2007; or Boeing Service Bulletin 757-57-0061, Revision 
1, dated May 24, 2007; as applicable. If the secondary fuel barrier 
does not cover the minimum specified area, apply more secondary fuel 
barrier before further flight, in accordance with the Accomplishment 
Instructions of Boeing Service Bulletin 757-57-0060, Revision 2, 
dated May 24, 2007; or Boeing Service Bulletin 757-57-0061, Revision 
1, dated May 24, 2007; as applicable.

Measurement of Thickness of Secondary Fuel Barrier

    (i) For Group 1, Group 2, and Group 4 Configuration 1 airplanes 
identified in Boeing Service Bulletin 757-57-0060, Revision 2, dated 
May 24, 2007; and for Group 1, Group 2, and Group 3 Configuration 1 
airplanes identified in Boeing Service Bulletin 757-57-0061, 
Revision 1, dated May 24, 2007: Within 60 months after the effective 
date of this AD, measure the thickness of the secondary fuel 
barrier. If the thickness is less than or over the acceptable limits 
defined in Boeing Service Bulletin 757-57-0060, Revision 2, dated 
May 24, 2007; or Boeing Service Bulletin 757-57-0061, Revision 1, 
dated May 24, 2007; as applicable, apply more secondary fuel barrier 
or repair before further flight, in accordance with the 
Accomplishment Instructions of Boeing Service Bulletin 757-57-0060, 
Revision 2, dated May 24, 2007; or Boeing Service Bulletin 757-57-
0061, Revision 1, dated May 24, 2007; as applicable.
    (j) For Group 4, Configuration 2 airplanes identified in Boeing 
Service Bulletin 757-57-0060, Revision 2, dated May 24, 2007; and 
Group 3, Configuration 2 airplanes identified in Boeing Service 
Bulletin 757-57-0061, Revision 1, dated May 24, 2007: Within 60 
months, review the maintenance records to determine if there was a 
minimum of 0.005 inch of new secondary fuel barrier applied, or if 
the thickness of the secondary fuel barrier cannot be determined 
from the maintenance records, measure the thickness of the secondary 
fuel barrier. If the thickness is less than or over the acceptable 
limits specified in Boeing Service Bulletin 757-57-0060, Revision 2, 
dated May 24, 2007; or Boeing Service Bulletin 757-57-0061, Revision 
1, dated May 24, 2007; as applicable, apply more secondary fuel 
barrier or repair before further flight, in accordance with the 
Accomplishment Instructions of Boeing Service Bulletin 757-57-0060, 
Revision 2, dated May 24, 2007; or Boeing Service Bulletin 757-57-
0061, Revision 1, dated May 24, 2007; as applicable.

[[Page 66203]]

No Reporting Requirement

    (k) Although Boeing Service Bulletin 757-57-0060, Revision 2, 
dated May 24, 2007; and Boeing Service Bulletin 757-57-0061, 
Revision 1, dated May 24, 2007; specify to submit certain 
information to the manufacturer, this AD does not include that 
requirement.

Alternative Methods of Compliance (AMOCs)

    (l)(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 e-mailed to: 9-NM-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.

Related Information

    (m)(1) For more information about this AD, contact Kevin Nguyen, 
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle 
Aircraft Certification Office (ACO), 1601 Lind Avenue, SW., Renton, 
Washington 98057-3356; phone: 425-917-6501; fax: 425-917-6590; e-
mail: kevin.nguyen@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; e-mail 
me.boecom@boeing.com; Internet https://www. boeingfleet.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 17, 2011.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2011-27652 Filed 10-25-11; 8:45 am]
BILLING CODE 4910-13-P