Document ID: FAA-2009-0477-0005
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Boeing Model 747-100, -100B, -100B SUD, -200B, and -300 Series Airplanes; and Model 747SP and 747SR Series Airplanes
Posted Date: 2009-08-27T04:00Z

[Federal Register: August 27, 2009 (Volume 74, Number 165)]
[Rules and Regulations]               
[Page 43629-43632]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr27au09-6]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0477; Directorate Identifier 2008-NM-191-AD; 
Amendment 39-16003; AD 2009-18-07]
RIN 2120-AA64

 
Airworthiness Directives; Boeing Model 747-100, -100B, -100B SUD, 
-200B, and -300 Series Airplanes; and Model 747SP and 747SR Series 
Airplanes

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

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SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD), which applies to certain Boeing Model 747 series airplanes. That 
AD currently requires repetitive inspections to detect cracks in 
various areas of the fuselage internal structure, and related 
investigative/corrective actions if necessary. This new AD requires 
additional repetitive inspections for cracking of certain fuselage 
structure, and related investigative/corrective actions if necessary. 
This AD results from fatigue tests and analysis by Boeing that 
identified areas of the fuselage where fatigue cracks can occur. We are 
issuing this AD to prevent the loss of the structural integrity of the 
fuselage, which could result in rapid depressurization of the airplane.

DATES: This AD becomes effective October 1, 2009.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in the AD as of October 1, 
2009.

ADDRESSES: 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.myboeingfleet.com.

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 AD, the regulatory evaluation, 
any comments received, and other information. The address for the 
Docket Office (telephone 800-647-5527) is the Document Management 
Facility, U.S. Department of Transportation, Docket Operations, M-30, 
West Building Ground Floor, Room W12-140, 1200 New Jersey Avenue, SE., 
Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Ivan Li, Aerospace Engineer, Airframe 
Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 1601 Lind 
Avenue, SW., Renton, Washington 98057-3356; telephone (425) 917-6437; 
fax (425) 917-6590.

SUPPLEMENTARY INFORMATION:

Discussion

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 to include an AD that supersedes AD 2005-20-30, amendment 
39-14327 (70 FR 59252, October 12, 2005). The existing AD applies to 
certain Boeing Model 747 series airplanes. That NPRM was published in 
the Federal Register on May 26, 2009 (74 FR 24712). That NPRM proposed 
to continue to require repetitive inspections to detect cracks in 
various areas of the fuselage internal structure, and related 
investigative/corrective actions if necessary. That NPRM also proposed 
to require additional repetitive inspections for cracking of certain 
fuselage structure, and related investigative/corrective actions if 
necessary.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comment that has been 
received on the NPRM. Boeing concurs with the NPRM.

Conclusion

    We have carefully reviewed the available data, including the 
comment that has been received, and determined that air safety and the 
public interest require adopting the AD as proposed.

Costs of Compliance

    There are about 209 airplanes of the affected design in the 
worldwide fleet. The following table provides the estimated costs for 
U.S. operators to comply with this AD. The average labor rate is $80 
per work hour.

[[Page 43630]]

                                             Table--Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                          Cost per
                                                                Work    airplane, per  Number of U.S.-   Fleet
                           Action                              hours     inspection      registered       cost
                                                                            cycle         airplanes
----------------------------------------------------------------------------------------------------------------
Inspections (required by AD 2005-20-30).....................      130         $10,400              69   $717,600
Additional inspections in Area 1 (new action)...............        6             480              69     33,120
Additional inspections in Area 6 (new action)...............        1              80              69      5,520
----------------------------------------------------------------------------------------------------------------

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 AD will not have federalism 
implications under Executive Order 13132. This AD will 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 that this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866;
    (2) Is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979); and
    (3) Will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this AD and placed it in the AD docket. See the ADDRESSES 
section for a location to examine the regulatory evaluation.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the FAA amends 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 Federal Aviation Administration (FAA) amends Sec.  39.13 by 
removing amendment 39-14327 (70 FR 59252, October 12, 2005) and by 
adding the following new airworthiness directive (AD):

2009-18-07 Boeing: Amendment 39-16003. Docket No. FAA-2009-0477; 
Directorate Identifier 2008-NM-191-AD.

Effective Date

    (a) This AD becomes effective October 1, 2009.

Affected ADs

    (b) This AD supersedes AD 2005-20-30.

Applicability

    (c) This AD applies to Boeing Model 747-100, 747-100B, 747-100B 
SUD, 747-200B, 747-300, 747SP, and 747SR series airplanes; 
certificated in any category; identified in Boeing Service Bulletin 
747-53A2349, Revision 3, dated October 2, 2008.

Subject

    (d) Air Transport Association (ATA) of America Code 53: 
Fuselage.

Unsafe Condition

    (e) This AD results from fatigue tests and analysis by Boeing 
that identified areas of the fuselage where fatigue cracks can 
occur. We are issuing this AD to prevent the loss of the structural 
integrity of the fuselage, which could result in rapid 
depressurization of the airplane.

Compliance

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

Restatement of Requirements of AD 2002-10-10 With Revised Service 
Information (Excluding Upper Deck Floor Beams)

Repetitive Inspections

    (g) Prior to the accumulation of 22,000 total flight cycles, or 
within 1,000 flight cycles after June 11, 1993 (the effective date 
of AD 93-08-12, amendment 39-8559, which was superseded by AD 2002-
10-10), whichever occurs later, unless accomplished previously 
within the last 2,000 flight cycles; and thereafter at intervals not 
to exceed 3,000 flight cycles: Perform an internal detailed 
inspection to detect cracks in the areas of the fuselage internal 
structure specified in paragraphs (g)(1) through (g)(6) of this AD; 
in accordance with Boeing Service Bulletin 747-53-2349, dated June 
27, 1991; Boeing Alert Service Bulletin 747-53A2349, Revision 1, 
dated October 12, 2000; Boeing Service Bulletin 747-53A2349, 
Revision 2, dated April 3, 2003; or Boeing Alert Service Bulletin 
747-53A2349, Revision 3, dated October 2, 2008. After the effective 
date of this AD, only Revision 3 of Boeing Alert Service Bulletin 
747-53A2349 may be used. Continue doing the inspections until the 
inspections required by paragraph (j) of this AD are done.
    (1) Section 42 upper lobe frames.
    (2) Section 46 lower lobe frames.
    (3) Section 42 lower lobe frames.
    (4) Main entry door cutouts.
    (5) Section 41 body station 260, 340, and 400 bulkheads.
    (6) Main entry doors.

    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 an intensity deemed appropriate. Inspection aids such as 
mirror, magnifying lenses, etc., may be necessary. Surface cleaning 
and elaborate procedures may be required.''

    (h) Prior to the accumulation of 25,000 total flight cycles, or 
within 1,000 flight cycles after June 11, 1993, whichever is later, 
unless already done within the last 2,000 flight cycles; and 
thereafter at intervals not to exceed 3,000 flight cycles: Do an 
internal detailed inspection to detect cracks in the Section 46 
upper lobe frames, in accordance with Boeing Service Bulletin 747-
53-2349, dated June 27, 1991; Boeing Alert Service Bulletin 747-
53A2349, Revision 1, dated October 12, 2000; Boeing Service Bulletin 
747-53A2349, Revision 2, dated April 3, 2003; or Boeing Alert 
Service Bulletin 747-53A2349, Revision 3, dated October 2, 2008. 
After the effective date of this AD, only

[[Page 43631]]

Revision 3 of Boeing Alert Service Bulletin 747-53A2349 may be used.

Repair of Cracks Detected During Paragraph (g) or (h) Inspections

    (i) Before further flight, repair any cracks detected during the 
inspections done per paragraph (g) or (h) of this AD by doing the 
actions specified in paragraph (i)(1) or (i)(2) of this AD, as 
applicable.
    (1) Repair in accordance with a method approved by the Manager, 
Seattle Aircraft Certification Office (ACO), FAA; or using a method 
approved in accordance with paragraph (p) of this AD.
    (2) Repair in accordance with Boeing Service Bulletin 747-
53A2349, Revision 2, dated April 3, 2003; or Boeing Alert Service 
Bulletin 747-53A2349, Revision 3, dated October 2, 2008. After the 
effective date of this AD, only Revision 3 of Boeing Alert Service 
Bulletin 747-53A2349 may be used. Where either revision of the 
service bulletin specifies to contact Boeing for repair 
instructions, repair in accordance with a method approved by the 
Manager, Seattle ACO; or use a method approved in accordance with 
paragraph (p) of this AD.

Restatement of Requirements of AD 2005-20-30 With Revised Service 
Information

Repetitive Inspections

    (j) Do an internal detailed inspection to detect cracking in the 
areas of the fuselage internal structure specified in paragraphs 
(j)(1), (j)(2), and (j)(3) of this AD, and internal and external 
detailed inspections of the areas specified in paragraphs (j)(4), 
(j)(5), (j)(6), and (j)(7) of this AD. Do the inspections in 
accordance with Boeing Service Bulletin 747-53A2349, Revision 2, 
dated April 3, 2003; or Boeing Alert Service Bulletin 747-53A2349, 
Revision 3, dated October 2, 2008. After the effective date of this 
AD, only Revision 3 of Boeing Alert Service Bulletin 747-53A2349 may 
be used. Do the inspections at the applicable time specified in 
paragraph (k) of this AD. Accomplishment of these inspections 
terminates the requirements of paragraph (g) of this AD.
    (1) Section 42 upper lobe frames.
    (2) Section 46 lower lobe frames.
    (3) Section 42 lower lobe frames.
    (4) Main entry door cutouts.
    (5) Nose wheel well bulkheads, sidewall panels, and station 
(STA) 360 and 380 floor beams. These areas include Section 41 body 
station 260, 340, and 400 bulkheads.
    (6) Main entry doors.
    (7) Main electronics bay access door cutout.
    (k) Do the inspections required by paragraph (j) of this AD at 
the applicable time specified in paragraph (k)(1), (k)(2), or (k)(3) 
of this AD. Repeat the inspections thereafter at intervals not to 
exceed 3,000 flight cycles.
    (1) For airplanes on which the inspections required by 
paragraphs (g)(1), (g)(2), (g)(3), (g)(4), and (g)(6) of this AD 
have been done before November 16, 2005 (the effective date of AD 
2005-20-30), but the inspections required by paragraphs (j)(5) and 
(j)(7) of this AD have not been done: Within 3,000 flight cycles 
since accomplishment of the most recent inspection required by 
paragraphs (g)(1), (g)(2), (g)(3), (g)(4), and (g)(6) of this AD, 
except that the inspections specified in paragraphs (j)(5) and 
(j)(7) of this AD may be done within 3,000 flight cycles since 
accomplishment of the most recent inspection required by paragraphs 
(g)(1), (g)(2), (g)(3), (g)(4), and (g)(6) of this AD, or within 
1,000 flight cycles after November 16, 2005, whichever is later.
    (2) For airplanes on which the inspections required by 
paragraphs (j)(5) and (j)(7) have been done before November 16, 
2005: Within 3,000 flight cycles since accomplishment of the most 
recent inspection required by paragraphs (j)(5) and (j)(7) of this 
AD, or within 1,000 flight cycles after November 16, 2005, whichever 
is later.
    (3) For airplanes on which the inspections required by paragraph 
(g) of this AD have not been done before November 16, 2005: Prior to 
the accumulation of 22,000 total flight cycles, or within 1,000 
flight cycles after November 16, 2005, whichever is later.

Repair of Cracks Detected During Paragraph (j) Inspection

    (l) Before further flight, repair any cracking found during any 
inspection required by paragraph (j) of this AD in accordance with 
Boeing Service Bulletin 747-53A2349, Revision 2, dated April 3, 
2003; or Boeing Alert Service Bulletin 747-53A2349, Revision 3, 
dated October 2, 2008. After the effective date of this AD, only 
Revision 3 of Boeing Alert Service Bulletin 747-53A2349 may be used. 
Where any revision of the service bulletin specifies to contact 
Boeing for repair instructions, repair in accordance with a method 
approved by the Manager, Seattle ACO; or use a method approved in 
accordance with paragraph (p) of this AD.

New Requirements of This AD

Inspections and Repair

    (m) Do initial and repetitive detailed inspections for cracking 
in the areas specified in Table 1 of this AD using applicable 
internal and external detailed inspection methods; and repair all 
cracks, by doing all the applicable actions in accordance with the 
Accomplishment Instructions of Boeing Alert Service Bulletin 747-
53A2349, Revision 3, dated October 2, 2008, except as required by 
paragraph (n) of this AD. Do the initial and repetitive inspections 
at the times specified in paragraph 1.E., ``Compliance,'' of the 
service bulletin, except as required by paragraph (o) of this AD. 
Repair all cracks before further flight after detection.

                     Table 1--Additional Inspections
------------------------------------------------------------------------
Inspect the addition portion of area 1 and
    area 6 as specified in Boeing Alert      For airplanes identified as
 Service Bulletin 747-53A2349, Revision 3,   these groups in the service
   dated October 2, 2008 (``the service              bulletin--
               bulletin'')--
------------------------------------------------------------------------
In Area 1: Fuselage frames at body          1 through 7 inclusive.
 stations 260-520 in areas where the upper
 deck floor beams are attached (Figure 11
 of the Accomplishments Instructions of
 the service bulletin).
In Area 6: Fuselage frames at body          6 and 7.
 stations 400-500 in areas above the Main
 Entry Door 1 cutouts, from the upper
 chord of the upper deck floor beams to
 Stringer 8 (Figure 12 of the
 Accomplishment Instructions of the
 service bulletin).
------------------------------------------------------------------------

Exceptions to Certain Procedures

    (n) If any crack is found during any inspection required by 
paragraph (m) of this AD, and Boeing Alert Service Bulletin 747-
53A2349, Revision 3, dated October 2, 2008, specifies to contact 
Boeing for appropriate action: Before further flight, repair the 
crack using a method approved in accordance with the procedures 
specified in paragraph (p) of this AD.
    (o) Where Boeing Alert Service Bulletin 747-53A2349, Revision 3, 
dated October 2, 2008, specifies a compliance time after the date on 
Boeing Alert Service Bulletin 747-53A2349, Revision 3, dated October 
2, 2008, this AD requires compliance within the specified compliance 
time after the effective date of this AD.

Alternative Methods of Compliance (AMOCs)

    (p)(1) The Manager, Seattle ACO, FAA, has the authority to 
approve AMOCs for this AD, if requested using the procedures found 
in 14 CFR 39.19. Send information to ATTN: Ivan Li, Aerospace 
Engineer, Airframe Branch, ANM-120S, FAA, Seattle Aircraft 
Certification Office, 1601 Lind Avenue, SW., Renton, Washington 
98057-3356; telephone (425) 917-6437; fax (425) 917-6590. Or, e-mail 
information to 9-ANM-Seattle-ACO-AMOC-Requests@faa.gov.
    (2) To request a different method of compliance or a different 
compliance time for this AD, follow the procedures in 14 CFR 39.19. 
Before using any approved AMOC on any airplane to which the AMOC 
applies, notify your principal maintenance inspector (PMI) or 
principal avionics inspector (PAI), as appropriate, or lacking a 
principal inspector, your local Flight Standards District Office. 
The AMOC approval letter must specifically reference this AD.
    (3) AMOCs approved previously in accordance with AD 2005-20-30 
are approved as AMOCs with the corresponding provisions of this AD.
    (4) An AMOC that provides an acceptable level of safety may be 
used for any repair

[[Page 43632]]

required by this AD, if it is approved by an Authorized 
Representative for the Boeing Commercial Airplanes Delegation Option 
Authorization Organization who 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.

Material Incorporated by Reference

    (q) You must use Boeing Alert Service Bulletin 747-53A2349, 
Revision 3, dated October 2, 2008, as applicable, to do the actions 
required by this AD, unless the AD specifies otherwise.
    (1) The Director of the Federal Register approved the 
incorporation by reference of this service information under 5 
U.S.C. 552(a) and 1 CFR part 51.
    (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.myboeingfleet.com.
    (3) You may review copies of the 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 or 425-227-1152.
    (4) You may also review copies of the service information that 
is incorporated by reference at the National Archives and Records 
Administration (NARA). For information on the availability of this 
material at NARA, call 202-741-6030, or go to: http://
www.archives.gov/federal_register/code_of_federal_regulations/
ibr_locations.html.

    Issued in Renton, Washington, on August 17, 2009.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. E9-20579 Filed 8-26-09; 8:45 am]

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