Document ID: FAA-2010-0232-0007
Agency: faa
Document Type: Rule
Title: Airworthiness Directives: Boeing Co. Model 737-200, -300, -400, and -500 Series Airplanes
Posted Date: 2010-12-28T05:00Z

[Federal Register Volume 75, Number 248 (Tuesday, December 28, 2010)]
[Rules and Regulations]
[Pages 81427-81430]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 2010-31992]

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

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2010-0232; Directorate Identifier 2009-NM-032-AD; 
Amendment 39-16549; AD 2010-26-10]
RIN 2120-AA64

Airworthiness Directives; The Boeing Company Model 747-200C, -
200F, -400, -400D, and -400F Series Airplanes

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

ACTION: Final rule.

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

SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD), which applies to certain Model 747-200C, -200F, -400, -400D, and 
-400F series airplanes. That AD currently requires repetitive 
inspections for cracks in the overlapping (upper) skin of the upper 
fastener row of the lap joints of the fuselage skin in sections 41, 42, 
and 46; and related investigative and corrective actions, if necessary. 
This new AD expands the inspection area in the existing AD, and adds a 
modification of certain lap joints and certain post-repair inspections 
of the lap joints. Accomplishing the modification would end the 
repetitive inspections required by the existing AD for the length of 
lap joint that is modified. This AD results from a structural review of 
affected skin lap joints for widespread fatigue damage. We are issuing 
this AD to prevent fatigue cracking in certain lap joints, which could 
result in rapid depressurization of the airplane.

DATES: This AD becomes effective February 1, 2011.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in the AD as of February 1, 
2011.
    On April 13, 2006 (71 FR 12122, March 9, 2006), the Director of the 
Federal Register approved the incorporation by reference of a certain 
other publication listed in the AD.

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: Nicholas Han, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98057-3356; telephone (425) 
917-6449; 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 2006-05-09, Amendment 
39-14506 (71 FR 12122, March 9, 2006). The existing AD applies to 
certain Model 747-200C, -200F, -400, -400D, and -400F series airplanes. 
That NPRM was published in the Federal Register on March 18, 2010 (75 
FR 13046). That NPRM proposed to continue to require repetitive 
inspections for cracks in the overlapping (upper) skin of the upper 
fastener row of the lap joints of the fuselage skin in Sections 41, 42, 
and 46; and related investigative and corrective actions, if necessary. 
That NPRM also proposed to expand the inspection area in the existing 
AD, and add a modification of certain lap joints and certain post-
repair inspections of the lap joints. Accomplishing the modification 
would end the repetitive inspections required by the existing AD.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comments that have been 
received on the NPRM.

Request To Revise Certain Language in Paragraph (k) of the NPRM

    Boeing asked that we revise the language in paragraph (k) of the 
NPRM to indicate that additional actions are required in the area of 
the modification for operation beyond 15,000 total flight cycles after 
doing the proposed modification. Boeing stated that Revision 2 of 
Boeing Alert Service Bulletin 747-53A2499 is currently in work at the 
Boeing Company, and that Revision 2 recommends accomplishing additional 
actions after doing the modification.
    Since this comment was submitted, we have received and reviewed 
Boeing Service Bulletin 747-53A2499, Revision 2, dated August 12, 2010. 
Boeing Alert Service Bulletin 747-53A2499, dated August 11, 2005; and 
Revision 1, dated October 30, 2008; were referred to in the NPRM as the 
appropriate source of service information for accomplishing the 
actions. No more work is necessary for airplanes on which Boeing Alert 
Service Bulletin 747-53A2499, Revision 1, dated October 30, 2008, was 
used for doing the required actions. Revision 2 of this service 
bulletin moves certain airplanes from Group 1 to Groups 15 and 16, adds 
post-modification actions, and contains editorial changes.
    We have revised paragraphs (c), (g), (h), (i), (j), and (k) of this 
AD to refer to

[[Page 81428]]

Boeing Service Bulletin 747-53A2499, Revision 2, dated August 12, 2010. 
In addition, we have removed Notes 1 and 2 of this AD since that 
information is incorporated into Boeing Service Bulletin 747-53A2499, 
Revision 2, dated August 12, 2010. We have also added a new paragraph 
(n) to the AD to give credit for accomplishing the specified actions in 
accordance with Boeing Alert Service Bulletin 747-53A2499, Revision 1, 
dated October 30, 2008.
    Although Boeing Service Bulletin 747-53A2499, Revision 2, dated 
August 12, 2010, includes post-modification actions, this AD will not 
mandate those actions. The threshold for the skin lap joint 
modification mandated by this AD is 30,000 total flight cycles. Adding 
15,000 flight cycles to the threshold would extend the compliance time 
for the recommended additional actions to 45,000 total flight cycles. 
We have determined that it is highly unlikely that a Model 747 airplane 
will reach that number of total flight cycles. This determination also 
takes into consideration the proposed wide spread fatigue damage (WFD) 
operating rules imposing operating limits that could be significantly 
lower than 45,000 total flight cycles.
    In light of these factors, we have determined that this final rule 
must be issued without any further delay due to the severity of the 
unsafe condition addressed by this AD. Further rulemaking might be 
issued in the future to mandate the additional actions included in 
Boeing Service Bulletin 747-53A2499, Revision 2, dated August 12, 2010. 
We have not changed the AD in this regard.

Request To Delay AD Pending New Service Information

    Japan Airlines (JAL) asked that we delay issuance until the 
manufacturer can release Revision 2 of Boeing Alert Service Bulletin 
747-53A2499. JAL stated that Boeing has issued Service Bulletin 
Information Notices 747-53A2499 IN 01, dated April 2, 2009; and 747-
53A2499 IN 02, dated September 10, 2009; to Boeing Alert Service 
Bulletin 747-53A2499, Revision 1, dated October 30, 2008, to notify 
operators of a typo and revised drawings. JAL noted that operators 
cannot accomplish a correct inspection and modification unless the 
information provided in Boeing Service Bulletin Information Notices 
747-53A2499 IN 01 and 747-53A2499 IN 02 is used. JAL added that 
including Revision 2 of this service bulletin would reduce unnecessary 
burden on both operators and the manufacturer.
    All Nippon Airways (ANA) also asked that the modification be done 
in accordance with Revision 2 of Boeing Alert Service Bulletin 747-
53A2499 instead of Boeing Alert Service Bulletin 747-53A2499, Revision 
1, dated October 30, 2008. ANA stated that it has already performed the 
terminating modification at stringer 6 using Boeing Alert Service 
Bulletin 747-53A2499, Revision 1, and had to request AMOCs during the 
modification because certain drawings in Boeing Alert Service Bulletin 
747-53A2499, dated August 11, 2005; and Revision 1, dated October 30, 
2008; were not specific to the modification. ANA added that this will 
reduce the AMOC requests to this proposed AD, in addition to reducing 
the maintenance burden.
    We partially agree with the commenters. We do not agree to delay 
this AD, due to the severity of the unsafe condition. However, as 
described previously, Boeing has issued Boeing Service Bulletin 747-
53A2499, Revision 2, dated August 12, 2010. Therefore, we have revised 
the requirements in this AD to allow the use of Boeing Service Bulletin 
747-53A2499, Revision 2, dated August 12, 2010, for accomplishing the 
specified actions.

Conclusion

    We reviewed the relevant data, considered the comments received, 
and determined that air safety and the public interest require adopting 
the AD with the changes described previously. We also determined that 
these changes will not increase the economic burden on any operator or 
increase the scope of the AD.

Costs of Compliance

    There are about 735 airplanes of the affected design in the 
worldwide fleet. This AD affects 96 airplanes of U.S. registry.
    The actions that are required by AD 2006-05-09 and retained in this 
AD take about 541 work-hours per airplane, at an average labor rate of 
$85 per work-hour. Based on these figures, the estimated cost of the 
currently required actions is $45,985 per airplane, per inspection 
cycle.
    The new Area 2 inspections take about 124 work-hours per airplane, 
at an average labor rate of $85 per work-hour. Based on these figures, 
the estimated cost of the new inspections specified in this AD for U.S. 
operators is $1,011,840, or $10,540 per airplane, per inspection cycle.
    The new modification takes about 4,799 work hours per airplane, at 
an average labor rate of $85 per work-hour. Required parts cost per 
airplane will be minimal. Based on these figures, the estimated cost of 
the new modification specified in this AD for U.S. operators is 
$39,159,840, or $407,915 per airplane.

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:

[[Page 81429]]

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 39-14506 (71 FR 12122, March 9, 2006) and by adding 
the following new airworthiness directive (AD):

2010-26-10 The Boeing Company: Amendment 39-16549. FAA-2010-0232; 
Directorate Identifier 2009-NM-032-AD.

Effective Date

    (a) This AD becomes effective February 1, 2011.

Affected ADs

    (b) This AD supersedes AD 2006-05-09.

Applicability

    (c) This AD applies to The Boeing Company Model 747-200C, -200F, 
-400, -400D, and -400F series airplanes, certificated in any 
category; as identified in Boeing Service Bulletin 747-53A2499, 
Revision 2, dated August 12, 2010.

Subject

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

Unsafe Condition

    (e) This AD results from a structural review of affected skin 
lap joints for widespread fatigue damage. The Federal Aviation 
Administration is issuing this AD to prevent fatigue cracking in 
certain lap joints, 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 2006-05-09, With Revised Service 
Information

Initial Inspections and Related Investigative and Corrective Actions

    (g) For airplanes identified in Boeing Alert Service Bulletin 
747-53A2499, dated August 11, 2005: At the applicable time specified 
in Table 1 of this AD, do an external surface high frequency eddy 
current (HFEC), external low frequency eddy current (LFEC), and 
internal LFEC inspection, as applicable, for cracks in the 
overlapping (upper) skin of the upper fastener row of the lap joints 
of the fuselage skin in sections 41, 42, and 46, and any applicable 
related investigative and corrective actions by doing all of the 
actions in accordance with the Accomplishment Instructions of Boeing 
Alert Service Bulletin 747-53A2499, dated August 11, 2005; Revision 
1, dated October 30, 2008; or Boeing Service Bulletin 747-53A2499, 
Revision 2, dated August 12, 2010. Do any applicable related 
investigative and corrective actions before further flight. As of 
the effective date of this AD, only Boeing Service Bulletin 747-
53A2499, Revision 2, dated August 12, 2010, may be used.

                    Table 1--Initial Compliance Time
------------------------------------------------------------------------
 For airplanes on which Structural
Significant Items (SSIs) F-25G, F-                Inspect--
         25H, and F-25I--
------------------------------------------------------------------------
(1) Have not been inspected in      Before the accumulation of 22,000
 accordance with paragraph (i) of    total flight cycles, or within
 AD 2004-07-22 R1, Amendment 39-     1,000 flight cycles after April 13,
 15326, using the HFEC method.       2006 (the effective date of AD 2006-
                                     05-09), whichever occurs later.
(2) Have been inspected in          Within 3,000 flight cycles after the
 accordance with paragraph (i) of    most recent supplemental structural
 AD 2004-07-22 R1, using the HFEC    inspection document (SSID)
 method.                             inspection of each applicable
                                     structural significant item (as
                                     given in Boeing Document D6-35022,
                                     ``SSID for Model 747 Airplanes,''
                                     Revision G, dated December 2000),
                                     or within 1,000 flight cycles after
                                     April 13, 2006, whichever occurs
                                     later.
------------------------------------------------------------------------

Repetitive Inspections

    (h) Repeat the applicable inspections required by paragraph (g) 
of this AD thereafter at intervals not to exceed those specified in 
paragraph 1.E., ``Compliance,'' (including the note) of Boeing Alert 
Service Bulletin 747-53A2499, dated August 11, 2005; Revision 1, 
dated October 30, 2008; or Boeing Service Bulletin 747-53A2499, 
Revision 2, dated August 12, 2010. As of the effective date of this 
AD, only Boeing Service Bulletin 747-53A2499, Revision 2, dated 
August 12, 2010, may be used.

New Requirements of This AD

Repetitive Inspections/Investigative and Corrective Actions

    (i) For all airplanes: Do an external HFEC inspection of the lap 
joints in Sections 41, 42, and 46 for cracks, by doing all the 
actions, including all applicable related investigative and 
corrective actions, specified in the Accomplishment Instructions of 
Boeing Service Bulletin 747-53A2499, Revision 2, dated August 12, 
2010. Do the inspection at the applicable time specified in 
paragraph 1.E. of Boeing Service Bulletin 747-53A2499, Revision 2, 
dated August 12, 2010; except as required by paragraph (m) of this 
AD. Do all applicable related investigative and corrective actions 
before further flight. Repeat the inspection thereafter at the times 
specified in paragraph 1.E. of Boeing Service Bulletin 747-53A2499, 
Revision 2, dated August 12, 2010. Accomplishment of the inspections 
required by this paragraph terminates the inspections required by 
paragraphs (g) and (h) of this AD.
    (j) For areas on which a lap joint repair was installed and the 
repair doubler is greater than or equal to 40 inches long: Do 
initial and repetitive internal HFEC inspections for cracks by doing 
all the actions, including all applicable corrective actions, 
specified in the Accomplishment Instructions of Boeing Service 
Bulletin 747-53A2499, Revision 2, dated August 12, 2010, except as 
required by paragraph (l) of this AD. Do the inspections and 
corrective actions at the times specified in paragraph 1.E. of 
Boeing Service Bulletin 747-53A2499, Revision 2, dated August 12, 
2010, except as required by paragraph (m) of this AD.

Terminating Action

    (k) Modify the applicable lap joints in Sections 41 and 42 by 
doing all the applicable actions specified in the Accomplishment 
Instructions of Boeing Service Bulletin 747-53A2499, Revision 2, 
dated August 12, 2010, at the time specified in paragraph 1.E. of 
Boeing Service Bulletin 747-53A2499, Revision 2, dated August 12, 
2010; except as required by paragraphs (l) and (m) of this AD. 
Accomplishing this modification terminates the repetitive 
inspections of the skin lap joints in Sections 41 and 42 required by 
paragraphs (i) and (j) of this AD for the length of lap joint that 
is modified.

Exceptions to Service Bulletin Procedures

    (l) Where Boeing Service Bulletin 747-53A2499, Revision 2, dated 
August 12, 2010, 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 (o) of this 
AD.
    (m) Where Boeing Service Bulletin 747-53A2499, Revision 2, dated 
August 12, 2010, specifies a compliance time after the date of that 
service bulletin, this AD requires compliance within the specified 
compliance time after the effective date of this AD.

Credit for Actions Done Using Previous Service Information

    (n) Actions done before the effective date of this AD in 
accordance with Boeing Alert Service Bulletin 747-53A2499, Revision 
1, dated October 30, 2008, are acceptable for compliance with the 
corresponding requirements of this AD.

[[Page 81430]]

Alternative Methods of Compliance (AMOCs)

    (o)(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. Send information to 
Attn: Nicholas Han, Aerospace Engineer, Airframe Branch, ANM-120S, 
FAA, Seattle ACO, 1601 Lind Avenue, SW., Renton, Washington 98057-
3356; telephone (425) 917-6449; fax (425) 917-6590. Information may 
be e-mailed 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) An AMOC that provides an acceptable level of safety may be 
used for any repair required by this AD, if it is approved by the 
Boeing Commercial Airplanes Organization Designation Authorization 
(ODA) or other person authorized by the Manager, Seattle ACO, to 
make those findings. For a repair method to be approved, the repair 
must meet the certification basis of the airplane and the approval 
must specifically refer to this AD.
    (4) AMOCs approved previously in accordance with AD 2006-05-09 
are approved as alternative methods of compliance with the 
corresponding requirements of this AD.

Material Incorporated by Reference

    (p) You must use Boeing Alert Service Bulletin 747-53A2499, 
dated August 11, 2005; or Boeing Service Bulletin 747-53A2499, 
Revision 2, dated August 12, 2010; 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 Boeing Service Bulletin 747-53A2499, 
Revision 2, dated August 12, 2010, under 5 U.S.C. 552(a) and 1 CFR 
part 51.
    (2) The Director of the Federal Register previously approved the 
incorporation by reference of Boeing Alert Service Bulletin 747-
53A2499, dated August 11, 2005, on April 13, 2006 (71 FR 12122, 
March 9, 2006).
    (3) 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.
    (4) 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.
    (5) 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 December 13, 2010.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2010-31992 Filed 12-27-10; 8:45 am]
BILLING CODE 4910-13-P