Document ID: FAA-2008-0759-0005
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Boeing Model 777 Series Airplanes
Posted Date: 2009-06-25T04:00Z

[Federal Register: June 25, 2009 (Volume 74, Number 121)]
[Proposed Rules]               
[Page 30245-30247]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr25jn09-17]                         

[[Page 30245]]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2009-0571; Directorate Identifier 2009-NM-004-AD]
RIN 2120-AA64

 
Airworthiness Directives; Boeing Model 777 Series Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: We propose to adopt a new airworthiness directive (AD) for all 
Boeing Model 777 series airplanes. This proposed AD would require 
inspections for scribe lines in the skin along lap joints, butt joints, 
certain external doublers, and the large cargo door hinges; and related 
investigative and corrective actions if necessary. This proposed AD 
results from reports of scribe lines found at lap joints and butt 
joints, around external doublers, and at locations where external 
decals had been cut. We are proposing this AD to detect and correct 
scribe lines, which can develop into fatigue cracks in the skin. 
Undetected fatigue cracks can grow and cause sudden decompression of 
the airplane.

DATES: We must receive comments on this proposed AD by August 10, 2009.

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: U.S. Department of Transportation, Docket 
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New 
Jersey Avenue, SE., Washington, DC 20590, 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 or 
425-227-1152.

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 (telephone 800-647-5527) is in the 
ADDRESSES section. Comments will be available in the AD docket shortly 
after receipt.

FOR FURTHER INFORMATION CONTACT: Berhane Alazar, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98057-3356; telephone (425) 
917-6577; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION: 

Comments Invited

    We invite you to send any written relevant data, views, or 
arguments about this proposed AD. Send your comments to an address 
listed under the ADDRESSES section. Include ``Docket No. FAA-2009-0571; 
Directorate Identifier 2009-NM-004-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of this proposed AD. We 
will consider all comments received by the closing date and may amend 
this proposed AD because of those comments.
    We will post all comments we receive, without change, to http://
www.regulations.gov, including any personal information you provide. We 
will also post a report summarizing each substantive verbal contact we 
receive about this proposed AD.

Discussion

    We have received a report indicating that scribe lines have been 
found by one operator on one Model 777 airplane. On this airplane, 
scribe lines were found around the edges of the area where a large 
decal had been installed. The operator believed that the scribe lines 
were made when the decal was removed. No cracks were found at the 
scribe line locations. On other airplane models, scribe lines appear to 
have been made when sealant was removed as part of preparation of the 
airplane for repainting, and in some cases resulted in significant 
cracking. Although no such cracking has been found on Model 777 
airplanes, fatigue cracks can develop in the skin at scribe line 
locations and have been found on some airplane models. Such fatigue 
cracks, if not corrected, could grow large and cause sudden 
decompression of the airplane.

Related ADs

    This proposed AD is similar to two existing ADs. AD 2006-07-12, 
amendment 39-14539 (71 FR 16211, March 31, 2006), applies to Boeing 
Model 737-100, -200, -200C, -300, -400, and -500 series airplanes. AD 
2007-19-07, amendment 39-15198 (72 FR 60244, October 24, 2007), applies 
to all Boeing Model 757-200, -200PF, and -200CB series airplanes. Those 
ADs require inspections to detect scribe lines in the fuselage skin at 
certain lap joints, butt joints, external repair doublers, and other 
areas; and related investigative/corrective actions if necessary. Those 
actions resulted from reports of fuselage skin cracks adjacent to the 
skin lap joints on airplanes that had scribe lines.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 777-53A0054, dated 
August 7, 2008. The service bulletin describes procedures for 
exploratory detailed inspections to detect scribe lines in affected lap 
joint and butt joint locations, external repair doubler locations, and 
large cargo door hinges. The service bulletin specifies removing paint 
and sealant from affected areas before the initial exploratory 
inspection. The compliance time for the exploratory inspections is 
15,000, 32,000, or 45,000 total flight cycles (depending on the 
inspection location).
    The service bulletin specifies related investigative and corrective 
actions. The related investigative actions include performing 
repetitive detailed, high frequency eddy current, or ultrasonic 
inspections of the scribe lines to detect cracks, and the corrective 
actions include repairing scribe lines and cracks. The service bulletin 
specifies to repair cracks before further flight.
    The service bulletin specifies repairing scribe lines before 
further flight, except when a limited return to service (LRTS) program 
for qualifying scribe lines would allow return to service for a limited 
period before scribe lines are repaired. The LRTS program includes 
repetitive inspections to detect cracks where scribe lines are found. 
To qualify for an LRTS program, scribe lines must meet certain criteria 
based on their depth and location. The service bulletin specifies final 
repair by using the structural repair manual or

[[Page 30246]]

contacting Boeing for instructions, which would eliminate the need for 
the repetitive inspections of the LRTS program. The repetitive 
intervals for the LRTS program range from 1,200 to 5,000 flight cycles, 
depending on the depth and location of the scribe lines and the 
configuration of the airplane.
    The service bulletin notes that certain inspections would not be 
required under the following conditions:
     The airplane had never been stripped or repainted.
     The area under the wing-to-body fairings had never been 
stripped or repainted.
     For each repair, the airplane had never been stripped or 
repainted since the repair was installed.
     No sealant had been removed except in accordance with the 
specified sealant removal processes as given in Appendix A of the 
service bulletin.
     No fillet seal exists at a certain lap joint or was 
previously removed from that lap joint.
    The service bulletin specifies submitting inspection results to 
Boeing. The service bulletin also provides procedures for addressing 
scribe lines detected before the initial inspection threshold.

FAA's Determination and Requirements of This Proposed AD

    We are proposing this AD because we evaluated all relevant 
information and determined the unsafe condition described previously is 
likely to exist or develop in other products of the same type design. 
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 Service Bulletin.'' This 
proposed AD would also require sending the results of the exploratory 
inspections to Boeing.

Differences Between the Proposed AD and Service Bulletin

    Where the note below Table 6 in paragraph 1.E., ``Compliance,'' of 
Boeing Alert Service Bulletin 777-53A0054, dated August 7, 2008, 
specifies to ``contact Boeing for inspection requirements for operation 
beyond 60,000 total flight-cycles after first repaint,'' this AD 
proposes to require contacting the FAA for inspection requirements for 
those airplanes.
    Where the service bulletin specifies contacting the manufacturer 
for instructions on how to repair certain conditions, this proposed AD 
would require repairing those conditions in one of the following ways:
     Using a method that we approve; or
     Using data that meet the certification basis of the 
airplane, and that have been approved by an Authorized Representative 
for the Boeing Commercial Airplanes Delegation Option Authorization 
Organization whom we have authorized to make those findings.

Costs of Compliance

    We estimate that this proposed AD would affect 129 airplanes of 
U.S. registry. The following table provides the estimated costs for 
U.S. operators to comply with this proposed AD. A work-hour estimate is 
not available for the inspection for an external repair doubler since 
the inspection required can be different depending on the in-service 
repair history of the airplane. This inspection affects up to 129 U.S.-
registered airplanes.

                                                                 Table--Estimated Costs
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                                                                                                                  Number of U.S.-
             Action                   Work hours       Average labor         Parts           Cost per product       registered          Fleet cost
                                                       rate per hour                                                 airplanes
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Exploratory Inspection.........  9 to 34............             $80  None..............  $720 to $2,720........             129  $92,880 to $350,880.
--------------------------------------------------------------------------------------------------------------------------------------------------------

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), 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.
    You can find our regulatory evaluation and the estimated costs of 
compliance in the AD Docket.

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 AD:

Boeing: Docket No. FAA-2009-0571; Directorate Identifier 2009-NM-
004-AD.

Comments Due Date

    (a) We must receive comments by August 10, 2009.

[[Page 30247]]

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 777 series airplanes, 
certificated in any category, as identified in Boeing Alert Service 
Bulletin 777-53A0054, dated August 7, 2008.

Subject

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

Unsafe Condition

    (e) This AD results from reports of scribe lines found at lap 
joints and butt joints, around external doublers, and at locations 
where external decals had been cut. We are issuing this AD to detect 
and correct scribe lines, which can develop into fatigue cracks in 
the skin. Undetected fatigue cracks can grow and cause sudden 
decompression 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.

Inspection

    (g) At the applicable times specified in paragraph 1.E., 
``Compliance,'' of Boeing Alert Service Bulletin 777-53A0054, dated 
August 7, 2008, except as provided in paragraphs (h) and (j) of this 
AD, do detailed exploratory inspections for scribe lines in the skin 
along lap joints, butt joints, certain external doublers, and the 
large cargo door hinges. Do all applicable related investigative and 
corrective actions at the times specified in the service bulletin, 
by accomplishing all actions specified in the Accomplishment 
Instructions of the service bulletin, except as provided by 
paragraph (i) of this AD.

    Note 1:  The inspection exemptions described in NOTES 1.-5. in 
paragraph 1.E. of Boeing Alert Service Bulletin 777-53A0054, dated 
August 7, 2008, apply to this AD.

Exceptions to Service Bulletin Specifications

    (h) Where Boeing Alert Service Bulletin 777-53A0054, dated 
August 7, 2008, specifies a compliance time after the date on the 
service bulletin, this AD requires compliance within the specified 
compliance time after the effective date of this AD.
    (i) Where Boeing Alert Service Bulletin 777-53A0054, dated 
August 7, 2008, specifies to contact Boeing for appropriate action, 
accomplish applicable actions using a method approved in accordance 
with the procedures specified in paragraph (l) of this AD.
    (j) Where paragraph 1.E. of Boeing Alert Service Bulletin 777-
53A0054, dated August 7, 2008, specifies to ``contact Boeing for 
inspection requirements for operation beyond 60,000 total flight-
cycles after first repaint,'' for those airplanes, this AD requires 
contacting the Manager, Seattle Aircraft Certification Office (ACO), 
for all inspection requirements of this AD.

Report

    (k) At the applicable time specified in paragraph (k)(1) or 
(k)(2) of this AD: Submit a report of the findings (both positive 
and negative) of the inspections required by paragraph (g) of this 
AD. You may use Appendix B of Boeing Alert Service Bulletin 777-
53A0054, dated August 7, 2008. Send the report to Boeing Commercial 
Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207. The report 
must contain, at a minimum, the inspection results, a description of 
any discrepancies found, the airplane serial number, and the number 
of flight cycles and flight hours on the airplane. Under the 
provisions of the Paperwork Reduction Act (44 U.S.C. 3501 et seq.), 
the Office of Management and Budget (OMB) has approved the 
information collection requirements contained in this AD and has 
assigned OMB Control Number 2120-0056.
    (1) If the inspection was done on or after the effective date of 
this AD: Submit the report within 30 days after the inspection.
    (2) If the inspection was done before the effective date of this 
AD: Submit the report within 30 days after the effective date of 
this AD.

Alternative Methods of Compliance (AMOCs)

    (l)(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: Berhane Alazar, Aerospace 
Engineer, Airframe Branch, ANM-120S, FAA, Seattle Aircraft 
Certification Office, 1601 Lind Avenue, SW., Renton, Washington 
98057-3356; telephone (425) 917-6577; 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) An AMOC that provides an acceptable level of safety may be 
used for any repair 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.

    Issued in Renton, Washington, on June 17, 2009.
Dorr M. Anderson,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. E9-14991 Filed 6-24-09; 8:45 am]

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