Document ID: FAA-2007-28990-0008
Agency: faa
Document Type: Rule
Title: Airworthiness Directives; Boeing Model 757-200, -200CB, and -300 Series Airplanes
Posted Date: 2007-12-17T05:00Z

[Federal Register: December 17, 2007 (Volume 72, Number 241)]
[Rules and Regulations]               
[Page 71214-71216]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr17de07-7]                         

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2007-28990; Directorate Identifier 2007-NM-033-AD; 
Amendment 39-15304; AD 2007-26-02]
RIN 2120-AA64

 
Airworthiness Directives; Boeing Model 757-200, -200CB, and -300 
Series Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are adopting a new airworthiness directive (AD) for certain 
Boeing Model 757-200, -200CB, and -300 series airplanes. This AD 
requires repetitive detailed inspections with a borescope for cracks of 
the intercostal tee clips; or repetitive detailed inspections for 
cracks of the intercostal tee clips and attachment fasteners at the 
number 3 and number 4 doorstops of the passenger door cutouts; and 
related investigative and corrective actions if necessary. This AD also 
provides an optional terminating action for the repetitive inspections. 
This AD results from reports of cracked intercostal tee clips at the 
number 3 and number 4 doorstops of the passenger door cutouts. We are 
issuing this AD to detect and correct cracking of the tee clips, which 
could result in additional stress on the adjacent tee clips, 
surrounding intercostals, edge frame, door structure and doorstops. 
This additional stress could cause further cracking or breaking of the 
tee clips, which could result in failure of the door to seal and 
consequent rapid decompression of the airplane.

DATES: This AD is effective January 22, 2008.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of January 22, 
2008.
    We must receive comments on this AD by January 22, 2008.

ADDRESSES: For service information identified in this AD, contact 
Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-
2207.

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: Jason Deutschman, 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

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 to include an airworthiness directive (AD) that would apply to 
certain Boeing Model 757-200, -200CB, and -300 series airplanes. That 
NPRM was published in the Federal Register on August 16, 2007 (72 FR 
45961). That NPRM proposed to require repetitive inspections for cracks 
of the intercostal tee clips and attachment fasteners at the number 3 
and number 4 doorstops of the passenger door cutouts, or repetitive 
inspections for cracks of the intercostal tee clips; and related 
investigative/corrective actions if necessary. That NPRM also provides 
an optional

[[Page 71215]]

terminating action for the repetitive inspections.

Comments

    We gave the public the opportunity to participate in developing 
this AD. We considered the comments received.

Support for the NPRM

    Continental Airlines (CAL) supports the NPRM and notes that it has 
an on-going customized passenger door maintenance program already in 
place to inspect the subject area on its airplanes at 4C and 8C heavy 
checks. CAL adds that it has found no cracks on its airplanes, but 
intends to incorporate the terminating action provided in the NPRM at 
the next 4C or 8C opportunity.

Request To Include Access and Close-up Costs

    Boeing asks that the costs to gain and close access for the 
proposed detailed inspection be included to better reflect the cost 
difference between the two inspection options provided in the NPRM 
(detailed versus borescope). Boeing estimates 9.5 work hours to gain 
access by removing existing galleys, and Boeing estimates another 10 
work hours to replace the galleys after inspection to close access. 
Boeing states that this adds a total of 19.5 hours of work at a cost of 
$1,560 per airplane based on an average labor rate of $80 per work 
hour. This adds up to an additional cost to the fleet of $505,440 over 
the $51,840 cost that is shown. This access cost is not incurred if the 
alternative borescope inspection method is used; however, if repairs 
are to be performed, either to address cracking or to terminate 
inspections, the access and close-out costs would be incurred in 
addition to parts costs in order to perform the required part 
replacements. Boeing adds that this would affect the supplementary 
information in the estimated Costs of Compliance paragraph.
    We acknowledge Boeing's concerns. However, because operators are 
given the option of doing the detailed inspection or the detailed 
inspection with a borescope (which takes longer), the cost depends on 
which inspection is done. The cost impact figures discussed in AD 
rulemaking actions represent only the time necessary to perform the 
specific actions actually required by the AD. These figures typically 
do not include incidental costs, such as the time required to gain 
access and close up, or the costs of ``on-condition'' actions such as 
repairs (that is, actions needed to correct an unsafe condition). We 
have made no change to the AD in this regard.

Clarification of Summary Language

    We revised the Summary section of this final rule to specify the 
repetitive inspection methods.

Conclusion

    We reviewed the relevant data, considered the comments received, 
and determined that air safety and the public interest require adopting 
the AD as proposed.

Difference Between the Proposed AD and Service Information

    The service bulletin specifies to contact the manufacturer for 
instructions on how to repair certain conditions, but this AD requires 
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

    There are about 912 airplanes of the affected design in the 
worldwide fleet. This AD affects about 324 airplanes of U.S. registry.
    The detailed inspection, if accomplished, takes about 2 work hours 
per airplane, at an average work rate of $80 per work hour. Based on 
these figures, the estimated cost of the detailed inspections required 
by this AD is $51,840, or $160 per airplane, per inspection cycle.
    The borescope inspection, if accomplished, takes about 3 work hours 
per airplane, at an average work rate of $80 per work hour. Based on 
these figures, the estimated cost of the borescope inspections required 
by this AD is $77,760, or $240 per airplane, per inspection cycle.

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

    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.
    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.

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 FAA amends Sec.  39.13 by adding the following new AD:

2007-26-02 Boeing: Amendment 39-15304. Docket No. FAA-2007-28990; 
Directorate Identifier 2007-NM-033-AD.

Effective Date

    (a) This airworthiness directive (AD) is effective January 22, 
2008.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 757-200, -200CB, and -300 
series airplanes, certificated in any category; as identified in

[[Page 71216]]

Boeing Alert Service Bulletin 757-53A0093, dated November 8, 2006.

Unsafe Condition

    (d) This AD results from reports of cracked intercostal tee 
clips at the number 3 and number 4 doorstops of the passenger door 
cutouts. We are issuing this AD to detect and correct cracking of 
the tee clips, which could result in additional stress on the 
adjacent tee clips, surrounding intercostals, edge frame, door 
structure and doorstops. This additional stress could cause further 
cracking or breaking of the tee clips, which could result in failure 
of the door to seal and consequent rapid decompression of the 
airplane.

Compliance

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

Repetitive Inspections/Investigative and Corrective Actions

    (f) Before the accumulation of 20,000 total flight cycles or 
within 3,000 flight cycles after the effective date of this AD, 
whichever is later: Do the applicable inspection specified in 
paragraph (f)(1) or (f)(2) of this AD by doing all the actions 
including all applicable related investigative (additional detailed 
inspections if necessary) and corrective actions; except as provided 
by paragraph (g) of this AD; in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 757-53A0093, dated 
November 8, 2006. All related investigative and corrective actions 
must be done before further flight.
    (1) Do a detailed inspection for cracks of the intercostal tee 
clips and attachment fasteners at the number 3 and number 4 
doorstops of the passenger door cutouts. Repeat the inspection 
thereafter at intervals not to exceed 3,000 flight cycles until 
accomplishment of the terminating action specified in paragraph (h) 
of this AD.
    (2) Do a detailed inspection with a borescope for cracks of the 
intercostal tee clips. Repeat the inspection thereafter at intervals 
not to exceed 3,000 flight cycles until accomplishment of the 
terminating action specified in paragraph (h) of this AD.
    (g) If any cracked structure is found during any inspection 
required by this AD, and the Accomplishment Instructions of Boeing 
Alert Service Bulletin 757-53A0093, dated November 8, 2006, specify 
to contact Boeing for appropriate action: Before further flight, 
repair any cracked structure using a method approved in accordance 
with the procedures specified in paragraph (i)(2) of this AD.

Optional Terminating Action

    (h) Replacing both intercostal tee clips on the left and right 
sides with new tee clips in accordance with Part 3 of the 
Accomplishment Instructions of Boeing Alert Service Bulletin 757-
53A0093, dated November 8, 2006, terminates the repetitive 
inspections required by this AD.

Alternative Methods of Compliance (AMOCs)

    (i)(1) The Manager, Seattle Aircraft Certification Office (ACO), 
FAA, has the authority to approve AMOCs for this AD, if requested in 
accordance with the procedures found in 14 CFR 39.19.
    (2) 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.
    (3) 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 appropriate principal inspector (PI) in the FAA 
Flight Standards District Office (FSDO), or lacking a PI, your local 
FSDO.

Material Incorporated by Reference

    (j) You must use Boeing Alert Service Bulletin 757-53A0093, 
dated November 8, 2006, 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, P.O. Box 3707, Seattle, Washington 
98124-2207.
    (3) You may review copies of the service information 
incorporated by reference at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington; or 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 10, 2007.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
 [FR Doc. E7-24337 Filed 12-14-07; 8:45 am]

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