Airworthiness Directives; Boeing Model 747 Series Airplanes

[Federal Register Volume 68, Number 2 (Friday, January 3, 2003)]
[Rules and Regulations]
[Pages 257-259]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-27]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NM-84-AD; Amendment 39-13005; AD 2002-26-17]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 747 Series Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment supersedes an existing airworthiness directive 
(AD), applicable to certain Boeing Model 747 series airplanes, that 
currently requires a one-time inspection to identify all alloy steel 
bolts on the body station 1480 bulkhead splice, and corrective action 
if necessary; and provides for optional terminating action for certain 
requirements of that AD. This amendment requires accomplishment of the 
previously optional terminating action. The actions specified by this 
AD are intended to prevent cracked or broken bolts, which could result 
in structural damage and rapid depressurization of the airplane. This 
action is intended to address the identified unsafe condition.

DATES: Effective February 7, 2003.
    The incorporation by reference of certain publications, as listed 
in the regulations, was approved previously by the Director of the 
Federal Register as of May 8, 2002 (67 FR 19641, April 23, 2002).

ADDRESSES: The service information referenced in this AD may be 
obtained from Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, 
Washington 98124-2207. This information may be examined at the Federal 
Aviation Administration (FAA), Transport Airplane Directorate, Rules 
Docket, 1601 Lind Avenue, SW., Renton, Washington; or at the Office of 
the Federal Register, 800 North Capitol Street, NW., suite 700, 
Washington, DC.

FOR FURTHER INFORMATION CONTACT: Rick Kawaguchi, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
227-1153; fax (425) 227-1181.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) by superseding AD 2002-08-10, 
amendment 39-12718 (67 FR 19641, April 23, 2002), which is applicable 
to certain Boeing Model 747 series airplanes, was published in the 
Federal Register on June 21, 2002 (67 FR 42204). The action proposed to 
continue to require a one-time inspection to identify all alloy steel 
bolts on the body station (BS) 1480 bulkhead splice, and corrective 
action if necessary. That action also proposed to mandate the 
previously optional terminating action.

Comments

    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. Due consideration has been given to 
the comments received.

Request to Remove Paragraph (f)

    One commenter asks that paragraph (f) of the proposed AD be 
removed. The commenter states that paragraph (c) of the proposed AD 
conflicts with paragraph (f) because paragraph (f) states, ``As of the 
effective date of this AD, no person may install an alloy steel bolt on 
the BS 1480 bulkhead splice on any airplane.'' The commenter notes that 
Boeing Alert Service Bulletin 747-53A2390, Revision 1, is referenced as 
the applicable source of service information in AD 2001-11-06, 
amendment 39-12248 (66 FR 31124, July 16, 2001); that AD is specified 
in paragraph (c) of the proposed AD. The commenter adds that paragraph 
(c) allows reinstallation of alloy steel bolts following a magnetic 
particle inspection, which creates the conflict between paragraphs (c) 
and (f).
    The FAA partially agrees with the commenter. We agree that there is 
some inconsistency between the requirements of paragraphs (c) and (f) 
of the proposed AD, but we do not agree that paragraph (f) should be 
removed. The inspections to identify alloy steel bolts, as required by 
paragraph (a) of the proposed AD, are one-time only. An operator could 
install new alloy steel bolts in areas previously identified as having 
Inconel 718 bolts after doing the inspection. Unless proper records are 
maintained, an operator will not know whether the repetitive 
inspections of alloy steel bolts with no cracking, which is corrective 
action for the inspection required by paragraph (a), would apply. For 
clarification, we have changed paragraph (f) in this final rule to 
state, ``Except as provided by paragraph (c) of this AD: As of the 
effective date of this AD, no person may install an alloy steel bolt on 
the BS 1480 bulkhead splice on any airplane.''

Request to Change Paragraph (a)

    One commenter asks that paragraph (a) of the proposed AD be changed 
to remove the term ``detailed methods'' as an inspection that can be 
used for identification of an alloy steel bolt. The commenter states 
that the referenced service bulletin contains no detailed instructions 
for identifying the bolts by a detailed visual inspection. The 
commenter adds that an operator may be able to identify the bolt by a 
visual inspection, but only if the operator knows the bolt codes marked 
on the heads of the alloy steel bolts.
    We do not agree with the commenter. On page 34 of the referenced 
service bulletin, instructions are provided for a detailed inspection, 
including the bolt codes for identifying alloy steel bolts for

[[Page 258]]

Groups 3 and 4 airplanes. No change to the final rule is necessary in 
this regard.

Request to Change Paragraph (d)

    One commenter asks that paragraph (d) of the proposed AD be changed 
so the wording is similar to that specified in paragraphs (b)(2) and 
(b)(3) of the proposed AD. The commenter states that paragraph (d) 
would require installation of Inconel 718 bolts per Boeing Alert 
Service Bulletin 747-53A2477. This requirement could contradict the 
requirements in AD 2001-11-06, which requires that inspections and 
repairs be done per Boeing Alert Service Bulletin 747-53A2390, Revision 
1. Service Bulletin 747-53A2390, Revision 1, provides for the 
installation of several different sizes of Inconel 718 bolts, depending 
on which level of repair may be required, but the bolts may not be the 
same bolts specified in Service Bulletin 747-53A2477. The commenter 
adds that such inconsistency will lead to many requests for alternative 
methods of compliance.
    We do not agree with the commenter that paragraph (d) of the 
proposed AD could contradict the requirements in AD 2001-11-06. The 
applicability section of this AD excludes airplanes on which the 
bulkhead splice areas have been modified in accordance with Plan ``B'' 
of AD 2001-11-06. If an operator has replaced alloy steel bolts with 
Inconel 718 bolts per Plan ``B,'' no further action is required by this 
final rule. No change to the final rule is necessary in this regard.

Reporting Requirement

    The service bulletin recommends that inspection findings be 
submitted to the manufacturer. However, this AD does not require that 
operators submit reports of inspection findings.

Conclusion

    After careful review of the available data, including the comments 
noted above, the FAA has determined that air safety and the public 
interest require the adoption of the rule with the change previously 
described. The FAA has determined that this change will neither 
increase the economic burden on any operator nor increase the scope of 
the AD.

Cost Impact

    There are approximately 582 airplanes of the affected design in the 
worldwide fleet. The FAA estimates that 178 airplanes of U.S. registry 
will be affected by this AD.
    The inspection that is currently required by AD 2002-08-10 takes 
approximately 58 work hours per airplane to accomplish (including 
access and close), at an average labor rate of $60 per work hour. Based 
on these figures, the cost impact of the currently required actions on 
U.S. operators is estimated to be $619,440, or $3,480 per airplane.
    The terminating action required in this AD action will take 
approximately 86 work hours per airplane to accomplish, at an average 
labor rate of $60 per work hour. Required parts could cost as much as 
approximately $1,414 per airplane. Based on these figures, the cost 
impact of the requirements of this AD on U.S. operators is estimated to 
be $1,170,172, or $6,574 per airplane.
    The cost impact figures discussed above are based on assumptions 
that no operator has yet accomplished any of the requirements of this 
AD action, and that no operator would accomplish those actions in the 
future if this AD were not adopted. 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, planning time, or time necessitated by other 
administrative actions.

Regulatory Impact

    The regulations adopted herein 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. Therefore, it 
is determined that this final rule does not have federalism 
implications under Executive Order 13132.
    For the reasons discussed above, I certify that this action (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. A final evaluation has been prepared for this action 
and it is contained in the Rules Docket. A copy of it may be obtained 
from the Rules Docket at the location provided under the caption 
ADDRESSES.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (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. Section 39.13 is amended by removing amendment 39-12718 (67 FR 
19641, April 23, 2002), and by adding a new airworthiness directive 
(AD), amendment 39-13005, to read as follows:

2002-26-17 Boeing: Amendment 39-13005. Docket 2002-NM-84-AD. 
Supersedes AD 2002-08-10, Amendment 39-12718.

    Applicability: Model 747 series airplanes, certificated in any 
category, line numbers 1 through 750 inclusive, excluding airplanes 
on which the bulkhead splice areas have been modified in accordance 
with Plan ``B'' of AD 2001-11-06, amendment 39-12248.

    Note 1: This AD applies to each airplane identified in the 
preceding applicability provision, regardless of whether it has been 
otherwise modified, altered, or repaired in the area subject to the 
requirements of this AD. For airplanes that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (g) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.

    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent cracked or broken bolts, which could result in 
structural damage and rapid depressurization of the airplane, 
accomplish the following:

Restatement of Certain Requirements of AD 2002-08-10

Inspection

    (a) At the applicable time specified by paragraph (a)(1) or 
(a)(2) of this AD: Inspect the BS 1480 bulkhead splice to identify 
all alloy steel bolts by using a magnet or, if applicable, detailed 
methods, in accordance with Boeing Alert Service Bulletin 747-
53A2477, dated February 28, 2002.

    Note 2: For the purposes of this AD, a detailed inspection is 
defined as: ``An intensive visual examination of a specific 
structural area, system, installation, or assembly to detect damage, 
failure, or irregularity. Available lighting is normally

[[Page 259]]

supplemented with a direct source of good lighting at intensity 
deemed appropriate by the inspector. Inspection aids such as mirror, 
magnifying lenses, etc., may be used. Surface cleaning and elaborate 
access procedures may be required.''

    (1) For airplanes on which the bulkhead splice inspection 
specified by AD 2001-11-06 has NOT been accomplished within 15 
months before May 8, 2002 (the effective date of AD 2002-08-10, 
amendment 39-12718): Inspect within 90 days after May 8, 2002.
    (2) For airplanes on which the bulkhead splice inspection 
specified by AD 2001-11-06 HAS been accomplished within 15 months 
before May 8, 2002: Inspect within 18 months since the most recent 
inspection.

Corrective Actions

    (b) For each alloy steel bolt found during the inspection 
required by paragraph (a) of this AD: Before further flight, inspect 
those bolts using torque test or ultrasonic methods to detect cracks 
or breakage, in accordance with Boeing Alert Service Bulletin 747-
53A2477, dated February 28, 2002, except as required by paragraph 
(e) of this AD.
    (1) For each uncracked and unbroken alloy steel bolt found: 
Repeat the inspection specified by paragraph (b) of this AD 
thereafter at least every 18 months, until the terminating action of 
paragraph (d) of this AD is accomplished.
    (2) For any cracked or broken bolt found: Before further flight, 
replace it with an Inconel 718 bolt. Such replacement terminates the 
requirements of this AD for that bolt only.
    (3) If any cracked or broken bolt is found anywhere along the 
splice during any inspection required by paragraph (b) of this AD: 
Before further flight, reinspect, using ultrasonic methods, any 
remaining alloy steel bolts that were initially inspected using 
torque test methods, and replace any cracked or broken bolt with an 
Inconel 718 bolt. Such replacement terminates the requirements of 
this AD for that bolt only.

Magnetic Particle Inspection

    (c) Plan ``A'' inspections required by AD 2001-11-06 are 
acceptable for compliance with the inspection requirements of 
paragraph (b) of this AD, provided a magnetic particle inspection 
and applicable corrective actions are performed on any alloy steel 
bolt removed during any Plan ``A'' inspection before the bolt is 
reinstalled. The magnetic particle inspection and corrective actions 
must be performed in accordance with Boeing Alert Service Bulletin 
747-53A2477, dated February 28, 2002, except as required by 
paragraph (e) of this AD.

New Requirements of This AD

Terminating Action

    (d) Within 6 years after the effective date of this AD: Replace 
all alloy steel bolts in the BS 1480 bulkhead splice with Inconel 
718 bolts, in accordance with Boeing Alert Service Bulletin 747-
53A2477, dated February 28, 2002, except as required by paragraph 
(e) of this AD. Replacement of all alloy steel bolts terminates the 
requirements of this AD.

Exceptions to Service Information

    (e) If Boeing Alert Service Bulletin 747-53A2477, dated February 
28, 2002, specifies to contact Boeing for appropriate action: Before 
further flight, repair in accordance with a method approved by the 
Manager, Seattle Aircraft Certification Office (ACO), FAA; or per 
data meeting the type certification basis of the airplane approved 
by a Boeing Company Designated Engineering Representative who has 
been authorized by the Manager, Seattle ACO, to make such findings. 
For a repair method to be approved, the approval must specifically 
reference this AD.

Part Installation

    (f) Except as provided by paragraph (c) of this AD: As of the 
effective date of this AD, no person may install an alloy steel bolt 
on the BS 1480 bulkhead splice on any airplane.

Alternative Methods of Compliance

    (g) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Seattle ACO, FAA. Operators shall 
submit their requests through an appropriate FAA Principal 
Maintenance Inspector, who may add comments and then send it to the 
Manager, Seattle ACO.

    Note 3: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Seattle ACO.

Special Flight Permits

    (h) Special flight permits may be issued in accordance with 
Sec. Sec.  sections 21.197 and 21.199 of the Federal Aviation 
Regulations (14 CFR 21.197 and 21.199) to operate the airplane to a 
location where the requirements of this AD can be accomplished.

Incorporation by Reference

    (i) Unless otherwise specified in this AD, the actions shall be 
done in accordance with Boeing Alert Service Bulletin 747-53A2477, 
dated February 28, 2002. This incorporation by reference was 
approved previously by the Director of the Federal Register as of 
May 8, 2002 (67 FR 19641, April 23, 2002). Although the service 
bulletin references a reporting requirement and completion of the 
attached Evaluation Form, such reporting and evaluation are not 
required by this AD. Copies may be obtained from Boeing Commercial 
Airplane Group, P.O. Box 3707, Seattle, Washington 98124-2207. 
Copies may be inspected at the FAA, Transport Airplane Directorate, 
1601 Lind Avenue, SW., Renton, Washington; or at the Office of the 
Federal Register, 800 North Capitol Street, NW., suite 700, 
Washington, DC.

Effective Date

    (j) This amendment becomes effective on February 7, 2003.

    Issued in Renton, Washington, on December 24, 2002.
Charles D. Huber,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 03-27 Filed 1-2-03; 8:45 am]
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