Airworthiness Directives; Boeing Model 747 Airplanes

[Federal Register Volume 70, Number 131 (Monday, July 11, 2005)]
[Rules and Regulations]
[Pages 39644-39647]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-13432]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-20243; Directorate Identifier 2004-NM-153-AD; 
Amendment 39-14185; AD 2005-14-08]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 747 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 747-100, -200, -300, and 
747SP series airplanes. That AD currently requires certain inspections 
to find missing or alloy-steel taperlock fasteners (bolts) in the 
diagonal brace underwing fittings, and corrective actions if necessary. 
For airplanes with missing or alloy-steel fasteners, that AD also 
mandates replacement of certain fasteners with new fasteners, which 
constitutes terminating action for certain inspections. This new AD 
expands the applicability to include additional airplane models and 
requires a new inspection to determine fastener material and to find 
missing or broken fasteners, and related investigative/corrective 
actions if necessary. This AD is prompted by reports indicating that 
cracked fasteners made of A286 material were found on airplanes that 
had only fasteners made of A286 material installed in the area common 
to the diagonal brace underwing fittings. We are issuing this AD to 
prevent loss of the underwing fitting load path due to missing or 
damaged alloy-steel or A286 taperlock fasteners, which could result in 
separation of the engine and strut from the airplane.

DATES: This AD becomes effective August 15, 2005.
    The incorporation by reference of Boeing Alert Service Bulletin 
747-57A2312, Revision 1, dated April 29, 2004, is approved by the 
Director of the Federal Register as of August 15, 2005.
    On August 1, 2001 (66 FR 34094, June 27, 2001), the Director of the 
Federal Register approved the incorporation by reference of Boeing 
Alert Service Bulletin 747-57A2312, dated June 15, 2000.

ADDRESSES: For service information identified in this AD, contact 
Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-
2207.
    Docket: The AD docket contains the proposed AD, comments, and any 
final disposition. You can examine the AD docket on the Internet at 
http://dms.dot.gov, or in person at the Docket Management Facility 
office between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The Docket Management Facility office (telephone (800) 647-
5227) is located on the plaza level of the Nassif Building at the U.S. 
Department of Transportation, 400 Seventh Street SW., room PL-401, 
Washington, DC. This docket number is FAA-2005-20243; the directorate 
identifier for this docket is 2004-NM-153-AD.

FOR FURTHER INFORMATION CONTACT: Nicholas Kusz, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
917-6432; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend part 39 of the 
Federal Aviation Regulations (14 CFR part 39) with an AD to supersede 
AD 2001-13-06, amendment 39-12286 (66 FR 34094, June 27, 2001). The 
existing AD applies to certain Boeing Model 747-100, -200, -300, and 
747SP series airplanes. The proposed AD was published in the Federal 
Register on February 1, 2005 (70 FR 5066), to continue to require the 
actions required by the existing AD. The proposed AD would also expand 
the applicability to include additional airplane models and would 
require a new inspection to determine fastener material and to find 
missing or broken fasteners, 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 comments that have been 
submitted on the proposed AD.

Support for the Proposed AD

    One commenter supports the proposed AD.

Request To Increase Initial Inspection Threshold

    One commenter requests that we revise paragraph (h)(1) of the 
proposed AD to increase the initial inspection threshold from 12 months 
to 18 months after the effective date of the AD for the inspection in 
that paragraph. The commenter states that this would allow the 
inspection to be performed during a regularly scheduled C-check.
    We agree. Our intent was that the affected fasteners be inspected 
during a regularly scheduled maintenance visit in which time permits 
the fuel tank to be opened. We have revised paragraph (h)(1) of this AD 
to specify a compliance threshold of 18 months after the effective date 
of the AD.

Request To Clarify Subject Fasteners

    One commenter requests that we revise paragraph (h) to clarify that 
the inspections required by that paragraph apply to the aft-most 10 
fasteners in the diagonal brace underwing fitting, not ``all fasteners 
in the diagonal brace underwing fitting,'' as stated in the proposed 
AD. We agree and have revised paragraph (h) of this AD accordingly.

Conclusion

    We have carefully reviewed the available data, including the 
comments that have been submitted, and determined that air safety and 
the public interest require adopting the AD with the changes described 
previously. We have determined that these changes will neither increase 
the economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

    There are about 739 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, at an average labor rate of $65 
per work hour.

[[Page 39645]]



                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                         Number of
                                                                             Cost per      U.S.-
              Action                Work hours            Parts              airplane    registered   Fleet cost
                                                                                         airplanes
----------------------------------------------------------------------------------------------------------------
Detailed and magnetic inspection             2  None.....................         $130           60       $7,800
 (required by AD 2001-13-06).
Detailed and magnetic inspections            3  None.....................          195          140       27,300
 (new requirement).
----------------------------------------------------------------------------------------------------------------

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. 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 FAA amends Sec.  39.13 by removing amendment 39-12286 (66 FR 
34094, June 27, 2001) and by adding the following new airworthiness 
directive (AD):

2005-14-08 Boeing: Amendment 39-14185. Docket No. FAA-2005-20243; 
Directorate Identifier 2004-NM-153-AD.

Effective Date

    (a) This AD becomes effective August 15, 2005.

Affected ADs

    (b) This AD supersedes AD 2001-13-06, amendment 39-12286.

Applicability

    (c) This AD applies to Model 747-100, 747-100B, 747-100B SUD, 
747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 
747SR, and 747SP series airplanes; certificated in any category; as 
identified in Boeing Alert Service Bulletin 747-57A2312, Revision 1, 
dated April 29, 2004.

Unsafe Condition

    (d) This AD was prompted by reports indicating that cracked 
fasteners made of A286 material were found on airplanes that had 
only fasteners made of A286 material installed in the area common to 
the diagonal brace underwing fittings. We are issuing this AD to 
prevent loss of the underwing fitting load path due to missing or 
damaged alloy-steel or A286 taperlock fasteners, which could result 
in separation of the engine and strut from 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.

Requirements of AD 2001-13-06

Repetitive Inspections

    (f) For Boeing Model 747-100, 747-200, 747-300, and 747SP series 
airplanes equipped with titanium diagonal brace underwing fittings, 
as identified in Boeing Alert Service Bulletin 747-57A2312, dated 
June 15, 2000: Within 12 months after August 1, 2001 (the effective 
date of AD 2001-13-06, amendment 39-12286), do a one-time detailed 
inspection of the diagonal brace underwing fitting at the Number 1 
and Number 4 engine pylons to find missing taperlock fasteners 
(bolts), and a magnetic inspection to find alloy-steel fasteners per 
Part 1 of the Accomplishment Instructions of Boeing Alert Service 
Bulletin 747-57A2312, dated June 15, 2000; or Revision 1, dated 
April 29, 2004.

    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.''


    (1) If no alloy-steel fasteners are found and no fasteners are 
missing, no further action is required by this paragraph.
    (2) If any alloy-steel fasteners are found or any fasteners are 
missing, before further flight, do an ultrasonic inspection of the 
alloy-steel fasteners to find damage per Part 2 of the 
Accomplishment Instructions of the service bulletin.
    (i) If no damaged alloy-steel fasteners are found, and no 
fasteners are missing: Repeat the ultrasonic inspection thereafter 
at intervals not to exceed 18 months until accomplishment of the 
terminating action required by paragraph (g) of this AD.
    (ii) If any damaged alloy-steel fasteners are found, or any 
fasteners are missing: Before further flight, do an ultrasonic 
inspection of all 10 aft fasteners (including non-alloy steel) per 
Part 2 of the Accomplishment Instructions of the service bulletin. 
Before further flight, replace damaged and missing fasteners with 
new fasteners per Part 3 of the Accomplishment Instructions of the 
service bulletin, except as provided by paragraph (l) of this AD. 
Thereafter, repeat the inspection of the remaining alloy-steel 
fasteners at intervals not to exceed 18 months until accomplishment 
of the terminating action required by paragraph (g) or the optional 
terminating action specified in paragraph (m) of this AD.

[[Page 39646]]

Terminating Action

    (g) For Boeing Model 747-100, 747-200, 747-300, and 747SP series 
airplanes equipped with titanium diagonal brace underwing fittings, 
as identified in Boeing Alert Service Bulletin 747-57A2312, dated 
June 15, 2000: Within 48 months after August 1, 2001, do the actions 
required by paragraphs (g)(1) and (g)(2), or (g)(3) of this AD, per 
Boeing Alert Service Bulletin 747-57A2312, dated June 15, 2000; or 
Revision 1, dated April 29, 2004. Accomplishment of the actions 
specified in this paragraph constitutes terminating action for the 
repetitive inspection requirements of paragraph (f) of this AD.
    (1) Perform an open-hole high frequency eddy current (HFEC) 
inspection to detect cracks, corrosion, or damage at the bolt hole 
locations of the aft 10 taperlock fasteners in the diagonal brace 
underwing fitting at the Number 1 and Number 4 engine pylons per 
Part 3 of the Accomplishment Instructions of the service bulletin. 
If any cracking is detected, before further flight, perform 
applicable corrective actions per the service bulletin, except as 
provided by paragraph (l) of this AD.
    (2) Before further flight: Replace all 10 aft taperlock 
fasteners with new, improved fasteners per Part 3 of the 
Accomplishment Instructions of the service bulletin.
    (3) Do an ultrasonic inspection to find damaged fasteners per 
Part 2 of the Accomplishment Instructions of the service bulletin. 
Before further flight, replace all damaged non-alloy steel and all 
alloy-steel fasteners with new fasteners per Part 3 of the 
Accomplishment Instructions of the service bulletin. Do an open-hole 
HFEC inspection before installation of the new fasteners; if any 
cracking, corrosion, or damage is found, before further flight, 
perform applicable corrective actions per the service bulletin, 
except as provided by paragraph (l) of this AD.

New Requirements of This AD

Inspection for Missing/Broken Fasteners and to Determine Material 
Type

    (h) For the aft 10 taperlock fasteners in the diagonal brace 
underwing fitting at the Number 1 and Number 4 engine pylons: 
Perform the inspections in paragraphs (h)(1) and (h)(2) of this AD, 
as applicable.
    (1) For airplanes not identified in paragraph (f) of this AD: 
Within 18 months after the effective date of this AD, perform a 
detailed inspection to ensure that all fasteners are installed and 
unbroken, and a magnetic inspection to detect alloy-steel fasteners, 
in accordance with Part 1 of the Accomplishment Instructions of 
Boeing Alert Service Bulletin 747-57A2312, Revision 1, dated April 
29, 2004.
    (2) For all airplanes: Before the initial inspection threshold 
specified in Section 1.E., Table 1, of Boeing Alert Service Bulletin 
747-57A2312, Revision 1, dated April 29, 2004; or within 18 months 
after the effective date of this AD; whichever is later; perform 
detailed and magnetic inspections, as applicable, to detect A286 
fasteners in the diagonal brace underwing fitting at the Number 1 
and Number 4 engine pylons, as specified in Part 1 of the 
Accomplishment Instructions of Boeing Alert Service Bulletin 747-
57A2312, Revision 1, dated April 29, 2004. For the purposes of this 
AD, an A286 fastener is any fastener to which the magnet is not 
attracted, and which cannot be conclusively determined to be 
BACB30NX (TI material) or BACB30US (Inconel material) fasteners.

Ultrasonic Inspection for Damage

    (i) For all alloy-steel or A286 fasteners identified during the 
inspections in accordance with paragraph (h) of this AD: Before 
further flight, perform an ultrasonic inspection for damage 
(including, but not limited to, cracking or corrosion) of each 
alloy-steel and A286 fastener, in accordance with Part 2 of the 
Accomplishment Instructions of Boeing Alert Service Bulletin 747-
57A2312, Revision 1, dated April 29, 2004. If any bolt is missing or 
found damaged during the inspection required by this paragraph: 
Before further flight, perform an ultrasonic inspection for damage 
of all 10 subject fasteners, in accordance with Part 2 of the 
Accomplishment Instructions of the service bulletin. Doing the 
actions required by this paragraph within the compliance time 
specified in paragraph (f) of this AD eliminates the need to do 
paragraph (f) of this AD.

Undamaged Fastener: Repetitive Inspections or No Further Action

    (j) For any fastener that is found to be installed and undamaged 
during the inspections required by paragraph (i) of this AD, do 
paragraph (j)(1), (j)(2), or (j)(3) of this AD, as applicable.
    (1) If no damage is found during the inspections required by 
paragraph (i) of this AD, and all 10 fasteners in the diagonal brace 
underwing fitting at the Number 1 and Number 4 engine pylons are 
either BACB30NX or BACB30US fasteners: No further action is required 
by this AD, though the restrictions of paragraph (n) of this AD, 
``Parts Installation,'' apply.
    (2) For any undamaged alloy steel fastener: Repeat the 
ultrasonic inspection specified in paragraph (i) of this AD at 
intervals not to exceed 18 months, until the actions in paragraph 
(m) of this AD are done.
    (3) For any undamaged A286 fastener: Repeat the ultrasonic 
inspection specified in paragraph (i) of this AD at intervals not to 
exceed 8,000 flight cycles, until the actions in paragraph (m) of 
this AD are done.

Repetitive Ultrasonic Inspections and Corrective Actions

    (k) For any missing or damaged fastener found during the 
inspections required by paragraph (i) or (j) of this AD: Before 
further flight, install a new, improved fastener in any location 
where a fastener is missing, and replace any damaged fastener with a 
new, improved fastener, in accordance with Part 3 of the 
Accomplishment Instructions of Boeing Alert Service Bulletin 747-
57A2312, Revision 1, dated April 29, 2004. Do an open-hole HFEC 
inspection for cracking, corrosion, or damage before installing the 
new fastener. If any cracking, corrosion, or damage is found: Before 
further flight, perform applicable corrective actions in accordance 
with the service bulletin, except as provided by paragraph (l) of 
this AD.

Repair

    (l) If any damage (including but not limited to cracking or 
corrosion) of the bolt hole that exceeds the limits specified in 
Boeing Alert Service Bulletin 747-57A2312, Revision 1, dated April 
29, 2004, is found during any inspection required by this AD, and 
the service bulletin specifies to contact Boeing for appropriate 
action: Before further flight, repair per a method approved by the 
Manager, Seattle Aircraft Certification Office (ACO), FAA; or 
according to data meeting the certification basis of the airplane 
approved by an Authorized Representative for the Boeing Delegation 
Option Authorization Organization who the Manager, Seattle ACO, has 
authorized to make this finding. For a repair method to be approved 
by the Manager, Seattle ACO, as required by this paragraph, the 
Manager's approval letter must specifically reference this AD.

Optional Terminating Action

    (m) Replacement of all alloy steel and A286 fasteners with new, 
improved fasteners in accordance with Part 3 of the Accomplishment 
Instructions of Boeing Alert Service Bulletin 747-57A2312, Revision 
1, dated April 29, 2004 (including performing an open-hole eddy 
current inspection for cracking of the fastener holes and repairing, 
as applicable), constitutes terminating action for the repetitive 
inspection requirements of this AD.

Parts Installation

    (n) For Boeing Model 747-100, 747-200, 747-300, and 747SP series 
airplanes equipped with titanium diagonal brace underwing fittings, 
as identified in Boeing Alert Service Bulletin 747-57A2312, dated 
June 15, 2000: As of August 1, 2001, no person may install, on any 
airplane, a fastener having part number (P/N) BACB30PE() * (); or 
any other fastener made of 4340, 8740, PH13-8 Mo, or H-11 steel; in 
the locations specified in this AD.
    (o) Except as provided by paragraph (n) of this AD, as of the 
effective date of this AD no person may install, on any airplane, a 
fastener having P/N BACB30PE() * (); or any other fastener made of 
4340, 8740, PH13-8 Mo, A286, or H-11 steel; in the locations 
specified in this AD.

Alternative Methods of Compliance (AMOCs)

    (p)(1) The Manager, Seattle ACO, 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 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) AMOCs approved previously according to AD 2001-13-06, 
amendment 39-12286 (66

[[Page 39647]]

FR 34094, June 27, 2001), are approved as AMOCs for the inspection 
requirements of this AD only at fastener locations where the AMOC 
provided for installing either BACB30NX or BACB30US fasteners.

Material Incorporated by Reference

    (q) You must use Boeing Alert Service Bulletin 747-57A2312, 
dated June 15, 2000; or Boeing Alert Service Bulletin 747-57A2312, 
Revision 1, dated April 29, 2004; to perform the actions that are 
required by this AD, unless the AD specifies otherwise.
    (1) The Director of the Federal Register approves the 
incorporation by reference of Boeing Alert Service Bulletin 747-
57A2312, Revision 1, dated April 29, 2004, in accordance with 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-
57A2312, dated June 15, 2000, as of August 1, 2001 (66 FR 34094, 
June 27, 2001).
    (3) To get copies of the service information, contact Boeing 
Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207. 
To view the AD docket, go to the Docket Management Facility, U.S. 
Department of Transportation, 400 Seventh Street SW., room PL-401, 
Nassif Building, Washington, DC. To review copies of the service 
information, go to the National Archives and Records Administration 
(NARA). For information on the availability of this material at the 
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 June 29, 2005.
Kevin M. Mullin,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-13432 Filed 7-8-05; 8:45 am]
BILLING CODE 4910-13-P

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