Airworthiness Directives; Boeing Model 777-200 and -300 Series Airplanes Equipped With Rolls Royce Model RB211 TRENT 800 Engines

[Federal Register Volume 70, Number 68 (Monday, April 11, 2005)]
[Rules and Regulations]
[Pages 18285-18287]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-6903]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-20885; Directorate Identifier 2005-NM-050-AD; 
Amendment 39-14049; AD 2005-07-24]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 777-200 and -300 Series 
Airplanes Equipped With Rolls Royce Model RB211 TRENT 800 Engines

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

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Boeing Model 777-200 and -300 series airplanes. This AD 
requires inspecting the thrust reversers for damage of the insulation 
blankets, the inner wall, and the compression and drag link fittings; 
and repair if necessary. This AD also requires applying sealant to 
certain areas of the thrust reverser. This AD is prompted by two 
reports of thrust reverser failure; investigation revealed that the 
inner wall of the thrust reversers had collapsed from exposure to hot 
engine core compartment air. We are issuing this AD to prevent failure 
of a thrust reverser and adjacent components and their consequent 
separation from the airplane, which could result in a rejected takeoff 
(RTO) and cause asymmetric thrust and consequent loss of control of the 
airplane during reverse thrust operation. If an RTO does not occur, 
these separated components could cause structural damage to the 
airplane or damage to other airplanes and possible injury to people on 
the ground.

DATES: Effective April 26, 2005.
    The incorporation by reference of certain publications listed in 
the AD is approved by the Director of the Federal Register as of April 
26, 2005.
    We must receive comments on this AD by June 10, 2005.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD.
    <bullet> DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
    <bullet> Government-wide Rulemaking Web site: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
    <bullet> Mail: Docket Management Facility; U.S. Department of 
Transportation, 400 Seventh Street SW., Nassif Building, room PL-401, 
Washington, DC 20590.
    <bullet> Fax: (202) 493-2251.
    <bullet> Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street SW., Washington, DC, between 9 a.m. 
and 5 p.m., Monday through Friday, except Federal holidays.
    For service information identified in this AD, contact Boeing 
Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207.
    You can examine the contents of this AD docket on the Internet at 
http://dms.dot.gov, or in person at the Docket Management Facility, 
U.S. Department of Transportation, 400 Seventh Street SW., room PL-401, 
on the plaza level of the Nassif Building, Washington, DC. This docket 
number is FAA-2005-20885; the directorate identifier for this docket is 
2005-NM-050-AD.

Examining the Dockets

    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 DOT 
street address stated in the ADDRESSES section. Comments will be 
available in the AD docket shortly after the DMS receives them.

FOR FURTHER INFORMATION CONTACT: Margaret Langsted, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Seattle Aircraft Certification 
Office, 1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone 
(425) 917-6500; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION: We have received two reports indicating 
failure of the thrust reversers during takeoff on certain Boeing Model 
777-200 and -300 series airplanes. Investigation of both incidents 
revealed that the composite inner wall of the thrust reverser collapsed 
as a result of the migration of hot engine core compartment air 
underneath the insulation blankets, which overheated the composite 
structure. In the second incident, the outer sleeve of the primary 
nozzle had detached from the airplane and impacted an automobile on the 
ground, causing significant damage. Investigation of the first incident 
revealed that debris from the right engine had departed the airplane 
and was left on the runway. The flightcrew was not aware of the failure 
until arrival at the destination airport. Extensive damage was found to 
the inner wall of the thrust reverser, with large sections of the 
composite structure missing. Both failures occurred on airplanes that 
had each accumulated more than 6,000 total flight cycles. Subsequent 
inspection of the thrust reversers on airplanes that had accumulated 
between 6,000 and 9,000 total flight cycles indicated areas of 
delamination and annealed compression pads of the inner wall. The cause 
of the delamination is exposure to hot engine core compartment air, 
which can also cause thermal damage to the compression and drag link 
fittings. These conditions, if not corrected, could result in a 
rejected takeoff (RTO) and cause asymmetric thrust and consequent loss 
of control of the airplane during reverse thrust operation. If an RTO 
does not occur, these separated components could cause structural 
damage to the airplane or damage to other airplanes and possible injury 
to people on the ground.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 777-78A0059, dated 
February 24, 2005. The service bulletin describes procedures for one-
time detailed and special detailed inspections of the thrust reversers, 
as applicable, for damage of the insulation blankets, inner wall, and 
compression and drag link fittings; and repair if necessary. The 
compliance times for the inspections range from 3 months to 24 months, 
depending on the number of total flight cycles on the airplane. The 
damage includes over-temperature conditions such as brown to blackened 
scorching and disbonding. The repair includes repair or replacement of 
any

[[Page 18286]]

damaged insulation blankets with new blankets, and replacement of any 
damaged fittings with new fittings. The service bulletin recommends 
reporting the inspection schedule and results to Boeing.
    The service bulletin also recommends prior or concurrent 
accomplishment of Boeing Special Attention Service Bulletin 777-78-
0060, dated February 24, 2005. That service bulletin describes 
procedures for applying sealant to the seams of the thrust reverser 
insulation blankets and around the HP3 ducts, and insulating and 
sealing the compression pad fittings.
    Accomplishing the actions specified in the service information is 
intended to adequately address the unsafe condition.

FAA's Determination and Requirements of This AD

    The unsafe condition described previously is likely to exist or 
develop on other airplanes of the same type design. Therefore, we are 
issuing this AD to prevent failure of a thrust reverser and adjacent 
components and their consequent separation from the airplane, which 
could result in a rejected takeoff (RTO) and cause asymmetric thrust 
and consequent loss of control of the airplane during reverse thrust 
operation. If an RTO does not occur, these separated components could 
cause structural damage to the airplane or damage to other airplanes 
and possible injury to people on the ground. This AD requires 
accomplishing the actions specified in the service information 
described previously, except as discussed under ``Differences Between 
the AD and the Service Information.''

Differences Between the AD and the Service Information

    You should note that, although Boeing Alert Service Bulletin 777-
78A0059 describes procedures for reporting information to the 
manufacturer, this AD will not require those actions. We do not need 
this information.
    Boeing Alert Service Bulletin 777-78A0059 recommends prior or 
concurrent accomplishment of Boeing Special Attention Service Bulletin 
777-78-0060; however, this AD requires accomplishment of that service 
bulletin immediately after each inspection to prevent further damage.
    The service bulletins specify that you may contact the manufacturer 
for repair or replacement instructions, but this AD requires you to 
repair or replace in one of the following ways:
    <bullet> Using a method that we approve; or
    <bullet> Using data that meet the certification basis of the 
airplane that have been approved by an Authorized Representative for 
the Boeing Delegation Option Authorization Organization who has been 
authorized by the FAA to make those findings.

FAA's Determination of the Effective Date

    An unsafe condition exists that requires the immediate adoption of 
this AD; therefore, providing notice and opportunity for public comment 
before the AD is issued is impracticable, and good cause exists to make 
this AD effective in less than 30 days.

Comments Invited

    This AD is a final rule that involves requirements that affect 
flight safety and was not preceded by notice and an opportunity for 
public comment; however, we invite you to submit any relevant written 
data, views, or arguments regarding this AD. Send your comments to an 
address listed under ADDRESSES. Include ``Docket No. FAA-2005-20885; 
Directorate Identifier 2005-NM-050-AD'' at the beginning of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the AD. We will consider 
all comments received by the closing date and may amend the AD in light 
of those comments.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this AD. Using the search function of our docket 
Web site, anyone can find and read the comments in any of our dockets, 
including the name of the individual who sent the comment (or signed 
the comment on behalf of an association, business, labor union, etc.). 
You can review the DOT's complete Privacy Act Statement in the Federal 
Register published on April 11, 2000 (65 FR 19477-78), or you can visit 
http://dms.dot.gov.

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 the 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.
    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 adding the following new airworthiness 
directive (AD):

2005-07-24 Boeing: Amendment 39-14049. Docket No. FAA-2005-20885; 
Directorate Identifier 2005-NM-050-AD.

Effective Date

    (a) This AD becomes effective April 26, 2005.

[[Page 18287]]

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 777-200 and -300 series 
airplanes; certificated in any category; equipped with Rolls Royce 
Model RB211 TRENT 800 engines; as identified in Boeing Alert Service 
Bulletin 777-78A0059, dated February 24, 2005.

Unsafe Condition

    (d) This AD was prompted by two reports of thrust reverser 
failures; investigation revealed that the inner wall of the thrust 
reversers had collapsed from exposure to hot engine core compartment 
air. The FAA is issuing this AD to prevent failure of a thrust 
reverser and adjacent components and their consequent separation 
from the airplane, which could result in a rejected takeoff (RTO) 
and cause asymmetric thrust and consequent loss of control of the 
airplane during reverse thrust operation. If an RTO does not occur, 
these separated components could cause structural damage to the 
airplane or damage to other airplanes and possible injury to people 
on the ground.

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.

Inspections

    (f) Accomplish one-time detailed and special detailed 
inspections, as applicable, of the thrust reversers for damage of 
the insulation blankets, inner wall, and compression and drag link 
fittings, in accordance with the Accomplishment Instructions of 
Boeing Alert Service Bulletin 777-78A0059, dated February 24, 2005. 
Accomplish the inspection at the applicable compliance time 
specified in paragraph 1.E. ``Compliance'' of the service bulletin; 
except, where the service bulletin specifies a compliance time 
relative to the date after the release of the service bulletin, this 
AD requires compliance relative to the effective date of this AD.

Repair/Replacement

    (g) If any damage is found during any inspection required by 
this AD: Before further flight, do applicable repairs and replace 
damaged fittings with new fittings, in accordance with the 
Accomplishment Instructions of Boeing Alert Service Bulletin 777-
78A0059, dated February 24, 2005. Where the service bulletin 
specifies to contact Boeing for appropriate action, before further 
flight, do applicable repairs and replace damaged fittings with new 
fittings in accordance with a method approved by the Manager, 
Seattle Aircraft Certification Office (ACO), FAA; or in accordance 
with data meeting the certification basis of the airplane approved 
by an Authorized Representative for the Boeing Delegation Option 
Authorization (DOA) 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.

Application of Sealant

    (h) Before further flight after accomplishing the inspection and 
any applicable repair, as required by paragraphs (f) and (g) of this 
AD: Apply sealant to the seams of the thrust reverser insulation 
blankets and around the HP3 ducts, and insulate and seal the 
compression pad fittings, in accordance with the Accomplishment 
Instructions of Boeing Special Attention Service Bulletin 777-78-
0060, dated February 24, 2005.

No Reporting

    (i) Although Boeing Alert Service Bulletin 777-78A0059, dated 
February 24, 2005, specifies reporting certain information to 
Boeing, this AD does not require that action.

Alternative Methods of Compliance (AMOCs)

    (j)(1) The Manager, Seattle 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 DOA 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.

Material Incorporated by Reference

    (k) You must use Boeing Alert Service Bulletin 777-78A0059, 
dated February 24, 2005; and Boeing Special Attention Service 
Bulletin 777-78-0060, dated February 24, 2005; as applicable; to 
perform the actions that are required by this AD, unless the AD 
specifies otherwise. The Director of the Federal Register approves 
the incorporation by reference of these documents in accordance with 
5 U.S.C. 552(a) and 1 CFR part 51. 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 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 March 31, 2005.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-6903 Filed 4-8-05; 8:45 am]
BILLING CODE 4910-13-P

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