Airworthiness Directives; Boeing Model 747-100, -100B, -100B SUD, -200B, -200C, -300, -400, and -400D Series Airplanes; and Model 747SR Series Airplanes

[Federal Register Volume 70, Number 96 (Thursday, May 19, 2005)]
[Rules and Regulations]
[Pages 28800-28803]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-9876]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2004-19796; Directorate Identifier 2004-NM-61-AD; 
Amendment 39-14095; AD 2005-10-18]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 747-100, -100B, -100B SUD, 
-200B, -200C, -300, -400, and -400D Series Airplanes; and Model 747SR 
Series Airplanes

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

ACTION: Final rule.

-----------------------------------------------------------------------

SUMMARY: The FAA is superseding an existing airworthiness directive 
(AD), which applies to certain Boeing Model 747 series airplanes. That 
AD currently requires a one-time inspection to determine the material 
type of the stop support fittings of the main entry doors (MEDs). That 
AD also currently requires repetitive detailed inspections to detect 
cracks of certain stop support fittings of the MEDs, and replacement of 
any cracked stop support fitting with a certain new stop support 
fitting. This new AD adds new inspections, and replacement if 
necessary, of the stop support fittings of MED 3, and adds airplanes to 
the applicability. This AD is prompted by reports of MED 3 having 
certain stop support fittings that are susceptible to stress corrosion 
cracking. We are issuing this AD to detect and correct stress corrosion 
cracking of the stop support fittings of the MEDs, which could result 
in damage to the adjacent forward edge frame of the door and consequent 
loss of a MED and rapid decompression of the airplane.

DATES: This AD becomes effective June 23, 2005.
    The incorporation by reference of Boeing Service Bulletin 747-53-
2358, Revision 1, dated April 19, 2001; and Boeing Special Attention 
Service Bulletin 747-53-2485, dated January 8, 2004; as listed in the 
AD, is approved by the Director of the Federal Register as of June 23, 
2005.
    On January 25, 1999 (63 FR 70316, December 21, 1998), the Director 
of the Federal Register approved the incorporation by reference of 
Boeing Service Bulletin 747-53-2358, dated August 26, 1993.

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-2004-19796; the directorate 
identifier for this docket is 2004-NM-61-AD.

FOR FURTHER INFORMATION CONTACT: Ivan Li, Aerospace Engineer, Airframe 
Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 1601 Lind 
Avenue, SW., Renton, Washington 98055-4056; telephone (425) 917-6437; 
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 98-26-13, amendment 39-10954 (63 FR 70316, December 21, 1998). The 
existing AD applies to certain Boeing Model 747 series airplanes. The 
proposed AD was published in the Federal Register on December 3, 2004 
(69 FR 70204), to continue to require a one-time inspection to 
determine the material type of the stop support fittings of the main 
entry doors (MEDs), repetitive detailed inspections to detect cracks of 
certain stop support fittings of the MEDs, and replacement of any 
cracked stop support fitting with a certain new stop support fitting. 
The proposed AD also adds new inspections, and replacement if 
necessary, of the stop support fittings of MED 3, and adds airplanes to 
the applicability.

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.

Concur With the Proposed AD

    One commenter concurs with the proposed AD and has no additional 
comments.

Request To Add Provision to State Operators Are Not in Violation of 
Proposed AD

    One commenter requests that a provision be added to the proposed AD 
to state that operators ``are not in violation of paragraphs (f) and 
(g)'' of the proposed AD if it is determined that some of the fittings 
replaced in accordance with paragraphs (f) and (g) were made of the 
incorrect material. The commenter states that paragraphs (f) and (g) of 
the proposed AD specify that fittings be replaced with fittings made of 
the correct material. The commenter also states that paragraph (h) of 
the proposed AD specifies that replaced fittings be inspected to 
determine if the fittings are made of the correct material. Therefore, 
if an operator accomplishes the inspection specified in paragraph (h) 
of the proposed AD and finds fittings made of the incorrect material, 
then the operator would be in violation of the paragraphs (f) and (g) 
of the proposed AD.
    We agree that an operator is not in violation of paragraphs (f), 
(g), and (l) of the final rule if fittings were replaced in good faith 
with fittings supplied by Boeing that are determined to be made

[[Page 28801]]

of the incorrect material during the inspection required by paragraph 
(h) of the final rule. As stated in the preamble of the proposed AD, 
``the new stop support fittings supplied by Boeing as the replacement 
fitting for MED 3 may not have been made from the correct material 
type.'' Thus, operators may have unknowingly installed replacement 
fittings made of the incorrect material and should not be penalized if 
the inspection required by paragraph (h) of the final rule determines 
there are fittings made of the incorrect material. However, operators 
must then do the applicable inspections/replacement required by 
paragraph (k) of the final rule. We have not changed the final rule in 
this regard.

Request To Remove Requirement to Remove Foam and Inspect/Drill Drain 
Hole

    One commenter requests that the actions specified in Boeing Special 
Attention Service Bulletin 747-53-2485 (cited in the proposed AD as the 
appropriate source of service information for accomplishing the 
proposed inspections) to remove foam and inspect/drill drain holes be 
removed from the requirements of the proposed AD. The commenter states 
it has established that the foam need not be removed to do the 
conductivity test. The commenter also states that ``this has been 
acknowledged in the Boeing telex SR 1-48729376/Message No 1-TETPP.''
    We agree that removal of the foam and inspecting/drilling drain 
holes should not be required. Paragraphs (h) and (i) of the proposed AD 
specify only that an inspection to determine material type of the stop 
support fittings be done in accordance with Boeing Special Attention 
Service Bulletin 747-53-2485 and paragraph (k) of the proposed AD 
specifies that an inspection for cracks of the stop support fittings be 
done in accordance with the service bulletin. Removing foam and 
inspecting/drilling drain holes are not a part of these inspections and 
are not part of the corrective action needed to address the identified 
unsafe condition (stress corrosion cracking of the stop support 
fittings of the main entry doors). Because removing foam and 
inspecting/drilling drain holes are described in the Accomplishment 
Instructions of the service bulletin, we have added Note 2 to the final 
rule for clarification that these actions are not required when doing 
any inspection required by paragraphs (h), (i), and (k) of the final 
rule.

Request for Credit for Inspection

    One commenter has no technical objections to the proposed AD. 
However, the commenter requests that if a stop support fitting was 
replaced before the effective date of the proposed AD and a 
conductivity test per Boeing 747 Nondestructive Test Manual D6 7170, 
Part 6, Chapter 51-00-00, Figure 20, was done during the replacement, 
then the one-time high frequency eddy current (HFEC) inspection 
specified in paragraph (h)(1) of the proposed AD need not be required.
    We agree that, for any stop support fitting replaced before the 
effective date of the final rule on which a conductivity test per 
Boeing 747 Nondestructive Test Manual D6-7170, Part 6, Chapter 51-00-
00, Figure 20, has been done, then the one-time HFEC inspection 
specified in paragraph (h)(1) of the final rule does not need to be 
done. The conductivity test per Boeing 747 Nondestructive Test Manual 
D6-7170, Part 6, Chapter 51-00-00, Figure 20, is the HFEC inspection 
specified in the final rule. The final rule specifies that the HFEC be 
done in accordance with Boeing Special Attention Service Bulletin 747-
53-2485, and the service bulletin refers to Boeing 747 Nondestructive 
Test Manual D6-7170, Part 6, Chapter 51-00-00, Figure 20. Paragraph (e) 
of the final rule gives credit for actions done before the effective 
date of the final rule. We have not changed the final rule in this 
regard.

Request To Revise One-Time HFEC Inspection

    One commenter requests that the one-time HFEC inspection specified 
in paragraph (h)(1) of the proposed AD be revised to be applicable only 
to fittings that were replaced before the effective date of AD 98-26-
13. The commenter notes that paragraph (c) of AD 98-26-13 mandates that 
no person shall install a stop fitting made from either 7079-T651 or 
7075-T651 material on any airplane as of January 25, 1999 (the 
effective date of AD 98-26-13). The commenter concludes that all stop 
support fittings installed after the effective date of AD 98-26-13 are 
required to be made from 7075-T73 or 7050-T451 aluminum.
    We disagree with the request to revise the one-time HFEC 
inspection. As stated in the preamble of the proposed AD, ``the new 
stop support fittings supplied by Boeing as the replacement fitting for 
MED 3 may not have been made from the correct material type.'' 
Therefore, operators complying with AD 98-26-13 could have unknowingly 
installed support fittings supplied by Boeing that were made of the 
incorrect material (7079-T651 or 7075-T651 material). Because of this 
possibility, the final rule requires a one-time HFEC inspection of any 
stop support fittings that were replaced before the effective date of 
the final rule. We have not changed the final rule in this regard.

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 change described 
previously. We have determined that this change will neither increase 
the economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

    There are about 814 airplanes of the affected design in the 
worldwide fleet. There are about 119 airplanes of U.S. registry that 
will be affected by this AD. The following table provides the estimated 
costs for U.S. operators to comply with this AD.

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                             Average
                           Action                             Work  hours   labor rate     Parts       Cost per
                                                                             per hour                    door
----------------------------------------------------------------------------------------------------------------
HFEC Inspection (required by AD 98-26-13)...................            1          $65        (\1\)          $65
Detailed Inspection as applicable (required by AD 98-26-13).            2           65        (\1\)          130
Optional Terminating Action (specified in AD 98-26-13)......          124           65      $13,000       21,060
Detailed Inspection and HFEC Inspection as applicable (new              3           65        (\1\)          195
 action)....................................................
Replacement as applicable (new action)......................          120           65       17,724      25,524
----------------------------------------------------------------------------------------------------------------
\1\ None.


[[Page 28802]]

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 39-10954 (63 FR 
70316, December 21, 1998), and by adding the following new 
airworthiness directive (AD):

2005-10-18 Boeing: Amendment 39-14095. Docket No. FAA-2004-19796; 
Directorate Identifier 2004-NM-61-AD.

Effective Date

    (a) This AD becomes effective June 23, 2005.

Affected ADs

    (b) This AD supersedes AD 98-26-13, amendment 39-10954.

Applicability

    (c) This AD applies to Boeing Model 747-100, -100B, -100B SUD, -
200B, -200C, -300, -400, and -400D series airplanes; and Model 747SR 
series airplanes; having line numbers 1 through 1301 inclusive; 
certificated in any category.

Unsafe Condition

    (d) This AD was prompted by reports of main entry door (MED) 3 
having certain stop support fittings that are susceptible to stress 
corrosion cracking. We are issuing this AD to detect and correct 
stress corrosion cracking of the stop support fittings of the MEDs, 
which could result in damage to the adjacent forward edge frame of 
the door and consequent loss of a MED and 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.

Requirements of AD 98-26-13

Inspections and Corrective Action

    (f) For Model 747-100, -100B, -100B SUD, -200, -200B, -200C, -
300, -400, and 747SR series airplanes having line numbers 1 through 
830 inclusive: Within 18 months after January 25, 1999 (the 
effective date of AD 98-26-13, amendment 39-10954), perform a high 
frequency eddy current (HFEC) inspection to determine the material 
type of the stop support fittings of the MEDs, in accordance with 
the Accomplishment Instructions of Boeing Service Bulletin 747-53-
2358, dated August 26, 1993; or Boeing Service Bulletin 747-53-2358, 
Revision 1, dated April 19, 2001. Perform the inspection only at 
those locations where the material type of the stop support fittings 
is unknown, as specified in Figure 3, Table 1, of either service 
bulletin. As of the effective date of this AD, do the actions in 
accordance with Boeing Service Bulletin 747-53-2358, Revision 1, 
dated April 19, 2001.
    (1) If the fitting is made from 7075-T73 or 7050-T7451 material, 
no further action is required by this AD for that fitting; however, 
the requirements of paragraph (l) of this AD still apply.
    (2) If the fitting is not made from 7075-T73 or 7050-T7451 
material, before further flight, perform a detailed inspection to 
detect cracks of the stop support fitting of the MEDs, in accordance 
with the applicable service bulletin.

    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 
mirrors magnifying lenses, etc. may be necessary. Surface cleaning 
and elaborate procedures may be required.''

    (i) If no crack is detected, repeat the detailed inspection 
thereafter at intervals not to exceed 36 months or 2,000 flight 
cycles, whichever occurs first.
    (ii) If any crack is detected, before further flight, replace 
the fitting with a stop support fitting made from 7075-T73 or 7050-
T7451 material, in accordance with the applicable service bulletin.
    (g) For Model 747-100, -100B, -100B SUD, -200, -200B, -200C, -
300, -400, and 747SR series airplanes having line numbers 1 through 
830 inclusive: Replacement of the stop support fitting of the MEDs 
with a stop support fitting made from 7075-T73 material, in 
accordance with Boeing Service Bulletin 747-53-2358, dated August 
26, 1993; or replacement with a stop support fitting made from 7075-
T73 or 7050-T7451 material, in accordance with Boeing Service 
Bulletin 747-53-2358, Revision 1, dated April 19, 2001; constitutes 
terminating action for the repetitive inspection requirements of 
paragraph (f) of this AD for the replaced fitting. As of the 
effective date of this AD, only Boeing Service Bulletin 747-53-2358, 
Revision 1, dated April 19, 2001, may be used.

New Requirements of This AD

    Note 2: Operators are not required to remove foam and inspect/
drill drain holes as specified in Paragraph 3.B.1.e. and the Notes 
of the Accomplishment Instructions of Boeing Special Attention 
Service Bulletin 747-53-2485, dated January 8, 2004, when doing any 
inspection required by paragraphs (h), (i), and (k) of this AD.

Inspection for Material Type

    (h) For Model 747-100, -100B, -100B SUD, -200B, -200C, -300, -
400, and -400D series airplanes, and Model 747SR series airplanes, 
having line numbers 1 through 830 inclusive on which the actions 
specified in the Accomplishment Instructions of Boeing Service 
Bulletin 747-53-2358, dated August 26, 1993; or Boeing Service 
Bulletin 747-53-2358, Revision 1, dated April 19, 2001; have been 
done: Do the inspection specified in paragraph (h)(1) or (h)(2) of 
this AD, as applicable, at the time specified.
    (1) Except as provided by paragraph (h)(2) of this AD, if any 
stop support fitting, 2L through 6L and 2R through 6R, of MED 3, was 
replaced before the effective date of this AD: Perform a one-time 
HFEC inspection to determine the material type of the stop support 
fittings of MED 3 that were replaced, in accordance with the 
Accomplishment Instructions of Boeing Special Attention

[[Page 28803]]

Service Bulletin 747-53-2485, dated January 8, 2004, at the later of 
the times specified in paragraphs (h)(1)(i) and (h)(1)(ii) of this 
AD.
    (i) Within 72 months after the stop support fitting of MED 3 was 
replaced.
    (ii) Within 18 months after the effective date of this AD.
    (2) If any stop support fitting, 2L through 6L and 2R through 
6R, of MED 3, cannot be determined conclusively by reviewing 
airplane maintenance records that the fitting was not replaced, 
within 18 months after the effective date of this AD, perform a one-
time HFEC inspection to determine the material type of the stop 
support fitting, in accordance with the Accomplishment Instructions 
of Boeing Special Attention Service Bulletin 747-53-2485, dated 
January 8, 2004.
    (i) For airplanes having line numbers 831 through 1301 
inclusive: At the later of the times specified in paragraphs (i)(1) 
and (i)(2) of this AD, perform a one-time HFEC inspection to 
determine the material type of the stop support fittings of MED 3 in 
accordance with the Accomplishment Instructions of Boeing Special 
Attention Service Bulletin 747-53-2485, dated January 8, 2004.
    (1) Before 72 months since the date of issuance of the original 
Airworthiness Certificate or the date of issuance of the original 
Export Certificate of Airworthiness.
    (2) Within 18 months after the effective date of this AD.

No Further Action

    (j) If, during any HFEC inspection required by paragraph (h) or 
(i) of this AD, any fitting is found to be made of 7075-T73 or 7050-
T7451 material, no further action is required by this AD for that 
fitting; however, paragraph (l) of this AD still applies.

Initial and Repetitive Inspections for Cracking and Corrective Action

    (k) If, during any HFEC inspection required by paragraph (h) or 
(i) of this AD, any fitting is found not to be made of 7075-T73 or 
7050-T7451 material, before further flight, perform a detailed 
inspection for cracks of the fitting in accordance with the 
Accomplishment Instructions of Boeing Special Attention Service 
Bulletin 747-53-2485, dated January 8, 2004.
    (1) If no crack is detected, repeat the detailed inspection 
specified in paragraph (k) of this AD thereafter at intervals not to 
exceed 36 months or 2,000 flight cycles, whichever comes first. 
Doing the replacement specified in paragraph (k)(2) of this AD ends 
the repetitive inspections for the replaced fitting.
    (2) If any crack is detected, before further flight, replace the 
fitting with a fitting made of 7075-T73 or 7050-T7451 material in 
accordance with the Accomplishment Instructions of Boeing Special 
Attention Service Bulletin 747-53-2485, dated January 8, 2004. No 
further action is required by this AD for that fitting; however, 
paragraph (l) of this AD still applies.

Parts Installation

    (l) As of the date specified in paragraph (l)(1) or (l)(2) of 
this AD, as applicable, no person shall install on any airplane a 
stop support fitting of the MEDs made from either 7079-T651 or 7075-
T651 material.
    (1) For airplanes having line numbers 1 through 830 inclusive: 
As of January 25, 1999.
    (2) For airplanes having line numbers 831 through 1301 
inclusive: As of the effective date of this AD.

Alternative Methods of Compliance (AMOCs)

    (m)(1) The Manager, Seattle Aircraft Certification Office (ACO), 
FAA, has the authority to approve AMOCs for this AD, if requested 
using the procedures found in 14 CFR 39.19.
    (2) AMOCs, approved previously per AD 98-26-13, amendment 39-
10954, are approved as AMOCs with paragraph (f) or (g) of this AD, 
as applicable. However, any stop support fitting, 2L through 6L and 
2R through 6R, of MED 3 that was replaced is still required to be 
inspected as required in paragraph (h) of this AD.

Material Incorporated by Reference

    (n) You must use the service information that is specified in 
Table 1 of this AD 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 Service Bulletin 747-53-2358, 
Revision 1, dated April 19, 2001; and Boeing Special Attention 
Service Bulletin 747-53-2485, dated January 8, 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 Service Bulletin 747-53-2358, 
dated August 26, 1993, as of January 25, 1999 (63 FR 70316, December 
21, 1998).
    (3) To get copies of the service information, go to 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.

                                  Table 1.--Material Incorporated by Reference
----------------------------------------------------------------------------------------------------------------
                Service bulletin                        Revision level                        Date
----------------------------------------------------------------------------------------------------------------
Boeing Service Bulletin 747-53-2358............  Original....................  August 26, 1993.
Boeing Service Bulletin 747-53-2358............  1...........................  April 19, 2001.
Boeing Special Attention Service Bulletin 747-   Original....................  January 8, 2004.
 53-2485.
----------------------------------------------------------------------------------------------------------------


    Issued in Renton, Washington, on May 9, 2005.
Jeffrey E. Duven,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-9876 Filed 5-18-05; 8:45 am]
BILLING CODE 4910-13-P

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