Airworthiness Directives; Boeing Model 747 Airplanes

[Federal Register Volume 71, Number 46 (Thursday, March 9, 2006)]
[Rules and Regulations]
[Pages 12125-12129]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 06-2144]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-22715; Directorate Identifier 2005-NM-108-AD; 
Amendment 39-14503; AD 2006-05-06]
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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[[Page 12126]]

SUMMARY: The FAA is superseding three existing airworthiness directives 
(ADs) that apply to certain Boeing Model 747 airplanes. The existing 
ADs currently require repetitive inspections of the body station (BS) 
2598 bulkhead, and corrective action if necessary. This new AD adds a 
requirement to modify the bulkhead, including a one-time inspection and 
corrective action if necessary, which terminates certain repetitive 
inspections. This AD also requires a post-modification inspection of 
the modified area. This AD results from new reports of cracking in all 
three areas that require inspection in accordance with the existing 
ADs. We are issuing this AD to prevent fatigue cracking of the BS 2598 
bulkhead structure, which could result in inability of the structure to 
carry horizontal stabilizer flight loads, and loss of controllability 
of the airplane.

DATES: This AD becomes effective April 13, 2006.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications as of April 13, 2006.
    On October 27, 2003 (68 FR 54990, September 22, 2003), the Director 
of the Federal Register approved the incorporation by reference of 
Boeing Alert Service Bulletin 747-53A2467, dated July 26, 2001.
    On August 28, 2001 (66 FR 38365, July 24, 2001), the Director of 
the Federal Register approved the incorporation by reference of Boeing 
Alert Service Bulletin 747-53A2427, Revision 2, dated October 5, 2000.
    On August 16, 2001 (66 FR 36443, July 12, 2001), the Director of 
the Federal Register approved the incorporation by reference of Boeing 
Service Bulletin 747-53A2449, Revision 1, dated May 24, 2001.

ADDRESSES: You may examine the 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., Nassif Building, 
Room PL-401, Washington, DC.
    Contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, 
Washington 98124-2207, for service information identified in this 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:

Examining the Docket

    You may examine the airworthiness directive (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 street address stated in the ADDRESSES section.

Discussion

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 to include an AD that would supersede the ADs identified in 
the following table:

                                                  Existing ADs
----------------------------------------------------------------------------------------------------------------
                  AD                     Amendment   Federal Register reference            Requirements
----------------------------------------------------------------------------------------------------------------
2001-14-07............................     39-12318  66 FR 36443 (July 12,       Repetitive high-frequency eddy
                                                      2001).                      current (HFEC) inspections to
                                                                                  detect cracking of the
                                                                                  bulkhead frame support at body
                                                                                  station (BS) 2598 under the
                                                                                  hinge support fittings of the
                                                                                  horizontal stabilizer, and
                                                                                  repair if necessary.
2001-15-03............................     39-12337  66 FR 38365 (July 24,       Repetitive HFEC inspections to
                                                      2001).                      detect cracking of the forward
                                                                                  and aft inner chords and the
                                                                                  splice fitting of the forward
                                                                                  inner chord of the BS 2598
                                                                                  bulkhead, and repair if
                                                                                  necessary.
2003-19-08............................     39-13311  68 FR 54990 (September 22,  Repetitive detailed inspections
                                                      2003).                      to detect discrepancies of
                                                                                  certain areas of the forward
                                                                                  and aft sides of the BS 2598
                                                                                  bulkhead, and repair if
                                                                                  necessary.
----------------------------------------------------------------------------------------------------------------

The existing ADs apply to certain Boeing Model 747 airplanes. That NPRM 
was published in the Federal Register on October 19, 2005 (70 FR 
60744). That NPRM proposed to continue to require repetitive 
inspections of the BS 2598 bulkhead, and corrective action if 
necessary. That NPRM also proposed to add a requirement to modify the 
bulkhead, including a one-time inspection and corrective action if 
necessary, which would terminate certain repetitive inspections. That 
NPRM also proposed to require a post-modification inspection of the 
modified area.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comment that has been 
received on the NPRM. The commenter supports the NPRM.

Clarification of Alternative Method of Compliance (AMOC) Paragraph

    We have revised this action to clarify the appropriate procedure 
for notifying the principal inspector before using any approved AMOC on 
any airplane to which the AMOC applies.

Conclusion

    We have carefully reviewed the available data, including the 
comment that has been received, 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 1,147 airplanes of the affected design in the 
worldwide fleet and 280 U.S.-registered airplanes. The following table 
provides the estimated costs for U.S. operators to comply with this AD.

[[Page 12127]]



                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                  Average hourly                     Cost per
             Actions                Work hours      labor rate      Parts cost       airplane       Fleet cost
----------------------------------------------------------------------------------------------------------------
Inspection required by AD 2001-               18             $65              $0          $1,170        $327,600
 14-07 (per inspection cycle)...
HFEC inspection required by AD                 2              65               0             130          36,400
 2001-15-03 (per inspection
 cycle).........................
Detailed inspection required by                2              65               0             130          36,400
 AD 2001-15-03 (per inspection
 cycle).........................
Inspection required by AD 2003-                4              65               0             260          72,800
 19-08 (per inspection cycle)...
Modification....................             126              65          33,716          41,906      11,733,680
----------------------------------------------------------------------------------------------------------------

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, dection 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 and placed it in the AD docket. 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 Federal Aviation Administration (FAA) amends Sec.  39.13 by 
removing amendment 39-12318 (66 FR 36443, July 12, 2001), amendment 39-
12337 (66 FR 38365, July 24, 2001), and amendment 39-13311 (68 FR 
54990, September 22, 2003), and by adding the following new 
airworthiness directive (AD):

2006-05-06 Boeing: Amendment 39-14503. Docket No. FAA-2005-22715; 
Directorate Identifier 2005-NM-108-AD.

Effective Date

    (a) This AD becomes effective April 13, 2006.

Affected ADs

    (b) This AD supersedes ADs 2001-14-07, 2001-15-03, and 2003-19-
08.

Applicability

    (c) This AD applies to Boeing 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; line numbers 1 through 1307 inclusive.

Unsafe Condition

    (d) This AD results from reports of cracking in areas required 
to be inspected by the superseded ADs identified in paragraph (b) of 
this AD. We are issuing this AD to prevent fatigue cracking of the 
body station (BS) 2598 bulkhead structure, which could result in 
inability of the structure to carry horizontal stabilizer flight 
loads, and loss of controllability 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.

Restatement of AD 2001-14-07

Repetitive High Frequency Eddy Current (HFEC) Inspections

    (f) Before the accumulation of 10,000 total flight cycles, or 
within 1,000 flight cycles after August 16, 2001 (the effective date 
of AD 2001-14-07), whichever occurs later: Do an open-hole HFEC 
inspection to find cracking of the bulkhead frame support under the 
hinge support fittings of the horizontal stabilizer on the left and 
right sides at BS 2598, in accordance with Figure 2 of the 
Accomplishment Instructions of Boeing Service Bulletin 747-53A2449, 
Revision 1, dated May 24, 2001; or Revision 2, dated March 14, 2002. 
Repeat the inspection after that at intervals not to exceed 3,000 
flight cycles. Inspections accomplished before August 16, 2001, per 
Boeing Alert Service Bulletin 747-53A2449, dated June 8, 2000, are 
considered acceptable for compliance with the applicable inspection 
specified in this paragraph.

Repair

    (g) If any cracking is found during any inspection required by 
paragraph (f) of this AD, before further flight, repair in 
accordance with a method approved by the Manager, Seattle Aircraft 
Certification Office (ACO), FAA, or using a method approved in 
accordance with paragraph (n) of this AD.

Restatement of Certain Requirements of AD 2001-15-03

Repetitive Inspections

    (h) Do a surface HFEC inspection of the forward and aft inner 
chords, the frame support, and the splice fitting of the forward 
inner chord of the upper corner of the station 2598 bulkhead to find 
cracking, in accordance with the Accomplishment Instructions of 
Boeing Alert Service Bulletin 747-53A2427, Revision 2, dated October 
5, 2000; or Revision 3, dated September 27, 2001; at the latest of 
the times specified in paragraphs (h)(1) and (h)(2) of this AD, as 
applicable. Repeat the inspection after that at intervals not to 
exceed 1,500 flight cycles.

[[Page 12128]]

    (1) For airplanes having line numbers 1 through 1241 inclusive:
    (i) Before the accumulation of 6,000 total flight cycles.
    (ii) Within 500 flight cycles after August 28, 2001 (the 
effective date of AD 2001-15-03).
    (iii) For airplanes inspected before August 28, 2001, in 
accordance with Boeing Alert Service Bulletin 747-53A2427, dated 
December 17, 1998 (including inspections of the splice fitting), or 
Revision 1, dated October 28, 1999: Within 1,500 flight cycles after 
accomplishment of the last inspection done in accordance with the 
original service bulletin or Revision 1, as applicable.
    (2) For airplanes having line numbers 1242 through 1307 
inclusive:
    (i) Before the accumulation of 16,000 total flight cycles.
    (ii) Within 500 flight cycles after August 28, 2001.
    (iii) For airplanes inspected before August 28, 2001, in 
accordance with Boeing Alert Service Bulletin 747-53A2427, dated 
December 17, 1998 (including inspections of the splice fitting), or 
Revision 1, dated October 28, 1999: Within 1,500 flight cycles after 
accomplishment of the last inspection done in accordance with the 
original service bulletin or Revision 1, as applicable.

Repair

    (i) If any cracking is found during the inspections required by 
paragraph (h) of this AD, before further flight, repair in 
accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 747-53A2427, Revision 2, dated October 5, 2000; or 
Revision 3, dated September 27, 2001; except where the alert service 
bulletin specifies that the manufacturer may be contacted for 
disposition of certain repair conditions, before further flight, 
repair in accordance with a method approved by the Manager, Seattle 
ACO, or using a method approved in accordance with the procedures 
specified in paragraph (n) of this AD.

Restatement of AD 2003-19-08

Repetitive Inspections

    (j) Before the accumulation of 10,000 total flight cycles, or 
within 1,000 flight cycles after October 27, 2003 (the effective 
date of AD 2003-19-08), whichever is later: Do a detailed inspection 
of the body station 2598 bulkhead for discrepancies (cracking, 
elongated fastener holes) of the areas specified in paragraphs 
(j)(1) and (j)(2) of this AD, in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 747-53A2467, dated 
July 26, 2001; or Revision 1, dated April 28, 2005. Repeat the 
inspections after that at intervals not to exceed 3,000 flight 
cycles.
    (1) The lower aft inner chords.
    (2) The upper aft outer chords, and the diagonal brace 
attachment fittings, flanges, and rods.


    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.''

Repair

    (k) If any discrepancy is found during any inspection required 
by paragraph (j) of this AD: Before further flight, repair in 
accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 747-53A2467, dated July 26, 2001; or Revision 1, 
dated April 28, 2005. If the service bulletin specifies to contact 
Boeing for appropriate action: Before further flight, repair in 
accordance with a method approved by the Manager, Seattle ACO, or 
using a method approved in accordance with the procedures specified 
in paragraph (n) of this AD.

New Requirements of This AD

Modification

    (l) Before the accumulation of 20,000 total flight cycles, or 
within 48 months after the effective date of this AD, whichever 
occurs later: Modify the bulkhead by doing all applicable actions 
including surface and open-hole HFEC inspections for cracking of the 
upper forward inner chord, aft inner chord, upper splice fitting, 
and frame support fitting, as specified in the Accomplishment 
Instructions of Boeing Service Bulletin 747-53-2473, dated March 24, 
2005. Repair any cracks before further flight in accordance with the 
service bulletin. Where the service bulletin specifies that the 
manufacturer may be contacted for disposition of certain repair 
conditions: Before further flight, repair the cracks using a method 
approved in accordance with the procedures specified in paragraph 
(n) of this AD. Accomplishment of the modification terminates the 
repetitive inspections required by paragraphs (f), (h), and (j)(1) 
of this AD.

Inspection

    (m) Within 20,000 flight cycles after the modification required 
by paragraph (l) of this AD, inspect the BS 2598 bulkhead for 
cracks, and repair any cracks before further flight, in accordance 
with a method approved by the Manager, Seattle ACO.

Alternative Methods of Compliance (AMOCs)

    (n)(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) AMOCs approved previously according to AD 2000-08-21, 
amendment 39-11707, and AD 2001-15-03 are approved as AMOCs for the 
corresponding requirements of paragraphs (h) and (i) of this AD. (AD 
2000-08-21 was superseded by AD 2001-15-03.)
    (3) AMOCs approved previously according to AD 2001-14-07 are 
approved as AMOCs for the corresponding requirements of paragraphs 
(f) and (g) of this AD.
    (4) AMOCs approved previously according to AD 2003-19-08 are 
approved as AMOCs for the corresponding requirements of paragraphs 
(j) and (k) of this AD.
    (5) Before using any AMOC approved in accordance with 14 CFR 
39.19 on any airplane to which the AMOC applies, notify the 
appropriate principal inspector in the FAA Flight Standards 
Certificate Holding District Office.
    (6) 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.

Material Incorporated by Reference

    (o) You must use the service information identified in Table 1 
of this AD, as applicable, to perform the actions that are required 
by this AD, unless the AD specifies otherwise.

            Table 1.--All Material Incorporated by Reference
------------------------------------------------------------------------
                                  Revision
   Boeing service bulletin         level                 Date
------------------------------------------------------------------------
Alert Service Bulletin 747-    2............  October 5, 2000.
 53A2427.
Alert Service Bulletin 747-    3............  September 27, 2001.
 53A2427.
Alert Service Bulletin 747-    Original.....  July 26, 2001.
 53A2467.
Service Bulletin 747-53A2467.  1............  April 28, 2005.
Service Bulletin 747-53-2473.  Original.....  March 24, 2005.
Service Bulletin 747-53A2449.  1............  May 24, 2001.
Service Bulletin 747-53A2449.  2............  March 14, 2002.
------------------------------------------------------------------------

    (1) The Director of the Federal Register approved the 
incorporation by reference of service bulletins identified in Table 
2 of this AD, in accordance with 5 U.S.C. 552(a) and 1 CFR part 51.

[[Page 12129]]



            Table 2.--New Material Incorporated by Reference
------------------------------------------------------------------------
                                  Revision
   Boeing service bulletin         level                 Date
------------------------------------------------------------------------
Alert Service Bulletin 747-    3............  September 27, 2001.
 53A2427.
Service Bulletin 747-53A2467.  1............  April 28, 2005.
Service Bulletin 747-53-2473.  Original.....  March 24, 2005.
Service Bulletin 747-53A2449.  2............  March 14, 2002.
------------------------------------------------------------------------

    (2) On October 27, 2003 (68 FR 54990, September 22, 2003), the 
Director of the Federal Register approved the incorporation by 
reference of Boeing Alert Service Bulletin 747-53A2467, dated July 
26, 2001.
    (3) On August 28, 2001 (66 FR 38365, July 24, 2001), the 
Director of the Federal Register approved the incorporation by 
reference of Boeing Alert Service Bulletin 747-53A2427, Revision 2, 
dated October 5, 2000.
    (4) On August 16, 2001 (66 FR 36443, July 12, 2001), the 
Director of the Federal Register approved the incorporation by 
reference of Boeing Service Bulletin 747-53A2449, Revision 1, dated 
May 24, 2001.
    (5) Contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, 
Washington 98124-2207, for a copy of this service information. You 
may review copies at the Docket Management Facility, U.S. Department 
of Transportation, 400 Seventh Street SW., Room PL-401, Nassif 
Building, Washington, DC; on the Internet at http://dms.dot.gov; or 
at 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 February 22, 2006.
Michael J. Kaszycki,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 06-2144 Filed 3-8-06; 8:45 am]
BILLING CODE 4910-13-P

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