Airworthiness Directives; Boeing Model 757 Airplanes

[Federal Register Volume 71, Number 118 (Tuesday, June 20, 2006)]
[Rules and Regulations]
[Pages 35381-35383]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 06-5501]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-20689; Directorate Identifier 2004-NM-197-AD; 
Amendment 39-14655; AD 2006-13-03]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757 Airplanes

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

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Boeing Model 757 airplanes. This AD requires, for certain 
airplanes, reworking the spar bonding path and reapplying sealant; and, 
for certain other airplanes, testing the electrical bond between the 
engine fuel feed hose and the wing front spar and, if applicable, 
reworking the spar bonding path and reapplying sealant. This AD also 
requires, for all airplanes, an inspection to ensure the electrical 
bonding jumper is installed between the engine fuel feed tube and the 
adjacent wing station. This AD also requires operators that may have 
installed an incorrect O-ring to install the correct part and do a re-
test. This AD results from fuel system reviews conducted by the 
manufacturer. We are issuing this AD to prevent arcing or sparking at 
the interface between the bulkhead fittings of the engine fuel feed 
tube and the front spar during a lightning strike, which could provide 
a possible ignition source for the fuel vapor inside the fuel tank and 
result in a fuel tank explosion.

DATES: This AD becomes effective July 25, 2006.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in the AD as of July 25, 2006.

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: Tom Thorson, Aerospace Engineer, 
Propulsion Branch, ANM-140S, Seattle Aircraft Certification Office, 
FAA, 1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone 
(425) 917-6508; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION:

Examining the Docket

    You may 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 street address stated in the 
ADDRESSES section.

Discussion

    The FAA issued a supplemental notice of proposed rulemaking (NPRM) 
to amend 14 CFR part 39 to include an AD that would apply to certain 
Boeing Model 757 airplanes. That supplemental NPRM was published in the 
Federal Register on April 4, 2006 (71 FR 16721). That supplemental NPRM 
proposed to require, for certain airplanes, reworking the spar bonding 
path and reapplying sealant; and, for certain other airplanes, testing 
the electrical bond between the engine fuel feed hose and the wing 
front spar and, if applicable, reworking the spar bonding path and 
reapplying sealant. That supplemental NPRM also proposed to require, 
for all airplanes, an inspection to ensure the electrical bonding 
jumper is installed between the engine fuel feed tube and the adjacent 
wing station. That supplemental NPRM also proposed to require operators 
that may have installed an incorrect O-ring to install the correct part 
and do a re-test.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comments received.

Request To Give Additional Credit for Original Issues of Service 
Bulletins

    Boeing points out that the supplemental NPRM gives credit only for 
the actions in paragraph (h)(1) to operators who did the work in 
accordance with the original issue of Boeing Service Bulletins 757-
28A0076 and 757-28A0077. (Boeing Service Bulletins 757-28A0076 and 757-
28A0077, Revision 1, both dated October 20, 2005, were referenced as 
the appropriate source of service information for accomplishing the 
required actions.) Boeing states that the original issues of the 
service bulletins are also acceptable for compliance with the actions 
in paragraphs (g), (h)(2), and (i) of the supplemental NPRM. Boeing 
states that referring to paragraphs (g), (h)(2), and (i) would give 
credit for previous rework of the spar bonding path between the end 
fitting of the fuel hose and the front spar to meet the bonding 
resistance requirements and application of sealant to the end fitting 
of the fuel feed hose on the forward and aft sides of the front spar, 
and to the fitting and tube coupling on both sides of the dry bay wall, 
and previous inspection for installation of a bonding jumper in the 
tank.
    We agree. The actions in paragraph (g), (h)(2), and (i) of the 
supplemental NPRM may be accomplished in accordance with the original 
issues of the service bulletins. We have revised paragraph (l) of the 
final rule to add a reference to paragraphs (g), (h)(2), and (i). In 
addition, the FAA notes that the actions in paragraph (j) of the final 
rule are still required to be done in accordance with Revision 1 of 
Boeing Service Bulletins 757-28A0076 and 757-28A0077.

[[Page 35382]]

Revised Service Bulletin Reference

    Paragraph (l) of the supplemental NPRM gives the date of the 
original issue of Boeing Service Bulletins 757-28A0076 and 757-28A0077 
as August 24, 2004. The actual date of the original issue of these 
service bulletins is August 27, 2004. We have revised paragraph (l) of 
the final rule to correct the date.

Conclusion

    We have carefully reviewed the available data, including the 
comments received, 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 1,040 airplanes of the affected design in the 
worldwide fleet. This AD affects about 700 airplanes of U.S. registry. 
The average labor rate is estimated to be $80 per work hour. Parts 
would be supplied from operator stock. The following table provides the 
estimated costs for U.S. operators to comply with this AD.

                             Estimated Costs
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                                                               Cost per
           Action/Airplanes affected             Work hours    airplane
------------------------------------------------------------------------
Hose fitting and spar bonding rework and                 11         $880
 sealant application (Group 1 airplanes)......
Bonding test and sealant application (Group 2            12          960
 airplanes that pass bonding test)............
Bonding test, hose fitting and spar bonding              18        1,440
 rework and sealant application (Group 2
 airplanes that fail bonding test)............
Replace O-ring for airplanes that incorporated            3          240
 original release of the service bulletins....
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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 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 
adding the following new airworthiness directive (AD):

2006-13-03 Boeing: Amendment 39-14655. Docket No. FAA-2005-20689; 
Directorate Identifier 2004-NM-197-AD.

Effective Date

    (a) This AD becomes effective July 25, 2006.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 757-200, -200PF, and -200CB 
series airplanes as identified in Boeing Service Bulletin 757-
28A0076, Revision 1, dated October 20, 2005; and Model 757-300 
series airplanes as identified in Boeing Service Bulletin 757-
28A0077, Revision 1, dated October 20, 2005; certificated in any 
category.

Unsafe Condition

    (d) This AD results from fuel system reviews conducted by the 
manufacturer. We are issuing this AD to prevent arcing or sparking 
at the interface between the bulkhead fittings of the engine fuel 
feed tube and the front spar during a lightning strike, which could 
provide a possible ignition source for the fuel vapor inside the 
fuel tank and result in a fuel tank explosion.

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.

Service Bulletin References

    (f) The term ``service bulletin(s),'' as used in this AD, means 
the Accomplishment Instructions of the following service bulletins, 
as applicable.
    (1) For Model 757-200, -200CB, and -200PF series airplanes: 
Boeing Service Bulletin 757-28A0076, Revision 1, dated October 20, 
2005.
    (2) For Model 757-300 series airplanes: Boeing Service Bulletin 
757-28A0077, Revision 1, dated October 20, 2005.

Hose Fitting and Spar Bonding Rework and Sealant Application

    (g) For Group 1 airplanes as identified in the service 
bulletins: Within 60 months after the effective date of this AD, 
rework the spar bonding path between the end fitting of the fuel 
feed hose and the front spar, and apply sealant to the hose fitting 
on the forward and aft side of the front spar and to the fitting and 
tube coupling on both sides of the dry bay wall, in accordance with 
the applicable service bulletin.

Bonding Resistance Test

    (h) For Group 2 airplanes as identified in the service 
bulletins: Within 60 months after the effective date of this AD, do 
a bonding resistance test between the fuel feed hose and the front 
spars of the left and right wings, in accordance with the service 
bulletins.
    (1) If the test meets required resistance limits, before further 
flight, apply sealant to

[[Page 35383]]

the end fitting of the fuel feed hose on the aft side of the front 
spar and to the fitting and tube coupling on both sides of the dry 
bay wall, in accordance with the applicable service bulletin.
    (2) If the test does not meet required resistance limits, before 
further flight, remove any existing sealant at the front spar; 
rework the spar bonding path between the end fitting of the fuel 
feed hose and the front spar to meet bonding resistance test 
requirements; and apply sealant to the end fitting of the fuel feed 
hose on the forward and aft sides of the front spar, and to the 
fitting and tube coupling on both sides of the dry bay wall, in 
accordance with the applicable service bulletin.

Inspection of Electrical Bonding Jumper

    (i) For all airplanes as identified in the service bulletins: 
Within 60 months after the effective date of this AD, perform a 
general visual inspection and applicable corrective actions to 
ensure that an electrical bonding jumper is installed between the 
engine fuel feed tube and the adjacent wing station 285.65 rib in 
the left and right wing fuel tanks, in accordance with the 
applicable service bulletin.

Replacement of O-Ring and Test

    (j) For airplanes on which the actions in paragraphs (g) or 
(h)(2) of this AD were done before the effective date of this AD in 
accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 757-28A0076, dated August 27, 2004; and Boeing 
Alert Service Bulletin 757-28A0077, dated August 27, 2004; as 
applicable: Within 60 months after the effective date of this AD, 
replace the O-ring, part number (P/N) MS29513-330 with a new O-ring, 
P/N MS29513-328, and do a leak test before further flight after 
reassembly. Do all actions in accordance with Part B of the 
Accomplishment Instructions of the applicable service bulletin.

Exception to Accomplishment Instructions in Service Bulletins

    (k) Although Boeing Service Bulletin 757-28A0076, Revision 1; 
and Boeing Service Bulletin 757-28A0077, Revision 1; both dated 
October 20, 2005, permit operator's equivalent procedures (OEP), 
this AD would require using the referenced airplane maintenance 
manuals, except that operators may use their own FAA-approved OEPs 
to drain the left and right engine fuel tubes, to drain and 
ventilate the fuel tanks, and to enter the fuel tanks.

Actions Accomplished in Accordance With Original Issues of Service 
Bulletins

    (l) Actions done before the effective date of this AD in 
accordance with Boeing Alert Service Bulletin 757-28A0076 and Boeing 
Alert Service Bulletin 757-28A0077, both dated August 27, 2004, are 
acceptable for compliance with the corresponding requirements of 
paragraphs (g), (h)(1), (h)(2), and (i) of this AD.

Alternative Methods of Compliance (AMOCs)

    (m)(1) The Manager, Seattle Aircraft Certification Office, FAA, 
has the authority to approve AMOCs for this AD, if requested in 
accordance with the procedures found in 14 CFR 39.19.
    (2) Before using any AMOC approved in accordance with Sec.  
39.19 on any airplane to which the AMOC applies, notify the 
appropriate principal inspector in the FAA Flight Standards 
Certificate Holding District Office.

Material Incorporated by Reference

    (n) You must use Boeing Service Bulletin 757-28A0076, Revision 
1, dated October 20, 2005; or Boeing Service Bulletin 757-28A0077, 
Revision 1, dated October 20, 2005; as applicable; to perform the 
actions that are required by this AD, unless the AD specifies 
otherwise. The Director of the Federal Register approved the 
incorporation by reference of these documents in accordance with 5 
U.S.C. 552(a) and 1 CFR part 51. 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 June 9, 2006.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 06-5501 Filed 6-19-06; 8:45 am]
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