Airworthiness Directives; The Boeing Company Model 777-200, -200LR, -300, and -300ER Series Airplanes

[Federal Register Volume 76, Number 197 (Wednesday, October 12, 2011)]
[Rules and Regulations]
[Pages 63163-63167]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2011-25754]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2010-1312; Directorate Identifier 2010-NM-220-AD; 
Amendment 39-16826; AD 2011-21-03]
RIN 2120-AA64


Airworthiness Directives; The Boeing Company Model 777-200, -
200LR, -300, and -300ER Series Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are adopting a new airworthiness directive (AD) for the 
products listed above. This AD requires installing foreign object 
debris (FOD) rubber shields over the primary and secondary external 
power connectors for certain airplanes, and wrapping silicone tape 
around the hydraulic tube for certain other airplanes. This AD was 
prompted by a report of a fire in the main equipment center due to 
failure of an external power connector, which

[[Page 63164]]

caused high-temperature arcing and subsequent splatter of molten copper 
on an adjacent hydraulic tube, creating a hole in the tube and spraying 
hydraulic fluid into the power connector, resulting in a fire. In 
addition there were several reports of overheating or arcing of 
external power connectors, and one report of a fire due to arcing 
caused by FOD. We are issuing this AD to prevent FOD from entering the 
primary and secondary external power connectors, which could result in 
overheating or arcing and consequent fire in the main equipment center.

DATES: This AD is effective November 16, 2011.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in the AD as of November 16, 
2011.

ADDRESSES: For service information identified in this AD, contact 
Boeing Commercial Airplanes, Attention: Data & Services Management, 
P.O. Box 3707, MC 2H-65, Seattle, Washington 98124-2207; telephone 206-
544-5000, extension 1; fax 206-766-5680; e-mail [email protected]; 
Internet https://www.myboeingfleet.com. You may review copies of the 
referenced service information at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington. For information 
on the availability of this material at the FAA, call 425-227-1221.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov; or in person at the Docket Management Facility 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The AD docket contains this AD, the regulatory evaluation, 
any comments received, and other information. The address for the 
Docket Office (phone: 800-647-5527) is Document Management Facility, 
U.S. Department of Transportation, Docket Operations, M-30, West 
Building Ground Floor, Room W12-140, 1200 New Jersey Avenue, SE., 
Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Georgios Roussos, Aerospace Engineer, 
Systems and Equipment Branch, ANM-130S, FAA, Seattle Aircraft 
Certification Office, 1601 Lind Avenue, SW., Renton, Washington 98057-
3356; phone: (425) 917-6482; fax: (425) 917-6590; e-mail: 
[email protected].

SUPPLEMENTARY INFORMATION:

Discussion

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 to include an airworthiness directive (AD) that would apply to 
the specified products. That NPRM published in the Federal Register on 
January 18, 2011 (76 FR 2846). That NPRM proposed to require installing 
foreign object debris (FOD) rubber shields over the primary and 
secondary external power connectors for certain airplanes, and wrapping 
fire-resistant silicone tape around the hydraulic tube for certain 
other airplanes.

Comments

    We gave the public the opportunity to participate in developing 
this AD. The following presents the comments received on the proposal 
and the FAA's response to each comment.

Support for the NPRM

    American Airlines has accomplished the modifications on the 
majority of its fleet, and has no objection to the actions and 
compliance times in the NPRM (76 FR 2846, January 18, 2011). The 
National Transportation Safety Board supports the NPRM.

Request To Use Latest Production Hydraulic Tube

    Japan Airlines (JAL), Continental Airlines, and All Nippon Airways 
(ANA) asked that operators be allowed to use the latest production 
hydraulic tube having part number (P/N) 272W4190-192, which already has 
the silicone tape pre-wrapped, in lieu of modifying the existing 
hydraulic tube assembly by installing the silicone tape in accordance 
with Boeing Special Attention Service Bulletin 777-29-0032, dated 
August 9, 2007. JAL also noted a concern about procuring the hydraulic 
tube.
    We do not agree with the request to use the latest production 
hydraulic tube as an acceptable alternative to installing the silicone 
tape. Based on the latest information received from Boeing engineering, 
the following applies to any possible hydraulic tube replacement: Any 
hydraulic tube having P/N 272W4190-192 (as specified in Boeing Special 
Attention Service Bulletin 777-29-0032, dated August 9, 2007), cannot 
be a direct replacement for the existing part. Hydraulic tubes having 
P/Ns 272W4190-93, -168, and -192 for production installation require 
the use of permaswage fittings on either side of the tube. Removal of 
the tube for its replacement requires that the tube be physically cut 
past the permaswage fitting, thus making it longer than the original 
production part. We have made no change to the AD in this regard.

Request To Include Instructions for Continued Airworthiness

    Continental and ANA also noted that the service information does 
not contain proper instructions for continued airworthiness (ICAs) to 
install the tape on the new line, or inclusion of the equivalent 
production part number in the Boeing 777 illustrated parts catalog 
(IPC). Continental added that a pre- and post-service bulletin 
configuration should be included to provide instructions to use a newer 
part or to accomplish the actions specified in the service information 
again.
    We acknowledge the commenters' concern, but we do not agree. The 
Boeing ICAs do include a statement indicating that the production tubes 
are reworked by using the procedures in Boeing Special Attention 
Service Bulletin 777-29-0032, dated August 9, 2007. Since there is not 
direct replacement with a production tube, we are working with Boeing 
to identify additional information necessary in support of replacing 
the hydraulic tube. We have made no change to the AD in this regard.

Request To Include Information Notices

    United Airlines asked that we revise the NPRM (76 FR 2846, January 
18, 2011) to refer to Boeing Service Bulletin Information Notices 777-
29-0032 IN 01, dated November 29, 2007, and 777-29-0032 IN 02, dated 
December 11, 2008, which include clarifications to the Accomplishment 
Instructions of Boeing Special Attention Service Bulletin 777-29-0032, 
dated August 9, 2007.
    We acknowledge that these information notices may be useful to 
operators to clarify certain instructions specified in Boeing Special 
Attention Service Bulletin 777-29-0032, dated August 9, 2007. However, 
Boeing has provided these notices to operators. We do not reference 
information notices in ADs because those documents are not FAA-
reviewed. In addition, the information notices do not contain technical 
information and are not necessary to accomplish the actions required by 
the AD. We have made no change to the AD in this regard.

Request To Change the Applicability

    Boeing requested that the applicability section in the NPRM (76 FR 
2846, January 18, 2011) be changed. Boeing stated that the 
applicability should be limited to the airplanes identified in the 
referenced service information, which include only those airplanes on 
which the modifications required by the AD have not been accomplished 
in production.

[[Page 63165]]

    We agree with the commenter for the reason provided and have 
limited the applicability section in this AD accordingly, in lieu of 
specifying ``all'' airplanes of the affected model.

Request To Clarify Tape Qualities

    Boeing asked that we delete the term ``fire-resistant,'' which 
describes ``silicone tape,'' as specified in the Summary section, 
Relevant Service Information section, and paragraph (g)(2) of the NPRM 
(76 FR 2846, January 18, 2011). Boeing stated that the product data 
sheet identifies the tape as ``high temperature arc- and track-
resistant tape,'' but not ``fire-resistant.''
    We agree with the commenter for the reason provided. However, the 
term ``fire-resistant'' was used in the NPRM (76 FR 2846, January 18, 
2011) because it is specified as such in the referenced service 
information. We have removed it from the Summary section and paragraph 
(g)(2) of this AD. The Relevant Service Information section of the 
preamble does not reappear in the final rule.

Request To Clarify Terminology of Tape Dimensions

    Boeing asked that we change the language in the ``Exception to 
Service Information'' section in paragraph (h) of the NPRM (76 FR 2846, 
January 18, 2011) as follows: ``Figure 1 of the Accomplishment 
Instructions of Boeing Special Attention Service Bulletin 777-29-0032, 
dated August 9, 2007, does not identify the units of the dimensions of 
the silicone tape installed on the hydraulic tube; those dimensions are 
identified in inches.'' Boeing noted that the dimensions of the tape 
are identified, but the units of the dimensions are missing. Boeing 
added that, although the tape can be used as ``electrical'' tape, for 
this application it is more appropriate to identify it as ``silicone'' 
tape.
    We agree with the commenter for the reasons provided. The word 
``electrical'' was used in the NPRM (76 FR 2846, January 18, 2011) 
because it is specified as such in the referenced service information. 
We have changed paragraph (h) of this AD to reiterate the commenter's 
suggested language.

Request To Provide Additional Credit

    Boeing asked that the service information specified in paragraph 
(i) of the NPRM (76 FR 2846, January 18, 2011) under ``Credit for 
Actions Accomplished in Accordance with Previous Service Information'' 
be changed to include Boeing Special Attention Service Bulletin 777-29-
0032, dated August 9, 2007 (referred to in the NPRM as the service 
information to use for installing the silicone tape). Boeing stated 
that the modification accomplished by this service bulletin before the 
effective date of the AD is identical to the modification accomplished 
by this service bulletin after the effective date of the AD.
    We do not agree that the subject service bulletin should be added 
to paragraph (i) of this AD. Operators are already given credit for 
previously accomplished actions as allowed by the phrase in paragraph 
(f) of this AD which states the following: ``Comply with this AD within 
the compliance times specified, unless already done.'' We have made no 
change to the AD in this regard.

Request To Exclude Certain Proposed Actions

    Delta Airlines asked that Boeing Special Attention Service Bulletin 
777-29-0032, dated August 9, 2007, be excluded from the NPRM (76 FR 
2846, January 18, 2011). Delta stated that since the root cause of the 
external power connector fires and overheating was related to foreign 
object debris (FOD) shorting out the external power connector inside 
the airplane, once the FOD shields are installed per Boeing Service 
Bulletin 777-24-0102, Revision 1, dated June 17, 2010, the protective 
tape identified in Boeing Special Attention Service Bulletin 777-29-
0032, dated August 9, 2007, serves no purpose. Delta added that if 
damage to the hydraulic tubing is still a concern even after 
accomplishment of this service bulletin, a routing change to the 
hydraulic tubing would be a better solution to protecting the tubing 
from a fire/overheat condition. Delta noted that the tape being 
installed is not fireproof, only fire-resistant. Delta also stated that 
the instructions for installing the tape specified in Boeing Special 
Attention Service Bulletin 777-29-0032, dated August 9, 2007, would be 
difficult to comply with. Subsequent inspections of the tape 
installation to ensure compliance with the NPRM would also be difficult 
when judging the overlap and number of tape wraps, since the tape 
installation is based on the amount of stretch and a percentage of 
overlap.
    We do not agree to remove Boeing Special Attention Service Bulletin 
777-29-0032, dated August 9, 2007, from this AD. Installation of the 
FOD shields is not the only action necessary to address the identified 
unsafe condition. FOD shields alone do not resolve the potential for 
overheating and arcing of the electrical connectors. Based on our 
evaluation, we have determined that the connector design, lack of 
proper connector maintenance actions, and the proximity of the 
hydraulic tubing to the connectors can result in a fire; therefore, 
accomplishing the actions required by this AD will minimize the threat 
of fire on the airplane.
    Additionally, although the silicone tape is not fireproof, 
installing the tape provides an acceptable level of protection to the 
hydraulic tubing in the event of overheating or arcing of the 
connectors. The procedures for installing the tape are not difficult 
for compliance and include easy access and liberal application of the 
tape; several operators have already done this modification and did not 
encounter any problems. Further, it is the responsibility of operators 
to maintain the AD-mandated configuration, and this can be done using 
the procedures specified in Boeing Special Attention Service Bulletin 
777-29-0032, dated August 9, 2007. In light of these factors, we have 
made no change to the AD.

Conclusion

    We reviewed the relevant data, considered 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

    We estimate that this AD will affect 126 airplanes of U.S. 
registry. We estimate the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                         Number of
               Action                       Labor cost         Parts cost    Cost per    airplanes    Fleet cost
                                                                             product      affected
----------------------------------------------------------------------------------------------------------------
Install FOD rubber shields..........  6 work-hour x $85 per          $134         $644          124      $79,856
                                       hour = $510.

[[Page 63166]]

 
Wrap silicone tape..................  2 work-hour x $85 per             0          170          126       21,420
                                       hour = $170.
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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

    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),
    (3) Will not affect intrastate aviation in Alaska, and
    (4) 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.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    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):

2011-21-03 The Boeing Company: Amendment 39-16826; Docket No. FAA-
2010-1312; Directorate Identifier 2010-NM-220-AD.

Effective Date

    (a) This AD is effective November 16, 2011.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to The Boeing Company Model 777-200, -200LR, 
-300, and -300ER series airplanes; certificated in any category; as 
identified in Boeing Service Bulletin 777-24-0102, Revision 1, dated 
June 17, 2010; and Boeing Special Attention Service Bulletin 777-29-
0032, dated August 9, 2007.

Subject

    (d) Joint Aircraft System Component (JASC)/Air Transport 
Association (ATA) of America Codes 29: Hydraulic power; and 24: 
Electrical power.

Unsafe Condition

    (e) This AD was prompted by a report of a fire in the main 
equipment center due to failure of an external power connector, 
which caused high-temperature arcing and subsequent splatter of 
molten copper on an adjacent hydraulic tube, creating a hole in the 
tube and spraying hydraulic fluid into the power connector, 
resulting in a fire. In addition there were several reports of 
overheating or arcing of external power connectors, and one report 
of a fire due to arcing caused by foreign object debris (FOD). We 
are issuing this AD to prevent FOD from entering the primary and 
secondary external power connectors, which could result in 
overheating or arcing and consequent fire in the main equipment 
center.

Compliance

    (f) Comply with this AD within the compliance times specified, 
unless already done.

Modification

    (g) Within 36 months after the effective date of this AD, do the 
actions required by paragraphs (g)(1) and (g)(2) of this AD.
    (1) For airplanes identified in Boeing Service Bulletin 777-24-
0102, Revision 1, dated June 17, 2010: Install FOD rubber shields 
over the primary and secondary external power connectors, in 
accordance with the Accomplishment Instructions of Boeing Service 
Bulletin 777-24-0102, Revision 1, dated June 17, 2010.
    (2) For airplanes identified in Boeing Special Attention Service 
Bulletin 777-29-0032, dated August 9, 2007: Wrap silicone tape 
around the hydraulic tube, in accordance with the Accomplishment 
Instructions of Boeing Special Attention Service Bulletin 777-29-
0032, dated August 9, 2007.

Exception to Service Information

    (h) Figure 1 of the Accomplishment Instructions of Boeing 
Special Attention Service Bulletin 777-29-0032, dated August 9, 
2007, does not identify the units of the dimensions of the silicone 
tape installed on the hydraulic tube; those dimensions are 
identified in inches.

Credit for Actions Accomplished in Accordance With Previous Service 
Information

    (i) Actions done before the effective date of this AD in 
accordance with Boeing Service Bulletin 777-24-0102, dated July 12, 
2007, are acceptable for compliance with the corresponding 
requirements of paragraph (g)(1) of this AD.

Alternative Methods of Compliance (AMOCs)

    (j)(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. In accordance with 14 
CFR 39.19, send your request to your principal inspector or local 
Flight Standards District Office, as appropriate. If sending 
information directly to the manager of the ACO, send it to the 
attention of the person identified in the Related Information 
section of this AD. Information may be e-mailed to: [email protected].
    (2) Before using any approved AMOC, notify your Principal 
Maintenance Inspector or Principal Avionics Inspector, as 
appropriate, or lacking a principal inspector, your local Flight 
Standards District Office.

Related Information

    (k) For more information about this AD, contact Georgios 
Roussos, Aerospace Engineer, Systems and Equipment Branch, ANM-130S, 
FAA, Seattle Aircraft Certification Office, 1601 Lind Avenue, SW., 
Renton, Washington 98057-3356; phone: (425) 917-6482; fax: (425) 
917-6590; e-mail: [email protected].
    (l) For service information identified in this AD, contact 
Boeing Commercial

[[Page 63167]]

Airplanes, Attention: Data & Services Management, P.O. Box 3707, MC 
2H-65, Seattle, Washington 98124-2207; telephone 206-544-5000, 
extension 1; fax 206-766-5680; e-mail [email protected]; Internet 
https://www.myboeingfleet.com. You may review copies of the 
referenced service information at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington. For 
information on the availability of this material at the FAA, call 
425-227-1221.

Material Incorporated by Reference

    (m) You must use Boeing Service Bulletin 777-24-0102, Revision 
1, dated June 17, 2010; or Boeing Special Attention Service Bulletin 
777-29-0032, dated August 9, 2007; as applicable; to do the actions 
required by this AD, unless the AD specifies otherwise.
    (1) The Director of the Federal Register approved the 
incorporation by reference of the service information contained 
under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) For service information identified in this AD, contact 
Boeing Commercial Airplanes, Attention: Data & Services Management, 
P.O. Box 3707, MC 2H-65, Seattle, WA 98124-2207; telephone 206-544-
5000, extension 1; fax 206-766-5680; e-mail [email protected]; 
Internet  https://www.myboeingfleet.com.
    (3) You may review copies of the service information at the FAA, 
Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, 
Washington. For information on the availability of this material at 
the FAA, call 425-227-1221.
    (4) You may also review copies of the service information that 
is incorporated by reference at the National Archives and Records 
Administration (NARA). For information on the availability of this 
material at an NARA facility, 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 September 27, 2011.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2011-25754 Filed 10-11-11; 8:45 am]
BILLING CODE 4910-13-P

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