Airworthiness Directives; The Boeing Company Airplanes

[Federal Register Volume 78, Number 55 (Thursday, March 21, 2013)]
[Rules and Regulations]
[Pages 17294-17297]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2013-05589]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2012-0597; Directorate Identifier 2012-NM-054-AD; 
Amendment 39-17377; AD 2013-05-05]
RIN 2120-AA64


Airworthiness Directives; The Boeing Company Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: We are adopting a new airworthiness directive (AD) for certain 
The Boeing Company Model 777-200, -200LR, -300, and -300ER series 
airplanes. This AD was prompted by reports of in-service events related 
to electrical power system malfunctions resulting in damage to 
electrical load management system (ELMS) P200 and P300 power panels and 
the surrounding area. This AD requires installing enclosure trays to 
contain debris in certain ELMS panels, and replacing certain ELMS 
contactors. We are issuing this AD to prevent contactor failures, which 
could result in uncontained hot debris flow due to ELMS contactor 
breakdown, consequent smoke and heat damage to airplane structure and 
equipment during ground operations, and possible injuries to passengers 
and crew.

DATES: This AD is effective April 25, 2013.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in the AD as of April 25, 
2013.

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; Internet https://www.myboeingfleet.com. You may review copies of the referenced service 
information at the FAA, 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, Seattle Aircraft Certification 
Office (ACO), FAA, 1601 Lind Avenue SW., Renton, Washington 98057-3356; 
phone: 425-917-6482; fax: 425-917-6590; email: 
[email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 to include an AD that would apply to the specified products. 
That NPRM published in the Federal Register on June 18, 2012 (77 FR 
36206). That NPRM proposed to require installing enclosure trays to 
contain debris in certain ELMS panels, and replacing certain ELMS 
contactors in the P200 and P300 ELMS panels.

Comments

    We gave the public the opportunity to participate in developing 
this AD. The following presents the comments received on the proposal 
(77 FR 36206, June 18, 2012) and the FAA's response to each comment.

Request To Allow Certain Installations of Removed Contactors

    Cathay Pacific Airways (Cathay) and All Nippon Airways (All Nippon) 
requested that we clarify the proposed requirement to discard the 
removed contactors. The commenters requested that we identify certain 
inspection criteria that would allow further use of these contactors on 
non-AD-affected locations and ease the financial burden of discarding 
removed but serviceable power contactors.
    We partially agree with the request. The note in paragraphs 3.B.3 
and 3.B.4 of the Accomplishment Instructions of Boeing Special 
Attention Service Bulletin 777-24-0112, Revision 2, dated December 14, 
2011, specifies discarding these parts. We agree that power contactors 
that have been appropriately overhauled to the manufacturer's original 
specifications may meet criteria for safe operation in non-AD-affected 
locations. But this AD applies to the affected airplanes, not the 
contactors; the AD therefore cannot mandate the disposition of 
contactors removed from

[[Page 17295]]

the airplane. Further, power contactors that are removed from the AD-
affected ELMS panel location are considered compromised parts and may 
not be installed ``as is'' in other non-AD-affected locations. We have 
added new paragraph (j)(2) in this final rule to provide for the re-
installation of the contactors, provided they are first inspected and 
tested, and repaired if necessary, in accordance with a method approved 
by the Seattle Aircraft Certification Office (ACO).

Concern for Effect of Ongoing Maintenance on AD Compliance

    Cathay was concerned that operators would have difficulty ensuring 
compliance with the proposed requirements in ongoing maintenance. 
According to Cathay, operators are unable to purge the stock with part 
number (P/N) ELM827-1 contactors still installed on the P100 panel.
    We acknowledge Cathay's concern for allowing installation of the P/
N ELM827-1 contactors within the P100 ELMS panel. We disagree, however, 
with Cathay's inference that this is difficult to accomplish on the 
other panel, because proper maintenance documentation and personnel 
training can secure ongoing compliance with the AD requirements. 
Furthermore, we are not aware of any issues associated with these power 
contactors within the P100 ELMS panel that would warrant any regulatory 
action against this panel installation. We have not changed the final 
rule regarding this issue.

Request To Allow Contactor Replacement as Optional

    Korean Air Lines and Air France requested that we reconsider the 
proposed requirement to replace the power contactors. Korean Air Lines 
stated that Boeing introduced, in addition to the tray installation, 
certain improvements to the ELMS panel, such as the installation of a 
cooling duct and internal inspection of the panel. Korean Air Lines 
considered these additional improvements sufficient to provide safety 
for the passengers. Korean Air Lines requested that the power contactor 
replacement become optional if the tray enclosures and the cooling duct 
were installed. Air France explained its choice to replace the power 
contactor within the P300 ELMS panel because inspections revealed a 
number of panels and contactors with evidence of overheating and/or 
silver deposits. Air France further pointed to inspections on the P200 
ELMS panel that did not identify any damage. Air France asserted that 
there is no technical or reliability benefit to the requirement to 
replace the power contactors, and requested that we reconsider the 
requirement.
    We disagree. Our data indicate a number of in-service failures of 
power contactors installed within the P200 and P300 ELMS panels. While 
installation of the tray enclosures may limit the extent of the damage 
within the affected power panel, power contactor failures nevertheless 
generate excessive heat and smoke that may lead to aircraft emergency 
evacuation and potential passenger injuries. While the cooling duct 
provides a better operating environment for the power contactors, its 
installation does not necessarily address the kind of internal 
contactor failures that may result from operating at power levels so 
near the rated capacity and could lead to thermal degradation of 
materials, which further reduce contactor protection and can lead to 
loose parts within the contactor that may increase the probability of 
arcing. We have not changed the final rule regarding this issue.

Request To Clarify Cost Estimate

    United Airlines questioned the high cost of the replacement parts 
relative to parts outsourcing and liability concerns. Air France 
considered that the cost of the replacement is not justified by any 
technical or reliability benefit, and offered two solutions: (1) a 
substantially reduced contactor price or (2) use of P/N ELM827-1 as 
spares, provided certain preventive measures were taken.
    We partially agree. We have been informed that Boeing is 
negotiating certain price reductions with its contactor supplier. 
However, we have determined that replacement of these parts is 
necessary for continued safe flight, and we have therefore not changed 
the final rule regarding this issue. Regarding use of P/N ELM827-1 as 
spares, as discussed previously, we have added new paragraph (j)(2) in 
this final rule to provide for re-installation of the contactors, if 
done using a method approved by the Seattle ACO.

Request To Allow Credit for Certain Revised Service Information

    Boeing requested that we revise Note 1 to paragraph (g) of the NPRM 
(77 FR 36206, June 18, 2012) to include prior revisions of the 
specified Smiths service information. Boeing added that Boeing Special 
Attention Service Bulletin 777-24-0106, dated July 20, 2007 (referenced 
in the NPRM as the appropriate source of service information for the 
tray installation), does not identify a specific revision level of the 
Smiths service information. Boeing reported that the next revision of 
Boeing Service Bulletin 777-24-0106 will include the revision levels 
per the proposed AD, but that the subsequent changes, which are related 
to ease of installation only, were not necessary to ensure safety.
    We agree that the changes introduced to the referenced revised GE 
Aviation (Smiths) service information are not necessary to ensure 
safety. We have determined that the information in Note 1 to paragraph 
(g) of the NPRM (77 FR 36206, June 18, 2012), as well as Note 2 to 
paragraph (h) of the NPRM, is unnecessary; these notes have been 
removed from the AD.

Concern Regarding Quality Oversight

    Recognizing the proposed requirement to upgrade to the more robust 
contactors, as specified in the NPRM (77 FR 36206, June 18, 2012), and 
noting the benefits of containment trays, United Airlines expressed its 
hope that the NPRM addressed all compromised areas of concern regarding 
the equipment. The commenter also expressed concern about contactor 
quality oversight.
    We infer that the commenter agrees with the requirements of this 
final rule. We also recognize the importance of parts quality oversight 
to prevent failures on high-power contactors that could potentially 
cause significant airplane damage. We understand that both Boeing and 
the parts supplier have increased their quality oversight of the 
contactors. There is no need to change the final rule regarding this 
issue.

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 and minor editorial 
changes. We have determined that these minor changes:
    <bullet> Are consistent with the intent that was proposed in the 
NPRM (77 FR 36206, June 18, 2012) for correcting the unsafe condition; 
and
    <bullet> Do not add any additional burden upon the public than was 
already proposed in the NPRM (77 FR 36206, June 18, 2012).
    We also determined that these changes will not increase the 
economic burden on any operator or increase the scope of the AD.

Costs of Compliance

    We estimate that this AD affects 128 airplanes of U.S. registry. We 
estimate the following costs to comply with this AD:

[[Page 17296]]



                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
Tray installation.....................  3 work-hours x $85 per            $1,729          $1,984        $253,952
                                         hour = $255.
Contactor replacement.................  6 work-hours x $85 per            49,317          49,827       6,377,856
                                         hour = $510.
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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):

2013-05-05 The Boeing Company: Amendment 39-17377; Docket No. FAA-
2012-0597; Directorate Identifier 2012-NM-054-AD.

(a) Effective Date

    This AD is effective April 25, 2013.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to The Boeing Company Model 777-200, -200LR, -
300, and -300ER series airplanes; certificated in any category; as 
identified in Boeing Special Attention Service Bulletin 777-24-0106, 
dated July 20, 2007; and Boeing Special Attention Service Bulletin 
777-24-0112, Revision 2, dated December 14, 2011.

(d) Subject

    Joint Aircraft System Component (JASC)/Air Transport Association 
(ATA) of America Code 24, Electrical power.

(e) Unsafe Condition

    This AD was prompted by reports of in-service events related to 
electrical power system malfunctions resulting in damage to 
electrical load management system (ELMS) P200 and P300 power panels 
and the surrounding area. We are issuing this AD to prevent 
contactor failures, which could result in uncontained hot debris 
flow due to ELMS contactor breakdown, consequent smoke and heat 
damage to airplane structure and equipment during ground operations, 
and possible injuries to passengers and crew.

(f) Compliance

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

(g) Tray Installation

    For airplanes identified in Boeing Special Attention Service 
Bulletin 777-24-0106, dated July 20, 2007: Within 36 months after 
the effective date of this AD, install enclosure trays to contain 
debris in the ELMS panels, in accordance with the Accomplishment 
Instructions of Boeing Special Attention Service Bulletin 777-24-
0106, dated July 20, 2007.

(h) Contactor Replacement

    For airplanes identified in Boeing Special Attention Service 
Bulletin 777-24-0112, Revision 2, dated December 14, 2011: Within 60 
months after the effective date of this AD, replace specified 
electrical power contactors in the ELMS P200 and P300 power panels 
with new contactors, in accordance with the Accomplishment 
Instructions of Boeing Special Attention Service Bulletin 777-24-
0112, Revision 2, dated December 14, 2011, except as provided by 
paragraph (j)(2) of this AD.

(i) Credit for Previous Actions

    This paragraph provides credit for the replacement of the ELMS 
contactors required by paragraph (h) of this AD, if those actions 
were performed before the effective date of this AD using Boeing 
Special Attention Service Bulletin 777-24-0112, dated February 19, 
2009; or Revision 1, dated June 30, 2011. These service bulletins 
are not incorporated by reference in this AD.

(j) Parts Installation

    (1) Except as required by paragraph (j)(2) of this AD: As of the 
effective date of this AD, no person may install, on any airplane, a 
contactor having part number ELM827-1 in the ELMS panels and 
locations identified in this AD, except as required by paragraph 
(j)(2) of this AD.
    (2) This paragraph provides operators with the option not to 
discard the removed power contactors, in contrast with the note in 
steps 3.B.3 and 3.B.4 of the Accomplishment Instructions of Boeing 
Special Attention Service Bulletin 777-24-0112, Revision 2, dated 
December 14, 2011. This AD allows re-installation of removed power 
contactors, if done using a method approved in accordance with the 
procedures specified in paragraph (k) of this AD.

(k) Alternative Methods of Compliance (AMOCs)

    (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 emailed to: [email protected].
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the local flight standards district office/certificate holding 
district office.

[[Page 17297]]

(l) Related Information

    (1) For more information about this AD, contact Georgios 
Roussos, Aerospace Engineer, Systems and Equipment Branch, ANM-130S, 
Seattle Aircraft Certification Office (ACO), FAA, 1601 Lind Avenue 
SW., Renton, Washington 98057-3356; phone: 425-917-6482; fax: 425-
917-6590; email: [email protected].
    (2) 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; Internet https://www.myboeingfleet.com.

(m) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Boeing Special Attention Service Bulletin 777-24-0106, dated 
July 20, 2007.
    (ii) Boeing Special Attention Service Bulletin 777-24-0112, 
Revision 2, dated December 14, 2011.
    (3) 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; Internet https://www.myboeingfleet.com.
    (4) You may view this 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.
    (5) You may view this service information that is incorporated 
by reference at the National Archives and Records Administration 
(NARA). For information on the availability of this material at 
NARA, call 202-741-6030, or go to: http://www.archives.gov/federal-register/cfr/ibr-locations.html.

    Issued in Renton, Washington, on February 28, 2013.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2013-05589 Filed 3-20-13; 8:45 am]
BILLING CODE 4910-13-P

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