Airworthiness Directives; The Boeing Company Airplanes

[Federal Register Volume 80, Number 142 (Friday, July 24, 2015)]
[Rules and Regulations]
[Pages 43940-43944]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2015-17978]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2014-1052; Directorate Identifier 2014-NM-140-AD; 
Amendment 39-18210; AD 2015-15-01]
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 superseding Airworthiness Directive (AD) 2004-13-02, 
which applied to certain The Boeing Company Model 747-100, -200B, and -
200F series airplanes. AD 2004-13-02 required repetitive inspections to 
find discrepancies in the upper and lower skins of the fuselage lap 
joints, and repair if necessary. This new AD adds post-repair 
inspections for cracking and corrosion, and repair if necessary; 
structural modification at the lap joints; and post-modification 
inspections for cracking and corrosion, and repair if necessary. This 
AD was prompted by an evaluation by the design approval holder (DAH) 
that indicates the longitudinal lap joints are subject to widespread 
fatigue damage (WFD). The actions mandated by this AD are necessary to 
reach the limit of validity (LOV). We are issuing this AD to detect and 
correct fatigue cracking in the upper and lower skins of the fuselage 
lap joints, which could result in sudden fracture and failure of a lap 
joint and rapid in-flight decompression of the airplane fuselage.

[[Page 43941]]


DATES: This AD is effective August 28, 2015.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of August 28, 
2015.

ADDRESSES: 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; Internet https://www.myboeingfleet.com. You may view this referenced service information 
at the FAA, Transport Airplane Directorate, 1601 Lind Avenue SW., 
Renton, WA. For information on the availability of this material at the 
FAA, call 425-227-1221. It is also available on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2014-
1052.

Examining the AD Docket

    You may examine the AD docket on the Internet at http://www.regulations.gov by searching for and locating Docket No. FAA-2014-
1052; 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 Docket 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: Bill Ashforth, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office 
(ACO), 1601 Lind Avenue SW., Renton, WA 98057-3356; phone: 425-917-
6432; 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 supersede AD 2004-13-02, Amendment 39-13682 (69 FR 35237, 
June 24, 2004). AD 2004-13-02 applied to certain The Boeing Company 
Model 747-100, -200B, and -200F series airplanes. The NPRM published in 
the Federal Register on January 23, 2015 (80 FR 3506). The NPRM was 
prompted by an evaluation by the DAH that indicates the longitudinal 
lap joints are subject to WFD. A structural modification at the lap 
joint, and post-modification repetitive inspections of the skin, 
existing internal doubler, or splice strap for cracks, and corrective 
actions if necessary, are necessary to reach the limit of validity 
(LOV). The NPRM proposed to continue to require repetitive inspections 
to find discrepancies in the upper and lower skins of the fuselage lap 
joints, and repair if necessary; and to add post-repair inspections for 
cracking and corrosion, and repair if necessary; structural 
modification at the lap joints; and post-modification inspections for 
cracking and corrosion, and repair if necessary. We are issuing this AD 
to detect and correct fatigue cracking in the upper and lower skins of 
the fuselage lap joints, which could result in sudden fracture and 
failure of a lap joint and rapid in-flight decompression of the 
airplane fuselage.

Comments

    We gave the public the opportunity to participate in developing 
this AD. The following presents the comments received on the NPRM (80 
FR 3506, January 23, 2015) and the FAA's response to each comment.

Support for the NPRM (80 FR 3506, January 23, 2015)

    Boeing stated that it concurs with the content of the proposed rule 
(80 FR 3506, January 23, 2015).

Request To Increase Inspection Frequency for Certain Airplanes

    An anonymous commenter expressed an opinion that there may be more 
reason to check airplanes that are frequently pressurized to a greater 
than 2.0 per-square-inch (psi) range than those that are not 
pressurized to that extent. The commenter also asked if there should be 
a weighted system that requires inspections sooner if an airplane has 
proportionally more flight cycles in the greater-than-, rather than the 
less-than, 2.0-psi differentials.
    We do not agree with the commenter's request for different 
inspection intervals based on pressurization ranges. The proposed 
inspection intervals were based on airplanes flying in a normal 
condition, which included full pressurization. In the past, if an 
operator had documentation substantiating flight cycles of less than 
2.0 psi, some of the inspection requirements could be reduced. This 
reduced inspection requirement was relieving in nature and occurred 
roughly 10 years ago. We have since determined that fleet findings did 
not support this relief and have disallowed reduced inspection 
requirements in future ADs. We have not provided this relief in this 
AD. We have not changed this final rule in this regard.

Request To Increase WFD Rule Applicability

    An anonymous commenter requested a reason why the WFD regulation 
applies only to Boeing and not to any other airplane manufacturer. The 
commenter stated that it seems like this type of WFD would be present 
in more than just Boeing airplanes, and yet the regulation and 
requirement for inspection seems to single out Boeing. The commenter 
suggested that it would make sense to consolidate and apply these 
requirements equally over all the types of airplanes.
    We do not agree with the commenter's request. On May 24, 2012, we 
made effective Amendment 26-6 of 14 CFR 26.21, ``Limit of Validity,'' 
of the Federal Aviation Regulations (14 CFR 26.21). This regulation 
required all design approval holders (DAHs) to develop an LOV for 
affected airplanes, which affected several manufacturers and models 
(not exclusively Boeing). The LOV is established by means of 
engineering data that support the structural maintenance program that 
corresponds to the period of time, stated as a number of total 
accumulated flight cycles or flight hours or both, during which it is 
demonstrated that WFD will not occur in the airplane. We have not 
changed this final rule in this regard.

Conclusion

    We reviewed the relevant data, considered the comments received, 
and determined that air safety and the public interest require adopting 
this AD as proposed except for minor editorial changes. We have 
determined that these minor changes:
    <bullet> Are consistent with the intent that was proposed in the 
NPRM (80 FR 3506, January 23, 2015) for correcting the unsafe 
condition; and
    <bullet> Do not add any additional burden upon the public than was 
already proposed in the NPRM (80 FR 3506, January 23, 2015).
    We also determined that these changes will not increase the 
economic burden on any operator or increase the scope of this AD.

Related Service Information Under 1 CFR Part 51

    We reviewed Boeing Alert Service Bulletin 747-53A2463, Revision 2, 
dated June 16, 2014. The service information describes procedures for 
inspections and repairs of cracks and corrosion in the skin at lap 
joints in the fuselage. This service information is reasonably 
available because the

[[Page 43942]]

interested parties have access to it through their normal course of 
business or by the means identified in the ADDRESSES section of this 
AD.

Costs of Compliance

    We estimate that this AD affects 2 airplanes of U.S. registry.
    We estimate the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                               Parts                             Cost on U.S.
              Action                       Labor cost           cost     Cost per product         operators
----------------------------------------------------------------------------------------------------------------
Inspections [actions retained      5,628 work-hours x $85          $0  $478,380 per          $956,760 per
 from AD 2004[dash]13[dash]02,      per hour = $478,380 per             inspection cycle.     inspection cycle.
 Amendment 39[dash]13682 (69 FR     inspection cycle.
 35237, June 24, 2004)].
Modification [new action]........  Up to 3,764                     $0  Up to $319,940......  Up to $639,880.
                                    work[dash]hours x $85
                                    per hour = $319,940.
Post-modification/                 Up to 3,764                     $0  Up to $319,940 per    Up to $639,880 per
 post[dash]repair inspections       work[dash]hours x $85               inspection cycle.     inspection cycle.
 [new action].                      per hour = $319,940 per
                                    inspection cycle.
----------------------------------------------------------------------------------------------------------------

    We have received no definitive data that would enable us to provide 
cost estimates for the on-condition actions specified in this AD.

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),
    (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 removing Airworthiness Directive (AD) 
2004-13-02, Amendment 39-13682 (69 FR 35237, June 24, 2004), and adding 
the following new AD:

2015-15-01 The Boeing Company: Amendment 39-18210; Docket No. FAA-
2014-1052; Directorate Identifier 2014-NM-140-AD.

(a) Effective Date

    This AD is effective August 28, 2015.

(b) Affected ADs

    This AD replaces AD 2004-13-02, Amendment 39-13682 (69 FR 35237, 
June 24, 2004).

(c) Applicability

    This AD applies to The Boeing Company Model 747-100, -200B, and 
-200F series airplanes, certificated in any category, as identified 
in Boeing Alert Service Bulletin 747-53A2463, Revision 2, dated June 
16, 2014.

(d) Subject

    Air Transport Association (ATA) of America Code 53, Fuselage.

(e) Unsafe Condition

    This AD was prompted by an evaluation by the design approval 
holder (DAH) that indicates the longitudinal lap joints are subject 
to widespread fatigue damage (WFD). We are issuing this AD to detect 
and correct fatigue cracking in the upper and lower skins of the 
fuselage lap joints, which could result in sudden fracture and 
failure of a lap joint and rapid in-flight decompression of the 
airplane fuselage.

(f) Compliance

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

(g) Inspections for Corrosion, and Corrective Actions

    For airplanes identified as Groups 2 through 14 in Boeing Alert 
Service Bulletin 747-53A2463, Revision 2, dated June 16, 2014: 
Except as provided by paragraph (l)(3) of this AD, at the applicable 
time specified in paragraph 1.E., ``Compliance,'' of Boeing Alert 
Service Bulletin 747-53A2463, Revision 2, dated June 16, 2014, do an 
external low frequency eddy current inspection for corrosion at the 
upper row of fasteners in the lap joint, and do all applicable 
corrective actions, in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 747-53A2463, Revision 
2, dated June 16, 2014, except as provided by paragraph (l)(1) of 
this AD. Do all applicable corrective actions before further flight. 
Repeat the inspection at the upper row of fasteners in the lap joint 
thereafter at the applicable intervals specified in paragraph 1.E., 
``Compliance,'' of Boeing Alert Service Bulletin 747-53A2463, 
Revision 2, dated June 16, 2014, except as provided by paragraph 
(l)(3) of this AD. Accomplishment of a structural modification in 
accordance with Part 5 of Boeing Alert Service Bulletin 747-53A2463, 
Revision 2, dated June 16, 2014, except as provided by paragraph 
(l)(1) of this AD, terminates the inspection requirements of this 
paragraph in the area of the modification only. The actions required 
by paragraph (j) of this AD are still applicable in the area of the 
modification.

(h) Inspections for Cracking, and Corrective Actions

    For airplanes identified as Groups 2 through 14 in Boeing Alert 
Service Bulletin

[[Page 43943]]

747-53A2463, Revision 2, dated June 16, 2014: Except as provided by 
paragraph (l)(3) of this AD, at the applicable time specified in 
paragraph 1.E., ``Compliance,'' of Boeing Alert Service Bulletin 
747-53A2463, Revision 2, dated June 16, 2014, do an internal medium 
frequency eddy current inspection for skin cracks at the lower row 
of fasteners in the lap joint, and do all applicable corrective 
actions, in accordance with the Accomplishment Instructions of 
Boeing Alert Service Bulletin 747-53A2463, Revision 2, dated June 
16, 2014, except as provided by paragraph (l)(1) of this AD. Do all 
applicable corrective actions before further flight. Repeat the 
inspection at the lower row of fasteners in the lap joint thereafter 
at the applicable intervals specified in paragraph 1.E., 
``Compliance,'' of Boeing Alert Service Bulletin 747-53A2463, 
Revision 2, dated June 16, 2014, except as provided by paragraph 
(l)(3) of this AD. Accomplishment of a structural modification in 
accordance with Part 5 of Boeing Alert Service Bulletin 747-53A2463, 
Revision 2, dated June 16, 2014, except as provided by paragraph 
(l)(1) of this AD, terminates the inspection requirements of this 
paragraph in the area of the modification only. The actions required 
by paragraph (j) of this AD are still applicable in the area of the 
modification.

(i) Structural Modification

    For airplanes identified as Groups 2 through 14 in Boeing Alert 
Service Bulletin 747-53A2463, Revision 2, dated June 16, 2014: At 
the applicable time specified in paragraph 1.E., ``Compliance,'' of 
Boeing Alert Service Bulletin 747-53A2463, Revision 2, dated June 
16, 2014, except as provided by paragraph (l)(2) of this AD, do a 
structural modification at the lap joints, and all applicable 
corrective actions, in accordance with the Accomplishment 
Instructions of Boeing Alert Service Bulletin 747-53A2463, Revision 
2, dated June 16, 2014, except as provided by paragraph (l)(1) of 
this AD. Do all applicable corrective actions before further flight. 
Accomplishment of the structural modification required by this 
paragraph terminates the inspections required by paragraphs (g), 
(h), and (k) of this AD in the area of the modification only. The 
actions required by paragraph (j) of this AD are still applicable in 
the area of the modification.

(j) Post-Modification Inspections and Corrective Actions

    For airplanes on which the actions required by paragraph (i) of 
this AD have been done: At the applicable time specified in 
paragraph 1.E., ``Compliance,'' of Boeing Alert Service Bulletin 
747-53A2463, Revision 2, dated June 16, 2014, except as provided by 
paragraph (l)(2) of this AD, do an internal high frequency eddy 
current (HFEC) inspection for cracks of the skin or existing 
internal doublers, and an open-hole HFEC inspection for splice strap 
cracks, in accordance with the Accomplishment Instructions of Boeing 
Alert Service Bulletin 747-53A2463, Revision 2, dated June 16, 2014. 
If any cracking is found, before further flight, repair using a 
method approved in accordance with the procedures specified in 
paragraph (n) of this AD. Repeat the inspections of the skin, 
internal doublers, and splice straps thereafter at the applicable 
intervals specified in paragraph 1.E., ``Compliance,'' of Boeing 
Alert Service Bulletin 747-53A2463, Revision 2, dated June 16, 2014.

(k) Post-Repair Inspections and Corrective Actions

    For airplanes with any new or existing external doubler repair 
accomplished at a lap joint and the repair doubler length is 40 
inches or longer: At the applicable time specified in paragraph 
1.E., ``Compliance,'' of Boeing Alert Service Bulletin 747-53A2463, 
Revision 2, dated June 16, 2014, except as provided by paragraph 
(l)(2) of this AD, do an internal HFEC inspection for cracking or 
corrosion of the repairs, and do all applicable corrective actions, 
in accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 747-53A2463, Revision 2, dated June 16, 2014, 
except as provided by paragraph (l)(1) of this AD. Do all applicable 
corrective actions before further flight. Repeat the inspection of 
external doubler repairs accomplished at lap joints thereafter at 
the applicable intervals specified in paragraph 1.E., 
``Compliance,'' of Boeing Alert Service Bulletin 747-53A2463, 
Revision 2, dated June 16, 2014. Accomplishment of a structural 
modification in accordance with Part 5 of Boeing Alert Service 
Bulletin 747-53A2463, Revision 2, dated June 16, 2014, except as 
provided by paragraph (l)(1) of this AD, terminates the inspection 
requirements of this paragraph in the area of the modification only. 
The actions required by paragraph (j) of this AD are still 
applicable in the area of the modification.

(l) Exceptions

    (1) If, during any action required by this AD, Boeing Alert 
Service Bulletin 747-53A2463, Revision 2, dated June 16, 2014, 
specifies to contact Boeing for an inspection or modification 
procedure, or repair instructions: Before further flight, do the 
inspection, or modification, or repair using a method approved in 
accordance with the procedures specified in paragraph (n) of this 
AD.
    (2) Where Paragraph 1.E., ``Compliance,'' of Boeing Alert 
Service Bulletin 747-53A2463, Revision 2, dated June 16, 2014, 
specifies a compliance time ``after the Revision 2 date of this 
service bulletin,'' this AD requires compliance within the specified 
compliance time after the effective date of this AD.
    (3) For the compliance threshold and repetitive interval 
calculations for inspections required by paragraphs (g) and (h) of 
this AD, the provisions specified in paragraphs (l)(3)(i) and 
(l)(3)(ii) of this AD apply regarding differential pressure.
    (i) For inspections done before the effective date of this AD: 
Flight cycles in which the cabin differential pressure was at 2.0 
pounds-per-square-inch (psi) or less need not be counted in the 
flight-cycle determination, provided that flight cycles with 
momentary spikes in cabin differential pressure above 2.0 psi were 
included as full pressure flight cycles. For this provision to 
apply, all cabin pressure records must have been maintained for each 
airplane. No fleet-averaging of cabin pressure is allowed.
    (ii) For inspections done on or after the effective date of this 
AD: All flight cycles must be counted, regardless of differential 
pressure.

(m) Credit for Previous Actions

    This paragraph provides credit for actions required by 
paragraphs (g) and (h) of this AD, if those actions were performed 
before the effective date of this AD using the service information 
identified in paragraph (m)(1) or (m)(2) of this AD.
    (1) Boeing Alert Service Bulletin 747-53A2463, dated March 7, 
2002, including Appendices A, B, and C, dated March 7, 2002, which 
was incorporated by reference in AD 2004-13-02, Amendment 39-13682 
(69 FR 35237, June 24, 2004).
    (2) Boeing Alert Service Bulletin 747-53A2463, Revision 1, dated 
April 16, 2009, which is not incorporated by reference in this AD.

(n) 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 paragraph (o)(1) 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.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any repair required by this AD, if it is approved by the 
Boeing Commercial Airplanes Organization Designation Authorization 
(ODA) that 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.
    (4) AMOCs approved for AD 2004-13-02, Amendment 39-13682 (69 FR 
35237, June 24, 2004), are approved as AMOCs for the corresponding 
provisions of paragraphs (g) and (h) of this AD.

(o) Related Information

    (1) For more information about this AD, contact Bill Ashforth, 
Aerospace Engineer, Airframe Branch, ANM-120S, FAA, Seattle Aircraft 
Certification Office (ACO), 1601 Lind Avenue SW., Renton, WA 98057-
3356; phone: 425-917-6432; fax: 425-917-6590; email: 
[email protected].
    (2) Service information identified in this AD that is not 
incorporated by reference is available at the addresses specified in 
paragraphs (p)(3) and (p)(4) of this AD.

(p) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference

[[Page 43944]]

(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 Alert Service Bulletin 747-53A2463, Revision 2, dated 
June 16, 2014.
    (ii) Reserved.
    (3) For Boeing 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; Internet 
https://www.myboeingfleet.com.
    (4) You may view this service information at FAA, Transport 
Airplane Directorate, 1601 Lind Avenue SW., Renton, WA. 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 July 10, 2015.
Michael Kaszycki,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2015-17978 Filed 7-23-15; 8:45 am]
BILLING CODE 4910-13-P

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