Airworthiness Directives; The Boeing Company Airplanes

[Federal Register Volume 80, Number 247 (Thursday, December 24, 2015)]
[Rules and Regulations]
[Pages 80234-80236]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2015-31715]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2015-1281; Directorate Identifier 2014-NM-241-AD; 
Amendment 39-18346; AD 2015-25-08]
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 all The 
Boeing Company Model 777 airplanes. This AD was prompted by an 
evaluation by the design approval holder (DAH) indicating that the lap 
splices of the aft pressure bulkhead webs are subject to widespread 
fatigue damage (WFD) on aging Model 777 airplanes that have accumulated 
at least 38,000 total flight cycles. This AD requires repetitive 
inspections for any crack in the aft webs of the radial lap splices of 
the aft pressure bulkhead, and, if necessary, corrective actions. We 
are issuing this AD to detect and correct fatigue cracking in the aft 
webs of the radial lap splices of the aft pressure bulkhead; such 
cracking could result in reduced structural integrity of the airplane, 
decompression of the cabin, and collapse of the floor structure.

DATES: This AD is effective January 28, 2016.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of January 28, 
2016.

ADDRESSES: For service information identified in this final rule, 
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-2015-
1281.

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-2015-
1281; 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: Eric Lin, Aerospace Engineer, Airframe 
Branch, ANM-120S, FAA, Seattle Aircraft Certification Office (ACO), 
1601 Lind Avenue SW., Renton, WA 98057-3356; phone: 425-917-6412; fax: 
425-917-6590; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Discussion

    We issued a notice of proposed rulemaking (NPRM) to amend 14 CFR 
part 39 by adding an AD that would apply to all The Boeing Company 
Model 777 airplanes. The NPRM published in the Federal Register on May 
12, 2015 (80 FR 27116). The NPRM was prompted by an evaluation by the 
DAH indicating that the lap splices of the aft pressure bulkhead webs 
are subject to WFD on aging Model 777 airplanes that have accumulated 
at least 38,000 total flight cycles. The NPRM proposed to require 
repetitive inspections for any crack in the aft webs of the radial lap 
splices of the aft pressure bulkhead, and, if necessary, corrective 
actions. We are issuing this AD to detect and correct fatigue cracking 
in the aft webs of the radial lap splices of the aft pressure bulkhead; 
such cracking could result in reduced structural integrity of the 
airplane, decompression of the cabin, and collapse of the floor 
structure.

Comments

    We gave the public the opportunity to participate in developing 
this AD. The following presents the comments received on the NPRM (80 
FR 27116, May 12, 2015) and the FAA's response to each comment.
    FedEx Express stated:
    <bullet> All of its Boeing Model 777s would be affected.
    <bullet> The proposed inspection threshold and intervals would fit 
into its maintenance schedule.
    <bullet> The number of man-hours and elapsed time to accomplish the 
inspections would not impact the overall span-time of its maintenance 
schedule.
    <bullet> The proposed inspections do not require any special 
inspection techniques, training, or tooling.

Request To Clarify Unsafe Condition

    Boeing requested that the unsafe condition statement in the NPRM 
(80 FR 27116, May 12, 2015) be revised to specify that the unsafe 
condition exists on aging airplanes, rather than new airplanes. Boeing 
stated that its analysis concluded that airplanes would have to 
accumulate at least 38,000 total flight cycles before the lap splices 
of the aft pressure bulkhead webs would be subject to WFD.
    We agree with Boeing's request and have revised the unsafe 
condition statement in the preamble and regulatory text of this final 
rule accordingly.

Request To Exclude a Service Information Action

    American Airlines (AA) requested that the first action specified in 
step 3.B.5. of the Accomplishment Instructions of Boeing Alert Service 
Bulletin 777-53A0078, dated December 5, 2014, be omitted from the 
requirements of the proposed AD (80 FR 27116, May 12, 2015). The action 
is to put the airplane back into a serviceable condition. AA stated 
that this action does not address the unsafe condition addressed by the 
proposed rule and that most operators would accomplish the proposed AD 
requirements during a maintenance visit. AA stated that in the context 
of a maintenance visit, returning the airplane to a serviceable 
condition immediately after completion of the inspections and any 
associated corrective actions would not be possible. AA indicated that 
an operator would wait until all of the maintenance items scheduled for 
that visit would have been completed before putting the airplane back 
into a serviceable condition.
    We agree with the commenter's statement that this action does not 
need to be required by this final rule; several other FAA regulations 
require restoring the airplane to a serviceable condition before 
further flight. However, the step of returning the airplane to a 
serviceable condition is not marked required for compliance (``RC'') in 
Boeing Alert Service Bulletin 777-53A0078, dated December 5, 2014; 
therefore, as noted in

[[Page 80235]]

paragraph (i)(4)(ii) of this AD, this step may be delayed using an 
accepted method in accordance with the operator's maintenance or 
inspection program without obtaining approval of an alternative method 
of compliance (AMOC). We have not changed this AD in this regard.

Request for Clarification of Relationship Between the NPRM (80 FR 
27116, May 12, 2015) and AD 2012-07-06, Amendment 39-17012 (77 FR 
21429)

    Air New Zealand requested clarification regarding the relationship 
between the NPRM (80 FR 27116, May 12, 2015) and AD 2012-07-06, 
Amendment 39-17012 (77 FR 21429, April 10, 2012). Specifically, the 
commenter asked if the NPRM would supersede AD 2012-07-06; if the AMOC 
approval included in AD 2012-07-06 would be included in the NPRM; and 
if the proposed inspections in the NPRM should be done in lieu of or in 
addition to the existing inspections required by AD 2012-07-06.
    We agree with the commenter's request for clarification. This is a 
new AD applicable to all The Boeing Company Model 777 airplanes and 
requires repetitive inspections for cracking in the aft webs of the 
radial lap splices of the aft pressure bulkhead, and corrective actions 
if necessary. AD 2012-07-06, Amendment 39-17012 (77 FR 21429, April 10, 
2012), is applicable to certain Model 777 airplanes and requires 
revising the maintenance program to update inspection requirements to 
detect fatigue cracking of principal structural elements throughout the 
airplane.
    An AMOC for AD 2012-07-06, Amendment 39-17012 (77 FR 21429, April 
10, 2012), was issued so operators could use the corresponding 
compliance times and inspections specified in Boeing Alert Service 
Bulletin 777-53A0078, dated December 5, 2014, for the inspection 
requirements for the corresponding locations specified in Boeing Model 
777 Structural Significant Item 53-80-I13A and paragraphs (g) and (h) 
of AD 2012-07-06. The information regarding this AMOC is included in 
Boeing Alert Service Bulletin 777-53A0078, dated December 5, 2014. 
Operators are required to accomplish the requirements in this new AD in 
accordance with the Accomplishment Instructions of Boeing Alert Service 
Bulletin 777-53A0078, dated December 5, 2014. If the actions of this 
new AD are done, the requirements of AD 2012-07-06 are met only for 
areas inspected in accordance with Boeing Alert Service Bulletin 777-
53A0078, dated December 5, 2014.
    Regarding the question about whether the AMOC approval included in 
AD 2012-07-06, Amendment 39-17012 (77 FR 21429, April 10, 2012), would 
be included in this AD, paragraph (i) of this AD contains the AMOC 
approval procedures for this AD. However, because the existing 
inspections required by AD 2012-07-06 are not sufficient to preclude 
WFD in this area, we have not included previous AMOCs issued for AD 
2012-07-06 as AMOCs for this AD. We have not changed this AD 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 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 (80 FR 27116, May 12, 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 27116, May 12, 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 777-53A0078, dated 
December 5, 2014. This service information describes procedures for 
inspections of the lap splices in the web of the aft pressure bulkhead 
for cracking, and corrective actions. This service information is 
reasonably available because the interested parties have access to it 
through their normal course of business or by the means identified in 
the ADDRESSES section.

Costs of Compliance

    We estimate that this AD affects 193 airplanes of U.S. registry.
    We estimate the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                 Cost on U.S.
             Action                    Labor cost         Parts cost      Cost per product        operators
----------------------------------------------------------------------------------------------------------------
Inspection......................  9 work-hours x $85               $0   $765 per inspection  $147,645 per
                                   per hour = $765                       cycle.               inspection cycle
                                   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

    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.

[[Page 80236]]

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):

2015-25-08 The Boeing Company: Amendment 39-18346; Docket No. FAA-
2015-1281; Directorate Identifier 2014-NM-241-AD.

(a) Effective Date

    This AD is effective January 28, 2016.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to all The Boeing Company Model 777-200, -200LR, 
-300, -300ER, and 777F series airplanes, certificated in any 
category.

(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 indicating that the lap splices of the aft pressure bulkhead 
webs are subject to widespread fatigue damage on aging Model 777 
airplanes that have accumulated at least 38,000 total flight cycles. 
We are issuing this AD to detect and correct fatigue cracking in the 
aft webs of the radial lap splices of the aft pressure bulkhead; 
such cracking could result in reduced structural integrity of the 
airplane, decompression of the cabin, and collapse of the floor 
structure.

(f) Compliance

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

(g) Inspection of Lap Splice in the Web of the Aft Pressure Bulkhead

    Except as required by paragraph (h) of this AD: At the times 
specified in paragraph 1.E., ``Compliance,'' of Boeing Alert Service 
Bulletin 777-53A0078, dated December 5, 2014, do a medium frequency 
eddy current inspection for any cracking in the aft webs of the 
radial lap splices of the aft pressure bulkhead, in accordance with 
the Accomplishment Instructions of Boeing Alert Service Bulletin 
777-53A0078, dated December 5, 2014. Repeat the inspection 
thereafter at intervals not to exceed 8,400 flight cycles from the 
previous inspection. If any crack is found during any inspection 
required by this AD, do the applicable corrective actions, in 
accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 777-53A0078, dated December 5, 2014. If a 
corrective action described in Boeing Alert Service Bulletin 777-
53A0078, dated December 5, 2014, specifies to contact Boeing for 
appropriate action: Before further flight, repair using a method 
approved in accordance with the procedures specified in paragraph 
(i) of this AD.

(h) Exception to Service Information Specifications

    Where Boeing Alert Service Bulletin 777-53A0078, dated December 
5, 2014, specifies a compliance time ``after the original issue date 
of this service bulletin,'' this AD requires compliance within the 
specified compliance time after the effective date of this AD.

(i) 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 (j) 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, modification, or alteration 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. To be approved, the 
repair method, modification deviation, or alteration deviation must 
meet the certification basis of the airplane and the approval must 
specifically refer to this AD.
    (4) For service information that contains steps that are labeled 
as Required for Compliance (RC), the provisions of paragraphs 
(i)(4)(i) and (1)(4)(ii) of this AD apply.
    (i) The steps labeled as RC, including substeps under an RC step 
and any figures identified in an RC step, must be done to comply 
with the AD. An AMOC is required for any deviations to RC steps, 
including substeps and identified figures.
    (ii) Steps not labeled as RC may be deviated from using accepted 
methods in accordance with the operator's maintenance or inspection 
program without obtaining approval of an AMOC, provided the RC 
steps, including substeps and identified figures, can still be done 
as specified, and the airplane can be put back in an airworthy 
condition.

(j) Related Information

    For more information about this AD, contact Eric Lin, Aerospace 
Engineer, Airframe Branch, ANM-120S, FAA, Seattle ACO, 1601 Lind 
Avenue SW., Renton, WA 98057-3356; phone: 425-917-6412; fax: 425-
917-6590; email: [email protected].

(k) 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 Alert Service Bulletin 777-53A0078, dated December 5, 
2014.
    (ii) Reserved.
    (3) 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.
    (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 December 10, 2015.
Michael Kaszycki,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2015-31715 Filed 12-23-15; 8:45 am]
 BILLING CODE 4910-13-P

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