Airworthiness Directives; The Boeing Company Airplanes

[Federal Register Volume 81, Number 242 (Friday, December 16, 2016)]
[Rules and Regulations]
[Pages 90955-90958]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2016-29251]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2015-3142; Directorate Identifier 2015-NM-003-AD; 
Amendment 39-18725; AD 2016-25-02]
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 787-8 airplanes. This AD was prompted by 
reports of the accumulation of very fine particle deposits in the power 
control unit (PCU) electro-hydraulic servo valves (EHSVs) used in the 
flight control system; this accumulation caused degraded performance 
due to reduced EHSV internal hydraulic supply pressures, resulting in 
the display of PCU fault status messages from the engine indication and 
crew alerting system (EICAS). This AD requires installing markers to 
limit the hydraulic system fluid used to a specific brand, doing 
hydraulic fluid tests of the hydraulic systems, replacing hydraulic 
system fluid if necessary, and doing all applicable related 
investigative and corrective actions. We are issuing this AD to address 
the unsafe condition on these products.

DATES: This AD is effective January 20, 2017.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of January 20, 
2017.

ADDRESSES: For service information identified in this final rule, 
contact Boeing Commercial Airplanes, Attention: Contractual & Data 
Services (C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 
90740; telephone 562-797-1717; 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-2015-3142.

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-
3142; 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: Fnu Winarto, Aerospace Engineer, 
Systems and Equipment Branch, ANM-130S, FAA, Seattle Aircraft 
Certification Office (ACO), 1601 Lind Avenue SW., Renton, WA 98057-
3356; phone: 425-917-6659; 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 certain The Boeing Company 
Model 787-8 airplanes. The NPRM published in the Federal Register on 
August 19, 2015 (80 FR 50233) (``the NPRM''). The NPRM was prompted by 
reports of the accumulation of very fine particle deposits in the PCU 
EHSVs used in the flight control system; this accumulation caused 
degraded performance due to reduced EHSV internal hydraulic supply 
pressures, resulting in the display of PCU fault status messages from 
the EICAS. The NPRM proposed to require installing markers to limit the 
hydraulic system fluid used to a specific brand, doing hydraulic fluid 
tests of the hydraulic systems, replacing hydraulic system fluid if 
necessary, and doing all applicable related investigative and 
corrective actions. We are issuing this AD to prevent the failure of 
flight control hydraulic PCUs, which could lead to reduced 
controllability of the airplane.

Comments

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

Request To Refer to Revised Service Information

    United Airlines (UAL) stated that there are many errors, omissions, 
and inconsistencies in Boeing Alert Service Bulletin B787-81205-
SB270026-00, Issue 001, dated November 25, 2014, and provided examples 
of those mistakes. UAL asked that this service information be revised 
to correct these problems.
    Boeing has issued Boeing Alert Service Bulletin B787-81205-
SB270026-00, Issue 002, dated June 13, 2016. The revised service 
information corrects typographical errors and makes clarifications to 
the Accomplishment Instructions in Boeing Alert Service Bulletin B787-
81205-SB270026-00, Issue 001, dated November 25, 2014. We have included 
Boeing Alert Service Bulletin B787-81205-SB270026-00, Issue 002, dated 
June 13, 2016, in paragraphs (c) and (h) of this AD. We have also 
included a new paragraph (i) in this AD to provide credit for actions 
done prior to the effective date of this AD using Boeing Alert Service 
Bulletin B787-81205-SB270026-00, Issue 001, dated November 25, 2014. 
The subsequent paragraphs have been redesignated accordingly.

Request To Clarify the Reason for the Unsafe Condition

    Boeing asked that we remove all references to hydraulic fluid 
contamination causing EHSV restriction, in the SUMMARY, the Discussion 
section of the NPRM, and paragraph (e) of the proposed AD. Boeing 
stated that the issue is not hydraulic fluid contamination causing EHSV 
restriction, but the accumulation of very fine particle deposits within 
the EHSV causing degraded performance due to reduced EHSV internal 
hydraulic supply pressures. Boeing added that the solution is to change 
the hydraulic fluid to a specific brand, considering that it has been 
verified to significantly reduce the rate of accumulation of particles 
in the EHSVs. Boeing concluded that this would clarify the cause of the 
EICAS messages.
    We agree that the reason for the unsafe condition should be 
clarified, for the reasons provided. Therefore, we have removed the 
references to hydraulic fluid contamination causing EHSV restriction 
and replaced that language with a more accurate reason for the unsafe 
condition in the SUMMARY, the Discussion section of the final rule, and 
paragraph (e) of this AD.

[[Page 90956]]

Request To Issue Global Alternative Method of Compliance (AMOC)

    UAL asked that a fleet-wide AMOC be issued for Boeing Service 
Bulletin B787-81205-SB290022-00, Issue 001, dated September 4, 2014, to 
correct a part number (P/N) reference. Task 1, Figure 1, and Task 2, 
Figure 1, of Boeing Service Bulletin B787-81205-SB290022-00, Issue 001, 
dated September 4, 2014, identify P/N 710Z7290-9##ALT1 for the left and 
right engine diagonal braces; however, the correct P/N is 710Z7290-9 
with no ##ALT suffix. UAL stated that the correct part number is 
identified in the Illustrated Parts Catalog (IPC).
    We acknowledge the commenter's concern that an incorrect part 
number for the left and right engine diagonal braces is identified in 
Boeing Service Bulletin B787-81205-SB290022-00, Issue 001, dated 
September 4, 2014. We have discussed this error with Boeing, and it was 
confirmed that the part number in the IPC (as noted by UAL) is correct 
and should be used. In light of this information, we do not agree that 
a global AMOC should be issued. However, we have added a new Note 2 to 
paragraph (g) of this AD to clarify the correct part number.

Request To Change Certain Instructions in the Service Information

    UAL stated that Boeing Service Bulletin B787-81205-SB290022-00, 
Issue 001, dated September 4, 2014, includes procedures for the HyJet V 
marker installation, which is a ``Required for Compliance (RC)'' item 
in Boeing Alert Service Bulletin B787-81205-SB270026-00, Issue 001, 
dated November 25, 2014, and must be done before or concurrently with 
that service information. UAL noted that there is no RC language in 
Boeing Service Bulletin B787-81205-SB290022-00, Issue 001, dated 
September 4, 2014, which makes the entire service bulletin ``RC.'' UAL 
asked that the steps that specify access and close be marked as non-RC 
steps.
    We do not agree to change Boeing Service Bulletin B787-81205-
SB290022-00, Issue 001, dated September 4, 2014, to mark the steps RC 
and non-RC. However, we do agree to clarify the steps that are required 
to accomplish the marker installation. Boeing Alert Service Bulletin 
B787-81205-SB270026-00, Issue 001, dated November 25, 2014, has an RC 
step that specifies to install markers. That RC step does not specify 
to perform access and close steps for the marker installation; 
therefore those access and close steps are not required by this AD. We 
have not changed this AD in this regard.
    UAL also asked we change the procedures in Part 4 of Boeing Alert 
Service Bulletin B787-81205-SB270026-00, Issue 001, dated November 25, 
2014, which specify options for either replacing the hydraulic fluid 
again, or draining and filling the hydraulic reservoir. UAL stated that 
if either option is used, then Part 2 of the service information titled 
``Cycle Hydraulic Fluid'' must again be done, or the airplane must be 
flown at least one flight cycle, and then a sample drawn for testing. 
UAL added that this procedure, done in accordance with the instructions 
in the referenced service information, results in excessive cycling if 
the operator needs to only replace a small amount of fluid and chooses 
the reservoir drain-and-fill option. UAL asked to use a procedure that 
would specify draining and filling the reservoir, flight control 
cycling, and taking a fresh sample for testing, all at the same time. 
UAL noted that Option 10 specifies ``Drain and Fill Hydraulic 
Reservoir'' and is acceptable to operate the flight controls six to 
eight times to let the fluid flow through all the systems. UAL stated 
that this is the procedure used by Boeing before taking fluid samples 
per the Boeing 787 Airplane Maintenance Manual.
    We do not agree to change the procedure for servicing the hydraulic 
fluid. Although UAL's proposal is an accepted procedure in the Boeing 
787 Airplane Maintenance Manual, this procedure does not include 
operating the other hydraulic-powered subsystems, such as the landing 
gear, thrust reverser, and brakes. Subsequently, it could result in 
stagnant fluid measurements not intermixing with other hydraulic system 
fluid following replacement of the hydraulic system fluid, and could 
generate fluid test samples that do not include the entire system. In 
light of these factors, we have not changed this AD in this regard.

Clarification to Paragraph (g) of This AD

    We have added a new Note 1 to paragraph (g) of this AD to refer to 
Boeing Service Bulletin B787-81205-SB290022-00, Issue 001, dated 
September 4, 2014, as an additional source of guidance for installing 
markers to allow servicing of hydraulic systems with only HyJet V 
hydraulic fluid.

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 for correcting the unsafe condition; and
    <bullet> Do not add any additional burden upon the public than was 
already proposed in the NPRM.
    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 have reviewed Boeing Alert Service Bulletin B787-81205-SB270026-
00, Issue 002, dated June 13, 2016. This service information describes 
procedures for installing markers to limit the hydraulic system fluid 
used to a specific brand; doing hydraulic fluid tests of the hydraulic 
systems, replacing the hydraulic system fluid if necessary, and related 
investigative 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 11 airplanes of U.S. registry.
    We estimate the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                     Cost per      Cost on U.S.
                Action                         Labor cost           Parts cost        product        operators
----------------------------------------------------------------------------------------------------------------
Install markers.......................  2 work-hours x $85 per               $95            $265          $2,915
                                         hour = $170.
Test and replace left, center, and      104 work-hours x $85 per           1,020           9,860         108,460
 right hydraulic system fluid.           hour = $8,840.
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[[Page 90957]]

    We estimate the following costs to do any necessary replacements 
that may be required based on the results of the inspection. We have no 
way of determining the number of aircraft that might need these 
replacements:

                                               On-Condition Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                     Cost per
                    Action                                 Labor cost               Parts cost        product
----------------------------------------------------------------------------------------------------------------
Replace power control unit of elevator........  9 x $85 per hour = $765.........        $108,000        $108,765
Replace power control unit of aileron.........  9 x $85 per hour = $765.........         118,000         118,765
----------------------------------------------------------------------------------------------------------------

    According to the manufacturer, some of the costs of this AD may be 
covered under warranty, thereby reducing the cost impact on affected 
individuals. We do not control warranty coverage for affected 
individuals. As a result, we have included all costs in our cost 
estimate.

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):

2016-25-02 The Boeing Company: Amendment 39-18725; Docket No. FAA-
2015-3142; Directorate Identifier 2015-NM-003-AD.

(a) Effective Date

    This AD is effective January 20, 2017.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to The Boeing Company Model 787-8 series 
airplanes, certificated in any category, as identified in Boeing 
Alert Service Bulletin B787-81205-SB270026-00, Issue 002, dated June 
13, 2016.

(d) Subject

    Air Transport Association (ATA) of America Code 27, Flight 
Control Systems.

(e) Unsafe Condition

    This AD was prompted by reports of the accumulation of very fine 
particle deposits in the power control unit (PCU) electro-hydraulic 
servo valves (EHSVs) used in the flight control system; this 
accumulation caused degraded performance due to reduced EHSV 
internal hydraulic supply pressures, resulting in the display of PCU 
fault status messages from the engine indication and crew alerting 
system (EICAS). We are issuing this AD to prevent failure of flight 
control hydraulic PCUs, which could lead to reduced controllability 
of the airplane.

(f) Compliance

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

(g) Marker Installation

    Within 36 months after the effective date of this AD, install 
markers to allow servicing of hydraulic systems with only HyJet V 
hydraulic fluid, in accordance with the Accomplishment Instructions 
of Boeing Alert Service Bulletin B787-81205-SB270026-00, Issue 002, 
dated June 13, 2016.

    Note 1 to paragraph (g) of this AD: Boeing Alert Service 
Bulletin B787-81205-SB270026-00, Issue 002, dated June 13, 2016, 
refers to Boeing Service Bulletin B787-81205-SB290022-00, Issue 001, 
dated September 4, 2014, as an additional source of guidance for 
installing markers to allow servicing of hydraulic systems with only 
HyJet V hydraulic fluid.


    Note 2 to paragraph (g) of this AD: Task 1, Figure 1, and Task 
2, Figure 1, of Boeing Service Bulletin B787-81205-SB290022-00, 
Issue 001, dated September 4, 2014, identify P/N 710Z7290-9##ALT1 
for the left and right engine diagonal braces; however, the correct 
P/N is 710Z7290-9 with no ##ALT suffix.

(h) Fluid Tests of the Left, Right, and Center Hydraulic Systems

    For airplanes identified in Boeing Alert Service Bulletin B787-
81205-SB270026-00, Issue 002, dated June 13, 2016, as Group 1, 
Configuration 2, Group 2: Within 36 months after the effective date 
of this AD, do hydraulic fluid tests of the left, right, and center 
hydraulic systems, replace the hydraulic system fluid, if necessary, 
and do all applicable related investigative and corrective actions, 
in accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin B787-81205-SB270026-00, Issue 002, dated June 13, 
2016. Do all applicable related investigative and corrective actions 
within 36 months after the effective date of this AD.

(i) Credit for Previous Actions

    This paragraph provides credit for the actions required by 
paragraphs (g) and (h) of this AD, if those actions were performed 
before the effective date of this AD using Boeing Alert Service 
Bulletin B787-81205-SB270026-00, Issue 001, dated November 25, 2014.

(j) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle Aircraft Certification Office (ACO), 
FAA, has the authority to approve AMOCs for this AD, if

[[Page 90958]]

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 (k)(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) For service information that contains steps that are labeled 
as Required for Compliance (RC), the provisions of paragraphs 
(j)(3)(i) and (j)(3)(ii) 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. If a step or sub-step is labeled ``RC Exempt,'' then 
the RC requirement is removed from that step or sub-step. 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.
    (4) 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.

(k) Related Information

    (1) For more information about this AD, contact Fnu Winarto, 
Aerospace Engineer, Systems and Equipment Branch, ANM-130S, FAA, 
Seattle ACO, 1601 Lind Avenue SW., Renton, WA 98057-3356; phone: 
425-917-6659; 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 (l)(3) and (l)(4) of this AD.

(l) 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 B787-81205-SB270026-00, Issue 
002, dated June 13, 2016.
    (ii) Reserved.
    (3) For service information identified in this AD, contact 
Boeing Commercial Airplanes, Attention: Contractual & Data Services 
(C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740; 
telephone 562-797-1717; Internet https://www.myboeingfleet.com.
    (4) You may view this 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.
    (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 November 25, 2016.
John P. Piccola, Jr.,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 2016-29251 Filed 12-15-16; 8:45 am]
 BILLING CODE 4910-13-P

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