AD 2002-26-13

[Federal Register Volume 68, Number 1 (Thursday, January 2, 2003)]
[Rules and Regulations]
[Pages 33-35]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 02-32865]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 99-NM-90-AD; Amendment 39-13001; AD 2002-26-13]
RIN 2120-AA64


Airworthiness Directives; McDonnell Douglas Model DC-9-11, -12, -
13, -14, -15, and -15F Airplanes; Model DC-9-21 Airplanes; Model DC-9-
31, -32, -32 (VC-9C), -32F, -32F (C-9A, C-9B), -33F, -34, and -34F 
Airplanes; Model DC-9-41 Airplanes; Model DC-9-51 Airplanes; Model DC-
9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), and DC-9-87 (MD-87) 
Airplanes; and Model MD-88 Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment adopts a new airworthiness directive (AD), 
applicable to certain McDonnell Douglas airplanes, that requires 
replacement of certain power relays, and subsequent repetitive 
cleaning, inspecting, repairing, and testing of certain replaced power 
relays. This amendment is prompted by reports indicating that the 
alternating current (AC) cross-tie relay shorted out internally, which 
caused severe smoke and burn damage to the relay, aircraft wiring, and 
adjacent panels. The actions specified by this AD are intended to 
prevent internal arcing of the left and right generator power relays, 
auxiliary power relays, and external power relays, and consequent smoke 
and/or fire in the cockpit and cabin.

DATES: Effective February 6, 2003.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of February 6, 2003.

ADDRESSES: The service information referenced in this AD may be 
obtained from Boeing Commercial Aircraft Group, Long Beach Division, 
3855 Lakewood Boulevard, Long Beach, California 90846, Attention: Data 
and Service Management, Dept. C1-L5A (D800-0024). This information may 
be examined at the Federal Aviation Administration (FAA), Transport 
Airplane Directorate, Rules Docket, 1601 Lind Avenue, SW., Renton, 
Washington; or at the FAA, Los Angeles Aircraft Certification Office, 
3960 Paramount Boulevard, Lakewood, California; or at the Office of the 
Federal Register, 800 North Capitol Street, NW., suite 700, Washington, 
DC.

FOR FURTHER INFORMATION CONTACT: Elvin Wheeler, Aerospace Engineer, 
Systems and Equipment Branch, ANM-130L, FAA, Los Angeles Aircraft 
Certification Office, 3960 Paramount Boulevard, Lakewood, California 
90712-4137; telephone (562) 627-5344; fax (562) 627-5210.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) to include an airworthiness 
directive (AD) that is applicable to certain McDonnell Douglas 
airplanes was published as a second supplemental notice of proposed 
rulemaking (NPRM) in the Federal Register on July 1, 2002 (67 FR 
44119). That action proposed to require replacement of certain power 
relays, and subsequent repetitive cleaning, inspecting, repairing, and 
testing of certain replaced power relays.

[[Page 34]]

Comments

    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. Due consideration has been given to 
the comment received.

Request To Reduce the Compliance Time

    One commenter, the National Transportation Safety Board (NTSB), 
agrees with the proposed replacement and repetitive maintenance 
requirements. However, the commenter does not agree with the proposed 
24-month compliance time, because it ``is a longer compliance time than 
is either necessary or prudent.'' The commenter states that it was 
informed by the FAA that the originally proposed 12-month compliance 
time was extended to 24 months because of the limited supply of 
replacement relays and the absence of any reports of failure of the 
power relays having part number (P/N) 914F567-3 in the six positions 
(left and right generator power, auxiliary power, and external power). 
The commenter notes that the power relay manufacturer has recommended 
replacement of P/N 914F567-3 power relays in those six positions and 
the cross-tie position (total of seven positions) since 1976.
    From this comment, we infer that the commenter requests that the 
compliance time be reduced from the proposed 24 months to 12 months. We 
do not agree. Concerning the power relay manufacturer's 1976 
recommendation, Sundstrand (Westinghouse) has re-reviewed all field 
data for power relays having P/N 914F567-3. It concluded that, in its 
opinion, the identified unsafe condition exists in the cross-tie 
position only. The power relays installed at the AC cross-tie position 
are more susceptible to phase-to-phase short than the other six 
positions (left and right generator power, auxiliary power, and 
external power) due to the installation orientation in an airplane. Its 
horizontal orientation allows for the buildup of conductive particle 
material between phase-to-phase circuits. Sundstrand (Westinghouse) 
also recommended that we not issue an AD for power relays having P/N 
914F567-3 that are in the left and right generator power, auxiliary 
power, and external power positions. Due to the lower likelihood of a 
short circuit resulting in internal arcing, we have determined that a 
24-month compliance time is appropriate to address the identified 
unsafe condition.
    However, as discussed in the preamble of the second supplemental 
NPRM, we have determined that the potential for an electrical short 
still exists when a power relay, Sundstrand (Westinghouse) P/N 914F567-
3, is installed in those six positions, though not as likely as in the 
cross-tie position. The accumulation of conductive particle material on 
any power relays, Sundstrand (Westinghouse) P/N 914F567-3, can build an 
electrical path to its adjacent terminal and cause a phase-to-phase 
short circuit. Such a short circuit will result in internal arcing of 
the power relays and consequent smoke and/or fire in the cockpit and 
cabin. This final rule addresses that potential unsafe condition by 
replacing the generator power relays, auxiliary power relays, and 
external power relays having Sundstrand (Westinghouse) P/N 914F567-3 
with a Sundstrand (Westinghouse) P/N 9008D09 series or 914F567-4, and 
periodically removing the build-up of conductive particle material from 
the generator power relays, auxiliary power relays, and external power 
relays, having Sundstrand (Westinghouse) P/N 914F567-4.

Explanation of Change to Applicability

    We have revised the applicability of the existing AD to identify 
model designations as published in the most recent type certificate 
data sheet for the affected models.

Conclusion

    After careful review of the available data, including the comment 
noted above, we have determined that air safety and the public interest 
require the adoption of the rule with the change previously described. 
We have determined that this change will neither increase the economic 
burden on any operator nor increase the scope of the AD.

Cost Impact

    There are approximately 1,991 Model DC-9-11, -12, -13, -14, -15, 
and -15F airplanes; Model DC-9-21 airplanes; Model DC-9-31, -32, -32 
(VC-9C), -32F, -32F (C-9A, C-9B), -33F, -34, and -34F airplanes; Model 
DC-9-41 airplanes; Model DC-9-51 airplanes; Model DC-9-81 (MD-81), DC-
9-82 (MD-82), DC-9-83 (MD-83), and DC-9-87 (MD-87) airplanes; and Model 
MD-88 airplanes; of the affected design in the worldwide fleet. The FAA 
estimates that 1,219 airplanes of U.S. registry will be affected by 
this AD, that it will take approximately 2 work hours per airplane to 
accomplish the required inspection, and that the average labor rate is 
$60 per work hour. Based on these figures, the cost impact of the AD on 
U.S. operators is estimated to be $146,280, or $120 per airplane.
    The cost impact figure discussed above is based on assumptions that 
no operator has yet accomplished any of the requirements of this AD 
action, and that no operator would accomplish those actions in the 
future if this AD were not adopted. The cost impact figures discussed 
in AD rulemaking actions represent only the time necessary to perform 
the specific actions actually required by the AD. These figures 
typically do not include incidental costs, such as the time required to 
gain access and close up, planning time, or time necessitated by other 
administrative actions.

Regulatory Impact

    The regulations adopted herein 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. Therefore, it 
is determined that this final rule does not have federalism 
implications under Executive Order 13132.
    For the reasons discussed above, I certify that this action (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); and (3) 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. A final evaluation has been prepared for this action 
and it is contained in the Rules Docket. A copy of it may be obtained 
from the Rules Docket at the location provided under the caption 
ADDRESSES.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.

[[Page 35]]

Sec.  39.13  [Amended]

    2. Section 39.13 is amended by adding the following new 
airworthiness directive:

2002-26-13 McDonnell Douglas: Amendment 39-13001. Docket 99-NM-90-
AD.

    Applicability: This AD applies to the following airplanes, 
certificated in any category, as listed in Boeing Alert Service 
Bulletin DC9-24A191, Revision 01, dated January 9, 2002:

McDonnell Douglas Model

DC-9-11, DC-9-12, DC-9-13, DC-9-14, DC-9-15, and DC-9-15F airplanes
DC-9-21 airplanes
DC-9-31, DC-9-32, DC-9-32 (VC-9C), DC-9-32F, DC-9-32F (C-9A, C-9B), 
DC-9-33F, DC-9-34, and DC-9-34F airplanes
DC-9-41 airplanes
DC-9-51 airplanes
DC-9-81 (MD-81), DC-9-82 (MD-82), DC-9-83 (MD-83), and DC-9-87 (MD-
87) airplanes
MD-88 airplanes

    Note 1: This AD applies to each airplane identified in the 
preceding applicability provision, regardless of whether it has been 
modified, altered, or repaired in the area subject to the 
requirements of this AD. For airplanes that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (e) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.

    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent internal arcing of the left and right generator power 
relays, auxiliary power relays, and external power relays, and 
consequent smoke and/or fire in the cockpit and cabin, accomplish 
the following:

Inspection

    (a) Within 24 months after the effective date of this AD, 
perform a one-time inspection of the left and right generator power 
relays, auxiliary power relays, and external power relays, to 
determine if Sundstrand (Westinghouse) part number (P/N) 914F567-3 
or -4 is installed, per Boeing Alert Service Bulletin DC9-24A191, 
Revision 01, dated January 9, 2002.

Replacement or Modification/Reidentification of Any Generator Power 
Relay, Auxiliary Power Relay, or External Power Relay, P/N 914F567-3

    (b) If any generator power relay, auxiliary power relay, or 
external power relay, Sundstrand (Westinghouse) P/N 914F567-3, is 
found installed during the inspection required by paragraph (a) of 
this AD, within 24 months after the effective date of this AD, do 
either action specified in paragraph (b)(1) or (b)(2) of this AD per 
the Accomplishment Instructions of Boeing Alert Service Bulletin 
DC9-24A191, Revision 01, dated January 9, 2002.
    (1) Replace power relay having Sundstrand (Westinghouse) P/N 
914F567-3 with either a serviceable power relay having Sundstrand 
(Westinghouse) P/N 9008D09 series or 914F567-4.
    (2) Modify the power relay, Sundstrand (Westinghouse) P/N 
914F567-3, to a -4 configuration.

Maintenance or Replacement of Any Generator Power Relay, Auxiliary 
Power Relay, or External Power Relay, P/N 914F567-4

    (c) If any generator power relay, auxiliary power relay, or 
external power relay, Sundstrand (Westinghouse) P/N 914F567-4, is 
found installed during the inspection required by paragraph (a) of 
this AD, clean, inspect, repair, and test the relay, or replace the 
power relay with a serviceable power relay having Sundstrand 
(Westinghouse) P/N 9008D09 series or 914F567-4; per Boeing Alert 
Service Bulletin DC9-24A191, Revision 01, dated January 9, 2002; at 
the time specified in paragraph (c)(1) of this AD, except as 
provided by paragraph (c)(2) of this AD.
    (1) Within 7,000 flight hours after installation of the 
generator power relay, auxiliary power relay, or external power 
relay, Sundstrand (Westinghouse) P/N 914F567-4, or within 24 months 
after the effective date of this AD, whichever occurs later.
    (2) For airplanes on which the flight hours since installation 
of any generator power relay, auxiliary power relay, or external 
power relay, Sundstrand (Westinghouse) P/N 914F567-4, cannot be 
determined: Within 24 months after the effective date of this AD.

Repetitive Maintenance of Generator Power Relay, Auxiliary Power Relay, 
or External Power Relay, Sundstrand (Westinghouse) P/N 914F567-4

    (d) Before or upon the accumulation of 7,000 flight hours on any 
generator power relay, auxiliary power relay, or external power 
relay, Sundstrand (Westinghouse) P/N 914F567-4 since accomplishing 
the action(s) required by either paragraph (b) or (c) of this AD, as 
applicable, clean, inspect, repair, and test; per Boeing Alert 
Service Bulletin DC9-24A191, Revision 01, dated January 9, 2002. 
Thereafter, repeat these actions at intervals not to exceed the 
accumulation of 7,000 flight hours on the power relay.

Alternative Methods of Compliance

    (e) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Los Angeles Aircraft Certification 
Office (ACO), FAA. Operators shall submit their requests through an 
appropriate FAA Principal Maintenance Inspector, who may add 
comments and then send it to the Manager, Los Angeles ACO.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Los Angeles ACO.

Special Flight Permits

    (f) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the airplane to a location where 
the requirements of this AD can be accomplished.

Incorporation by Reference

    (g) The actions shall be done in accordance with Boeing Alert 
Service Bulletin DC9-24A191, Revision 01, dated January 9, 2002. 
This incorporation by reference was approved by the Director of the 
Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 
51. Copies may be obtained from Boeing Commercial Aircraft Group, 
Long Beach Division, 3855 Lakewood Boulevard, Long Beach, California 
90846, Attention: Data and Service Management, Dept. C1-L5A (D800-
0024). Copies may be inspected at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the 
FAA, Los Angeles Aircraft Certification Office, 3960 Paramount 
Boulevard, Lakewood, California; or at the Office of the Federal 
Register, 800 North Capitol Street, NW., suite 700, Washington, DC.

Effective Date

    (h) This amendment becomes effective on February 6, 2003.

    Issued in Renton, Washington, on December 23, 2002.
Vi L. Lipski,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 02-32865 Filed 12-31-02; 8:45 am]
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