AD 2005-16-11

[Federal Register Volume 70, Number 155 (Friday, August 12, 2005)]
[Rules and Regulations]
[Pages 47086-47090]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 05-15882]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-20325; Directorate Identifier 2003-NM-129-AD; 
Amendment 39-14217; AD 2005-16-11]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 747-100, 747-100B, 747-
100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747SP, and 747SR 
Series Airplanes; Equipped With Pratt & Whitney Model JT9D-3 and -7 
Series Engines

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
certain Boeing transport category airplanes listed above. This AD 
requires repetitive inspections for cracks of the upper surface of the 
aft lower spar web of the inboard and outboard struts, as applicable; 
and repetitive inspections for cracks of the upper surface of the 
intermediate web bay of the aft lower spar. This AD also requires 
repetitive inspections and torque checks of the bolts common to the aft 
lower spar chords and the fitting of the rear engine mount bulkhead for 
missing, loose, or fractured bolts, as applicable; and corrective 
action, if necessary. This AD is prompted by reports of cracking in the 
aft lower spar web and reports of missing and fractured bolts. We are 
issuing this AD to detect and correct cracking of the aft lower spar 
web, and to prevent missing, loose, or fractured bolts common to the 
aft lower spar chords and the fitting of the rear engine mount 
bulkhead, which could result in the loss of the aft lower spar load 
path and reduced structural capability of the pylon, which may result 
in the separation of the engine from the airplane.

DATES: This AD becomes effective September 16, 2005.
    The incorporation by reference of a certain publication listed in 
the AD is approved by the Director of the Federal Register as of 
September 16, 2005.

ADDRESSES: For service information identified in this AD, contact 
Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-
2207.
    Docket: The AD docket contains the proposed AD, comments, and any 
final disposition. You can examine the AD docket on the Internet at 
http://

[[Page 47087]]

dms.dot.gov, or in person at the Docket Management Facility office 
between 9 a.m. and 5 p.m., Monday through Friday, except Federal 
holidays. The Docket Management Facility office (telephone (800) 647-
5227) is located on the plaza level of the Nassif Building at the U.S. 
Department of Transportation, 400 Seventh Street SW., room PL-401, 
Washington, DC. This docket number is FAA-2005-20325; the directorate 
identifier for this docket is 2003-NM-129-AD.

FOR FURTHER INFORMATION CONTACT: Candice Gerretsen, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
917-6428; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39 
with an AD for certain Boeing transport category airplanes. That 
action, published in the Federal Register on February 10, 2005 (70 FR 
7052), proposed to require repetitive inspections for cracks of the 
upper surface of the aft lower spar web of the inboard and outboard 
struts, as applicable; and repetitive inspections for cracks of the 
upper surface of the intermediate web bay of the aft lower spar. That 
action also proposed to require repetitive inspections and torque 
checks of the bolts common to the aft lower spar chords and the fitting 
of the rear engine mount bulkhead for missing, loose, or fractured 
bolts, as applicable; and corrective action, if necessary.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comments that have been 
submitted on the proposed AD.

Request To Revise Applicability

    One commenter requests that the applicability be revised to read:

    This AD applies to engine strut assemblies installed on Boeing 
Model 747-100, -100B, -100B SUD, -200B, -200C, -200F, and -300 
series airplanes, and Model 747-SP and 747 SR series airplanes; 
certificated in any category; equipped with Pratt and Whitney Model 
JT9D-3 and -7 series engines.

    The commenter contends that retired airplanes are not included in 
the applicability of the proposed AD and states that strut assemblies 
may be interchanged between airplanes.
    We do not agree to revise the applicability. Retired airplanes are 
included by variable number in Boeing Alert Service Bulletin 747-
54A2212, dated May 1, 2003 (referenced as the appropriate source of 
information for the applicability of the proposed AD). Also, it is our 
policy to not write the applicability of ADs against a part of the 
airframe, such as the strut. Section 39.3 (``Definition of 
airworthiness directives'') of the Federal Aviation Regulations (14 CFR 
39.3) specifies that airworthiness directives apply to the following 
products: aircraft, aircraft engine, propeller, or appliance (which is 
not part of the airframe). We have not changed the final rule in this 
regard.

Request To Advise Operators That Strut Assemblies Are Interchangeable

    The same commenter requests that a clause be added to advise 
operators that the strut assemblies are interchangeable and that, if a 
strut assembly is installed on another airplane, that airplane must be 
evaluated to determine if it is applicable to the proposed AD.
    We agree that the strut assembly is an interchangeable part. 
However, we do not agree to revise the final rule to advise operators 
that the strut assemblies are interchangeable because the strut is a 
serialized part that can be tracked. Operators should note that they 
are responsible for maintaining the configuration of its airplanes, 
especially in an area affected by an AD. As required by section 39.17 
of the Federal Aviation Regulations (14 CFR 39.17), for airplanes that 
have been modified, altered, or repaired so that the accomplishment of 
the requirements of this final rule is affected, the operator must 
request approval for an alternative method of compliance according to 
paragraph (q) of this AD.

Request To Define Airplane Groups by Pylon Web Thickness

    One commenter requests that the airplane groups be defined solely 
by pylon web thickness. The commenter states that the groups identified 
in the service bulletin do not reflect its airplane configuration. The 
commenter notes that it has Group 1 airplanes with 0.032-inch pylon 
webs, Group 3 airplanes with 0.025-inch pylon webs, and some airplanes 
with mixed 0.025-inch pylon webs and 0.032-inch pylon webs.
    We acknowledge that the service bulletin may not reflect an 
operator's current aircraft configuration because of post-delivery 
modifications. Since the groupings are not only defined by web 
thickness but also by the location of web stiffeners and the web 
material; we do not agree to revise the final rule to define airplane 
groups by pylon web thickness. Operators are responsible for 
maintaining the configuration of its airplanes. If the configuration of 
an airplane has been changed in an area affected by this final rule and 
the accomplishment of the requirements of this final rule is affected, 
operators must request approval for an alternative method of compliance 
according to paragraph (q) of this AD as required by 14 CFR 39.19.

Explanation of Change to Applicability

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

Conclusion

    We have carefully reviewed the available data, including the 
comments that have been submitted, and determined that air safety and 
the public interest require adopting the AD with the change described 
previously. We have determined that this change will neither increase 
the economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

    There are about 244 airplanes of the affected design in the 
worldwide fleet. This AD will affect about 82 airplanes of U.S. 
registry. The following table provides the estimated costs for U.S. 
operators to comply with this AD.

                                                 Estimated Costs
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                                                                                                     Cost per
  Applicable airplanes identified in                                               Average labor   airplane, per
  Boeing Alert Service Bulletin 747-             Action             Work hours     rate per hour    inspection
             54A2212 As--                                                                              cycle
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Groups 1-6............................  Web inspection..........               8             $65            $520
Groups 7-8............................  Web inspection..........               4              65             260
Groups 1-5............................  Web bay inspection......               4              65             260

[[Page 47088]]

 
Groups 1-6............................  Bolt inspection.........               4              65             260
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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

    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); 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.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this AD. See the ADDRESSES section for a location to 
examine the regulatory evaluation.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

0
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):

2005-16-11 Boeing: Amendment 39-14217. Docket No. FAA-2005-20325; 
Directorate Identifier 2003-NM-129-AD.

Effective Date

    (a) This AD becomes effective September 16, 2005.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 747-100, 747-100B, 747-100B 
SUD, 747-200B, 747-200C, 747-200F, 747-300, 747SP, and 747SR series 
airplanes; certificated in any category; equipped with Pratt & 
Whitney Model JT9D-3 and -7 series engines; as identified in Boeing 
Alert Service Bulletin 747-54A2212, dated May 1, 2003.

Unsafe Condition

    (d) This AD was prompted by reports of cracking in the aft lower 
spar web and reports of missing and fractured bolts. We are issuing 
this AD to detect and correct cracking of the aft lower spar web, 
and to prevent missing, loose, or fractured bolts common to the aft 
lower spar chords and the fitting of the rear engine mount bulkhead, 
which could result in the loss of the aft lower spar load path and 
reduced structural capability of the pylon, which may result in the 
separation of the engine from the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified, unless the 
actions have already been done.

Service Bulletin Reference

    (f) The term ``service bulletin,'' as used in this AD, means 
Boeing Alert Service Bulletin 747-54A2212, dated May 1, 2003.

Part 1--Web Inspections

    (g) At the applicable times specified in paragraph (g)(1), 
(g)(2), or (g)(3) of Table 1 of this AD, do initial and repetitive 
detailed inspections for cracks of the upper surface of the aft 
lower spar web of the inboard and outboard struts, as applicable; 
and before further flight, do any applicable repair; by doing all 
the actions specified in ``Part 1--Web Inspection'' of the Work 
Instructions of the service bulletin. For certain airplanes, the 
repetitive inspections may be deferred or ended provided that the 
optional stiffener addition specified in paragraph (k) of this AD is 
done.


    Note 1: For the purposes of this AD, a detailed inspection is 
``An intensive examination of a specific item, installation, or 
assembly to detect damage, failure, or irregularity. Available 
lighting is normally supplemented with a direct source of good 
lighting at an intensity deemed appropriate. Inspection aids such as 
mirrors, magnifying lenses, etc. may be necessary. Surface cleaning 
and elaborate procedures may be required.''


              Table 1.--Compliance Times for Web Inspection
------------------------------------------------------------------------
 For airplanes identified in   Initial compliance    Repetitive interval
  the Service Bulletin as--         time is--               is--
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(1) Group 1 airplanes on      Within 12 months      At intervals not to
 which the modification        after the effective   exceed 2,400 flight
 specified in Boeing Service   date of this AD.      cycles.
 Bulletin 747-54-2028, dated
 August 1, 1972, has been
 done; and Group 2 airplanes.
(2) Group 1 airplanes on      Within 6 months       At intervals not to
 which the modification        after the effective   exceed 350 flight
 specified in Boeing Service   date of this AD.      cycles.
 Bulletin 747-54-2028, dated
 August 1, 1972, has not
 been done; and Group 7
 airplanes.

[[Page 47089]]

 
(3) Group 3, 4, 5, 6, and 8   Within 12 months      At intervals not to
 airplanes.                    after the effective   exceed 1,200 flight
                               date of this AD.      cycles.
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Part 2--Intermediate Web Bay Inspection

    (h) At the applicable times specified in paragraph (h)(1) or 
(h)(2) of Table 2 of this AD, do initial and repetitive detailed 
inspections for cracks of the upper surface of the intermediate web 
bay of the aft lower spar; and before further flight do any 
applicable repair; by doing all the actions specified in ``Part 2--
Intermediate Web Bay Inspection'' of the Work Instructions of the 
service bulletin. The repetitive inspections may be ended provided 
that the optional intermediate stiffener addition specified in 
paragraph (l) of this AD is done.

     Table 2.--Compliance Times for Intermediate Web Bay Inspections
------------------------------------------------------------------------
 For airplanes identified in   Initial compliance    Repetitive interval
  the Service Bulletin as--         time is--               is--
------------------------------------------------------------------------
(1) Group 1 through 4         Within 6 months       At intervals not to
 airplanes on which the        after the effective   exceed 350 flight
 modification specified in     date of this AD.      cycles.
 Boeing Service Bulletin 747-
 71-2188, dated March 14,
 1983, has been done and on
 which the additional work
 specified in Boeing Service
 Bulletin 747-71-2188,
 Revision 1, dated January
 17, 1986; or Revision 2,
 dated March 26, 1987; has
 not been done.
(2) Group 5 airplanes on      Within 6 months       At intervals not to
 which the modification        after the effective   exceed 350 flight
 specified in Boeing Service   date of this AD.      cycles.
 Bulletin 747-54-2115, dated
 February 14, 1986; or
 Revision 1, dated May 12,
 1988; has not been done.
------------------------------------------------------------------------

Part 3--Maraging or H-11 Steel Bolt Inspection

    (i) For Group 1 through 6 airplanes identified in the service 
bulletin: Within 12 months after the effective date of this AD, do a 
detailed inspection and torque check of the bolts common to the aft 
lower spar chords and the fitting of the rear engine mount bulkhead 
for missing, loose, or fractured bolts, and do any applicable 
replacement (including related investigative actions and corrective 
action), by doing all the actions specified in ``Part 3--Maraging or 
H-11 Steel Bolt Inspection'' of the Work Instructions of the service 
bulletin, except as provided by paragraph (o) of this AD. Do any 
applicable replacements (including related investigative actions and 
corrective action) before further flight, except as provided by 
paragraph (j) of this AD. Repeat the actions thereafter at intervals 
not to exceed 18 months. The inspections and torque checks specified 
in paragraph (i) of this AD may be ended provided that the 
replacement specified in paragraph (n) of this AD is done.
    (j) If during any inspection required by paragraph (i) of this 
AD, one of the conditions specified in paragraphs (j)(1) and (j)(2) 
of this AD is found, do the applicable actions specified in 
paragraphs (j)(1) and (j)(2) of this AD.
    (1) If a missing or fractured bolt is found on the inboard strut 
in any one bay, within 36 months after replacing the bolt with a new 
bolt, do the replacement specified in paragraph (n) of this AD.
    (2) If two or more missing or fractured bolts are found in any 
one bay, before further flight, do the replacement specified in 
paragraph (n) of this AD.

Part 4--Optional Stiffener Addition

    (k) Except as provided by paragraph (o) of this AD, 
accomplishing the optional stiffener addition for the inboard and 
outboard struts, doing the related investigation actions, and doing 
any applicable repair, by doing all the actions specified in ``Part 
4--Stiffener Addition'' of the Work Instructions of the service 
bulletin before further flight after accomplishing the actions 
specified in paragraph (g) of this AD, defers or ends the repetitive 
inspections required by paragraph (g) of this AD as follows:
    (1) For airplanes listed in paragraph (g)(2) of Table 1 of this 
AD, accomplishing the optional stiffener addition extends the 
repetitive inspections required by paragraph (g) of this AD to 
intervals not to exceed 2,400 flight cycles.
    (2) For airplanes listed in paragraph (g)(3) of Table 1 of this 
AD, accomplishing the optional stiffener addition ends the 
repetitive inspections required by paragraph (g) of this AD.

Part 5--Optional Intermediate Stiffener Addition

    (l) For airplanes identified in paragraphs (h)(1) and (h)(2) of 
Table 2 of this AD: Accomplishing the optional intermediate 
stiffener addition for the inboard and outboard struts, by doing all 
the actions specified in ``Part 5--Intermediate Stiffener Addition'' 
of the Work Instructions of the service bulletin before further 
flight after accomplishing the actions specified in paragraph (h) of 
this AD, except as provided by paragraph (m) of this AD, ends the 
repetitive inspections required by paragraph (h) of this AD.
    (m) Where the service bulletin specifies to install stiffeners 
as shown in ``service bulletin 747-71-2188 Revision 1 or later 
releases (Group 1, 2, 3, and 4 Airplanes) or 747-54-2115 Original 
Issue or Revision 1 (Group 5 Airplanes),'' this AD requires that 
those actions be done in accordance with Boeing Service Bulletin 
747-71-2188, Revision 1, dated January 17, 1986, or Revision 2, 
dated March 26, 1987; or Boeing Service Bulletin 747-54-2115, dated 
February 14, 1986, or Revision 1, dated May 12, 1988; as applicable, 
except as provided by paragraph (o) of this AD.

Part 6--Maraging or H-11 Steel Bolt Replacement

    (n) For Group 1 through 6 airplanes identified in the service 
bulletin: Except as provided by paragraph (o) of this AD, replacing 
all Maraging or H-11 steel bolts with new inconel bolts, doing the 
related investigation actions, and doing any applicable corrective 
action, by doing all the actions specified in ``Part 6--Maraging or 
H-11 Steel Bolt Replacement'' of the Work Instructions of the 
service bulletin ends the inspections and torque checks required by 
paragraph (i) of this AD.

Contact the FAA

    (o) If during any action required by this AD the service 
bulletin specifies to contact Boeing for additional instructions; or 
if Boeing Service Bulletin 747-71-2188, Revision 1, dated January 
17, 1986, or Revision 2, dated March 26, 1987; or Boeing Service 
Bulletin 747-54-2115, dated February 14, 1986, or Revision 1, dated 
May 12, 1988; specifies to repair according to

[[Page 47090]]

operators equivalent procedures: Before further flight, repair 
according to a method approved by the Manager, Seattle Aircraft 
Certification Office (ACO), FAA; or according to data meeting the 
certification basis of the airplane approved by an Authorized 
Representative for the Boeing Delegation Option Authorization 
Organization who has been authorized by the Manager, Seattle ACO, to 
make those findings. For a repair method to be approved, the 
approval must specifically reference this AD.

Parts Installation

    (p) As of the effective date of this AD, no person may install a 
Maraging or H-11 steel bolt in the locations specified in this AD, 
on any airplane.

Alternative Methods of Compliance (AMOCs)

    (q) The Manager, Seattle ACO, FAA, has the authority to approve 
AMOCs for this AD, if requested in accordance with the procedures 
found in 14 CFR 39.19.

Material Incorporated by Reference

    (r) You must use Boeing Alert Service Bulletin 747-54A2212, 
dated May 1, 2003, to perform the actions that are required by this 
AD, unless the AD specifies otherwise. The Director of the Federal 
Register approves the incorporation by reference of this document in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51. To get copies of 
the service information, contact Boeing Commercial Airplanes, P.O. 
Box 3707, Seattle, Washington 98124-2207. To view the AD docket, go 
to the Docket Management Facility, U.S. Department of 
Transportation, 400 Seventh Street SW., room PL-401, Nassif 
Building, Washington, DC. To review copies of the service 
information, go to the National Archives and Records Administration 
(NARA). For information on the availability of this material at the 
NARA, call (202) 741-6030, or go to <a href="http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html">http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html</a>.

    Issued in Renton, Washington, on August 4, 2005.
Kevin M. Mullin,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-15882 Filed 8-11-05; 8:45 am]
BILLING CODE 4910-13-U