[Federal Register Volume 61, Number 56 (Thursday, March 21, 1996)]
[Rules and Regulations]
[Pages 11539-11541]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-6542]



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DEPARTMENT OF TRANSPORTATION
14 CFR Part 39

[Docket No. 95-NM-47-AD; Amendment 39-9545; AD 96-06-08]


Airworthiness Directives; McDonnell Douglas Model DC-10-10, -15, 
-30, and -40 Series Airplanes, and Model KC-10A (Military) Airplane

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that 
is applicable to certain McDonnell Douglas Model DC-10-10, -15, -30, 
and -40 series airplanes, and Model KC-10A (military) airplanes. This 
amendment requires inspection(s) to detect cracks of the attach bolts 
of the front spar support fitting of each wing, and replacement of 
attach bolts with ones that are corrosion resistant. This amendment is 
prompted by a report of failure of the attach bolts of the front spar 
fitting as a result of corrosion pitting. The actions specified by this 
AD are intended to prevent such stress corrosion, which could lead to 
the failure of the attach bolts of the front spar; this situation could 
result in reduced structural integrity of the wing.

DATES: Effective April 22, 1996.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of April 22, 1996.

ADDRESSES: The service information referenced in this AD may be 
obtained from McDonnell Douglas Corporation, 3855 Lakewood Boulevard, 
Long Beach, California 90846, Attention: Technical Publications 
Business Administration, Department C1-L51 (2-60). This information may 
be examined at the Federal Aviation Administration (FAA), Transport 
Airplane Directorate, Rules Docket, 1601 Lind Avenue SW., Renton,

[[Page 11540]]
Washington; or at the FAA, Los Angeles Aircraft Certification Office, 
Transport Airplane Directorate, 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: John Cecil, Aerospace Engineer, 
Airframe Branch, ANM-120L, FAA, Transport Airplane Directorate, Los 
Angeles Aircraft Certification Office, 3960 Paramount Boulevard, 
Lakewood, California 90712-4137; telephone (310) 627-5322; fax (310) 
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 Model 
DC-10-10, -15, -30, and -40 series airplanes, and Model KC-10A 
(military) airplanes, was published in the Federal Register on August 
30, 1995 (60 FR 45108). That action proposed to require inspection(s) 
to detect cracks of the attach bolts of the front spar support fitting 
of each wing, and replacement of attach bolts with ones that are 
corrosion resistant.
    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. Due consideration has been given to 
the comments received.
    One commenter supports the proposal.
    Another commenter requests that the proposal be revised to give 
operators ``credit'' for having accomplished the initial required 
ultrasonic inspection prior to the effective date of the final rule. 
This commenter is concerned that, if such credit is not specified in 
the AD, operators may be required to perform duplicate inspections 
needlessly.
    The FAA acknowledges this commenter's concerns, and finds that some 
clarification is necessary. Operators are always given credit for work 
accomplished prior to the effective date of an AD by means of the 
phrase in the compliance section of the rule that states, ``Required as 
indicated, unless accomplished previously.'' Since the ultrasonic 
inspection required by paragraph (a) of this AD is to be accomplished 
specifically in accordance with McDonnell Douglas DC-10 Service 
Bulletin 57-126, which was released on October 30, 1992, the 
possibility exists that some operators may have accomplished the 
initial ultrasonic inspection some years ago when the service bulletin 
was originally issued. For those operators, the ``unless accomplished 
previously'' phrase is intended to ensure that they not conduct a 
duplicate initial inspection.
    However, in light of this commenter's concerns, the FAA finds that 
the compliance time for repetitive inspections must be clarified. The 
intent of this AD is to establish a schedule of inspections that are to 
be conducted at 18-month intervals. Regardless of when the initial 
inspection was conducted, that inspection must be repeated within 18 
months afterwards. Accordingly, paragraph (a) of the final rule has 
been revised to clarify that the initial inspection is required within 
18 months after the effective date of the AD, unless it was 
accomplished previously within 18 months prior to the effective date. 
Paragraph (b) of the final rule has been clarified to specify that the 
inspection must then be repeated at an interval not to exceed 18 months 
after that initial inspection, and must be repeated again every 18 
months after that.
    One commenter states that the manufacturer has advised that it is 
developing revised procedures for accomplishment of the bolt 
replacement (which may include only partial replacement under certain 
conditions). The commenter requests that the FAA revise the proposed 
rule to make these new procedures available to affected operators.
    The FAA concurs with the commenter's request. Since issuance of the 
proposal, the FAA has reviewed and approved McDonnell Douglas Service 
Bulletin DC1057-126, Revision 1, dated March 1, 1996. This revised 
service bulletin is essentially identical to the McDonnell Douglas DC-
10 Service Bulletin 57-126, dated October 30, 1992, but provides 
procedures for replacing a minimum of 5 of the attach bolts of the 
front spar support fitting on each wing with corrosion-resistant attach 
bolts; and, at the next pylon removal after that replacement, replacing 
the remaining 1 attach bolt of the front spar support fitting on each 
wing. Accomplishment of the replacement of these six attach bolts 
eliminates the need for the repetitive inspections of them. These 
replacement procedures are identical to the procedures proposed in 
paragraph (b)(2) of the proposed rule. The FAA has revised the final 
rule to include the newly released (revised) service bulletin as an 
additional source of service information.
    After careful review of the available data, including the comments 
noted above, the FAA has determined that air safety and the public 
interest require the adoption of the rule with the changes previously 
described. The FAA has determined that these changes will neither 
increase the economic burden on any operator nor increase the scope of 
the AD.
    There are approximately 420 Model DC-10-10, -15, -30, and -40 
series airplanes, and Model KC-10A (military) airplanes of the affected 
design in the worldwide fleet. The FAA estimates that 237 airplanes of 
U.S. registry will be affected by this AD.
    It will take approximately 6 work hours per airplane to accomplish 
the required inspections, at an average labor rate of $60 per work 
hour. Based on these figures, the cost impact of the inspection 
requirements of this AD on U.S. operators is estimated to be $85,230, 
or $360 per airplane, per inspection cycle.
    It will take approximately 6 work hours per airplane to accomplish 
the required bolt replacement, at an average labor rate of $60 per work 
hour. Required parts will cost approximately $43,000 per airplane. 
Based on these figures, the cost impact of the replacement requirements 
of this AD on U.S. operators is estimated to be $10,276,320, or $43,360 
per airplane.
    The number of work hours indicated above does not include time for 
gaining access, removing and reinstalling engines, removing and 
reinstalling pylons, closing up, or performing functional checks. 
Additionally, it does not include time for preparation for the 
replacement, administrative functions, or nonproductive elapsed time.
    The cost impact figures discussed above are 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 regulations adopted herein will not have substantial direct 
effects 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, in 
accordance with Executive Order 12612, it is determined that this final 
rule does not have sufficient federalism implications to warrant the 
preparation of a Federalism Assessment.
    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

[[Page 11541]]
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 USC 106(g), 40113, 44701.


Sec. 39.13  [Amended]

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

96-06-08 McDonnell Douglas: Amendment 39-9545. Docket 95-NM-47-AD.

    Applicability: Model DC-10-10, -15, -30, and -40 series 
airplanes, and Model KC-10A (military) airplanes; as listed in 
McDonnell Douglas DC-10 Service Bulletin 57-126, dated October 30, 
1992; certificated in any category.

    Note 1: This AD applies to each airplane identified in the 
preceding applicability provision, regardless of whether it has been 
otherwise 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 (d) 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 reduced structural integrity of the wing, accomplish 
the following:
    (a) Within 18 months after the effective date of this AD, unless 
previously accomplished within the last 18 months prior to the 
effective date of this AD, perform an ultrasonic inspection to 
detect cracks in the 6 attach bolts of the front spar support 
fitting of each wing, in accordance with McDonnell Douglas DC-10 
Service Bulletin 57-126, dated October 30, 1992, or McDonnell 
Douglas Service Bulletin DC10-57-126, Revision 1, dated March 1, 
1996.
    (b) If no crack is detected on an attach bolt during the 
inspection specified in paragraph (a) of this AD, accomplish 
paragraphs (b)(1) and (b)(2) of this AD.
    (1) Within 18 months after accomplishing the inspection 
specified in paragraph (a) of this AD, repeat the ultrasonic 
inspection, and continue to repeat it thereafter at intervals not to 
exceed 18 months, until the procedures required by paragraph (b)(2) 
of this AD are accomplished.
    (2) Within 5 years after the effective date of this AD, replace 
a minimum of 5 of the attach bolts of the front spar support fitting 
on each wing with corrosion-resistant attach bolts, in accordance 
with the service bulletin. At the next pylon removal after that 
replacement, replace the remaining 1 attach bolt of the front spar 
support fitting on each wing. Accomplishment of the replacement 
constitutes terminating action for the repetitive inspection 
requirements of this AD for that attach bolt.
    (c) If any crack is detected on an attach bolt during any 
inspection required by paragraph (a) or (b)(1) of this AD, prior to 
further flight, replace the cracked attach bolt with a corrosion-
resistant attach bolt, in accordance with the service bulletin. 
Accomplishment of such replacement constitutes terminating action 
for the repetitive inspection requirements of this AD for that 
attach bolt only.
    (d) 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, Transport Airplane Directorate. 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.

    (e) 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.
    (f) The inspection and replacement procedures shall be done in 
accordance with McDonnell Douglas DC-10 Service Bulletin 57-126, 
dated October 30, 1992; or McDonnell Douglas Service Bulletin DC10-
57-126, Revision 1, dated March 1, 1996. 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 McDonnell Douglas Corporation, 3855 Lakewood 
Boulevard, Long Beach, California 90846, Attention: Technical 
Publications Business Administration, Department C1-L51 (2-60). 
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, Transport Airplane Directorate, 3960 
Paramount Boulevard, Lakewood, California; or at the Office of the 
Federal Register, 800 North Capitol Street NW., suite 700, 
Washington, DC.
    (g) This amendment becomes effective on April 22, 1996.

    Issued in Renton, Washington, on March 13, 1996.
James V. Devany,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 96-6542 Filed 3-20-96; 8:45 am]
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