[Federal Register Volume 61, Number 119 (Wednesday, June 19, 1996)]
[Proposed Rules]
[Pages 31059-31061]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-15601]



 ========================================================================
 Proposed Rules
                                                 Federal Register
 ________________________________________________________________________
 
 This section of the FEDERAL REGISTER contains notices to the public of 
 the proposed issuance of rules and regulations. The purpose of these 
 notices is to give interested persons an opportunity to participate in 
 the rule making prior to the adoption of the final rules.
 
 ========================================================================
 

  Federal Register / Vol. 61, No. 119 / Wednesday, June 19, 1996 / 
Proposed Rules  

[[Page 31059]]



DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 96-NM-24-AD]
RIN 2120-AA64


Airworthiness Directives; McDonnell Douglas Model DC-10-15 
Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: This document proposes the adoption of a new airworthiness 
directive (AD) that is applicable to all McDonnell Douglas Model DC-10-
15 airplanes. This proposal would require, among other things, 
inspections to detect discrepancies at various locations of pylons 1 
and 3, and correction of any discrepancy found. This proposal is 
prompted by a report of internal structural damage to the wing engine 
pylon that occurred during maintenance of a Model DC-10 series 
airplane. The actions specified by the proposed AD are intended to 
ensure the integrity of the structure and attachment of the wing engine 
pylon.

DATES: Comments must be received by July 29, 1996.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-103, 
Attention: Rules Docket No. 96-NM-24-AD, 1601 Lind Avenue, SW., Renton, 
Washington 98055-4056. Comments may be inspected at this location 
between 9 a.m. and 3 p.m., Monday through Friday, except Federal 
holidays.
    The service information referenced in the proposed rule 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 FAA, Transport Airplane Directorate, 1601 Lind 
Avenue, SW., Renton, Washington.

FOR FURTHER INFORMATION CONTACT: Ron Atmur, Aerospace Engineer, 
Airframe Branch, ANM-120L, FAA, Los Angeles Aircraft Certification 
Office, 3960 Paramount Boulevard, Lakewood, California 90712; telephone 
(310) 627-5224; fax (310) 627-5210.

SUPPLEMENTARY INFORMATION:

Comments Invited

    Interested persons are invited to participate in the making of the 
proposed rule by submitting such written data, views, or arguments as 
they may desire. Communications shall identify the Rules Docket number 
and be submitted in triplicate to the address specified above. All 
communications received on or before the closing date for comments, 
specified above, will be considered before taking action on the 
proposed rule. The proposals contained in this notice may be changed in 
light of the comments received.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the proposed rule. All 
comments submitted will be available, both before and after the closing 
date for comments, in the Rules Docket for examination by interested 
persons. A report summarizing each FAA-public contact concerned with 
the substance of this proposal will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this notice must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 96-NM-24-AD.'' The postcard will be date stamped and 
returned to the commenter.

Availability of NPRMs

    Any person may obtain a copy of this NPRM by submitting a request 
to the FAA, Transport Airplane Directorate, ANM-103, Attention: Rules 
Docket No. 96-NM-24-AD, 1601 Lind Avenue, SW., Renton, Washington 
98055-4056.

Discussion

    On May 16, 1980, the FAA issued AD 80-11-05 R1, amendment 39-3981 
(45 FR 35310, May 27, 1980), which is applicable to all McDonnell 
Douglas Model DC-10-10, -10F, -30, -30F, and -40 series airplanes. That 
AD requires a revision to the wing-pylon inspection programs for these 
airplanes, which includes various types of inspections to detect 
discrepancies, and the correction of any discrepancy found. That action 
was prompted by a report of internal structural damage to the wing 
engine pylon that occurred during maintenance of a Model DC-10 series 
airplane. The requirements of that AD are intended to ensure the 
integrity of the structure and attachment of the wing engine pylon.
    Since the issuance of AD 80-11-05 R1, the FAA certificated 
McDonnell Douglas Model DC-10-15 series airplanes for operation in the 
U.S. Subsequently, the FAA has determined that these airplanes also are 
subject to the unsafe condition addressed in AD 80-11-05 R1, since they 
are similar in type design to the airplane models addressed in that AD.

Explanation of Relevant Service Information

    The FAA has reviewed and approved McDonnell Douglas DC-10 Service 
Bulletin 54-74, dated December 21, 1979, which describes procedures for 
repetitive visual inspections to detect discrepancies at various 
locations of pylons 1 and 3, and correction of any discrepancy found. 
The service bulletin indicates that these locations include the 
following: the pylon aft bulkhead; the upper surface of the upper spar 
aft of station Yn=342.864 to the aft bulkhead; the lower surface of the 
upper spar and spar cap angles aft of station Yn=342.864 to the aft 
bulkhead; the center and lower (firewall) spar and spar cap angles; the 
thrust link installation; the lower and upper forward spherical bearing 
installation; the forward bulkhead; and the forward wing attach fitting 
(footstool) of the pylon.

Explanation of Requirements of Proposed Rule

    Since an unsafe condition has been identified that is likely to 
exist or develop on other products of this same type design, the 
proposed AD would require:
    1. At each pylon removal and installation, the engine and pylon 
must be removed and installed separately, and the pylon aft bulkhead 
lug must be protected from contact with certain attach bolt heads.

[[Page 31060]]

    2. Performance of various repetitive inspections to detect 
discrepancies at various locations of pylons 1 and 3, and correction of 
any discrepancy found.
    3. Submission of a pylon maintenance program that includes specific 
repetitive inspections at intervals of 20,000 hours time-in-service.
    Certain of these actions would be required to be accomplished in 
accordance with the service bulletin described previously; other 
actions would be required to be accomplished in accordance with the DC-
10 Nondestructive Testing Manual and the DC-10 Maintenance Manual.

Cost Impact

    There are approximately 7 Model DC-10-15 airplanes of the affected 
design in the worldwide fleet. The FAA estimates that 2 airplanes of 
U.S. registry would be affected by this proposed AD, that it would take 
approximately 22 work hours per airplane to accomplish the proposed 
actions, and that the average labor rate is $60 per work hour. Based on 
these figures, the cost impact of the proposed AD on U.S. operators is 
estimated to be $2,640, or $1,320 per airplane.
    The cost impact figure discussed above is based on assumptions that 
no operator has yet accomplished any of the proposed requirements of 
this AD action, and that no operator would accomplish those actions in 
the future if this AD were not adopted.

Regulatory Impact

    The regulations proposed herein would 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 
proposal would not have sufficient federalism implications to warrant 
the preparation of a Federalism Assessment.
    For the reasons discussed above, I certify that this proposed 
regulation (1) Is not a ``significant regulatory action'' under 
Executive Order 12866; (2) is not a ``significant rule'' under the DOT 
Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); 
and (3) if promulgated, 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 copy of the draft 
regulatory evaluation prepared for this action is contained in the 
Rules Docket. A copy of it may be obtained by contacting the Rules 
Docket at the location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

The Proposed Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration proposes to amend 
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.


Sec. 39.13  [Amended]

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

McDonnell Douglas: Docket 96-NM-24-AD.

    -Applicability: All Model DC-10-15 airplanes, certificated in 
any category.

    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 (k) 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 ensure the integrity of the structure and attachment of the 
wing engine pylon, accomplish the following:
    (a) At each pylon removal and installation that is accomplished 
after the effective date of this AD: The engine and pylon shall be 
removed and installed separately, unless such removal or 
installation, or both, as an assembly is accomplished in accordance 
with a method approved by the Manager, Los Angeles Aircraft 
Certification Office (ACO), FAA, Transport Airplane Directorate.
    (b) At each pylon removal and installation that is accomplished 
after the effective date of this AD: Protect the pylon aft bulkhead 
lug from contact with the clevis-to-wing attach bolt heads using 
part number (P/N) DZZ7268-1 in accordance with page 417, dated 
January 1, 1982, and page 427, dated May 1, 1985, of Chapter 54-00-
01 of the McDonnell Douglas DC-10 Maintenance Manual.
    (c) Prior to further flight following any pylon reinstallation 
that is accomplished after the effective date of this AD: Accomplish 
the requirements of paragraphs (c)(1), (c)(2), and (c)(3) of this 
AD.
    (1) Perform an inspection of the aft pylon bulkhead to detect 
cracking, in accordance with page 634, dated December 1, 1979, and 
page 634A, dated August 1, 1990, of Chapter 54-10-11 of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (2) Perform a visual inspection of the pylon aft spherical 
bearing and attaching hardware to verify the security of the nut and 
bolt.
    (3) Perform a visual inspection of the torque stripe for proper 
alignment.
    (d) Perform the inspections required by paragraph (e) of this AD 
at the later of the times specified in paragraphs (d)(1) and (d)(2) 
of this AD. Thereafter, repeat these inspections at intervals not to 
exceed 3,600 hours time-in-service or 12 months, whichever occurs 
later.
    (1) Prior to the accumulation of 3,600 total hours time-in-
service.
    (2) Within 3,600 hours time-in-service or 12 months after the 
effective date of this AD, whichever occurs later.
    (e) Perform the inspections required by paragraphs (e)(1) 
through (e)(5) of this AD at the times indicated in paragraph (d) of 
this AD.
    (1) Perform a visual inspection to detect cracking of the 
external surfaces of the thrust link forward (pylon) and aft (wing) 
attachment lugs, in accordance with paragraph 2.C.(1) of McDonnell 
Douglas DC-10 Service Bulletin 54-74, dated December 21, 1979.
    (2) Perform a visual inspection to detect discrepancies of the 
upper surface of the pylon upper spar aft of station Yn=342.864, in 
accordance with paragraph 2.G. of McDonnell Douglas DC-10 Service 
Bulletin 54-74, dated December 21, 1979.
    (3) Perform a visual inspection to detect discrepancies of the 
center and lower (firewall) spar and spar cap angles from the aft 
bulkhead to the forward bulkhead, in accordance with paragraph 2.M. 
of McDonnell Douglas DC-10 Service Bulletin 54-74, dated December 
21, 1979.
    (4) Perform an inspection for discrepancies at the various 
locations of the wing and tail specified on pages 601, 602, 602A, 
604, 605, 606, and 608, all dated November 1, 1986; page 603, dated 
May 1, 1986; and pages 604A and 607, dated May 1, 1987; of Chapter 
05-51-08 of the McDonnell Douglas DC-10 Maintenance Manual. 
Accomplish the inspections in accordance with the procedures 
specified on those pages of the McDonnell Douglas DC-10 Maintenance 
Manual.
    (5) Perform a visual inspection of the pylon aft spherical 
bearing and attaching hardware to verify the security of the nut and 
bolt, and inspect the torque stripe for alignment.
    (f) Within 30 days after the effective date of this AD: Submit a 
pylon maintenance program, as an amendment to the maintenance 
program, to the assigned FAA Principal Maintenance Inspector for 
approval. The pylon maintenance program shall specify that, prior to 
the accumulation of 20,000 total hours time-in-service, or within 
20,000 hours time-in-service since the last inspection, whichever 
occurs later, the operator will accomplish, as a minimum, the

[[Page 31061]]

actions specified in paragraphs (f)(1)through (f)(9) of this AD.
    (1) Perform a visual inspection to detect cracking of the pylon 
aft bulkhead, in accordance with paragraphs 2.E. and 2.F. of 
McDonnell Douglas DC-10 Service Bulletin 54-74, dated December 21, 
1979; and an eddy current inspection to detect cracking of the pylon 
aft bulkhead, in accordance with page 634, dated December 1, 1979, 
and page 634A, dated August 1, 1990, of Chapter 54-10-11 of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (2) Perform a visual inspection to detect discrepancies of the 
front spar bulkhead, in accordance with paragraph 2.H. of McDonnell 
Douglas DC-10 Service Bulletin 54-74, dated December 21, 1979.
    (3) Perform a visual inspection to detect cracking of the 
attachment fitting-to-pylon forward bulkhead (footstool) of the wing 
front spar; perform a detailed visual inspection to detect cracking, 
and loose or missing fasteners, of the wing pylon attachment; and 
verify that the pre-load indicating (PLI) washers cannot be rotated; 
in accordance with paragraph 2.L. of McDonnell Douglas DC-10 Service 
Bulletin 54-74, dated December 21, 1979.
    (4) Perform an inspection to verify that the attach bolt PLI 
washers on the lower spherical bearing plug cannot be rotated; 
verify that no interference exists between the plug forward flange 
aft face, and the forward face of the spherical bearing; and perform 
a detailed visual inspection of the plug in situ; in accordance with 
paragraph 2.I. of McDonnell Douglas DC-10 Service Bulletin 54-74, 
dated December 21, 1979.
    (5) Perform a visual inspection to verify the condition, 
security, and torque stripe alignment of the plug assembly of the 
forward upper spherical bearing installation, in accordance with 
paragraph 2.J. of McDonnell Douglas DC-10 Service Bulletin 54-74, 
dated December 21, 1979.
    (6) Perform a visual inspection to verify proper installation of 
the thrust link bolts, nuts, and retaining washers of the thrust 
link installation, in accordance with paragraph 2.C.(2) of McDonnell 
Douglas DC-10 Service Bulletin 54-74, dated December 21, 1979.
    (7) Perform an inspection of the aft spherical bearing, as 
specified in paragraphs (f)(7)(i) through (f)(7)(iv) of this AD.
    (i) Remove the aft spherical bearing through bolt. Inspect the 
inner bore of the bushing in situ using Magnaflux bolt and visual 
inspection techniques. Perform a visual inspection using a 10x 
(power) glass (or equivalent) to detect cracks of the forward and 
aft surfaces of the spherical bearing. Reinstall the through bolt.
    (ii) Verify that the torque of the through bolt is 1,200 to 
1,300 inch-pounds.
    (iii) Inspect the clearance of the aft spherical bearing forward 
face/clevis.
    (iv) Torque stripe the nut to bolt.
    (8) Perform an ultrasonic inspection to detect cracking of the 
bulkhead lug and wing clevis-to-wing attachment, including the 
bolts, in accordance with pages 635, 636, 638, 638A, and 638B, dated 
December 1, 1979; page 637, dated September 1, 1993; page 651, dated 
February 1, 1982; and page 652, dated August 1, 1992; of Chapter 54-
10-11 of the McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (9) Accomplish either paragraph (f)(9)(i) or (f)(9)(ii) of this 
AD.
    (i) Perform an X-ray inspection in situ to ensure the integrity 
of the steel thrust links, in accordance with page 632A, dated 
August 1, 1984, and page 632B, dated February 1, 1981, of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual. Or
    (ii) Perform an ultrasonic inspection in situ to ensure the 
integrity of the steel thrust links, in accordance with page 632C, 
dated August 1, 1985, and page 632D, dated August 1, 1984, of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (g) Prior to further flight after a pylon has been subjected to 
vertical or horizontal misalignment, or both (e.g., during 
maintenance), perform an inspection to detect cracking of the aft 
pylon bulkhead, in accordance with page 634, dated December 1, 1979, 
and page 634A, dated August 1, 1990, of Chapter 54-10-11 of the 
McDonnell Douglas DC-10 Nondestructive Testing Manual.
    (h) Prior to further flight following any event that produces 
high pylon loads: Perform an inspection of the pylon for structural 
integrity, in accordance with pages 601, 602, 602A, 604, 605, 606, 
and 608, dated November 1, 1986; page 603, dated May 1, 1986; and 
pages 604A and 607, dated May 1, 1987; of Chapter 05-51-08 of the 
McDonnell Douglas DC-10 Maintenance Manual.

    Note 2: Examples of events that produce high pylon loads, 
include, but are not limited to, the following:
     Hard or overweight landings (for the purpose of this 
AD, overweight landings are made at aircraft weights in excess of 
369,000 pounds);
     Severe turbulence encounters;
     Engine vibration that requires engine removal or 
critical engine failure, or both;
     Ground damage (work stands, etc.);
     Compressor stalls requiring engine removal; and
     Excursions from the runway of a nature that might have 
imposed loads more severe than those encountered normally on the 
runway.

    (i) Prior to further flight, correct any discrepancy found 
during any inspection required by this AD, in accordance with a 
method approved by the Manager, Los Angeles ACO; the Structural 
Repair Manual; or McDonnell Douglas DC-10 Service Bulletin 54-74, 
dated December 21, 1979; as appropriate.
    (j) Within 10 days after accomplishing the inspections required 
by this AD, report inspection results, positive or negative, to the 
FAA Principal Maintenance Inspector. The report shall include the 
information specified in paragraphs (j)(1) through (j)(5) of this 
AD. Information collection requirements contained in this regulation 
have been approved by the Office of Management and Budget (OMB) 
under the provisions of the Paperwork Reduction Act of 1980 (44 
U.S.C. 3501 et seq.) and have been assigned OMB Control Number 2120-
0056.
    (1) The ``N'' number of the airplane.
    (2) The total number of hours time-in-service accumulated on the 
airplane.
    (3) The pylon number of the airplane.
    (4) The specific paragraph (and subparagraph) of this AD that 
corresponds with the inspection results being reported.
    (5) Specific inspection results: For example, the location and 
size of cracking, specific location of discrepant fasteners, and 
part numbers.
    (k) 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 ACO. 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 3: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Los Angeles ACO.

    (l) 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.

    Issued in Renton, Washington, on June 13, 1996.
James V. Devany,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 96-15601 Filed 6-18-96; 8:45 am]
BILLING CODE 4910-13-U