[Federal Register Volume 62, Number 19 (Wednesday, January 29, 1997)]
[Proposed Rules]
[Pages 4213-4217]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 97-2220]


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DEPARTMENT OF TRANSPORTATION
14 CFR Part 39

[Docket No. 96-NM-43-AD]
RIN 2120-AA64


Airworthiness Directives; Airbus Model A300 Series Airplanes

AGENCY: Federal Aviation Administration, DOT.


[[Page 4214]]


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 Airbus Model A300 series 
airplanes. This proposal would require inspections of the lower door 
surrounding structure to detect cracks and corrosion, and repair, if 
necessary. This proposal also would require inspections to detect 
cracking of the holes of the corner doublers, the fail-safe ring, and 
the door frames of the door structures; and repair, if necessary. This 
proposal would require modification of the passenger/crew door frames, 
which, when accomplished, terminates certain inspections. This proposal 
is prompted by reports indicating that corrosion was found behind the 
scuff plates at exit and cargo doors, and fatigue cracks originated 
from certain fastener holes located in adjacent structure. The actions 
specified by the proposed AD are intended to detect and correct such 
corrosion and fatigue cracking, which could result in reduced 
structural integrity of the door surroundings.

DATES: Comments must be received by March 10, 1997.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-103, 
Attention: Rules Docket No. 96-NM-43-AD, 1601 Lind Avenue, SW., Renton, 
Washington 98055-4056. Comments may be inspected at this location 
between 9:00 a.m. and 3:00 p.m., Monday through Friday, except Federal 
holidays.
    The service information referenced in the proposed rule may be 
obtained from Airbus Industrie, 1 Rond Point Maurice Bellonte, 31707 
Blagnac Cedex, France. This information may be examined at the FAA, 
Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, 
Washington.

FOR FURTHER INFORMATION CONTACT: Charles Huber, Aerospace Engineer, 
Standardization Branch, ANM-113, FAA, Transport Airplane Directorate, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (206) 
227-2589; fax (206) 227-1149.

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-43-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-43-AD, 1601 Lind Avenue, SW., Renton, Washington 
98055-4056.

Discussion

    The Direction Generale de l'Aviation Civile (DGAC), which is the 
airworthiness authority for France, has notified the FAA that an unsafe 
condition may exist on all Airbus Model A300 series airplanes. The DGAC 
advises that it received reports indicating that corrosion was found 
behind the scuff plates at passenger/crew doors, emergency exits, and 
the bulk cargo door. The DGAC also advises that results of structural 
fatigue testing have revealed that cracks were found on the corner 
doublers of the forward, mid, and aft passenger/crew door frames; and, 
after various simulated flights, on the fail-safe ring and frames 14 
and 16A of the forward passenger/crew door. After 50,000 simulated 
flights, cracks measuring between 8.0 mm and 109.0 mm were found on the 
forward door frames and fail-safe ring. On the mid door frame, a 53.0 
mm crack was found after 60,493 simulated flights. A crack which 
measured 32.0 mm was found on the aft door frame after 106,000 
simulated flights. In all cases, the cracks originated at the fastener 
holes. In addition, cracks originating from corner doubler edges were 
found at the aft passenger/crew doors.
    Such corrosion and fatigue cracking, if not detected and corrected, 
could result in reduced structural integrity of the door surroundings.

Explanation of Relevant Service Information

    Airbus has issued Service Bulletin A300-53-204, Revision 6, dated 
October 11, 1993, which describes procedures for a one-time inspection 
to detect cracks and corrosion in the areas behind the scuff plates at 
passenger/crew doors, emergency exits, and the bulk cargo door, and 
repair, if necessary. Airbus also has issued Service Bulletin A300-53-
233, Revision 1, dated April 18, 1991, which describes procedures for 
corresponding repetitive inspections in these areas, and repair, if 
necessary.
    In addition, Airbus has issued Service Bulletin A300-53-227, 
Revision 1, dated April 29, 1992. This service bulletin describes 
procedures for repetitive inspections to detect cracking of the holes 
of the corner doublers, the fail-safe ring, and the door frames at the 
left- and right-hand forward, mid, and aft passenger/crew door 
structures; and repair, if necessary.
    Airbus also has issued Service Bulletin A300-53-192, Revision 7, 
dated July 13, 1992, which describes procedures for modification of the 
passenger/crew door frames. This modification consists of performing 
cold expansion procedures on the fastener holes in door frames, corner 
doublers, and fail-safe rings; and installing oversized Hi-Lok 
fasteners and additional steel doublers at door frame corners, where 
necessary, to improve the fatigue life of the corner doublers, fail-
safe rings, and door frames. Accomplishment of the modification 
eliminates the need for the repetitive inspections specified in Airbus 
Service Bulletin A300-53-227.
    The DGAC classified the inspection service bulletins as mandatory 
and issued French airworthiness directive (CN) 91-132-124(B), dated 
June 26, 1991, as amended by a Correction, dated August 21, 1991, in 
order to assure the continued airworthiness of these airplanes in 
France. (The DGAC did not classify the modification service bulletin as 
mandatory.)

FAA's Conclusions

    This airplane model is manufactured in France and is type 
certificated for operation in the United States under the provisions of 
section 21.29 of the Federal Aviation Regulations (14 CFR 21.29) and 
the applicable bilateral airworthiness agreement. Pursuant to this 
bilateral airworthiness agreement, the DGAC has kept the FAA informed

[[Page 4215]]

of the situation described above. The FAA has examined the findings of 
the DGAC, reviewed all available information, and determined that AD 
action is necessary for products of this type design that are 
certificated for operation in the United States.

Explanation of Requirements of Proposed Rule

    Since an unsafe condition has been identified that is likely to 
exist or develop on other airplanes of the same type design registered 
in the United States, the proposed AD would require inspections of the 
lower door surrounding structure to detect cracks and corrosion, and 
repair, if necessary. The proposed AD also would require inspections to 
detect cracking of the holes of the corner doublers, the fail-safe 
ring, and the door frames of the door structures; and repair, if 
necessary. In addition, the proposed AD would require modification of 
the passenger/crew door frames, which, when accomplished, constitutes 
terminating action for certain inspections. The actions would be 
required to be accomplished in accordance with the service bulletins 
described previously.

Differences Between Proposed Rule and Parallel French CN

    Operators should note that the French CN does not mandate 
modification of the passenger/crew door frames. However, the FAA finds 
that, since the design of Model A300 series airplanes is not damage 
tolerant, accomplishment of the modification described in Airbus 
Service Bulletin A300-53-192 must be required.
    Additionally, the FAA considers that long term continued 
operational safety will be better assured by actual modification of the 
airframe to remove the source of the problem, rather than by repetitive 
inspections. Long term inspections may not be providing the degree of 
safety assurance necessary for the transport airplane fleet. This has 
led the FAA to consider placing less emphasis on special procedures and 
more emphasis on design improvements. The proposed modification 
requirement is in consonance with this consideration.

Cost Impact

    The FAA estimates that 4 airplanes of U.S. registry would be 
affected by this proposed AD.
    It would take approximately 700 work hours per airplane to 
accomplish the proposed inspections, and that the average labor rate is 
$60 per work hour. Based on these figures, the cost impact of the 
proposed inspections on U.S. operators is estimated to be $168,000, or 
$42,000 per airplane.
    The FAA estimates that it would take approximately 330 work hours 
per airplane to accomplish the proposed modification, and that the 
average labor rate is $60 per work hour. Required parts would cost 
approximately $1,055 per airplane. Based on these figures, the cost 
impact of the proposed modification on U.S. operators is estimated to 
be $83,420, or $20,855 per airplane.
    The cost impact figures discussed above are 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:

Airbus: Docket 96-NM-43-AD.

    Applicability: All Model A300 series 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 
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 (h) 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 detect and correct corrosion behind the scuff plates at exit 
and cargo doors, and fatigue cracking in certain fastener holes 
located in adjacent structure, which could result in reduced 
structural integrity of the door surroundings, accomplish the 
following:
    (a) Perform an initial inspection of the areas behind the scuff 
plates below the passenger/crew doors and bulk cargo door to detect 
cracks and corrosion, in accordance with Airbus Service Bulletin 
A300-53-204, Revision 6, dated October 11, 1993; at the applicable 
time specified in paragraph (a)(1), (a)(2), (a)(3), or (a)(4) of 
this AD. If any crack or corrosion is found during this inspection, 
prior to further flight, repair in accordance with the service 
bulletin. Accomplishment of this inspection is not required for the 
mid and aft passenger/crew doors if a steel doubler that covers the 
entire inspection area is installed.
    (1) For airplanes on which Modifications 5382S6526 (for forward 
doors), 3690S4613 (for forward doors), and 5382D4741 (for all other 
doors) have been accomplished prior to delivery of the airplane: 
Perform the initial inspection within 9 years since manufacture, or 
within 1 year after the effective date of this AD, whichever occurs 
later.
    (2) For airplanes on which the procedures described in Airbus 
Service Information Letter (SIL) A300-53-033, Revision 2 (for all 
doors), dated November 23, 1984; or Airbus Service Bulletin A300-53-
169 (for forward doors), Revision 2, dated May 14, 1985; have been 
accomplished: Perform the initial inspection within 5 years after 
accomplishment of the SIL or the service bulletin, or within 1 year 
after the effective date of this AD, whichever occurs later.
    (3) For airplanes on which the procedures described in Airbus 
Service Bulletin A300-53-116 (for all doors), Revision 4, dated June 
30, 1983, have been accomplished: Perform the initial inspection 
within 2 years after accomplishment of the procedures in accordance 
with that service bulletin, or

[[Page 4216]]

within 1 year after the effective date of this AD, whichever occurs 
later.
    (4) For airplanes on which Modifications 5382S6526 (for forward 
doors), 3690S4613 (for forward doors), and 5382D4741 (for all other 
doors); and the procedures described in Airbus Service Bulletin 
A300-53-116, Revision 4, dated June 30, 1983; or Service Information 
Letter (SIL) A300-53-033, Revision 2, dated November 23, 1984; have 
not been accomplished: Perform the initial inspection within 1 year 
after the effective date of this AD.
    (b) Perform repetitive inspections of the areas behind the scuff 
plates below the passenger/crew doors and bulk cargo door to detect 
cracks and corrosion, in accordance with Airbus Service Bulletin 
A300-53-233, Revision 1, dated April 18, 1991, at the applicable 
times specified in paragraphs (b)(1) and (b)(2) of this AD. 
Accomplishment of these inspections is not required for the mid and 
aft passenger/crew doors if a steel doubler that covers the entire 
inspection area is installed.
    (1) For the forward and mid passenger/crew doors, the bulk cargo 
doors, the emergency exits, and the aft passenger/crew doors, except 
for the upper and lower edges of the fail-safe ring and the upper 
edges of the corner doubler: Perform the first inspection within 5 
years after accomplishing the inspection required by paragraph (a) 
of this AD; and repeat the inspection thereafter at intervals not to 
exceed 5 years following the immediately preceding inspection.
    (2) For the upper and lower edges of the fail-safe ring and the 
upper edges of the corner doubler of the aft passenger/crew doors: 
Perform the first inspection within 5 years or 10,000 landings after 
accomplishing the inspection required by paragraph (a) of this AD, 
whichever occurs first; and repeat the inspection thereafter at 
intervals not to exceed 5 years or 10,000 landings, whichever occurs 
first.
    (c) If any crack is found during any inspection required by 
paragraph (b) of this AD, prior to further flight, repair in 
accordance with Airbus Service Bulletin A300-53-233, Revision 1, 
dated April 18, 1991. Thereafter, perform the repetitive inspections 
required by paragraph (b) of this AD at the applicable times 
specified in paragraphs (b)(1) and (b)(2) of this AD.
    (d) If any corrosion is found during any inspection required by 
paragraph (b) of this AD, prior to further flight, repair in 
accordance with Airbus Service Bulletin A300-53-233, Revision 1, 
dated April 18, 1991. Thereafter, perform the repetitive inspections 
required by paragraph (b) of this AD at the applicable times 
specified in paragraphs (d)(1) and (d)(2) of this AD.
    (1) For the upper and lower edges of the fail-safe ring and the 
upper edges of the corner doubler of the aft passenger/crew doors, 
and for the mid passenger/crew doors: Inspect at intervals not to 
exceed 5 years or 8,000 landings, whichever occurs first.
    (2) For the forward passenger/crew doors, bulk cargo door, and 
emergency exits: Inspect at intervals not to exceed 5 years.
    (e) Perform inspections to detect cracking of the holes of the 
corner doublers, the fail-safe ring, and the door frames of the 
left- and right-hand forward, mid, and aft passenger/crew door 
structures, in accordance with Airbus Service Bulletin A300-53-227, 
Revision 1, dated April 29, 1992. Perform the inspections at the 
times specified in paragraphs (e)(1), (e)(2), and (e)(3) of this AD, 
as applicable. If any cracking is found, prior to further flight, 
repair in accordance with the service bulletin; or, if cracks cannot 
be eliminated in accordance with the service bulletin, repair in 
accordance with a method approved by the Manager, Standardization 
Branch, ANM-113, FAA, Transport Airplane Directorate.
    (1) Except as provided by paragraph (e)(2) of this AD, for the 
left- and right-hand forward and mid passenger/crew door structures 
of all airplanes: Inspect at the time specified in paragraph 
(e)(1)(i), (e)(1)(ii), (e)(1)(iii), or (e)(1)(iv) of this AD, as 
applicable.
    (i) For airplanes that have accumulated less than 20,000 total 
landings as of the effective date of this AD: Inspect prior to the 
accumulation of 20,000 total landings, or within 1,250 landings 
after the effective date of this AD, whichever occurs later.
    (ii) For airplanes that have accumulated 20,000 total landings 
or more, but less than 21,000 landings as of the effective date of 
this AD: Inspect prior to the accumulation of 21,000 total landings, 
or within 1,000 landings after the effective date of this AD, 
whichever occurs later.
    (iii) For airplanes that have accumulated 21,000 total landings 
or more, but less than 22,000 landings as of the effective date of 
this AD: Inspect prior to the accumulation of 22,000 total landings, 
or within 500 landings after the effective date of this AD, 
whichever occurs later.
    (iv) For airplanes that have accumulated 22,000 total landings 
or more as of the effective date of this AD: Inspect within 250 
landings after the effective date of this AD.
    (2) For the left-hand mid passenger/crew door structures of 
Model A300 C4 and F4 series airplanes: Inspect at the time specified 
in paragraph (e)(2)(i), (e)(2)(ii), (e)(2)(iii), or (e)(2)(iv) of 
this AD, as applicable.
    (i) For airplanes that have accumulated less than 12,000 total 
landings as of the effective date of this AD: Inspect prior to the 
accumulation of 12,000 total landings, or within 1,250 landings 
after the effective date of this AD, whichever occurs later.
    (ii) For airplanes that have accumulated 12,000 total landings 
or more, but less than 13,000 landings as of the effective date of 
this AD: Inspect prior to the accumulation of 13,000 total landings, 
or within 1,000 landings after the effective date of this AD, 
whichever occurs later.
    (iii) For airplanes that have accumulated 13,000 total landings 
or more, but less than 14,000 landings as of the effective date of 
this AD: Inspect prior to the accumulation of 14,000 total landings, 
or within 500 landings after the effective date of this AD, 
whichever occurs later.
    (iv) For airplanes that have accumulated 14,000 total landings 
or more as of the effective date of this AD: Inspect within 250 
landings after the effective date of this AD.
    (3) For the left- and right-hand aft passenger/crew door 
structures of all airplanes: Inspect prior to the accumulation of 
24,000 total landings, or within 250 landings after the effective 
date of this AD, whichever occurs later.
    (f) Repeat the inspections required by paragraph (e) of this AD 
at the times specified in paragraphs (f)(1), (f)(2), (f)(3), (f)(4), 
(f)(5), (f)(6), (f)(7), (f)(8), (f)(9), and (f)(10), as applicable, 
until the modification required by paragraph (g) of this AD is 
accomplished.
    (1) For the forward passenger/crew door structure of airplanes 
on which Airbus Modification No. 1282/S1862 has not been 
accomplished: Inspect at the intervals specified in paragraphs 
(f)(1)(i) and (f)(1)(ii), as applicable.
    (i) For the upper corners of the door structure: At intervals 
not to exceed 4,000 landings.
    (ii) For the lower corners of the door structure: At intervals 
not to exceed 7,500 landings.
    (2) For the forward passenger/crew door structure of airplanes 
on which Airbus Modification No. 1282/S1862 has been accomplished: 
Inspect at the intervals specified in paragraphs (f)(2)(i) and 
(f)(2)(ii), as applicable.
    (i) For the upper corners of the door structure: At intervals 
not to exceed 6,000 landings.
    (ii) For the lower corners of the door structure: At intervals 
not to exceed 10,000 landings.
    (3) For the forward passenger/crew door structure of the 
airplane having manufacturer's serial number 063, on which Airbus 
Modification No. 1282/S1862 has been accomplished partially: Inspect 
at the intervals specified in paragraph (f)(3)(i) or (f)(3)(ii), as 
applicable.
    (i) For the upper corners of the door structure: At intervals 
not to exceed 4,000 landings.
    (ii) For the lower corners of the door structure: At intervals 
not to exceed 7,500 landings.
    (4) For the left- and right-hand mid passenger/crew door 
structure on Model A300 B1, B2, and B4 series airplanes; and for the 
right-hand mid passenger/crew door structure on Model A300 C4 and F4 
series airplanes; on which an inspection required by paragraph (e) 
of this AD was accomplished using a Roto test technique: Inspect at 
intervals not to exceed 8,000 landings.
    (5) For the left- and right-hand mid passenger/crew door 
structure on Model A300 B1, B2, and B4 series airplanes; and for the 
right-hand mid passenger/crew door structure on Model A300 C4 and F4 
series airplanes; on which an inspection required by paragraph (e) 
of this AD was accomplished using an X-ray technique: Inspect at 
intervals not to exceed 3,500 landings.
    (6) For the left-hand mid passenger/crew door structure on Model 
A300 C4 and F4 series airplanes on which an inspection required by 
paragraph (e) of this AD was accomplished using a Roto test 
technique: Inspect at intervals not to exceed 5,200 landings.
    (7) For the left-hand mid passenger/crew door structure on Model 
A300 C4 and F4

[[Page 4217]]

series airplanes on which an inspection required by paragraph (e) of 
this AD was accomplished using an X-ray technique: Inspect at 
intervals not to exceed 2,300 landings.
    (8) For the aft passenger/crew door structure on which an 
inspection required by paragraph (e) of this AD was accomplished 
using a Roto test technique: Inspect at intervals not to exceed 
8,000 landings.
    (9) For the aft passenger/crew door structure on which an 
inspection required by paragraph (e) of this AD was accomplished 
using an X-ray technique: Inspect at intervals not to exceed 3,500 
landings.
    (10) For the areas around the fasteners in the vicinity of 
stringer 12 on the aft passenger/crew door structure on which an 
inspection required by paragraph (e) of this AD was accomplished 
using a visual technique: Inspect at intervals not to exceed 6,900 
landings.
    (g) Prior to the accumulation of 20,000 total landings, or 
within 1 year after the effective date of this AD, whichever occurs 
later: Modify the passenger/crew door structures in accordance with 
Airbus Service Bulletin A300-53-192, Revision 7, dated July 13, 
1992. Accomplishment of this modification constitutes terminating 
action for the repetitive inspections required by paragraph (f) of 
this AD.
    (h) 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, Standardization Branch, ANM-113, 
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, 
Standardization Branch, ANM-113.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Standardization Branch, ANM-113.

    (i) 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 January 23, 1997.
Darrell M. Pederson,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 97-2220 Filed 1-28-97; 8:45 am]
BILLING CODE 4910-13-P