[Federal Register Volume 64, Number 161 (Friday, August 20, 1999)]
[Proposed Rules]
[Pages 45483-45485]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 99-21685]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 99-NM-125-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757 Series Airplanes 
Equipped With Rolls Royce Engines

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 certain Boeing Model 757 series 
airplanes. This proposal would require modification of the nacelle 
strut and wing structure of certain Boeing Model 757 series airplanes 
equipped with Rolls Royce RB211 engines. This proposal is prompted by 
reports indicating that the actual operational loads applied to the 
nacelle are higher than the analytical loads that were used during the 
initial design. Such an increase in loading can lead to fatigue 
cracking in primary strut structure prior to an airplane's reaching its 
design service objective. The actions specified by the proposed AD are 
intended to prevent fatigue cracking in primary strut structure and 
consequent reduced structural integrity of the strut.

DATES: Comments must be received by October 4, 1999.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. 99-NM-125-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 Boeing Commercial Airplane Group, P.O. Box 3707, Seattle, 
Washington 98124-2207.
    This information may be examined at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington.

FOR FURTHER INFORMATION CONTACT: Rick Kawaguchi, Aerospace 
Engineer,Airframe Branch, ANM-120S, FAA, Transport Airplane 
Directorate, Seattle Aircraft Certification Office, 1601 Lind Avenue, 
SW., Renton, Washington 98055-4056; telephone (425) 227-1153; fax (425) 
227-1181.

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 99-NM-125-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-114, Attention: Rules 
Docket No. 99-NM-125-D, 1601 Lind Avenue, SW., Renton, Washington 
98055-4056.

Discussion

    The FAA has received reports indicating that the manufacturer has 
accomplished a structural reassessment of the damage tolerance 
capabilities of the Boeing Model 757 series airplane, equipped with 
Rolls Royce engines. This reassessment indicates that the actual 
operational loads applied to the nacelle strut and wing structure are 
higher than the analytical loads that were used during the initial 
design. Subsequent analysis and service history, which includes 
numerous reports of fatigue cracking on certain strut and wing 
structure, indicate that fatigue cracking can occur on the primary 
strut structure before an airplane reaches its design service objective 
of 20 years or 50,000 flight cycles. Analysis also indicates that such 
cracking, if it were to occur, would grow at a much greater rate than 
originally expected. Fatigue cracking in primary strut structure would 
result in reduced structural integrity of the strut.

Explanation of Relevant Service Information

    Boeing recently has developed a modification of the strut-to-wing 
attachment structure installed on Model 757 series airplanes equipped 
with Rolls Royce Model RB211 series engines. This modification 
significantly improves the load-carrying capability and durability of 
the strut-to-wing attachments. Such improvement also will substantially 
reduce the possibility of fatigue cracking and corrosion developing in 
the attachment assembly.
    The FAA has reviewed and approved Boeing Service Bulletin 757-54-
0035, dated July 17, 1997, which describes procedures to modify the 
nacelle strut

[[Page 45484]]

and wing structure of certain Boeing Model 757 series airplanes 
equipped with Rolls Royce RB211 engines. The modification consists of 
replacing many of the significant load-bearing components of the strut 
(e.g., the side link fittings assemblies, the upper link assembly, 
certain fuse bolt assemblies, etc.) with improved components. In 
addition, Table I of the service bulletin also identifies numerous 
related service bulletin modifications that must be accomplished before 
or at the same time as the service bulletin is accomplished. These 
modifications also entail the replacement of many of the significant 
load-bearing components of the strut with improved components.
    In addition, the service bulletin contains a formula for 
calculating an optional compliance threshold for the specified 
modification. This formula is intended to be used as an alternative to 
the 20-year calendar threshold specified in the service bulletin.
    Accomplishment of the actions specified in the service bulletin is 
intended to adequately address the identified unsafe condition.

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 accomplishment of the modifications specified 
in the service bulletin described previously, except as discussed 
below.

Differences Between Proposed Rule and Service Bulletin

    Operators should note that this proposed AD would provide a grace 
period of 3,000 flight cycles for airplanes that have already passed 
the initial compliance threshold specified in the service bulletin. The 
service bulletin was issued at a time when none of the affected 
airplanes had reached that initial compliance threshold.

Cost Impact

    There are approximately 394 airplanes of the affected design in the 
worldwide fleet. The FAA estimates that 176 airplanes of U.S. registry 
would be affected by this proposed AD, that it would take approximately 
1,049 work hours per airplane to accomplish the proposed modification, 
and that the average labor rate is $60 per work hour. This work hour 
figure includes the time it would take to remove and reinstall the 
struts from the airplane as well as the time to gain and close access 
to the adjacent wing structure. Based on these figures, the cost impact 
of the modification proposed by this AD on U.S. operators is estimated 
to be $11,077,440, or $62,940 per airplane.
    This cost impact figure does not reflect the cost of the 
terminating actions described in the service bulletins listed in 
paragraph I.C., Table I, ``Strut Improvement Bulletins,'' on page 6 of 
Boeing Service Bulletin 757-54-0035, that are proposed to be 
accomplished prior to, or concurrently with, the modification of the 
nacelle strut and wing structure. Since some operators may have 
accomplished certain modifications on some or all of the airplanes in 
its fleet, while other operators may not have accomplished any of the 
modifications on any of the airplanes in its fleet, the FAA is unable 
to provide a reasonable estimate of the cost of accomplishing the 
terminating actions described in the service bulletins listed in Table 
I of the service bulletin. As indicated earlier in this preamble, the 
FAA invites comments specifically on the overall economic aspects of 
this proposed rule. Any data received via public comments to this 
notice will aid the FAA in developing an accurate accounting of the 
cost impact of the rule.
    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. However, the FAA has been 
advised that manufacturer warranty remedies are available for part 
costs associated with accomplishing the actions required by this 
proposed AD. Therefore, the future economic cost impact of this rule on 
U.S. operators may be less than the cost impact figure indicated above.

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:

Boeing: Docket 99-NM-125-AD.

    Applicability: Model 757 series airplanes equipped with Rolls 
Royce engines, line numbers 1 through 735 inclusive; 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 (b) 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 fatigue cracking in primary strut structure and 
consequent reduced structural integrity of the strut, accomplish the 
following:
    (a) Modify the nacelle strut and wing structure in accordance 
with Boeing Service Bulletin 757-54-0035, dated July 17, 1997, at 
the later of the times specified in paragraph (a)(1) or (a)(2). All 
of the terminating actions described in the service bulletins listed 
in paragraph I.C., Table I, ``Strut Improvement Bulletins,'' on page 
6 of Boeing Service Bulletin 757-54-0035, must be accomplished in 
accordance with those service bulletins prior to, or concurrently 
with, the

[[Page 45485]]

accomplishment of the modification of the nacelle strut and wing 
structure required by this paragraph.
    (1) Prior to the accumulation of 37,500 total flight cycles, or 
prior to 20 years since the date of manufacture of the airplane, 
whichever occurs first.
    (2) Within 3,000 flight cycles after the effective date of this 
AD.

Alternative Methods of Compliance

    (b) 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, Seattle 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, Seattle ACO.

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

Special Flight Permits

    (c) Special flight permits may be issued in accordance with 
Secs. 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 August 16, 1999.
D.L. Riggin,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 99-21685 Filed 8-19-99; 8:45 am]
BILLING CODE 4910-13-P