[Federal Register Volume 64, Number 227 (Friday, November 26, 1999)]
[Proposed Rules]
[Pages 66419-66422]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 99-30801]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 99-NM-192-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 747 Series Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: This document proposes the supersedure of an existing 
airworthiness directive (AD), applicable to certain Boeing Model 747 
series airplanes, that currently requires a one-time inspection to 
determine the part number of the fuel shutoff spar valve for the 
outboard engines. That AD also requires replacement of certain valves 
with new valves, or modification of the spar valve body assembly, and 
various follow-on actions. This action would add new requirements to 
accomplish those actions on additional airplanes; and would require a 
one-time inspection of the maintenance records of certain airplanes to 
determine if the fuel shutoff spar valve for the outboard engines has 
ever been replaced, and various follow-on actions. This proposal is 
prompted by reports indicating that, due to high fuel pressure, certain 
fuel system components of the outboard engines have failed. The actions 
specified by the proposed AD are intended to prevent such high fuel 
pressure, which could result in failure of the fuel system components; 
this situation could result in fuel leakage, and, consequently, lead to 
an engine fire.

DATES: Comments must be received by January 10, 2000.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. 99-NM-192-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; or ITT Aerospace Controls, 28150 Industry Drive, 
Valencia, California 91355. This information may be examined at the 
FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, 
Washington.

FOR FURTHER INFORMATION CONTACT: Dionne M. Stanley, Aerospace Engineer, 
Propulsion Branch, ANM-140S, FAA, Transport Airplane Directorate, 
Seattle Aircraft Certification Office, 1601 Lind Avenue, SW., Renton, 
Washington 98055-4056; telephone (425) 227-2250; 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

[[Page 66420]]

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-192-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-192-AD, 1601 Lind Avenue, SW., Renton, Washington 
98055-4056.

Discussion

    On October 6, 1998, the FAA issued AD 98-21-29, amendment 39-10837 
(63 FR 55517, October 16, 1998), applicable to Boeing Model 747-100, -
200, -300, -400, 747SP, and 747SR series airplanes, having line numbers 
629 through 1006 inclusive, and powered by General Electric or Rolls-
Royce engines, to require a one-time visual inspection to determine the 
part number of the fuel shutoff valve for the outboard engines. That AD 
also requires replacement of certain valves with new valves, or 
modification of the spar valve body assembly, and various follow-on 
actions. That action was prompted by reports indicating that, due to 
high fuel pressure, certain fuel system components of the outboard 
engines have failed on in-service airplanes. The requirements of that 
AD are intended to prevent such high fuel pressure, which could result 
in failure of the fuel system components; this situation could result 
in fuel leakage, and, consequently, lead to an engine fire.

Actions Since Issuance of Previous Rule

    Since the issuance of that AD, the FAA has received two reports 
indicating that, due to high fuel pressure, the fuel system components 
of the outboard engine have failed on Model 747 series airplanes having 
line numbers 629 through 1006 inclusive, and powered by Pratt & Whitney 
engines. Therefore, these airplanes are also subject to the identified 
unsafe condition.
    In addition, since issuance of AD 98-21-29, the FAA has determined 
that Model 747 series airplanes having line numbers 1 through 628 
inclusive may also have improper engine fuel shutoff spar valves 
installed. Proper valves were installed during production; however, the 
potential exists that, during a maintenance action on these airplanes, 
the original valve was replaced with an improper valve. Therefore, 
these airplanes are also subject to the identified unsafe condition.

Explanation of Relevant Service Information

    The FAA has reviewed and approved Boeing Service Bulletin 747-
28A2199, Revision 1, dated October 1, 1998, and Revision 2, dated July 
8, 1999, which describe procedures for an inspection to determine the 
part number of the fuel shutoff spar valve for the outboard engines; 
and replacement of certain valves with new valves and various follow-on 
actions. These follow-on actions include aligning valve(s), performing 
a check to detect leaks, and correcting any discrepancy. Revision 2 of 
the service bulletin also describes procedures, for certain airplanes, 
for an inspection of the airplane maintenance records to determine if 
the fuel shutoff spar valves for the outboard engines have ever been 
replaced or if the engines in the inboard positions have ever been 
installed in the outboard positions, and an inspection to detect fuel 
leaks of the components between the fuel shutoff spar valve and the 
engine fuel shutoff valve and replacement of any discrepant part with a 
serviceable part. 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 supersede AD 98-21-29 to continue to require the 
actions specified in that AD. The proposed AD would add new 
requirements to accomplish those actions on additional airplanes; and 
would require a one-time inspection of the maintenance records of 
certain airplanes to determine if the fuel shutoff spar valve for the 
outboard engines has ever been replaced, and various follow-on actions 
that are specified in AD 98-21-29. Certain actions would be required to 
be accomplished in accordance with the service bulletin described 
previously.

Explanation of Changes Made to the Requirements of AD 98-21-29

    The FAA has incorporated previously approved alternative methods of 
compliance to AD 98-21-29. Paragraph (a) has been revised by adding 
Boeing Service Bulletin 747-28A2199, Revision 1, dated October 1, 1998, 
and Revision 2, dated July 8, 1999, as appropriate sources of service 
information. Paragraphs (b) and (c) have been revised by adding Boeing 
Service Bulletin 747-28A2199, Revision 2, dated July 8, 1999, as an 
appropriate source of service information. Additionally, a note has 
been added to identify the applicable maintenance manual sections for 
the inspections specified in paragraphs (b) and (c).
    The FAA also has clarified the inspection requirements contained in 
paragraphs (b) and (c) of the AD. Whereas AD 98-21-29 specified a one-
time inspection, the FAA has revised paragraphs (b) and (c) to clarify 
that its intent is to require a one-time general visual inspection. 
Additionally, a note has been added to the proposed rule to define that 
inspection.

Cost Impact

    There are approximately 987 airplanes of the affected design in the 
worldwide fleet. The FAA estimates that 208 airplanes of U.S. registry 
would be affected by this proposed AD.
    The one-time inspection to determine the part number of the valve 
that is currently required by AD 98-21-29 and retained in this proposed 
AD, which would affect approximately 59 airplanes of U.S. registry, 
takes approximately 4 work hours per airplane to accomplish, at an 
average labor rate of $60 per work hour. Based on these figures, the 
cost impact of this currently required inspection on U.S. operators is 
estimated to be $14,160, or $240 per airplane.
    Should an operator be required to accomplish the one-time 
inspection to detect leaks and cracks (after replacement of the valve 
or modification of the assembly) that is currently required by AD 98-
21-29 and retained in this proposed AD, it would take approximately 16 
work hours per airplane, at an average labor rate of $60 per work hour. 
Based on these figures, the cost impact of this inspection is estimated 
to be $960 per airplane.
    The new one-time inspection of the maintenance records of the 
airplane that is proposed in this AD action, which would affect 
approximately 149 airplanes of U.S. registry, would take approximately 
2 work hours per airplane to accomplish, at an average labor rate of 
$60 per work hour. Based on these figures, the cost impact of this 
inspection proposed by this AD on U.S. operators is estimated to be 
$17,880, or $120 per airplane.
    The cost impact figures discussed above are based on assumptions 
that no operator has yet accomplished any of the current or proposed 
requirements of this AD action, and that no operator

[[Page 66421]]

would accomplish those actions in the future if this AD were not 
adopted.
    Should an operator elect to modify the valve body assembly of the 
fuel system rather than replace a discrepant valve, it would take 
approximately 20 work hours per airplane, at an average labor rate of 
$60 per work hour. Required parts would cost approximately $404 (2 
kits) per airplane. Based on these figures, the cost impact of this 
inspection is estimated to be $1,604 per airplane.

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(f), 40113, 44701.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by removing amendment 39-10837 (63 FR 
55517, October 16, 1998), and by adding a new airworthiness directive 
(AD), to read as follows:

Boeing: Docket 99-NM-192-AD. Supersedes AD 98-21-29, Amendment 39-
10837.
    Applicability: Model 747 series airplanes, line numbers 1 
through 1006 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 (h)(1) 
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 high fuel pressure in components between the fuel 
shutoff spar valve and the engine fuel shutoff valve, which could 
result in failure of the fuel system components, lead to fuel 
leakage, and, consequently, lead to a possible engine fire, 
accomplish the following:

Restatement of Actions Required by AD 98-21-29, Amendment 39-10837:

One-Time Inspection

    (a) For airplanes having line numbers 629 through 1006 inclusive 
and powered by General Electric or Rolls-Royce engines: Within 18 
months after November 20, 1998 (the effective date of AD 98-21-29, 
amendment 39-10837), perform a one-time inspection to determine the 
part number of the fuel shutoff spar valve for the left- and right-
hand outboard engines, in accordance with Boeing Alert Service 
Bulletin 747-28A2199, dated August 1, 1996; Boeing Service Bulletin 
747-28A2199, Revision 1, dated October 1, 1998; or Boeing Service 
Bulletin 747-28A2199, Revision 2, dated July 8, 1999.

Replacement

    (1) If a valve having part number (P/N) S343T003-40 (ITT P/N 
125334D-1) is installed, no further action is required by this AD.
    (2) If a valve having P/N S343T003-40 (ITT P/N 125334D-1) is not 
installed, prior to further flight, accomplish either paragraph 
(a)(2)(i) or (a)(2)(ii) of this AD.
    (i) Replace the valve with a new valve, in accordance with the 
service bulletin. Prior to further flight following accomplishment 
of the replacement, align the valve(s), perform a check to detect 
leaks, and correct any discrepancy, in accordance with the service 
bulletin. Or
    (ii) Modify the valve body assembly of the fuel system in 
accordance with ITT Service Bulletin SB125120-28-01, ITT Service 
Bulletin SB107970-28-01, and ITT Service Bulletin SB125334-28-01; 
all dated July 15, 1996.

Inspection

    (b) For airplanes having line numbers 629 through 1006 inclusive 
and powered by General Electric or Rolls-Royce engines: Except as 
provided in paragraph (c) of this AD, prior to further flight 
following accomplishment of paragraph (a)(2) of this AD, perform a 
one-time general visual inspection to detect fuel leaks of the 
components between the fuel shutoff spar valve and the engine fuel 
shutoff valve on all four engines, in accordance with the applicable 
section that pertains to Rolls-Royce RB211 series engines or General 
Electric CF6-80C and CF6-45/50 series engines in Chapter 71 of the 
Boeing 747 Airplane Maintenance Manual (AMM), or Boeing Service 
Bulletin 747-28A2199, Revision 2, dated July 8, 1999. If any leak is 
detected, prior to further flight, replace the part with a 
serviceable part. No further action is required by this AD.

    Note 2: For the purposes of this AD, a general visual inspection 
is defined as: ``A visual examination of an interior or exterior 
area, installation, or assembly to detect obvious damage, failure, 
or irregularity. This level of inspection is made under normally 
available lighting conditions such as daylight, hangar lighting, 
flashlight, or drop-light, and may require removal or opening of 
access panels or doors. Stands, ladders, or platforms may be 
required to gain proximity to the area being checked.''

    (c) For airplanes having line numbers 629 through 1006 
inclusive, powered by General Electric or Rolls-Royce engines, and 
having maintenance records that positively demonstrate that the 
inboard engines have never been located in the outboard position: 
Prior to further flight following accomplishment of paragraph (a)(2) 
of this AD, perform a one-time general visual inspection to detect 
fuel leaks of the components between the fuel shutoff spar valve and 
the engine fuel shutoff valve on the outboard engines only, in 
accordance with the applicable section that pertains to Rolls-Royce 
RB211 series engines or General Electric CF6-80C and CF6-45/50 
series engines in Chapter 71 of the Boeing 747 AMM, or Boeing 
Service Bulletin 747-28A2199, Revision 2, dated July 8, 1999. If any 
leak is detected, prior to further flight, replace the part with a 
serviceable part. No further action is required by this AD.

    Note 3: Accomplishment of the actions specified in AMM 71-00-00/
501, Test No. 2, ``Fuel and Oil Leak Check,'' for Rolls-Royce RB211 
series engines, and AMM 71-00-00/501, Test No. 3, ``Ground Test--
Idle Leak Check ( or Idle Power),'' for General Electric CF6-80C and 
CF6-45/50 series engines, is acceptable for compliance with the 
actions specified by paragraphs (b) and (c) of this AD.

New Actions Required by This AD

Inspection

    (d) For airplanes having line numbers 1 through 628 inclusive: 
Within 18 months after the effective date of this AD, perform a one-
time inspection of the maintenance records of the airplane to 
determine if the fuel shutoff spar valve for the left- and right-

[[Page 66422]]

hand outboard engines has ever been replaced, in accordance with 
Boeing Service Bulletin 747-28A2199, Revision 2, dated July 8, 1999.
    (1) If neither valve has been replaced, no further action is 
required by this AD.
    (2) If either valve has been replaced, prior to further flight, 
accomplish paragraph (e) of this AD for that valve.
    (e) For airplanes having line numbers 629 through 1006 inclusive 
and powered by Pratt & Whitney engines, or for airplanes having line 
numbers 1 through 1006 inclusive and powered by General Electric or 
Rolls-Royce engines on which a fuel shutoff spar valve has been 
replaced: Within 18 months after the effective date of this AD, 
perform a one-time inspection to determine the part number of the 
fuel shutoff spar valve for the left- and right-hand outboard 
engines, as applicable, in accordance with Boeing Alert Service 
Bulletin 747-28A2199, dated August 1, 1996; Boeing Service Bulletin 
747-28A2199, Revision 1, dated October 1, 1998; or Boeing Service 
Bulletin 747-28A2199, Revision 2, dated July 8, 1999.

Replacement

    (1) If a valve having P/N S343T003-40 (ITT P/N 125334D-1) is 
installed, no further action is required by this AD.
    (2) If a valve having P/N 60B92406-161 (ITT P/N 125334-1), P/N 
60B92406-81 (ITT P/N 125120-1), or P/N 60B92406-201 (ITT P/N 107970-
1) is installed, accomplish either paragraph (f) or (g) of this AD, 
as applicable.
    (3) If a valve having P/N S343T003-40 (ITT P/N 125334D-1), P/N 
60B92406-161 (ITT P/N 125334-1), P/N 60B92406-81 (ITT P/N 125120-1), 
or P/N 60B92406-201 (ITT P/N 107970-1) is not installed, prior to 
further flight, accomplish either paragraph (e)(3)(i) or (e)(3)(ii), 
and either paragraph (f) or (g) of this AD, as applicable.
    (i) Replace the valve with a new valve, in accordance with the 
service bulletin. Prior to further flight following accomplishment 
of the replacement, align the valve(s), perform a check to detect 
leaks, and correct any discrepancy, in accordance with the service 
bulletin. Or
    (ii) Modify the valve body assembly of the fuel system in 
accordance with ITT Service Bulletin SB125120-28-01, ITT Service 
Bulletin SB107970-28-01, and ITT Service Bulletin SB125334-28-01; 
all dated July 15, 1996.

Inspection

    (f) Except as provided in paragraph (g) of this AD, prior to 
further flight following accomplishment of paragraph (e) of this AD, 
perform a one-time general visual inspection to detect fuel leaks of 
the components between the fuel shutoff spar valve and the engine 
fuel shutoff valve on all four engines, in accordance with Boeing 
Service Bulletin 747-28A2199, Revision 2, dated July 8, 1999. If any 
leak is detected, prior to further flight, replace the part with a 
serviceable part.
    (g) For airplanes having maintenance records that positively 
demonstrate that the inboard engines have never been located in the 
outboard position: Prior to further flight following accomplishment 
of paragraph (e) of this AD, perform a one-time general visual 
inspection to detect fuel leaks of the components between the fuel 
shutoff spar valve and the engine fuel shutoff valve on the outboard 
engines only, in accordance with Boeing Service Bulletin 747-
28A2199, Revision 2, dated July 8, 1999. If any leak is detected, 
prior to further flight, replace the part with a serviceable part.

Alternative Methods of Compliance

    (h)(1) 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.
    (h)(2) Alternative methods of compliance, approved previously in 
accordance with AD 98-21-29, amendment 39-10837, are approved as 
alternative methods of compliance with paragraph (a), (a)(1), 
(a)(2), (a)(2)(i), (b), and (c) of this AD.

    Note 4: 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

    (i) 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 November 19, 1999.
D.L. Riggin,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 99-30801 Filed 11-24-99; 8:45 am]
BILLING CODE 4910-13-P