[Federal Register Volume 68, Number 94 (Thursday, May 15, 2003)]
[Proposed Rules]
[Pages 26244-26247]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-12111]


-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-CE-57-AD]
RIN 2120-AA64


Airworthiness Directives; Cessna Aircraft Company Models 402C and 
414A Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

-----------------------------------------------------------------------

SUMMARY: This document proposes to supersede Airworthiness Directive 
(AD) 2000-23-01, which applies to all Cessna Aircraft Company (Cessna) 
Model 402C airplanes. AD 2000-23-01 currently requires repetitive 
inspections of the forward, aft, and auxiliary wing spars for cracks, 
and repair or replacement as necessary. Cessna has performed fatigue 
and crack growth analyses of the wings of these airplanes, and the 
Federal Aviation Administration (FAA) has evaluated this information 
and determined that a wing spar modification and inspections are 
necessary on the Model 414A airplanes as well as the Model 402C 
airplanes. This proposed AD would require you to inspect the wing spar 
caps for fatigue cracks with any necessary repair or replacement and to 
incorporate a spar strap modification on each wing spar. The actions 
specified by this proposed AD are intended to prevent wing spar cap 
failure due to undetected fatigue cracks. Such failure could result in 
loss of a wing with consequent loss of airplane control.

DATES: The Federal Aviation Administration (FAA) must receive any 
comments on this proposed rule on or before August 8, 2003.

ADDRESSES: Submit comments to FAA, Central Region, Office of the 
Regional Counsel, Attention: Rules Docket No. 2002-CE-57-AD, 901 
Locust, Room 506, Kansas City, Missouri 64106. You

[[Page 26245]]

may view any comments at this location between 8 a.m. and 4 p.m., 
Monday through Friday, except Federal holidays. You may also send 
comments electronically to the following address: [email protected]. Comments sent electronically must contain ``Docket No. 
2002-CE-57-AD'' in the subject line. If you send comments 
electronically as attached electronic files, the files must be 
formatted in Microsoft Word 97 for Windows or ASCII text.
    You may get service information that applies to this proposed AD 
from the Cessna Aircraft Company, Product Support, P.O. Box 7706, 
Wichita, Kansas 67277; telephone: (316) 517-5800; facsimile: (316) 942-
9006. You may also view this information at the Rules Docket at the 
address above.

FOR FURTHER INFORMATION CONTACT: Paul Nguyen, Aerospace Engineer, FAA, 
Wichita Aircraft Certification Office, 1801 Airport Road, Mid-Continent 
Airport, Wichita, Kansas 67209; telephone: (316) 946-4125; facsimile: 
(316) 946-4107.

SUPPLEMENTARY INFORMATION:

Comments Invited

    How do I comment on this proposed AD? The FAA invites comments on 
this proposed rule. You may submit whatever written data, views, or 
arguments you choose. You need to include the rule's docket number and 
submit your comments to the address specified under the caption 
ADDRESSES. We will consider all comments received on or before the 
closing date. We may amend this proposed rule in light of comments 
received. Factual information that supports your ideas and suggestions 
is extremely helpful in evaluating the effectiveness of this proposed 
AD action and determining whether we need to take additional rulemaking 
action.
    Are there any specific portions of this proposed AD I should pay 
attention to? The FAA specifically invites comments on the overall 
regulatory, economic, environmental, and energy aspects of this 
proposed rule that might suggest a need to modify the rule. You may 
view all comments we receive before and after the closing date of the 
rule in the Rules Docket. We will file a report in the Rules Docket 
that summarizes each contact we have with the public that concerns the 
substantive parts of this proposed AD.
    How can I be sure FAA receives my comment? If you want FAA to 
acknowledge the receipt of your mailed comments, you must include a 
self-addressed, stamped postcard. On the postcard, write ``Comments to 
Docket No. 2002-CE-57-AD.'' We will date stamp and mail the postcard 
back to you.

Discussion

    Has FAA taken any action to this point? Reports of fatigue cracks 
on Cessna 401, 402, and 411 series airplanes caused FAA to take AD 
action (AD 79-10-15 R2, Amendment 39-3711) to require repetitive 
inspections of the right and left wing spar lower cap areas for fatigue 
cracks and to require wing spar cap repair or replacement as necessary.
    Cessna Models 402C and 414A airplanes incorporate a similar design 
to those airplanes affected by AD 79-10-15 R2. We issued AD 2000-23-01, 
Amendment 39-11971 (65 FR 70645, November 27, 2000), to require 
repetitive inspections of the forward, aft, and auxiliary wing spars 
for cracks on Cessna Models 402C airplanes with repair or replacement 
as necessary.
    There is no similar AD action addressing the Model 414A airplanes.
    What has happened since AD 79-10-15 R2 and AD 2000-23-01 to 
initiate this proposed action? Since issuance of AD 79-10-15 and AD 
2000-23-01, Cessna has analyzed the wing, including fatigue and crack 
growth analyses, on the affected airplanes. Analysis included:

--A determination of the probable location and modes of damage based on 
analytical results, available test data, and service information;
--Classical fatigue analyses;
--Crack growth and residual strength analyses including use of linear 
elastic fracture mechanics methods;
--Full-scale ground testing to validate analytical models; and
--A Flight strain survey to develop stress spectra used in the 
analyses.

    The inspections required by AD 79-10-15 R2 in accordance with 
Cessna Service Bulletin ME79-16, Revision 3, are accomplished using a 
surface eddy current inspection method.
    Based on the analysis, Cessna has found that the eddy current 
method will not find the crack until it is .03 inch longer than the 
critical crack length. When the crack reaches the critical length, it 
is not reliably detectable because it is under the head of the 
fastener. Once the main spar cap is severed, the remaining structure 
will no longer meet the residual strength requirements. Wing separation 
could then occur under loading conditions significantly less than those 
established for the design limit load.
    Cessna reported only one instance where cracks were detected using 
the nondestructive inspection (NDI) eddy current procedure. There are 
other reported instances where cracks were detected visually in the 
wheel well area on the aft flange. The problem with visual inspections 
is the access doubler flanges cover a large percentage of the forward 
spar flange. This limits the effectiveness of the visual inspections.
    To meet industry NDI standards, cracks need to be found on Cessna 
Models 402C and 414A airplanes through NDI inspection methods with a 
90-percent probability of detection at a 95-percent confidence level.
    Cessna's analysis indicates that the probability and confidence 
levels are not being met.
    Is there service information that applies to this subject? Cessna 
has issued Service Bulletin MEB02-05 and Cessna Service Kit SK402-47, 
both dated June 24, 2002. This service information includes procedures 
for inspecting and modifying the lower wing spar caps.

The FAA's Determination and an Explanation of the Provisions of this 
Proposed AD

    What has FAA decided? After examining the circumstances and 
reviewing all available information related to the incidents described 
above, we have determined that:

--Cessna's analysis of the problems with the eddy current inspection on 
the wing spar cap area on the Cessna Models 401, 401A, 401B, 402A, 
402B, 411, and 411A airplane is valid;
--The unsafe condition referenced in this document also exists or could 
develop on Cessna Models 402C and 414A airplanes that are the same type 
design;
--The actions specified in the previously-referenced service 
information should be accomplished on the affected airplanes; and
--AD action should be taken in order to correct this unsafe condition.

    What would this proposed AD require? This proposed AD would 
supersede AD 2000-23-01 with a new AD that would apply to Cessna Models 
402C and 414A airplanes and would require you to:
--Inspect the wing spar caps for fatigue cracks;
--Repair or replace the wing spar caps as necessary; and
--Incorporate a spar strap modification on each wing spar.
    How does the revision to 14 CFR part 39 affect this proposed AD? On 
July 10, 2002, FAA published a new version of 14 CFR part 39 (67 FR 
47997, July 22, 2002), which governs FAA's AD system.

[[Page 26246]]

This regulation now includes material that relates to special flight 
permits, alternative methods of compliance, and altered products. This 
material previously was included in each individual AD. Since this 
material is included in 14 CFR part 39, we will not include it in 
future AD actions.

Cost Impact

    How many airplanes would this proposed AD impact? We estimate that 
this proposed AD affects 656 airplanes in the U.S. registry.
    What would be the cost impact of this proposed AD on owners/
operators of the affected airplanes? We estimate the following costs to 
accomplish the proposed modification and initial inspection:

--------------------------------------------------------------------------------------------------------------------------------------------------------
            Labor cost                             Parts cost                 Total cost per airplane             Total cost on U.S. operators
--------------------------------------------------------------------------------------------------------------------------------------------------------
485 workhours x $60 per hour =      $14,000 per airplane...................  $29,100 + $14,000 =        $43,100 x 656 = $28,273,600.
 $29,100 per airplane.                                                        $43,100 per airplane.
--------------------------------------------------------------------------------------------------------------------------------------------------------

    The above figures do not take into account the cost of repetitive 
inspections. The FAA does not have any way of determining the number of 
repetitive inspections each owner/operator would incur during the 
operating life of the affected airplanes.

Regulatory Impact

    Would this proposed AD impact various entities? The regulations 
proposed herein would not have a substantial direct effect 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, it is determined that this 
proposed rule would not have federalism implications under Executive 
Order 13132.
    Would this proposed AD involve a significant rule or regulatory 
action? For the reasons discussed above, I certify that this proposed 
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) 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 has been placed 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, under 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

0
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]

0
2. FAA amends Sec.  39.13 by removing Airworthiness Directive (AD) 
2000-23-01, Amendment 39-11971 (65 FR 70645, November 27, 2000), and by 
adding a new AD to read as follows:

Cessna Aircraft Company: Docket No. 2002-CE-57-AD; Supersedes AD 
2000-23-01, Amendment 39-11971.

    (a) What airplanes are affected by this AD? This AD affects 
Models 402C and 414A airplanes, all serial numbers, that are 
certificated in any category.
    (b) Who must comply with this AD? Anyone who wishes to operate 
any of the airplanes identified in paragraph (a) of this AD must 
comply with this AD.
    (c) What problem does this AD address? The actions specified by 
this AD are intended to prevent wing spar cap failure due to 
undetected fatigue cracks. Such failure could result in loss of a 
wing with consequent loss of airplane control.
    (d) What actions must I accomplish to address this problem? To 
address this problem, you must inspect the wing spar caps for 
fatigue cracks and repair or replace the wing spar caps as necessary 
and incorporate a spar strap modification on each wing spar in 
accordance with Cessna Service Bulletin MEB02-5, dated June 24, 
2002, and Cessna Service Kit SK402-47, dated June 24, 2002, as 
follows:

------------------------------------------------------------------------
               Compliance times                    Affected airplanes
------------------------------------------------------------------------
(1) Inspect and modify at whichever of the     Cessna Models 402C and
 following that occurs later and repair or      414A airplanes, serial
 replace as necessary prior to further flight   number 414A0001 through
 after the inspection, unless already           414A0047 and 414A0049
 accomplished (no repetitive actions            through 414A0200.
 necessary):
    (i) Upon accumulating 8,500 hours time-in-
     service (TIS) on a wing spar; or.
    (ii) Within the next 500 hours TIS after
     the effective date of this AD or 12
     months after the effective date of this
     AD, whichever occurs first.
(2) Inspect and modify at whichever of the     Cessna Models 402C and
 following that occurs first and repair or      414A airplanes, serial
 replace as necessary prior to further flight   numbers 414A0201 through
 after the inspection, unless already           414A1212.
 accomplished (no repetitive actions
 necessary):
    (i) Upon accumulating 14,500 hours TIS on
     a wing spar; or.
    (ii) Within the next 500 hours TIS after
     the effective date of this AD or 12
     months after the effective date of this
     AD, whichever occurs first.
------------------------------------------------------------------------

    (e) Can I comply with this AD in any other way?
    (1) To use an alternative method of compliance or adjust the 
compliance time, follow the procedures in 14 CFR 39.19. Send these 
requests to the Manager, Wichita Aircraft Certification Office 
(ACO). For information on any already approved alternative methods 
of compliance, contact Paul Nguyen, Aerospace Engineer, FAA, Wichita 
Aircraft Certification Office, 1801 Airport Road, Mid-Continent 
Airport, Wichita, Kansas 67209; telephone: (316) 946-4125; 
facsimile: (316) 946-4107.
    (2) Alternative methods of compliance approved in accordance 
with AD 2000-23-01 and AD 99-11-13 are not approved as alternative 
methods of compliance with this AD.
    (f) How do I get copies of the documents referenced in this AD? 
You may get copies of

[[Page 26247]]

the documents referenced in this AD from the Cessna Aircraft 
Company, Product Support, P.O. Box 7706, Wichita, Kansas 67277; 
telephone: (316) 517-5800; facsimile: (316) 942-9006. You may view 
these documents at FAA, Central Region, Office of the Regional 
Counsel, 901 Locust, Room 506, Kansas City, Missouri 64106.
    (g) Does this AD action affect any existing AD actions? This 
amendment supersedes AD 2000-23-01, Amendment 39-11971.

    Issued in Kansas City, Missouri, on May 9, 2003.
James E. Jackson,
Acting Manager, Small Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 03-12111 Filed 5-14-03; 8:45 am]
BILLING CODE 4910-13-P