[Federal Register Volume 68, Number 111 (Tuesday, June 10, 2003)]
[Proposed Rules]
[Pages 34557-34560]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-14525]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-NM-164-AD]
RIN 2120-AA64


Airworthiness Directives; McDonnell Douglas Model DC-10-10, -10F, 
-15, -30, -30F (KC-10A and KDC-10), -40, and -40F Airplanes; and Model 
MD-10-10F and -30F 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 certain McDonnell Douglas Model 
DC-10-10, -10F, -15, -30, -30F (KC-10A and KDC-10), -40, and -40F 
airplanes; and certain Model MD-10-10F and -30F airplanes. This 
proposal would require inspections for cracking and corrosion of the 
bolt assemblies and bushings on the hinge fittings of the inboard and 
outboard flaps of the left and right wings, and follow-on and 
corrective actions. This action is necessary to prevent failure of the 
bolt and bushing that attach the hinge fitting to the flap, which could 
result in loss of the flap and consequent reduced controllability of 
the airplane. This action is intended to address the identified unsafe 
condition.

DATES: Comments must be received by July 25, 2003.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. 2002-NM-164-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. Comments may be submitted via fax to (425) 227-1232. 
Comments may also be sent via the Internet using the following address: 
[email protected]. Comments sent via fax or the Internet must 
contain ``Docket No. 2002-NM-164-AD'' in the subject line and need not 
be submitted in triplicate. Comments sent via the Internet as attached 
electronic files must be formatted in Microsoft Word 97 or 2000 or 
ASCII text.
    The service information referenced in the proposed rule may be 
obtained from Boeing Commercial Aircraft Group, Long Beach Division, 
3855 Lakewood Boulevard, Long Beach, California 90846, Attention: Data 
and Service Management, Dept. C1-L5A (D800-0024). This information may 
be examined at the FAA, Transport Airplane Directorate, 1601 Lind 
Avenue, SW., Renton, Washington; or at the FAA, Los Angeles Aircraft 
Certification Office, 3960 Paramount Boulevard, Lakewood, California.

FOR FURTHER INFORMATION CONTACT: Ron Atmur, Aerospace Engineer, 
Airframe Branch, ANM-120L, FAA, Los Angeles Aircraft Certification 
Office, 3960 Paramount Boulevard, Lakewood, California 90712-4137; 
telephone (562) 627-5224; fax (562) 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 action may be changed in 
light of the comments received.
    Submit comments using the following format:
    [sbull] Organize comments issue-by-issue. For example, discuss a 
request to change the compliance time and a request to change the 
service bulletin reference as two separate issues.
    [sbull] For each issue, state what specific change to the proposed 
AD is being requested.
    [sbull] Include justification (e.g., reasons or data) for each 
request.
    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 action must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2002-NM-164-AD.'' The postcard will be date stamped 
and returned to the commenter.

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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. 2002-NM-164-AD, 1601 Lind Avenue, SW., Renton, Washington 
98055-4056.

Discussion

    The FAA has received reports indicating failure of the bolts and 
bushings that attach the hinge fittings to the inboard and outboard 
flaps on certain McDonnell Douglas Model DC-10 airplanes. In two cases, 
the failure was in the radius area of the bolt head; in one case, the 
failure was in the threaded portion of the bolt; in another case, both 
the head and threaded end had failed. Additional failures occurred in 
the lubrication hole in the middle of the shank. The cause of these 
failures has been attributed to hydrogen embrittlement. Subsequent to 
installation of new hinge bolts with improved corrosion protection, the 
corrosion and failures continued to occur.
    In addition, multiple reports have been received from operators of 
corrosion on the bolt and bushing. Investigation revealed that a lack 
of lubrication caused the initiation of corrosion, and the corrosion 
led to the stress corrosion failure of the bolt and bushing. The bolt 
and bushing provide a fail-safe mechanism at the flap hinge pivot 
point. Such conditions, if not corrected, could result in failure of 
the bolts and bushings that attach the hinge fitting to the flap, which 
could result in loss of the flap and consequent reduced controllability 
of the airplane.

Explanation of Relevant Service Information

    We have reviewed and approved Boeing Alert Service Bulletin DC10-
57A148, Revision 01, dated August 13, 2002, which describes procedures 
for magnetic particle and visual inspections for cracking and corrosion 
of the outboard pivot bolt assemblies and bushings on the hinge 
fittings of the inboard flaps of the left and right wings. The service 
bulletin also describes procedures for follow-on actions and repair of 
any discrepancy found, as follows:
    [sbull] Condition 1--No cracking or corrosion found: Option 1--
Reinstall each existing bushing, replace each existing pivot bolt 
assembly with a new assembly made from corrosion-resistant steel, and 
lubricate the assembly. Option 2--Reinstall each existing bushing and 
pivot bolt assembly, lubricate the assembly, repeat the lubrication at 
the intervals specified, and do repetitive ultrasonic inspections of 
each assembly for cracking at the intervals specified.
    [sbull] Condition 2--Corrosion on bolt and/or bushing: Option 1--
Replace each affected bushing with a new equivalent part, replace each 
affected pivot bolt assembly with a new assembly made from corrosion-
resistant steel, and lubricate the assembly. Option 2--Repair the 
existing bushing and pivot bolt assembly and reinstall them, lubricate 
the assembly, repeat the lubrication at the intervals specified, and do 
repetitive ultrasonic inspections of each assembly for cracking at the 
intervals specified.
    [sbull] Condition 3--Cracks in bolt and/or bushing: Option 1--
Replace each affected bushing with a new equivalent part, replace each 
affected pivot bolt assembly with a new assembly made from corrosion-
resistant steel, and lubricate the assembly. Option 2--Replace each 
affected bushing and pivot bolt assembly with new equivalent parts, 
lubricate the assembly, repeat the lubrication at the intervals 
specified, and do repetitive ultrasonic inspections of each assembly 
for cracking at the intervals specified.
    We also have reviewed and approved Boeing Alert Service Bulletin 
DC10-57A117, Revision 01, dated July 23, 2002, which describes 
procedures for magnetic particle and visual inspections for cracking 
and corrosion of the pivot bolt assemblies on the hinge fitting of the 
outboard flaps of the left and right wings. The service bulletin also 
describes procedures for follow-on actions and repair of any 
discrepancy found, as follows:
    [sbull] Condition 1--No cracking or corrosion found: Option 1--
Replace each existing pivot bolt assembly with a new assembly made from 
multi-phase material, and lubricate the assembly. Option 2--Reinstall 
each pivot bolt assembly, lubricate the assembly, repeat the 
lubrication at the intervals specified, and do repetitive ultrasonic 
inspections of each assembly for cracking at the intervals specified.
    [sbull] Condition 2--Corrosion on bolt: Option 1--Replace each 
affected pivot bolt assembly with a new assembly made from multi-phase 
material, and lubricate the assembly. Option 2--Repair the existing 
pivot bolt assembly and reinstall, lubricate the assembly, repeat the 
lubrication at the intervals specified, and do repetitive ultrasonic 
inspections of each assembly for cracking at the intervals specified.
    [sbull] Condition 3--Cracks in bolt: Option 1--Replace each 
affected pivot bolt assembly with a new assembly made from multi-phase 
material, and lubricate the assembly. Option 2--Replace each affected 
pivot bolt assembly with a new equivalent part, lubricate the assembly, 
repeat the lubrication at the intervals specified, and do repetitive 
ultrasonic inspections of each assembly for cracking at the intervals 
specified.
    Accomplishment of the actions specified in the service bulletins 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 actions specified in 
the service bulletin described previously.

Changes to 14 CFR part 39/Effect on the Proposed AD

    On July 10, 2002, the FAA issued a new version of 14 CFR part 39 
(67 FR 47997, July 22, 2002), which governs the FAA's airworthiness 
directives system. The regulation now includes material that relates to 
altered products, special flight permits, and alternative methods of 
compliance. Because we have now included this material in part 39, we 
no longer need to include it in each individual AD.

Cost Impact

    There are approximately 402 airplanes of the affected design in the 
worldwide fleet. The FAA estimates that 297 airplanes of U.S. registry 
would be affected by this proposed AD.
    It would take approximately 1 work hour per airplane to accomplish 
the proposed initial inspections, at an average labor rate of $60 per 
work hour. Based on these figures, the cost impact of the proposed 
inspections on U.S. operators is estimated to be $17,820, or $60 per 
airplane.
    It would take approximately 2 work hours per flap, to accomplish 
the proposed replacement, at an average labor rate of $60 per work 
hour. Required parts would cost approximately $2,982 for the outboard 
flap, and $2,825 for the inboard flap. Based on these figures, the cost 
impact of the proposed replacement on U.S. operators is estimated to be 
$1,795,959, or $6,047 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 proposed AD were not adopted. The

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cost impact figures discussed in AD rulemaking actions represent only 
the time necessary to perform the specific actions actually required by 
the AD. These figures typically do not include incidental costs, such 
as the time required to gain access and close up, planning time, or 
time necessitated by other administrative actions.

Regulatory Impact

    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 proposal would not have federalism implications 
under Executive Order 13132.
    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 2002-NM-164-AD.

    Applicability: Model DC-10-10, -10F, -15, -30, -30F (KC-10A and 
KDC-10), -40, and -40F airplanes; and Model MD-10-10F and -30F 
airplanes; certificated in any category.
    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent failure of the bolts and bushings that attach the 
hinge fitting to the flap, which could result in loss of the flap 
and consequent reduced controllability of the airplane, accomplish 
the following:

Initial General Visual and Magnetic Particle Inspections

    (a) Within 6 months after the effective date of this AD: Do 
initial general visual and magnetic particle inspections for 
cracking and corrosion of the pivot bolt assemblies and bushings on 
the hinge fittings of the inboard and outboard flaps of the left and 
right wings, per Boeing Alert Service Bulletin DC10-57A148, Revision 
01, dated August 13, 2002; and Boeing Alert Service Bulletin DC10-
57A117, Revision 01, dated July 23, 2002; as applicable. Before 
further flight, do the applicable follow-on and corrective actions 
required by paragraphs (a)(1), (a)(2), and (a)(3) of this AD.

    Note 1: 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 from within 
touching distance unless otherwise specified. A mirror may be 
necessary to enhance visual access to all exposed surfaces in the 
inspection area. This level of inspection is made under normally 
available lighting conditions such as daylight, hangar lighting, 
flashlight, or droplight 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.''

Follow-on and Corrective Actions

    (1) If no cracking or corrosion is found: Before further flight, 
do the actions specified in either (a)(1)(i) or (a)(1)(ii) of this 
AD per Condition 1 of the Work Instructions of the applicable 
service bulletin.
    (i) Do the actions specified in Option 1 of Condition 1 per the 
applicable service bulletin. The actions include (for the inboard 
flaps) reinstalling each existing bushing, replacing each existing 
pivot bolt assembly with a new assembly made from corrosion-
resistant steel, and lubricating the assembly; (for the outboard 
flaps) replacing each existing pivot bolt assembly with a new 
assembly made from multi-phase material, and lubricating the 
assembly.
    (ii) Do the actions specified in Option 2 of Condition 1 per the 
applicable service bulletin. The actions include (for the inboard 
flaps) reinstalling the existing bushing and pivot bolt assembly, 
lubricating the assembly, repeating the lubrication at the intervals 
specified, and doing repetitive ultrasonic inspections of the 
assembly for cracking at the intervals specified; (for the outboard 
flaps) reinstalling the pivot bolt assembly, lubricating the 
assembly, repeating the lubrication at the intervals specified, and 
doing repetitive ultrasonic inspections of the assembly for cracking 
at the intervals specified. Accomplishment of paragraph (a)(1)(i) 
terminates the requirements of this paragraph.
    (2) If corrosion is found: Before further flight, do the actions 
specified in either (a)(2)(i) or (a)(2)(ii) of this AD per Condition 
2 of the Work Instructions of the applicable service bulletin.
    (i) Do the actions specified in Option 1 of Condition 2 per the 
applicable service bulletin. The actions include (for the inboard 
flaps) replacing the affected bushing with a new equivalent part, 
replacing the affected pivot bolt assembly with a new assembly made 
from corrosion-resistant steel, and lubricating each assembly; (for 
the outboard flaps) replacing the affected pivot bolt assembly with 
a new assembly made from multi-phase material, and lubricating each 
assembly.
    (ii) Do the actions specified in Option 2 of Condition 2 per the 
applicable service bulletin. The actions include (for the inboard 
flaps) repairing and re-installing the existing bushing and affected 
pivot bolt assembly, lubricating each assembly, repeating the 
lubrication at the intervals specified, and doing repetitive 
ultrasonic inspections of the assembly for cracking at the intervals 
specified; (for the outboard flaps) repairing and installing the 
existing pivot bolt assembly, lubricating each assembly, repeating 
the lubrication at the intervals specified, and doing repetitive 
ultrasonic inspections of the assembly for cracking, at the 
intervals specified. Do the inspections until paragraph (a)(2)(i) of 
this AD has been done.
    (3) If cracking is found: Before further flight, do the actions 
specified in either paragraph (a)(3)(i) or (a)(3)(ii) of this AD per 
Condition 3 of the Work Instructions of the applicable service 
bulletin.
    (i) Do the actions specified in Option 1 of Condition 3 per the 
applicable service bulletin. The actions include (for the inboard 
flaps) replacing the affected bushing with a new equivalent part, 
replacing the affected pivot bolt assembly with a new assembly made 
from corrosion-resistant steel, and lubricating each assembly; (for 
the outboard flaps) replacing the affected pivot bolt assembly with 
a new assembly made from multi-phase material, and lubricating each 
assembly.
    (ii) Do the actions specified in Option 2 of Condition 3 per the 
applicable service bulletin. The actions include (for the inboard 
flaps) replacing the affected bushing and pivot bolt assembly with 
new equivalent parts, lubricating each assembly, repeating the 
lubrication at the intervals specified, and doing repetitive 
ultrasonic inspections of the assembly for cracking at the intervals 
specified; (for the outboard flaps) replacing the affected pivot 
bolt assembly with a new equivalent part, lubricating each assembly, 
repeating the lubrication at the intervals specified, and doing 
repetitive ultrasonic inspections of the assembly for cracking at 
the intervals specified. Do the inspections until paragraph 
(a)(3)(i) of this AD has been done.

Credit for Actions Done per Previous Issue of Service Bulletins

    (b) Accomplishment of the specified actions before the effective 
date of this AD per Boeing Alert Service Bulletin DC10-57A148, dated 
June 14, 2002; or Boeing Alert Service Bulletin DC10-57A117, dated 
February 11, 1991; is considered acceptable

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for compliance with the applicable requirements of paragraph (a) of 
this AD.

Alternative Methods of Compliance

    (c) In accordance with 14 CFR 39.19, the Manager, Los Angeles 
Aircraft Certification Office, FAA, is authorized to approve 
alternative methods of compliance for this AD.

    Issued in Renton, Washington, on June 4, 2003.
Ali Bahrami,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 03-14525 Filed 6-9-03; 8:45 am]
BILLING CODE 4910-13-P