[Federal Register Volume 68, Number 174 (Tuesday, September 9, 2003)]
[Proposed Rules]
[Pages 53055-53058]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-22890]


=======================================================================
-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2001-NM-89-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 777-200 and -300 Series 
Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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

SUMMARY: This document proposes the adoption of a new airworthiness 
directive (AD) that is applicable to certain Boeing Model 777-200 and -
300 series airplanes. For all airplanes, this proposal would require 
installation of a placard that advises of weight limits for a certain 
electrical rack, accomplishment of a one-time inspection and records 
check to determine the amount of weight currently installed in that 
rack, and removal of equipment from that rack if necessary. For certain 
airplanes, this proposal also would require a one-time inspection of 
the clevis end of the vertical tie rods that support the center stowage 
bins to measure the exposed thread, installation of placards that 
advise of weight limits for certain other electrical racks, a one-time 
inspection and records check to determine the amount of weight 
currently installed in certain other electrical racks, corrective 
actions, and replacement of the vertical tie rods for the center 
stowage bins or electrical racks with new improved tie rods, as 
applicable. This action is necessary to prevent failure of the tie rods 
supporting certain electrical racks and the center stowage bins, which 
could cause the racks or stowage bins to fall onto passenger seats 
below during an emergency landing, impeding an emergency evacuation or 
injuring passengers. This action is intended to address the identified 
unsafe condition.

DATES: Comments must be received by October 24, 2003.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. 2001-NM-89-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. 2001-NM-89-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 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: Robert Kaufman, Aerospace Engineer, 
Cabin Safety and Environmental Systems Branch, ANM-150S, FAA, Seattle 
Aircraft Certification Office, 1601 Lind Avenue, SW., Renton, 
Washington 98055-4056; telephone (425) 917-6433; fax (425) 917-6590.

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 2001-NM-89-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. 2001-NM-89-AD, 1601 Lind Avenue, SW., Renton, Washington 
98055-4056.

Discussion

    The FAA has received a report indicating that, under certain 
conditions on Boeing Model 777-200 and -300 series airplanes, the 
vertical tie rods that attach the center stowage bins and electrical 
racks to the airplane structure can break. Multiple broken tie rods 
could allow the center stowage bins and electrical racks to fall onto 
the passenger seats below during an emergency landing. This condition, 
if not corrected, could impede an emergency evacuation or result in 
injury to passengers.

Explanation of Relevant Service Information

    We have reviewed and approved Boeing Service Bulletin 777-25-0144, 
Revision 1, dated January 10, 2002. For all airplanes, the service 
bulletin describes procedures for installing a placard showing weight 
limits for electrical rack E7. For certain airplanes, the service 
bulletin also describes procedures for additional actions, as follows:
    [sbull] A one-time inspection of the clevis end of the vertical tie 
rods that support

[[Page 53056]]

the center stowage bins to measure the exposed thread, and installation 
of a threaded sleeve if necessary.
    [sbull] Replacement of the vertical tie rods that support the 
center stowage bins with new improved tie rods (including replacing the 
existing tie rod with a new improved tie rod, torquing the jam nuts, 
and inspecting through the witness hole to make sure tie rod threads 
are visible).
    [sbull] Replacement of the vertical tie rods that support 
electrical racks E9, E11, and E13 (including replacing the existing tie 
rod with a new improved tie rod, replacing an existing tie rod clamp 
with a new improved tie rod clamp, inspecting certain electrical racks 
for ``free play,'' adjusting jam nuts if necessary, and inspecting 
through the witness hole to make sure tie rod threads are visible); as 
applicable.
    [sbull] Installation of placards showing weight limits for 
electrical racks E9, E11, E13, and E15; as applicable.

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 applicable actions 
specified in the service bulletin described previously, except as 
discussed below under the heading ``Differences Between Proposed Rule 
and Service Bulletin.'' The proposed AD would also require a one-time 
records review and inspection to verify that the weight of equipment 
currently installed in certain electrical racks meets specified weight 
limits. This records review and inspection would involve determining 
what extra equipment has been installed in the subject racks of the 
airplane, performing a detailed inspection to determine that the 
subject equipment is installed on the airplane, calculating the total 
weight of the installed equipment, and comparing that total to the 
weight limit specified on the placard. If the weight of the equipment 
exceeds the limit specified on the placard, equipment must be removed 
from the rack to meet the requirement.
    In developing an appropriate compliance time for this action, we 
considered not only the degree of urgency associated with addressing 
the subject unsafe condition, but the normal maintenance schedules for 
the majority of affected operators. In consideration of these factors, 
we have determined that 5 years represents an appropriate interval of 
time allowable wherein the proposed actions can be accomplished during 
scheduled maintenance intervals for the majority of affected operators. 
We find that this will ensure an acceptable level of safety.

Clarification of Inspection Types

    The service bulletin refers to an inspection of the clevis end of 
the vertical support tie rod to determine whether a threaded sleeve is 
required. We find that, since the inspection involves measuring the 
length of the exposed thread, the procedures for this inspection 
constitute a detailed inspection. This type of inspection is defined in 
Note 1 of this proposed AD.
    As part of the procedures for replacing the vertical support tie 
rods, the service bulletin specifies to inspect through the witness 
hole to ensure that tie rod threads are visible. We find that this 
inspection constitutes a general visual inspection. This type of 
inspection is defined in Note 2 of the proposed AD.

Differences Between Proposed AD and Service Bulletin

    Operators should note that, although the service bulletin specifies 
that the manufacturer may be contacted for disposition of certain 
conditions, this proposal would require the disposition of those 
conditions per a method approved by the FAA.
    Operators also should note that, as explained previously, this 
proposed AD would require a one-time records review and an inspection 
that are not included in the service bulletin. We find that these 
additional actions are necessary to ensure that the weight of equipment 
currently installed in certain electrical racks is within the limits 
specified in the placards to be installed per the service bulletin 
referenced in this proposed AD.

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 (AMOCs). Because we have now included this material in part 
39, only the office authorized to approve AMOCs is identified in each 
individual AD.

Change to Labor Rate Estimate

    We have reviewed the figures we have used over the past several 
years to calculate AD costs to operators. To account for various 
inflationary costs in the airline industry, we find it necessary to 
increase the labor rate used in these calculations from $60 per work 
hour to $65 per work hour. The cost impact information, below, reflects 
this increase in the specified hourly labor rate.

Cost Impact

    There are approximately 282 airplanes of the affected design in the 
worldwide fleet. The FAA estimates that 84 airplanes of U.S. registry 
would be affected by this proposed AD.
    For all airplanes: The records check and inspection to determine 
the weight currently installed in electrical rack E7 would take 
approximately 1 work hour per airplane to accomplish, at an average 
labor rate of $65 per work hour. Based on these figures, the cost 
impact of this proposed records check and inspection on U.S. operators 
is estimated to be $5,460, or $65 per airplane.
    For all airplanes: It would take approximately 1 work hour to 
accomplish the proposed installation of a placard specifying weight 
limits for electrical rack E7, at an average labor rate of $65 per work 
hour. Required parts would cost approximately $29. Based on these 
figures, the cost impact of this proposed placard installation on U.S. 
operators is estimated to be $7,896, or $94 per electrical rack.
    For airplanes subject to the records check and inspection to 
determine the weight currently installed in electrical rack E9, E11, 
E13, or E15: It would take approximately 1 work hour per electrical 
rack to accomplish, at an average labor rate of $65 per work hour. 
Based on these figures, the cost impact of this proposed records check 
and inspection is estimated to be as much as $260 per airplane.
    For airplanes subject to the installation of a placard specifying 
weight limits for electrical rack E9, E11, E13, or E15: It would take 
approximately 1 work hour per electrical rack to accomplish, at an 
average labor rate of $65 per work hour. Required parts would cost 
approximately $29 per electrical rack. Based on these figures, the cost 
impact of this proposed installation is estimated to be as much as $376 
per airplane.
    For airplanes subject to the inspection of the clevis end of the 
vertical support tie rod for the center stowage bin to measure the 
exposed thread: It would take as much as 3 work hours per airplane 
(0.25 work hour per tie rod, with up to 12 subject tie rods per 
airplane) at an average labor rate of $65 per work hour. Based on these 
figures, the cost impact of this proposed inspection is estimated to be 
as much as $195 per airplane.

[[Page 53057]]

    For airplanes subject to the replacement of the vertical tie rods 
that support the center stowage bins: It would take as much as 6 work 
hours per airplane (0.5 work hour per tie rod, with up to 12 subject 
tie rods per airplane) at an average labor rate of $65 per work hour. 
Required parts would cost as much as $3,020 per airplane. Based on 
these figures, this proposed replacement is estimated to be as much as 
$3,410 per airplane.
    For airplanes subject to the replacement of the vertical tie rods 
that support the electrical racks: It would take as much as 2 work 
hours per airplane (0.5 work hour per tie rod with up to 4 subject tie 
rods per airplane) at an average labor rate of $65 per work hour. 
Required parts would cost as much as $3,012 per airplane. Based on 
these figures, this proposed replacement is estimated to be as much as 
$3,142 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 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. The manufacturer may 
cover the cost of parts associated with certain actions in this 
proposed AD, subject to warranty conditions. Manufacturer warranty 
remedies may also be available for labor costs associated with certain 
actions in this proposed AD. As a result, the costs attributable to the 
proposed AD may be less than stated above.

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 2001-NM-89-AD.

    Applicability: Model 777-200 and -300 series airplanes; line 
numbers 002 through 151 inclusive, 153 through 157 inclusive, 159 
through 195 inclusive, 197 through 211 inclusive, 213 through 237 
inclusive, 239 through 241 inclusive, and 243 through 282 inclusive; 
certificated in any category.
    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent failure of the vertical tie rods that attach the 
center stowage bins and electrical racks to the airplane structure, 
which could cause the center stowage bins and electrical racks to 
fall onto passenger seats below, impeding an emergency evacuation or 
injuring passengers, accomplish the following:

Inspection To Determine Weight and Placard Installation

    (a) For airplanes in the groups listed in the table under 
paragraph 3., Part 1, paragraph E., of the Accomplishment 
Instructions of Boeing Service Bulletin 777-25-0144, Revision 1, 
dated January 10, 2002: Within 5 years after the effective date of 
this AD, do the applicable actions in paragraphs (a)(1) and (a)(2) 
of this AD.
    (1) Install placards that show weight limits for electrical 
racks E7, E11, and E15; as applicable; per the Accomplishment 
Instructions of the service bulletin.
    (2) For each electrical rack on which a placard was installed 
per paragraph (a)(1) of this AD: Perform a one-time inspection and 
records check to determine the weight of equipment installed in that 
electrical rack. This records review and inspection must include 
determining what extra equipment has been installed, if any, in the 
subject rack of the airplane, performing a detailed inspection to 
determine that this equipment is installed on the airplane, 
calculating the total weight of the installed equipment, and 
comparing that total to the weight limit specified on the placard 
installed per paragraph (a)(1) of this AD. If the weight is outside 
the limits specified in the placard to be installed per the service 
bulletin, before further flight, remove equipment from the rack to 
meet the weight limit specified in the placard.

    Note 1: For the purposes of this AD, a detailed inspection is 
defined as: ``An intensive visual examination of a specific 
structural area, system, installation, or assembly to detect damage, 
failure, or irregularity. Available lighting is normally 
supplemented with a direct source of good lighting at intensity 
deemed appropriate by the inspector. Inspection aids such as mirror, 
magnifying lenses, etc., may be used. Surface cleaning and elaborate 
access procedures may be required.''

Inspection To Measure Exposed Thread

    (b) For airplanes in the groups listed in the table under 
paragraph 3., Part 1, paragraph C., of the Accomplishment 
Instructions of Boeing Service Bulletin 777-25-0144, Revision 1, 
dated January 10, 2002: Within 5 years after the effective date of 
this AD, perform a detailed inspection of the clevis end of the 
vertical support tie rod for the center stowage bin to measure the 
exposed thread, per the Accomplishment Instructions of the service 
bulletin. If the measurement of the exposed thread is outside the 
limits specified in Figure 2 of the service bulletin, before further 
flight, perform all corrective actions specified in steps 2 through 
15 inclusive of Figure 2 of the service bulletin. Perform the 
corrective actions per the Accomplishment Instructions of the 
service bulletin, except as provided by paragraph (e) of this AD.

Replacement of Tie Rods for Center Stowage Bin

    (c) For airplanes in Group 21, as listed in the Airplane Group 
column of the table under paragraph 3., Part 1, paragraph D., of the 
Accomplishment Instructions of Boeing Service Bulletin 777-25-0144, 
Revision 1, dated January 10, 2002: Within 5 years after the 
effective date of this AD, replace the vertical support tie rods for 
the center stowage bin with new improved tie rods (including 
replacing the existing tie rod with a new improved tie rod, torquing 
the jam nuts, performing a general visual inspection through the 
witness hole to make sure tie rod threads are visible, and making 
any applicable adjustment of the clevis) by doing all actions 
specified in steps 1 through 8 of Figure 3 of the service bulletin. 
Do these actions per the Accomplishment Instructions of the service 
bulletin, except as provided by paragraph (e) of this AD. Any 
required adjustment of the clevis must be done before further 
flight.

    Note 2:
    For the purposes of this AD, a general visual inspection is 
defined as: ``A visual examination of an interior or exterior

[[Page 53058]]

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.''

Inspection To Determine Weight, Tie Rod Replacement, and Placard 
Installation

    (d) For airplanes in the groups listed in the table under 
paragraph 3., Part 1, paragraph F., of the Accomplishment 
Instructions of Boeing Service Bulletin 777-25-0144, Revision 1, 
dated January 10, 2002: Do the actions in paragraphs (d)(1), (d)(2), 
and (d)(3) of this AD.
    (1) Within 5 years after the effective date of this AD, replace 
the vertical support tie rods for electrical racks E9, E11, and E13 
(including replacing the existing tie rods with new improved tie 
rods, replacing an existing tie rod clamp with a new improved tie 
rod clamp, performing a free-play inspection of certain electrical 
racks, adjusting jam nuts as applicable, performing a general visual 
inspection through the witness hole to make sure tie rod threads are 
visible, and making any applicable adjustment to ensure tie rod 
threads are visible) by doing all actions specified in Figures 5, 6, 
7, and 9 of the service bulletin; as applicable. Do these actions 
per the Accomplishment Instructions of the service bulletin. Any 
required adjustment must be done before further flight.
    (2) Before further flight after accomplishing paragraph (d)(1) 
of this AD, install placards that show weight limits for electrical 
racks E9, E11, and E13; as applicable; per the Accomplishment 
Instructions of the service bulletin.
    (3) For each electrical rack on which a placard was installed 
per paragraph (d)(2) of this AD: Before further flight after 
accomplishing paragraphs (d)(1) and (d)(2) of this AD, perform a 
one-time inspection and records check to determine the weight of 
equipment installed in that electrical rack. This records review and 
inspection must include determining what, if any, extra equipment 
has been installed in the subject racks of the airplane, performing 
a detailed inspection to determine that this equipment is installed 
on the airplane, calculating the total weight of the installed 
equipment, and comparing that total to the weight limit specified on 
the placard installed per paragraph (d)(2) of this AD. If the weight 
is outside the limits specified in the placard, before further 
flight, remove equipment from the rack to meet the weight limit 
specified in the placard.

Exception to Service Bulletin Instructions

    (e) Where the service bulletin specifies to contact Boeing for 
appropriate action, before further flight, repair per a method 
approved by the Manager, Seattle Aircraft Certification Office 
(ACO), FAA; or per data meeting the type certification basis of the 
airplane approved by a Boeing Company Designated Engineering 
Representative who has been authorized by the Manager, Seattle ACO, 
to make such findings. For a repair method to be approved, the 
approval must specifically reference this AD.

Alternative Methods of Compliance

    (f) In accordance with 14 CFR 39.19, the Manager, Seattle ACO, 
is authorized to approve alternative methods of compliance for this 
AD.


    Issued in Renton, Washington, on September 2, 2003.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 03-22890 Filed 9-8-03; 8:45 am]
BILLING CODE 4910-13-P