[Federal Register Volume 68, Number 238 (Thursday, December 11, 2003)]
[Proposed Rules]
[Pages 69053-69055]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 03-30675]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2003-16646]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757-200 Series 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 Boeing Model 757-200 
series airplanes. This proposal would require repetitive inspections of 
the intercostals that back up the door stops and hinges at door 2 left 
and door 2 right for cracks, and corrective action, if necessary. This 
proposal also would provide for an optional terminating action for the 
repetitive inspections. This action is necessary to prevent fatigue 
cracks from propagating in the intercostals, which could lead to the 
loss of a door in flight and subsequent rapid decompression. This 
action is intended to address the identified unsafe condition.

DATES: Comments must be received by January 26, 2004.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. FAA-2003-16646, 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. FAA-2003-16646'' 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: Mark Freisthler, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
917-6426, 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 FAA-2003-16646.'' 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. FAA-2003-16646, 1601 Lind Avenue, SW., Renton, Washington 
98055-4056.

Discussion

    The FAA has received reports of cracking in the intercostals that 
provide structural support for the door stops and hinges at door 2 left 
and door 2 right for Boeing Model 757-200 series airplanes. The cause 
of the cracks is fatigue caused by the cyclic pressurization of the 
cabin. If left undetected, the fatigue cracks will continue to 
propagate. This condition, if not corrected, could result in the loss 
of a door in flight and subsequent rapid decompression.

Explanation of Relevant Service Information

    The FAA has reviewed and approved Boeing Special Attention Service 
Bulletin 757-53-0086, dated March 14, 2002. The service bulletin 
describes the following procedures:
    [sbull] Performing an initial detailed inspection for cracks in the 
intercostals that back up the door stops and hinges at door 2 left and 
door 2 right;
    [sbull] For cases of no crack findings, performing repetitive dye 
penetrant or eddy current inspections for cracks in the intercostals 
that back up the door stops and hinges at door 2 left and door 2 right;

[[Page 69054]]

    [sbull] For cases of crack findings or for an optional terminating 
action, installing a preventative modification of the intercostal (i.e. 
cut off the integral clips at the bend relief on the forward end of the 
intercostals and install new, separate clips to attach the intercostals 
to the frame at station 660); and/or replacing the intercostal with a 
new improved intercostal. Accomplishment of the preventative 
modification or replacement would eliminate the need for the repetitive 
inspections.
    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 actions specified in 
the service bulletin described previously.
    The FAA is not proposing to mandate the preventative modification 
of each intercostal or the replacement of each intercostal for several 
reasons:
    1. Accessing the intercostals for inspection at the intervals is 
easily accomplished.
    2. The cracks at the intercostals are easily detected by means of a 
detailed inspection.
    3. The cracking of the intercostals could result in compromised 
structural integrity of the door stops; however, the detailed 
inspections will preclude the potential occurrence of continued 
cracking.

Cost Impact

    There are approximately 95 airplanes of the affected design in the 
worldwide fleet. The FAA estimates that 55 airplanes of U.S. registry 
would be affected by this proposed AD.
    We estimate that it would take approximately 8 work hours per 
airplane to accomplish the proposed inspection, and that the average 
labor rate is $65 per work hour. Based on these figures, the cost 
impact of the inspection on U.S. operators is estimated to be $28,600, 
or $520 per airplane, per inspection cycle.
    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 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 optional preventative modification terminating action, if done, 
would take approximately 50 work hours per airplane at an average labor 
rate of $65 per work hour. Based on these figures, we estimate the cost 
of this optional terminating action to be $3,250 per airplane.
    Parts for the optional replacement terminating action would cost 
approximately $692 for each Top Kit--Door Stop 1 Intercostal (L/H or R/
H) and $4,581 for each Top Kit--Intercostal Replacement (L/H or R/H).

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 FAA-2003-16646.

    Applicability: Model 757-200 series airplanes, line numbers 1 
through 95 inclusive; certificated in any category.
    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent fatigue cracks from propagating in the intercostals, 
which could lead to the loss of a door in flight and subsequent 
rapid decompression, accomplish the following:

Service Bulletin References

    (a) The term ``service bulletin,'' as used in this AD, means the 
Accomplishment Instructions of Boeing Special Attention Service 
Bulletin 757-53-0086, dated March 14, 2002.

Initial Inspection

    (b) Prior to the accumulation of 12,000 total flight cycles, or 
within 3,000 flight cycles after the effective date of this AD, 
whichever occurs later: Perform a detailed inspection for cracks of 
the intercostals that back up the door stops and hinges at door 2 
left and door 2 right, per Part I of the service bulletin.

No Crack Findings: Repetitive Inspections

    (c) If no crack is found during the inspection required by 
paragraph (b) of this AD, before further flight, do a dye penetrant 
or eddy current inspection for cracks of the intercostals that back 
up the door stops and hinges at door 2 left and door 2 right, per 
Part I of the service bulletin. Repeat thereafter at intervals not 
to exceed 3,000 flight cycles, until the preventative modification 
specified in paragraph (g) of this AD or the replacement specified 
in paragraph (h) of this AD has been accomplished.

Crack Findings: Modification/Replacement

    (d) If, during the inspections required by paragraph (b) and/or 
(c) of this AD, any intercostal for door stop 1, 4, 5, 6, upper 
hinge, or lower hinge has cracks, but not beyond the aft edge of the 
bend relief radius: Before further flight, do the preventative 
modification specified in paragraph (g) of this AD or the 
replacement specified in paragraph (h) of this AD.
    (e) If, during the inspections required by paragraph (b) and/or 
(c) of this AD, any intercostal for door stop 2 or 3 has cracks: 
Before further flight, do the replacement specified in paragraph (h) 
of this AD.
    (f) If, during the inspections required by paragraph (b) and/or 
(c) of this AD, any intercostal has cracks that extend beyond the 
aft edge of the bend relief radius: Before further flight, do the 
replacement specified in paragraph (h) of this AD.

Terminating Actions

    (g) Do the preventative modification on the intercostal per Part 
II of the service bulletin. Accomplishment of the preventative 
modification on an intercostal per Part II of the service bulletin 
constitutes terminating action for the repetitive inspection

[[Page 69055]]

requirements of this AD for the modified intercostal only.
    (h) Replace the intercostal with a new improved intercostal per 
Part III of the service bulletin. Accomplishment of the replacement 
of an intercostal with a new improved intercostal per Part III of 
the service bulletin constitutes terminating action for the 
repetitive inspection requirements of this AD for the replaced 
intercostal only.

Alternative Methods of Compliance

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

    Issued in Renton, Washington, on December 4, 2003.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 03-30675 Filed 12-10-03; 8:45 am]
BILLING CODE 4910-13-P