[Federal Register Volume 69, Number 89 (Friday, May 7, 2004)]
[Rules and Regulations]
[Pages 25481-25483]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-10240]



[[Page 25481]]

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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2004-NM-44-AD; Amendment 39-13622; AD 2004-09-32]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757-200 Series Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that 
is applicable to certain Boeing Model 757-200 series airplanes. This 
action requires initial and repetitive inspections of the fuselage skin 
and bear strap at the forward, upper corner of the L1 entry door cutout 
for cracking, and repair if necessary. This action also provides an 
optional terminating action for the repetitive inspections. This action 
is necessary to detect and correct cracking of the fuselage skin and 
bear strap at the forward, upper corner of the L1 entry door cutout, 
which could result in reduced structural integrity of the L1 entry door 
and consequent rapid decompression of the airplane. This action is 
intended to address the identified unsafe condition.

DATES: Effective May 24, 2004.
    The incorporation by reference of a certain publication listed in 
the regulations is approved by the Director of the Federal Register as 
of May 24, 2004.
    Comments for inclusion in the Rules Docket must be received on or 
before July 6, 2004.

ADDRESSES: Submit comments in triplicate to the Federal Aviation 
Administration (FAA), Transport Airplane Directorate, ANM-114, 
Attention: Rules Docket No. 2004-NM-44-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. 2004-NM-44-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 this AD may be obtained from 
Boeing Commercial Airplanes, 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; or at the 
National Archives and Records Administration (NARA). For information on 
the availability of this material at NARA, call (202) 741-6030, or go 
to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.

FOR FURTHER INFORMATION CONTACT: Dennis Stremick, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
917-6450; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION: The FAA has received reports of cracking in 
the fuselage skin and bear strap at the forward, upper corner of the L1 
entry door cutout on Boeing Model 757-200 series airplanes. A 6.0-inch 
crack was found on an airplane having 27,071 total flight cycles. A 
1.4-inch crack was also found on an airplane having 29,340 total flight 
cycles, and a 1.7-inch crack was found in the bear strap on an airplane 
having 26,686 total flight cycles. These cracks were found during 
visual inspections during maintenance and were attributed to fatigue 
caused by pressurization cycles.
    This condition, if not corrected, could result in reduced 
structural integrity of the L1 entry door and consequent rapid 
decompression of the airplane.

Explanation of Relevant Service Information

    The FAA has reviewed and approved Boeing Special Attention Service 
Bulletin 757-53-0089, dated March 18, 2004. The service bulletin 
describes procedures for performing initial and repetitive high 
frequency eddy current (HFEC) and low frequency eddy current (LFEC) 
inspections for cracking of the fuselage skin around the adjacent 
fasteners, along the edge of the skin and bear strap, and the bear 
strap around the fasteners adjacent at the forward, upper corner of the 
L1 entry door cutout; as applicable. The service bulletin specifies to 
contact Boeing for repair instructions for any cracks found during the 
HFEC and LFEC inspections.
    The service bulletin also describes procedures for accomplishing a 
preventative modification, which eliminates the need for the repetitive 
inspections. The modification includes performing a general visual 
inspection to ensure that the fastener edge margins adjacent to the 
forward, upper corner of the L1 entry door cutout are 0.5 inch or 
greater; and related investigative/corrective actions, if necessary. 
Related investigative actions include repeating the general visual 
inspection at specified intervals if the margins are less than 0.50 
inch or removing the fasteners and performing an HFEC inspection on the 
holes in the fuselage skin and bear strap if the margins are equal to 
or greater than 0.50 inch. The corrective actions include coldworking 
the fastener holes and installing over-sized fasteners if no crack is 
found during the HFEC inspection or contacting Boeing for repair 
instructions if any crack is found during either the general visual or 
the HFEC inspection. Accomplishment of the actions specified in the 
service bulletin is intended to adequately address the identified 
unsafe condition.

Explanation of the Requirements of the Rule

    Since an unsafe condition has been identified that is likely to 
exist or develop on other airplanes of the same type design registered 
in the United States, this AD requires accomplishment of the actions 
specified in the service bulletin described previously, except as 
discussed below. This AD also provides for optional terminating action 
for the repetitive inspections.

Differences Between This AD and the Service Bulletin

    Although the service bulletin specifies that operators contact the 
manufacturer for disposition of certain repair conditions, this AD 
requires operators to repair those conditions per a method approved by 
the 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 FAA to make such 
findings.

Determination of Rule's Effective Date

    Since a situation exists that requires the immediate adoption of 
this regulation, it is found that notice and opportunity for prior 
public comment hereon are impracticable, and that good cause exists for 
making this amendment effective in less than 30 days.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting flight safety and, thus, was not preceded by 
notice and an opportunity for public comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by

[[Page 25482]]

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 under the caption ADDRESSES. All 
communications received on or before the closing date for comments will 
be considered, and this rule may be amended in light of the comments 
received. Factual information that supports the commenter's ideas and 
suggestions is extremely helpful in evaluating the effectiveness of the 
AD action and determining whether additional rulemaking action would be 
needed.
    Submit comments using the following format:
     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.
     For each issue, state what specific change to the AD is 
being requested.
     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 rule that might 
suggest a need to modify the 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 that 
summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this rule must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket Number 2004-NM-44-AD.'' The postcard will be date stamped and 
returned to the commenter.

Regulatory Impact

    The regulations adopted herein will 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 final rule does not have federalism 
implications under Executive Order 13132.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and that it is not a ``significant regulatory 
action'' under Executive Order 12866. It has been determined further 
that this action involves an emergency regulation under DOT Regulatory 
Policies and Procedures (44 FR 11034, February 26, 1979). If it is 
determined that this emergency regulation otherwise would be 
significant under DOT Regulatory Policies and Procedures, a final 
regulatory evaluation will be prepared and placed in the Rules Docket. 
A copy of it, if filed, may be obtained from the Rules Docket at the 
location provided under the caption ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

0
Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends 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. Section 39.13 is amended by adding the following new airworthiness 
directive:

2004-09-32 Boeing: Amendment 39-13622. Docket 2004-NM-44-AD.

    Applicability: Model 757-200 series airplanes, line numbers 1 
through 90 inclusive; certificated in any category.
    Compliance: Required as indicated, unless accomplished 
previously.
    To detect and correct cracking of the fuselage skin and bear 
strap at the forward, upper corner of the L1 entry door cutout, 
which could result in reduced structural integrity of the L1 entry 
door and consequent rapid decompression of the airplane; accomplish 
the following:

Initial Inspections

    (a) Within 500 flight cycles after the effective date of this 
AD, or within 90 days after the effective date of this AD, whichever 
occurs later: Do the inspections of the forward, upper corner of the 
L1 entry door cutout specified in paragraphs (a)(1), (a)(2), and 
(a)(3) of this AD, per Part 1 of the Work Instructions of Boeing 
Special Attention Service Bulletin 757-53-0089, dated March 18, 
2004.
    (1) Do a high frequency eddy current (HFEC) inspection for 
cracking of the fuselage skin around the adjacent fasteners.
    (2) Do an HFEC inspection for cracking along the edge of the 
skin and bear strap.
    (3) Do a low frequency eddy current (LFEC) inspection of the 
bear strap.

No Crack Detected: Repetitive Inspections

    (b) If no crack is detected during any inspection required by 
paragraph (a) of this AD: Repeat the inspections required by 
paragraph (a) of this AD at intervals not to exceed 1,400 flight 
cycles.

Any Crack Detected: Repair

    (c) If any crack is detected during any inspection required by 
this AD, and 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 (DER) 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.

Optional Terminating Modification

    (d) As an alternative to accomplishing the inspections required 
by paragraphs (a) and (b) of this AD, do the optional preventative 
modification of the forward, upper corner of the L1 entry door 
cutout, and do all applicable related investigative/corrective 
actions by accomplishing all the actions specified in Part 2 of the 
Work Instructions of Boeing Special Attention Service Bulletin 757-
53-0089, dated March 18, 2004. Accomplishment of the modification 
constitutes terminating action for the repetitive inspection 
requirements of this AD.

Alternative Methods of Compliance

    (e)(1) In accordance with 14 CFR 39.19, the Manager, Seattle 
ACO, FAA, is authorized to approve alternative methods of compliance 
(AMOCs) for this AD.
    (2) An AMOC that provides an acceptable level of safety may be 
used for any repair required by this AD, if it is approved by a 
Boeing Company DER who has been authorized by the Manager, Seattle 
ACO, to make such findings.

Incorporation by Reference

    (f) Unless otherwise specified in this AD, the actions shall be 
done in accordance with Boeing Special Attention Service Bulletin 
757-53-0089, dated March 18, 2004. This incorporation by reference 
was approved by the Director of the Federal Register in accordance 
with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from 
Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 
98124-2207. Copies may be inspected at the FAA, Transport Airplane 
Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the 
National Archives and Records Administration (NARA). For information 
on the availability of this material at NARA, call (202) 741-6030, 
or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.

Effective Date

    (g) This amendment becomes effective on May 24, 2004.


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    Issued in Renton, Washington, on April 28, 2004.
Kevin M. Mullin,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 04-10240 Filed 5-6-04; 8:45 am]
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