[Federal Register Volume 69, Number 133 (Tuesday, July 13, 2004)]
[Proposed Rules]
[Pages 41997-42000]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-15791]


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DEPARTMENT OF TRANSPORTATION (DOT)

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2004-18583; Directorate Identifier 2002-NM-285-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 747-100, -100B, -100B SUD, 
-200B, -200C, -300, -400, and -400D Series Airplanes; and Model 747SR 
Series Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for certain Boeing Model 747-100, -100B, -100B SUD, -200B, -200C, -300, 
-400, and -400D series airplanes; and Model 747SR series airplanes. 
This proposed AD would require repetitive inspections of the forward 
corner reveals for the main entry door (MED) 3 for cracking, and 
corrective actions if necessary. This proposed AD is prompted by 
reports of cracking in the forward corner reveals for the MED 3. We are 
proposing this AD to detect and correct misalignment of the girt bar 
fitting due to fatigue failure of the forward corner reveals for MED 3, 
which could lead to the door escape slide departing from the airplane 
if the door is opened when the slide is deployed, and consequent 
injuries to passengers and crew using the door escape slide during an 
emergency evacuation.

DATES: We must receive comments on this proposed AD by August 27, 2004.

ADDRESSES: Use one of the following addresses to submit comments on 
this proposed AD.
     DOT Docket Web site: Go to http://dms.dot.gov and follow 
the instructions for sending your comments electronically.
     Government-wide rulemaking Web site: Go to http://www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility, U.S. Department of 
Transportation, 400 Seventh Street SW., Nassif Building, room PL-401, 
Washington, DC 20590.
     By fax: (202) 493-2251.
     Hand Delivery: room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street SW., Washington, DC, between 9 a.m. 
and 5 p.m., Monday through Friday, except Federal holidays.
    You can get the service information identified in this proposed AD 
from Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 
98124-2207.
    You may examine the contents of this AD docket on the Internet at 
http://dms.dot.gov, or at the Docket Management Facility, U.S. 
Department of Transportation, 400 Seventh Street SW., room PL-401, on 
the plaza level of the Nassif Building, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Nick Kusz, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
917-6432; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION:

Docket Management System (DMS)

    The FAA has implemented new procedures for maintaining AD dockets 
electronically. As of May 17, 2004, new AD actions are posted on DMS 
and assigned a docket number. We track each action and assign a 
corresponding directorate identifier. The DMS AD docket number is in 
the form ``Docket No. FAA-2004-99999.'' The Transport Airplane 
Directorate identifier is in the form ``Directorate Identifier 2004-NM-
999-AD.'' Each DMS AD docket also lists the directorate identifier 
(``Old Docket Number'') as a cross-reference for searching purposes.

Comments Invited

    We invite you to submit any written relevant data, views, or 
arguments regarding this proposed AD. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2004-18583; 
Directorate Identifier 2002-NM-285-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the proposed AD. We will 
consider all comments submitted by the closing date and may amend the 
proposed AD in light of those comments.
    We will post all comments we receive, without change, to http://dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this proposed AD. Using the search function of 
that website, anyone can find and read the comments in any of our 
dockets, including the name of the individual who sent the comment (or 
signed the comment on behalf of an association, business, labor union, 
etc.). You may review DOT's complete Privacy Act Statement in the 
Federal Register published on April 11, 2000 (65 FR 19477-78), or you 
may visit http://dms.dot.gov.
    We are reviewing the writing style we currently use in regulatory 
documents. We are interested in your comments on whether the style of 
this document is clear, and your suggestions to improve the clarity of 
our communications that affect you. You can get more information about 
plain language at http://www.faa.gov/language and http://www.plainlanguage.gov.

Examining the Docket

    You may examine the AD docket in person at the Docket Management 
Facility office between 9 a.m. and 5 p.m., Monday through Friday, 
except Federal holidays. The Docket Management Facility office 
(telephone (800) 647-5227) is located on the plaza level of the Nassif 
Building at the DOT street address stated in the ADDRESSES section. 
Comments will be available in the AD docket shortly after the DMS 
receives them.

Discussion

    We have received reports from eight operators indicating that 
cracking of the

[[Page 41998]]

lower forward corner reveals for main entry door (MED) 3 was found on 
Model 747 series airplanes. Of the twelve forward corner reveals that 
were cracked, eleven were made of cast 356 aluminum and one was made of 
6061 aluminum. The cause of the cracking of the forward corner reveals 
made of cast 356 aluminum is deflection of the airplane structure at 
the MED 3 frame. The cause of the cracking of the forward corner reveal 
made of 6061 aluminum was a manufacturing error during the 
manufacturing process. This condition, if not detected and corrected, 
could result in misalignment of the girt bar fitting due to fatigue 
failure of the forward corner reveals for MED 3, which could lead to 
the door escape slide departing from the airplane if the door is opened 
when the slide is deployed, and consequent injuries to passengers and 
crew using the door escape slide during an emergency evacuation.

Explanation of Related AD

    We have previously issued AD 96-23-05, amendment 39-9810 (61 FR 
58318, November 14, 1996), which applies to certain Boeing Model 747 
series airplanes. That AD requires repetitive inspections to detect 
cracks and/or corrosion of the girt bar support fitting at certain main 
entry doors, and repair or replacement of the support fitting. That AD 
also provides for various terminating actions for the repetitive 
inspections. Inspections, repair, and replacement required by that AD 
are done in accordance with Boeing Service Bulletin 747-53A2378, 
Revision 1, dated March 10, 1994. Accomplishment of the applicable 
repair in this proposed AD would constitute compliance with the 
requirements of paragraph (k)(2)(ii) of AD 96-23-05 for the repair of 
the corner casting (reveal) only.

Relevant Service Information

    We have reviewed Boeing Special Attention Service Bulletin 747-53-
2460, dated June 27, 2002, which describes procedures for performing 
repetitive detailed inspections of the forward corner reveals for MED 3 
for cracking, and follow-on and corrective actions, if necessary. Those 
actions include the following:
     Performing a material type inspection of the forward 
corner reveal to determine if it is made of cast 356 aluminum or 6061 
aluminum;
     Replacing forward corner reveals with forward corner 
reveals made of 6061 aluminum;
     Repairing the forward corner reveals (including inspecting 
for material type and inspecting for cracks); and
     Contacting the manufacturer for repair of forward corner 
reveals made of 6061 aluminum.
    We have determined that accomplishment of the actions specified in 
the service bulletin will adequately address the unsafe condition.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other airplanes 
of this same type design. Therefore, we are proposing this AD, which 
would require repetitive inspections of the forward corner reveals for 
the MED 3 for cracking, and corrective actions if necessary. The 
proposed AD would require you to use the service information described 
previously to perform these actions, except as discussed under 
``Differences Between the Proposed AD and the Service Bulletin.''

Differences Between the Proposed AD and the Service Bulletin

    Operators should note that, although the service bulletin specifies 
that, if the forward corner reveal is found to be made from 6061 
aluminum or if a new 6061 aluminum corner reveal is installed, no 
further action is necessary, this proposed AD would require repetitive 
inspections if the forward corner reveal is made of 6061 aluminum. The 
cracking that was found in a forward corner reveal made of 6061 
aluminum, as discussed previously, was detected after the service 
bulletin was issued. Therefore, we determined that all forward corner 
reveals need to be repetitively inspected to adequately ensure 
continued operational safety.
    In addition, operators should note that, although the service 
bulletin does not specify coordinating with the manufacturer if the 
repair of a forward corner reveal consists of installing a new forward 
corner reveal made of 6061 aluminum, operators must coordinate with the 
manufacturer to ensure that the new forward corner reveal is free from 
manufacturing defects before obtaining FAA approval for the repair.
    Although Figure 1 of the service bulletin says to ``repeat 
inspections every 3,000 flight-cycles'' and to ``perform the next 
inspection prior to 3,000 flight-cycles,'' this proposed AD requires 
repetitive inspections at intervals not to exceed 3,000 flight cycles 
for forward corner reveals made of cast 356 aluminum and repetitive 
inspections at intervals not to exceed 1,500 flight cycles for forward 
corner reveals made of 6061 aluminum.
    Operators should also note that, while Boeing Special Attention 
Service Bulletin 747-53-2460, dated June 27, 2002, specifies the 
effectivity to be ``all 747 airplanes line numbers 1 through 1037 
except for 747-SP's, Freighters and airplanes converted to Special 
Freighters,'' this proposed AD has an applicability of ``Model 747-100, 
-100B, -100B SUD, -200B, -200C, -300, -400, and -400D series airplanes; 
and Model 747SR series airplanes, line numbers 1 through 1,342 
inclusive, except freighters and airplanes converted to Boeing special 
freighters.'' The line numbers were changed to include airplanes with 
forward corner reveals made of 6061 aluminum that may have a 
manufacturing defect. It has been verified that airplanes with line 
number 1343 and up have forward corner reveals installed that are made 
from 6061 aluminum and do not have the manufacturing defect.
    Also operators should note that Figure 1 of the service bulletin 
specifies the initial inspection threshold to be ``At or prior to 7,000 
flight-cycles, or within 2,000 flight-cycles of the issue date of this 
service bulletin, or within 3,000 flight-cycles of the last inspection 
of the door 3 corner reveal as given in Boeing Service Bulletin 747-
53A2378, whichever is later.'' However, this proposed AD would require 
the initial inspection within 1,500 flight cycles after the effective 
date of the AD. We have determined that the threshold listed in Figure 
1 of the service bulletin would not address the identified unsafe 
condition soon enough to ensure an adequate level of safety for the 
affected fleet. In developing an appropriate compliance time for this 
AD, we considered new reports since the service bulletin was issued, 
the manufacturer's recommendation and the degree of urgency associated 
with the subject unsafe condition. In light of all of these factors, we 
find that requiring the initial inspection within 1,500 flight cycles 
represents an appropriate interval of time for affected airplanes to 
continue to operate without compromising safety.
    In addition, although the service bulletin specifies that the 
manufacturer may be contacted for disposition of certain repair 
conditions, this proposal would require the repair of those conditions 
to be accomplished 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 those findings.

[[Page 41999]]

    Furthermore, although step 5 of Figure 8 of the service bulletin 
specifies that operators may accomplish the actions on forward corner 
reveals made of cast 356 aluminum in accordance with ``an operator's 
equivalent procedure,'' this proposed AD would require operators to 
accomplish step 5 of Figure 8 only in accordance with the procedures 
specified in Standard Overhaul Practices Manual (SOPM) 20-20-02. An 
``operator's equivalent procedure'' may be used only if approved as an 
alternative method of compliance in accordance with paragraph (m) of 
this AD.
    The differences described above have been coordinated with the 
manufacturer.

Costs of Compliance

    This proposed AD would affect about 146 airplanes of U.S. registry 
and 926 airplanes worldwide. The proposed detailed inspection for 
cracking would take about 1 work hour per airplane, at an average labor 
rate of $65 per work hour. Based on these figures, the estimated cost 
of the proposed AD for U.S. operators is $9,490, or $65 per airplane, 
per inspection cycle.

Regulatory Findings

    We have determined that this proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD 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.
    For the reasons discussed above, I certify that the 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. 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.
    We prepared a regulatory evaluation of the estimated costs to 
comply with this proposed AD. See the ADDRESSES section for a location 
to examine the regulatory evaluation.

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 FAA proposes to amend 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. The FAA amends Sec.  39.13 by adding the following new 
airworthiness directive (AD):

Boeing: Docket No. FAA-2004-18583; Directorate Identifier 2002-NM-
285-AD. Comments Due Date.

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this AD action by August 27, 2004.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 747-100, -100B, -100B SUD, -
200B, -200C, -300, -400, and -400D series airplanes; and Model 747SR 
series airplanes, line numbers 1 through 1,342 inclusive, except 
freighters and airplanes converted to Boeing special freighters; 
certificated in any category.

Unsafe Condition

    (d) This AD was prompted by reports of cracking in the forward 
corner reveals for the main entry door (MED) 3. We are issuing this 
AD to detect and correct misalignment of the girt bar fitting due to 
fatigue failure of the forward corner reveals for MED 3, which could 
lead to the door escape slide departing from the airplane if the 
door is opened when the slide is deployed, and consequent injuries 
to passengers and crew using the door escape slide during an 
emergency evacuation.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified, unless the 
actions have already been done.

Service Bulletin References

    (f) The term ``service bulletin,'' as used in this AD, means the 
Accomplishment Instructions of Boeing Special Attention Service 
Bulletin 747-53-2460, dated June 27, 2002.

Initial Inspections

    (g) Within 1,500 flight cycles after the effective date of this 
AD, perform a detailed inspection of the forward corner reveals for 
MED 3 for cracking, in accordance with the service bulletin.

    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.''

No Cracking Found--Repetitive Inspections

    (h) If no crack is found during the detailed inspection required 
by paragraph (g) of this AD, before further flight, perform the 
material type inspection of the forward corner reveal to determine 
if it is made of cast 356 aluminum or 6061 aluminum, in accordance 
with the service bulletin.
    (1) If the forward corner reveal is made of cast 356 aluminum, 
repeat the detailed inspection required by paragraph (g) of this AD 
thereafter at intervals not to exceed 3,000 flight cycles.
    (2) If the forward corner reveal is made of 6061 aluminum, 
repeat the detailed inspection required by paragraph (g) of this AD 
thereafter at intervals not to exceed 1,500 flight cycles.

Cracking Found--Repair/Contact the FAA

    (i) If any crack is found during the detailed inspection 
required by paragraph (g) of this AD, before further flight, perform 
the material type inspection of the forward corner reveal to 
determine if it is made of cast 356 aluminum or 6061 aluminum, in 
accordance with the service bulletin.
    (1) If the forward corner reveal is made of cast 356 aluminum, 
before further flight, repair the forward corner reveal in 
accordance with the service bulletin or 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 those 
findings. For a repair method to be approved, the approval must 
specifically refer to this AD. Repeat the detailed inspection 
required by paragraph (g) of this AD thereafter at intervals not to 
exceed 3,000 flight cycles.
    (2) If the forward corner reveal is made of 6061 aluminum, 
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 those findings. For 
a repair method to be approved, the approval must specifically refer 
to this AD.

Operator's Equivalent Procedure

    (j) Although step 5 of Figure 8 of the service bulletin 
specifies that operators may accomplish the actions in accordance 
with ``an operator's equivalent procedure,'' this AD requires 
operators to accomplish step 5 of Figure 8 in accordance with only 
the procedures specified in Standard Overhaul Practices Manual 
(SOPM) 20-20-02. An ``operator's equivalent procedure'' may be used 
only if approved as an alternative method of compliance in 
accordance with paragraph (m) of this AD.

[[Page 42000]]

Parts Installation

    (k) As of the effective date of this AD, no person may install a 
door corner reveal made of cast 356 aluminum on any airplane in the 
location specified by this AD, except as provided by paragraph 
(i)(1) of this AD.

Compliance With AD 96-23-05 for MED 3 Only

    (l) Accomplishment of the applicable repair required by this AD 
constitutes compliance with the repair of the MED 3, lower forward 
corner casting (reveal) only, as required by paragraph (k)(2)(ii) of 
AD 96-23-05, amendment 39-9810 (which specifies the actions be done 
in accordance with Boeing Service Bulletin 747-53A2378, Revision 1, 
dated March 10, 1994). Accomplishment of the actions of this AD does 
not terminate the remaining requirements of AD 96-23-05.

Alternative Methods of Compliance

    (m) The Manager, Seattle Aircraft Certification Office, FAA, has 
the authority to approve AMOCs for this AD, if requested in 
accordance with the procedures found in 14 CFR 39.19.

    Issued in Renton, Washington, on June 30, 2004.
Kalene C. Yanamura,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 04-15791 Filed 7-12-04; 8:45 am]
BILLING CODE 4910-13-P