[Federal Register Volume 70, Number 18 (Friday, January 28, 2005)]
[Proposed Rules]
[Pages 4052-4054]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-1587]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-20137; Directorate Identifier 2004-NM-96-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757-200, -200PF, and -300 
Series Airplanes, Powered by Pratt & Whitney PW2000 Series Engines

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 757 series airplanes. This proposed AD would 
require repetitive inspections for loose or damaged components of the 
support brackets and associated fasteners for the hydraulic lines 
located in the nacelle struts, and any related investigative and 
corrective actions. This proposed AD is prompted by reports of damage 
and subsequent failure of the support brackets and associated fasteners 
for the hydraulic lines located internal to the upper fairing cavity of 
the nacelle struts. We are proposing this AD to prevent flammable 
fluids from leaking into the interior compartment of the nacelle struts 
where ignition sources exist, which could result in the ignition of 
flammable fluids and an uncontained fire.

DATES: We must receive comments on this proposed AD by March 14, 2005.

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.
    For service information identified in this proposed AD, contact 
Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-
2207.
    You can examine the contents of this AD docket on the Internet at 
http://dms.dot.gov, or in person 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: Technical information: Tom Thorson, 
Aerospace Engineer, Propulsion Branch, ANM-140S, FAA, Seattle Aircraft 
Certification Office, 1601 Lind Avenue, SW., Renton, Washington 98055-
4056; telephone (425) 917-6508; fax (425) 917-6590.
    Plain language information: Marcia Walters, [email protected].

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

[[Page 4053]]

Docket Number'') as a cross-reference for searching purposes.

Comments Invited

    We invite you to submit any relevant written data, views, or 
arguments regarding this proposed AD. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2005-20137; 
Directorate Identifier 2004-NM-96-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 can review DOT's complete Privacy Act Statement in the 
Federal Register published on April 11, 2000 (65 FR 19477-78), or you 
can 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 can examine the AD docket on the Internet at http://dms.dot.gov, or 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 of damage and subsequent failure of the 
support brackets and associated fasteners for the hydraulic lines 
located internal to the upper fairing cavity of the nacelle struts. 
These failures occurred on certain Model 757 series airplanes powered 
by Pratt & Whitney PW2000 series engines. These failures resulted in 
damage to the adjacent fuel lines and fuel leaks in the engine strut 
due to a fastener migrating through a support bracket and retainer 
channel, allowing the fastener to wear through the fuel supply tube. 
The hydraulic lines supply pressure from the hydraulic pumps to the 
airframe and are subject to high frequency pressure oscillations/
vibrations. Investigation by the manufacturer revealed that the 
operating pressure and surge loads from the hydraulic pumps are higher 
than originally expected and exceed the capability of the design for 
the support bracket structure.
    The hydraulic lines are located in the upper fairing compartment of 
the nacelle struts. The upper fairing compartment is a flammable 
leakage zone and is isolated from other strut compartments by a 
protective vapor barrier. The vapor barrier acts as a seal to keep 
flammable fluids and vapors from hydraulic and fuel line leaks out of 
the interior portion of the strut where pneumatic bleed air ducts are 
located. The surface temperature of the bleed air ducts is hot enough 
to be an ignition source. The reported condition of sheared or loose 
fasteners, or damage to the strut webs adjacent to the support brackets 
and associated fasteners, compromises the vapor barrier, which in turn 
could allow flammable fluids to leak into the interior compartments of 
the nacelle struts. Such a condition, if not corrected, could result in 
ignition of flammable fluids and an uncontained fire.

Relevant Service Information

    We have reviewed Boeing Service Bulletins 757-29-0064 (for Model 
757-200 and -200PF series airplanes) and 757-29-0065 (for Model 757-300 
series airplanes), both dated February 29, 2004. The service bulletins 
describe procedures for repetitive detailed inspections for loose or 
damaged components of the support brackets and associated fasteners for 
the hydraulic lines located in the nacelle struts, and related 
investigative and corrective actions. Evidence of damage includes 
excessive wear, fatigue cracks, or elongated fastener holes in the 
strut webs. If no damaged or loose parts are found, the service 
bulletins specify repeating the inspection of the support brackets and 
associated fasteners for the hydraulic lines at the intervals 
specified.
    The procedures for the related investigative and corrective actions 
include:
     Inspecting the fuel and hydraulic lines and strut webs for 
evidence of damage (e.g., chafing or holes) caused by a loose support 
bracket or line.
     Replacing or repairing damaged fuel lines.
     Replacing damaged hydraulic lines with new lines.
     Repairing damaged areas of the strut webs.
     Contacting the manufacturer for damage that is beyond the 
repair limitations specified in the service bulletin.
     Replacing damaged components with new, improved nickel 
alloy components.
    The service bulletin also includes procedures for a functional test 
of the hydraulic and fuel systems.
    Service Bulletin 757-29-0064 recommends prior or concurrent 
accomplishment of Boeing Service Bulletin 757-29-0043, dated June 21, 
1990. Service Bulletin 757-29-0043 describes procedures for replacing 
aluminum brackets, retainer channels, and attachment hardware for the 
hydraulic lines located in the nacelle struts. Service Bulletin 757-29-
0043 also describes procedures for replacing certain fuel and hydraulic 
lines with new lines if necessary.
    Accomplishing the actions specified in the service information is 
intended to adequately address the identified 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 accomplishing the actions specified in the service 
information described previously, except as discussed under 
``Difference Between the Service Bulletins and Proposed AD.''

Difference Between the Service Bulletins and Proposed AD

    Although the service bulletins specify that operators may contact 
the manufacturer for disposition of certain repair conditions, this 
proposed AD would require operators to repair those conditions per a 
method approved by the FAA.

Costs of Compliance

    This proposed AD would affect about 432 airplanes worldwide and 377 
airplanes of U.S. registry. The proposed

[[Page 4054]]

inspection/test would take about 35 work hours per airplane (including 
access and close-up), 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 $857,675, or $2,275 per airplane, per inspection/test 
cycle.

Authority for This Rulemaking

    The FAA's authority to issue rules regarding aviation safety is 
found in Title 49 of the United States Code. Subtitle I, Section 106, 
describes the authority of the FAA Administrator. Subtitle VII, 
Aviation Programs describes in more detail the scope of the agency's 
authority.
    This rulemaking is promulgated under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701, ``General 
requirements.'' Under that section, the FAA is charged with promoting 
safety flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
proposed AD.

Regulatory Findings

    We have determined that this proposed AD will not have federalism 
implications under Executive Order 13132. This proposed AD 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.
    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-2005-20137; Directorate Identifier 2004-NM-
96-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this AD action by March 14, 2005.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 757-200, -200PF, and -300 
series airplanes; powered by Pratt & Whitney PW2000 series engines; 
certificated in any category.

Unsafe Condition

    (d) This AD was prompted by reports of damage and subsequent 
failure of the support brackets and associated fasteners for the 
hydraulic lines located internal to the upper fairing cavity of the 
nacelle struts. We are issuing this AD to prevent flammable fluids 
from leaking into the interior compartment of the nacelle struts 
where ignition sources exist, which could result in the ignition of 
flammable fluids and an uncontained fire.

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.

Repetitive Inspections

    (f) Within 6,000 flight hours or 18 months after the effective 
date of this AD, whichever is first: Do a detailed inspection for 
loose or damaged components of the support brackets and associated 
fasteners for the hydraulic lines located in the nacelle struts by 
accomplishing all of the actions specified in Part 1, Part 2, and 
Part 3 of the Accomplishment Instructions of Boeing Service Bulletin 
757-29-0064 (for Model 757-200 and -200PF series airplanes) or 
Boeing Service Bulletin 757-29-0065 (for Model 757-300 series 
airplanes), both dated February 29, 2004; as applicable. Repeat the 
inspection thereafter at intervals not to exceed 6,000 flight hours 
or 18 months, whichever is first.

    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.''

Concurrent Service Bulletin

    (g) Prior to or concurrently with the accomplishment of 
paragraph (f) of this AD: Accomplish all of the actions specified in 
the Accomplishment Instructions of Boeing Service Bulletin 757-29-
0043, dated June 21, 1990.

Related Investigative and Corrective Actions

    (h) Except as required by paragraph (i) of this AD: If any loose 
or damaged parts are found during any inspection required by 
paragraph (f) of this AD, before further flight, do all of the 
related investigative and corrective actions specified in Part 1 and 
Part 2 of the Accomplishment Instructions of Boeing Service Bulletin 
757-29-0064, or Boeing Service Bulletin 757-29-0065, both dated 
February 29, 2004; as applicable.

Repair Information

    (i) If any damage is found during any inspection required by 
this AD, and the service bulletin specifies contacting Boeing for 
appropriate action: Before further flight, repair per a method 
approved by the Manager, Seattle Aircraft Certification Office 
(ACO), FAA. For a repair method to be approved, the approval letter 
must specifically refer to this AD.

    Note 2: There is no terminating action currently available for 
the repetitive inspections required by paragraph (f) of this AD.

Alternative Methods of Compliance (AMOCs)

    (j) The Manager, Seattle ACO, 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 January 18, 2005.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-1587 Filed 1-27-05; 8:45 am]
BILLING CODE 4910-13-P