[Federal Register Volume 70, Number 83 (Monday, May 2, 2005)]
[Proposed Rules]
[Pages 22618-22620]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-8655]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-21085; Directorate Identifier 2004-NM-252-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 727 Airplanes

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for all Boeing Model 727 airplanes. This proposed AD would require a 
one-time inspection of the lower lobe frames of body section 43 to find 
open holes between stringers 17L and 17R; repetitive high frequency 
eddy current (HFEC) inspections for cracks of all open holes; and 
related investigative and corrective actions if necessary. The proposed 
AD also would include the optional terminating action of installing 
rivets in all open tooling holes and all unused lining holes, which 
would terminate a repetitive open-hole HFEC inspection once a hole is 
plugged with a rivet. This proposed AD is prompted by reports of cracks 
at open tooling holes in the lower lobe frames of body section 43. We 
are proposing this AD to detect and correct cracks in the frames, which 
could result in cracks in the skin panels and rapid decompression of 
the airplane.

DATES: We must receive comments on this proposed AD by June 16, 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. This docket 
number is FAA-2005-21085; the directorate identifier for this docket is 
2004-NM-252-AD.

FOR FURTHER INFORMATION CONTACT: Daniel F. Kutz, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
917-6456; fax (425) 917-6590.

SUPPLEMENTARY INFORMATION: 

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-2005-21085; 
Directorate Identifier 2004-NM-252-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 Web site, 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.

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 a report of cracks at open tooling holes in 20 
lower lobe frames of body section 43 on Boeing Model 727 series 
airplanes. The cracks were found during fatigue tests, and initiated at 
open tooling holes in the frame webs between stringers 17L and 17R. The 
cracks were caused by cyclic pressurization and fatigue loading. This 
condition, if not corrected, could result in cracks in the frames, 
which could result in cracks in the skin panels and rapid decompression 
of the airplane.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 727-53A0227, dated 
September 16, 2004. The service bulletin describes procedures for doing 
the following inspections:

[[Page 22619]]

     A general visual inspection of the lower lobe frames of 
body section 43 to find open holes between stringers 17L and 17R.
     High frequency eddy current (HFEC) inspections for cracks 
of all open tooling holes.
    The service bulletin recommends that operators record the locations 
of all open holes for reference during modification. These open holes 
include open tooling holes and any lining holes between 0.156 and 0.166 
inch in diameter that operators may find when removing the cargo 
compartment lining.
    If any crack of an open hole is found during any inspection, the 
service bulletin describes procedures for corrective and related 
investigative actions. If the crack is less than 0.063 inch in length, 
the service bulletin describes procedures for drilling the hole to an 
oversize dimension, performing further HFEC inspections to determine 
when all cracks have been removed, and installing a rivet in the open 
hole. If the crack is 0.063 inch in length or greater, the service 
bulletin recommends repairing the crack according to a method approved 
by the FAA. The service bulletin notes that Chapter 51-40-3 or Chapter 
53-10-4 of the Boeing 727 Structural Repair Manual (SRM) are acceptable 
methods approved by the FAA.
    The service bulletin also describes, in ``Part 2--Modification,'' 
procedures for plugging all open tooling holes and all unused lining 
holes with rivets, which would end the need for the repetitive 
inspections for those plugged holes. This modification includes 
drilling the hole to an oversize dimension, performing further HFEC 
inspections of cracked holes to determine when all cracks have been 
removed, and installing a rivet in the open hole.
    Accomplishing the actions specified in the service information is 
intended to adequately address the unsafe condition.

Other Related Rulemaking

    On September 5, 1990, we issued AD 90-20-14, amendment 39-6730 (55 
FR 37864, October 23, 1990), applicable to certain Boeing Model 727 
series airplanes, which requires repetitive visual inspections of the 
forward cargo compartment sidewall frames for cracks, and repair if 
necessary. The actions required by that AD are intended to detect and 
correct cracks in the forward cargo compartment sidewall frames. AD 90-
20-14 does not affect the requirements of this AD. However, the 
inspections in Boeing Alert Service Bulletin 727-53A0227 are an 
alternative method of compliance (AMOC) for the detailed inspections 
required by paragraph A. of AD 90-20-14. Inspection thresholds and 
repeat intervals in AD 90-20-14 are not included in or affected by this 
AMOC.

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 
bulletin described previously, except as discussed under ``Difference 
Between the Proposed AD and the Service Bulletin.'' This proposed AD 
also would provide for optional terminating action for the repetitive 
inspections.
    The proposed AD would allow repetitive inspections to continue in 
lieu of the terminating action. In making this determination, we 
considered that long-term continued operational safety in this case 
will be adequately ensured by repetitive inspections to detect cracking 
before it represents a hazard to the airplane.

Difference Between the Proposed AD and the Service Bulletin

    The service bulletin specifies that you may contact the 
manufacturer for instructions on how to repair certain conditions, but 
this proposed AD would require you to repair those conditions in one of 
the following ways:
     Using a method that we approve; or
     Using data that meet the certification basis of the 
airplane, and that have been approved by an Authorized Representative 
for the Boeing Delegation Option Authorization Organization whom we 
have authorized to make those findings.

Costs of Compliance

    There are about 1,038 airplanes of the affected design in the 
worldwide fleet. This proposed AD would affect about 616 airplanes of 
U.S. registry. The proposed inspection would take between 8 and 15 work 
hours per airplane per inspection cycle, depending on the configuration 
of the airplane. The average labor rate is $65 per work hour. Based on 
these figures, the estimated cost of the proposed AD for U.S. operators 
is between $320,320 and $600,600, or between $520 and $975 per 
airplane, per inspection cycle.
    For operators that choose to do the optional terminating action of 
installing rivets in all open tooling holes and all unused lining 
holes, the actions would take between 13 and 23 work hours per 
airplane, depending on the configuration of the airplane. The average 
labor rate is $65 per work hour. Based on these figures, the estimated 
cost of the optional terminating action is between $845 and $1,495 per 
airplane.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. 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.
    We are issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701, ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe 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 
rulemaking action.

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,

[[Page 22620]]

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-2005-21085; Directorate Identifier 2004-NM-
252-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this AD action by June 16, 2005.

Affected ADs

    (b) Accomplishing the inspections in paragraph (g) of this AD is 
an alternative method of compliance (AMOC) for the inspections 
required by paragraph A. of AD 90-20-14, amendment 39-6730, if 
accomplished in accordance with the requirements of paragraph (j)(2) 
of this AD.

Applicability

    (c) This AD applies to all Boeing Model 727 series airplanes, 
certificated in any category.

Unsafe Condition

    (d) This AD was prompted by reports of cracks at open tooling 
holes in the lower lobe frames of body section 43. We are issuing 
this AD to detect and correct cracks in the frames, which could 
result in cracks in the skin panels and rapid decompression of the 
airplane.

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 Reference

    (f) The term ``service bulletin,'' as used in this AD, means the 
Accomplishment Instructions of Boeing Alert Service Bulletin 727-
53A0227, dated September 16, 2004.

Inspections

    (g) Before the accumulation of 40,000 total flight cycles, or 
within 3,500 flight cycles after the effective date of this AD, 
whichever occurs later: Do a general visual inspection of the lower 
lobe frames to find open holes between stringer 17L and stringer 17R 
of body section 43; and do an HFEC inspection for cracks of all open 
holes, including lining holes. Repeat the inspections at intervals 
not to exceed 3,500 flight cycles until the optional terminating 
action in paragraph (i) of this AD is accomplished. Do all 
inspections in accordance with the service bulletin.

Corrective Action

    (h) If any crack is found during any inspection required by 
paragraph (g) of this AD: Before further flight, do the applicable 
corrective action in paragraph (h)(1) or (h)(2) of this AD.
    (1) If the crack is less than 0.063 inch in length, do the 
corrective action and related investigative action in Figure 6 of 
the service bulletin.
    (2) If the crack is 0.063 inch in length or greater, repair the 
crack according to a method approved by the Manager, Seattle 
Aircraft Certification Office (ACO), FAA; or according to data 
meeting the certification basis of the airplane approved by an 
Authorized Representative for the Boeing Delegation Option 
Authorization Organization who has been authorized by the Manager, 
Seattle ACO, to make those findings. Chapters 51-40-3 and 53-10-4 of 
the Boeing 727 Structural Repair Manual (SRM) are approved methods. 
Except for these SRMs, for a repair method to be approved, the 
approval must specifically reference this AD.

Optional Terminating Action

    (i) Installing rivets in all open tooling holes, and all unused 
lining holes, according to Part 2 of the Work Instructions of the 
service bulletin terminates the repetitive inspection requirements 
of paragraph (g) of this AD only for those holes plugged with 
rivets. Terminating action for the repetitive inspection 
requirements of paragraph (g) of this AD is not permitted for all 
lining holes without installed rivets.

AMOCs

    (j)(1) 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.
    (2) The inspection methods specified in paragraph (g) of this AD 
are AMOCs to the inspection methods required by paragraph A. of AD 
90-20-14, amendment 39-6730. Inspection thresholds and repetitive 
intervals are not included in or affected by this AMOC. All other 
provisions of AD 90-20-14 that are not specifically mentioned above 
remain fully applicable and must be met.
    (3) 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 Authorized 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.

    Issued in Renton, Washington, on April 21, 2005.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-8655 Filed 4-29-05; 8:45 am]
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