[Federal Register Volume 70, Number 119 (Wednesday, June 22, 2005)]
[Proposed Rules]
[Pages 36064-36067]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-12297]



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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-21593; Directorate Identifier 2002-NM-328-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 727 Series 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 supersede an existing airworthiness 
directive (AD) for certain Boeing Model 727 series airplanes. That AD 
currently requires repetitive visual inspections for cracking of the 
forward entry doorway forward frame and repair if necessary. That AD 
also provides an optional modification that constitutes terminating 
action. This proposed AD would require adding new post-repair and post-
modification inspections for previously repaired or modified airplanes, 
mandating the optional modification, and adding airplanes to the 
applicability of the AD. This proposed AD is prompted by reports of 
cracking of the forward entry doorway forward frame of airplanes 
previously modified. We are proposing this AD to prevent the loss of 
the structural integrity of the forward entry doorway due to cracking 
of the frame at BS 303.9, and consequent cracking of the fuselage skin 
and rapid decompression of the airplane.

DATES: We must receive comments on this proposed AD by August 8, 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.
     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 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-2005-21593; the directorate identifier for this docket is 
2002-NM-328-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 written relevant data, views, or 
arguments regarding this proposed AD. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2005-21593; 
Directorate Identifier 2002-NM-328-AD'' at the beginning 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 received 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 our 
docket 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 the 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 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

    On April 11, 1991, we issued AD 91-09-07, amendment 39-6982 (56 FR 
18687, April 24, 1991), applicable to certain Boeing Model 727 series 
airplanes. That AD requires repetitive visual inspections for cracking 
of the forward entry doorway forward frame and repair if necessary. 
That AD also provides an optional modification that constitutes 
terminating action. That action was prompted by reports of cracking of 
the forward entry doorway forward frame of airplanes previously 
modified. We issued that AD to prevent loss of the structural integrity 
of the forward entry doorway.

Actions Since Existing AD Was Issued

    Since we issued AD 91-09-07, we have received several reports 
indicating cracking found on certain frames of certain Boeing Model 727 
series airplanes. The cracks were found on airplanes that had 
accomplished the optional terminating action specified in AD 91-09-07. 
Those airplanes had between 32,000 and 35,000 total flight cycles, and 
ranged between 0.25 inch and 0.50 inch long. The cracks initiated from 
the web cut-outs at stringer S-16L at Body Station (BS) 303.9, and were 
typically found during routine maintenance. Additionally, cracking was 
also reported on certain Model 727 series airplanes that were not 
included in the applicability of AD 91-09-07. The cracking is primarily 
attributed to cyclic fatigue loading at the frame web cut-outs. 
Cracking of the frames, if not corrected, could result in loss of the 
structural integrity of the forward entry doorway forward frame, and 
consequent cracking of the fuselage skin and rapid decompression of the 
airplane.

Related AD

    On January 16, 1990, we issued AD 90-06-09, amendment 39-6488 (55 
FR 8370, March 7, 1990), applicable to certain Boeing Model 727 series 
airplanes. That AD requires incorporation of certain structural 
modifications. That AD was prompted by reports of incidents involving 
fatigue cracking and corrosion in transport category airplanes that are 
approaching or have exceeded their design life goal.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin (ASB), 727-53A0153, 
Revision 7, dated August 14, 2003. For certain airplanes, the ASB 
describes procedures for accomplishing repetitive high frequency eddy 
current (HFEC)

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inspections and dimensional inspections to detect anomalies (e.g., 
minimum geometry requirements, jagged edges, chafing, nicks, or gouges) 
of the web cutouts at stringers S-15L and S-16L of the forward frame of 
the forward entry doorway. The ASB also describes repetitive HFEC 
inspections to detect cracking of the frame web, web assembly, and 
frame outer chord of the forward frame of the forward entry doorway, 
and repair procedures for cracking within certain limits. The ASB also 
specifies certain ``optional'' inspection methods to detect cracking 
(visual detailed, eddy current, penetrant, or X-Ray inspection). 
Additionally, the ASB describes procedures for an optional terminating 
modification that eliminates the need to perform the repetitive 
inspections. 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 products 
of this same type design. Therefore, we are proposing this AD, which 
would supersede AD 91-09-07. This proposed AD would continue to require 
repetitive visual inspections of the forward frame of the forward entry 
doorway for cracks. For certain airplanes, this proposed AD also would 
require a one-time HFEC inspection for cracks and a one-time 
dimensional inspection for anomalies of the web cutouts at stringers S-
15L and S-16L. The proposed AD also would require repetitive HFEC 
inspections for cracking of the frame web and outer chord between 
stringer S-14L and the floor, and corrective action if necessary. Since 
cracking has been reported on airplanes not specified in the previous 
AD, we have added those airplanes to the applicability of this proposed 
AD. Additionally, the proposed AD would require accomplishing the 
modification for airplanes that have not accomplished the previous 
optional modification. The modification terminates the repetitive 
inspection requirements of the proposed AD. This 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

    Although Boeing ASB 727-53A0153, Revision 7, dated August 14, 2003, 
specifies accomplishing repetitive dimensional inspections of the web 
cutouts, this proposed AD would require those specific inspections to 
be accomplished only one time, as well as applicable corrective 
actions. We have determined that, since the purpose of the inspection 
is to resolve any structural interference of static structure, it need 
not be inspected again. Although the Boeing ASB also describes certain 
``optional'' inspections in lieu of certain HFEC inspections, this 
proposed AD would require accomplishing the HFEC inspections. 
(Compliance times in Revision 7 are based on performing the HFEC 
inspections, and no compliance times were specified for the 
``optional'' inspections.) Operators should also note that the Boeing 
ASB specifies a grace period for the compliance time of one year. 
However, this proposed AD specifies a grace period of 1,800 flight 
cycles because cyclic loading is the mechanism of crack propagation, 
rather than calendar time. Additionally, where the ASB specifies 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 Manager, Seattle Aircraft 
Certification Office (ACO), FAA. The differences between the ASB and 
the proposed AD have been coordinated with the manufacturer.

Change to Existing AD

    This proposed AD would retain certain requirements of AD 91-09-07. 
Since AD 91-09-07 was issued, the AD format has been revised, and 
certain paragraphs have been rearranged. As a result, the corresponding 
paragraph identifiers have changed in this proposed AD, as listed in 
the following table:

                      Revised Paragraph Identifiers
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                                             Corresponding  requirement
        Requirement in AD 91-09-07              in this  proposed AD
------------------------------------------------------------------------
Paragraph (a).............................  Paragraph (f).
Paragraph (b).............................  Paragraph (g).
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Costs of Compliance

    There are about 1,038 Model 727 series airplanes of the affected 
design in the worldwide fleet. This proposed AD would affect about 616 
airplanes of U.S. registry.
    The actions that are required by AD 91-09-07 and retained in this 
proposed AD take about 58 work hours per airplane, at an average labor 
rate of $65 per work hour. Based on these figures, the estimated cost 
of the currently required actions is $3,770 per airplane, per 
inspection cycle.
    The new inspections would take about 5 to 6 work hours per 
airplane, depending on the airplane configuration, at an average labor 
rate of $65 per work hour. Based on these figures, the estimated cost 
of the new actions specified in the new inspections proposed in this AD 
is between $325 and $390 per airplane, per inspection cycle.
    The terminating action proposed by this AD would affect airplanes 
on which the previous optional modification has not been accomplished, 
and would take between 14 and 40 work hours per airplane, depending on 
the airplane configuration, at an average labor rate of $65 per work 
hour. Required parts for proposed terminating modification would cost 
between $877 and $6,749 per airplane, depending on the airplane 
configuration. Based on these figures, the estimated cost of the 
terminating action specified in this proposed AD is between $1,787 and 
$9,349 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.

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    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 removing amendment 39-6982 (56 FR 
18687, April 24, 1991) and adding the following new airworthiness 
directive (AD):

Boeing: Docket No. FAA-2005-21593; Directorate Identifier 2002-NM-
328-AD.

Comments Due Date

    (a) The Federal Aviation Administration must receive comments on 
this airworthiness directive (AD) action by August 8, 2005.

Affected ADs

    (b) This AD supersedes AD 91-09-07, amendment 39-6982 (56 FR 
18687, April 24, 1991).

Applicability

    (c) This AD applies to Model 727 series airplanes, certificated 
in any category; as identified in Boeing Alert Service Bulletin 727-
53A0153, Revision 7, dated August 14, 2003.

Unsafe Condition

    (d) This AD was prompted by reports of cracking of the forward 
frame of the forward entry doorway of airplanes previously modified. 
We are issuing this AD to prevent the loss of the structural 
integrity of the forward entry doorway due to cracking at Body 
Station (BS) 303.9, and consequent cracking of the fuselage skin 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.

Restatement of Certain Requirements of AD 91-09-07

    (f) For airplanes listed in Boeing Service Bulletin 727-53-0153, 
Revision 5, dated December 14, 1989: Visually inspect the forward 
entry doorway frame for cracks in accordance with Boeing Service 
Bulletin 727-53-0153, dated February 1, 1980, or Revisions 1 though 
5, at the earlier of the times indicated in subparagraphs (a)(1) or 
(a)(2) of this AD. Repeat the inspection at intervals not to exceed 
3,700 landings until accomplishment of the one-time high frequency 
eddy current (HFEC) inspection for cracking and the one-time 
dimensional inspection for anomalies required by paragraph (i) of 
this AD, or the one-time dimensional inspection for anomalies and 
the initial HFEC inspection for cracking of the forward frame of the 
forward entry doorway at BS303.9 specified in paragraph (h) of this 
AD, as applicable.
    (1) Within the next 1,850 landings after March 11, 1983 (the 
effective date of AD 83-03-01, amendment 39-4561), or prior to 
accumulating a total of 25,000 landings, whichever occurs later; or
    (2) Within the next 1,850 landings after May 16, 1986 (the 
effective date of AD 83-03-01 R1, amendment 39-5283), or prior to 
accumulating a total of 15,000 landings, whichever occurs later.
    (g) For airplanes modified in accordance with Boeing Service 
Bulletin 727-53-0153, dated February 1, 1980; through Revision 4, 
dated November 8, 1985; conduct the inspections described in 
paragraph (f) of this AD prior to the accumulation of 10,000 
landings after the modification or within the next 3,700 landings 
after May 28, 1991 (the effective date of AD 91-09-07), whichever 
occurs later. Repeat the inspection at intervals not to exceed 3,700 
landings until accomplishment of the one-time HFEC inspection for 
cracking and the one-time dimensional inspection for anomalies 
required by paragraph (i) of this AD, or the one-time dimensional 
inspection for anomalies and the initial HFEC inspection for 
cracking of the forward frame of the forward entry doorway at 
BS303.9 specified in paragraph (h) of this AD, as applicable.

New Requirements of This AD

Repetitive Inspections for Certain Airplanes

    (h) For Group l airplanes as defined by Boeing Alert Service 
Bulletin (ASB) 727-53A0153, Revision 7, dated August 14, 2003, with 
the exception of certain Group 1 airplanes specified in paragraph 
(i) of this AD: Perform a one-time dimensional inspection for 
anomalies (e.g., minimum dimension requirements, jagged edges, 
chaffing, nicks, or gouges) of the web cutouts at stringers S-15 and 
S-16, and HFEC inspections for cracking of the forward frame of the 
forward entry doorway at BS 303.9; in accordance with Figure 1 of 
the Accomplishment Instructions of Revision 7 of the ASB at the 
times specified in paragraph (h)(1) or (h)(2) of this AD, as 
applicable. With the exception of the one-time dimensional 
inspection (Step 1 of Figure 1) of the web cutouts at S-15L and S-
16L, repeat the HFEC inspections for cracking of the forward frame 
of the forward entry doorway at BS 303.9 at intervals not to exceed 
3,700 flight cycles until the requirements of paragraph (l) of this 
AD have been accomplished.
    (1) For Group 1 airplanes that have not been modified or 
repaired in accordance with any issue of the service bulletin 
through Revision 7 inclusive: Perform the inspection before the 
accumulation of 15,000 total flight cycles, or within 1,800 flight 
cycles after the effective date of this AD, whichever occurs later.
    (2) For Group 1 airplanes that have been modified in accordance 
with Repair Kit 65C20303-1 in accordance with any issue of the 
service bulletin through Revision 4 inclusive: Perform the 
inspection before the accumulation of 10,000 flight cycles after the 
modification, or within 1,800 flight cycles after the effective date 
of this AD, whichever occurs later.

One-Time Inspections and Terminating Actions for Certain Other 
Airplanes

    (i) For Group 1 airplanes, as defined by Boeing ASB 727-53A0153, 
Revision 7, dated August 14, 2003, that have been modified in 
accordance with Revision 5 or 6 of Boeing Service Bulletin 727-53-
0153, or that have been repaired in accordance with Boeing Repair 
Kits 65C20303-8 or -25 as specified in Revision 2 through Revision 6 
inclusive of the service bulletin: Within 4,500 flight cycles after 
the effective date of this AD, do a one-time HFEC for cracking and a 
dimensional inspection for any anomaly (e.g., minimum dimension 
requirements, jagged edges, chaffing, nicks or gouges) of the web 
cutouts at stringers S-15L and S-16L of the forward frame of the 
forward entry doorway at BS 303.9, in accordance with Step 1 and 
Step 2 of Figure 1 of the Accomplishment Instructions of Revision 7 
of the ASB. For these airplanes, accomplishment of the HFEC, 
dimensional inspections, and any applicable corrective actions, 
constitute terminating actions for all the repetitive inspection 
requirements of this AD.

Inspections for Group 2 Airplanes

    (j) For Group 2 airplanes, as defined by Boeing ASB 727-53A0153, 
Revision 7, dated August 14, 2003, that have not been modified or 
repaired in accordance with Revision 7 of the service bulletin: 
Before the accumulation of 17,000 total flight cycles, or within 
4,500 flight cycles after the effective date of this AD, whichever 
occurs later, perform a one-time dimensional inspection for 
anomalies (e.g., minimum dimension requirements, jagged edges, 
chafing, nicks, or gouges) of the web cutouts at stringers S-15 and 
S-16, and HFEC inspections for cracking of the forward frame of the 
forward entry doorway at BS 303.9; in accordance with Figure 2 of 
the Accomplishment Instructions of Revision 7 of the ASB. With the 
exception of the one-time dimensional inspection (Step 1 of Figure 
2) of the web cutouts at S-15L and S-16L, repeat the HFEC 
inspections for

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cracking of the forward frame of the forward entry doorway at BS 
303.9 at intervals not to exceed 3,700 flight cycles until the 
requirements of paragraph (l) of this AD have been accomplished.

Corrective Actions

    (k) If any cracking is detected during any HFEC inspection, or 
any anomaly is detected during any dimensional inspection required 
by this AD: Before further flight, accomplish the actions in 
paragraph (k)(1) or (k)(2) of this AD, as applicable.
    (1) For any cracking that is within the limits specified in the 
Accomplishment Instructions of Boeing ASB 727-53A0153, Revision 7, 
dated August 14, 2003: Repair the cracking in accordance with the 
Revision 7 of the ASB.
    (2) For any cracking that is outside the limits specified in the 
Accomplishment Instructions of the ASB or for any anomaly that is 
detected during any dimensional inspection required by this AD: 
Repair in accordance with a method approved by the Manager, Seattle 
Aircraft Certification (ACO), FAA; or in accordance with data 
meeting the type certification basis of the airplane approved by an 
Authorized Representative for the Boeing Delegation Option 
Authorization Organization who has been authorized by the FAA to 
make those findings. For a repair method to be approved, the repair 
must meet the certification basis of the airplane, and the approval 
must specifically reference this AD.

Terminating Actions for Certain Airplanes

    (l) For airplanes specified in paragraph (l)(1) or (l)(2) of 
this AD: Prior to the accumulation of 60,000 total flight cycles, or 
within 1,800 flight cycles after the effective date of this AD, 
whichever occurs later, perform the inspections specified in Figure 
1 or Figure 2, as applicable, of Revision 7 of Boeing ASB 727-
53A0153, dated August 14, 2003, and as specified by paragraph (h) or 
(j) of this AD, as applicable. Before further flight, following the 
inspections, modify the forward frame in accordance with the 
Accomplishment Instructions of Revision 7 of the ASB. Concurrent 
accomplishment of the inspections and modification constitutes 
terminating action for the repetitive inspections required by this 
AD.
    (1) Group 1 airplanes that have not been modified or repaired in 
accordance with Boeing Repair Kits 65C20303-8 or -25, as specified 
in Boeing Service Bulletin 727-53-0153, Revision 2, dated December 
3, 1982; Revision 3, dated June 17, 1983; Revision 4, dated November 
8, 1985; Revision 5, dated December 14, 1989; Revision 6, dated 
August 27, 1992; or Revision 7 of Boeing ASB 727-53A0153, dated 
August 14, 2003.
    (2) Group 2 airplanes that have not been repaired or modified in 
accordance with Revision 7 of Boeing ASB 727-53A0153, dated August 
14, 2003.

    Note 1: Accomplishment of the terminating actions specified in 
paragraphs (i) or (l) of this AD does not relieve the operator of 
responsibility to comply with the inspection requirements of the 
operator's standard structural maintenance program.

Alternative Methods of Compliance (AMOCs)

    (m)(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) An AMOC that provides an acceptable level of safety may be 
used for any repair required by this AD, if it is 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. For a repair method to be 
approved, the repair must meet the certification basis of the 
airplane, and the approval must specifically refer to this AD.
    (3) AMOCs approved previously in accordance with AD 91-09-07, 
amendment 39-6982, are approved as AMOCs with the corresponding 
requirements and provisions of this AD.
    (4) Accomplishment of the actions specified in paragraph (l) of 
this AD constitutes an AMOC with paragraph (A) of AD 90-06-09, 
amendment 39-6488, only for the structural modification requirements 
specified in Boeing Service Bulletin 727-53-0153, Revision 4 or 
earlier revisions.

    Issued in Renton, Washington, on June 10, 2005.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-12297 Filed 6-21-05; 8:45 am]
BILLING CODE 4910-13-P