[Federal Register Volume 70, Number 240 (Thursday, December 15, 2005)]
[Proposed Rules]
[Pages 74237-74240]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 05-24052]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-23313; Directorate Identifier 2005-NM-111-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 727, 727C, 727-100, and 
727-100C 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 adopt a new airworthiness directive (AD) 
for all Boeing Model 727, 727C, 727-100, and 727-100C series airplanes. 
This proposed AD would require repetitive inspections for cracks in the 
body skin and bear strap at the upper and lower hinge cutouts of the 
mid-cabin galley doorway, along the upper fastener row of the stringer 
14R lap splice, and in the doorstop fitting adjacent to the upper hinge 
cutout; and corrective action if necessary. This proposed AD also 
provides for optional terminating action for certain inspections. This 
proposed AD results from reports of skin and bear strap cracking at the 
upper and lower hinge cutout and along the upper fastener row of the 
stringer 14R lap splice, and cracking in the doorstop fitting adjacent 
to the upper hinge cutout. There are also reports of cracking on 
airplanes previously modified to prevent such cracking. We are 
proposing this AD to find and fix fatigue cracking of the fuselage, 
which could result in reduced structural integrity and consequent rapid 
decompression of the airplane.

DATES: We must receive comments on this proposed AD by January 30, 
2006.

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,

[[Page 74238]]

400 Seventh Street SW., Washington, DC, between 9 a.m. and 5 p.m., 
Monday through Friday, except Federal holidays.
    Contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, 
Washington 98124-2207 for the service information identified in this 
proposed 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. Include the docket number ``FAA-
2005-23313; Directorate Identifier 2005-NM-111-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 
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 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.

Examining the Docket

    You may 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 Docket Management System 
receives them.

Discussion

    We have received a report indicating that a 0.73 inch long skin 
crack was found at the upper corner of the upper hinge cutout of the 
mid-cabin galley doorway on a Model 727 series airplane. The crack was 
similar to cracking found and fixed previously on other Model 727 
series airplanes. Further inspections revealed a 1 inch crack in the 
bear strap, and cracks in the doorstop fitting adjacent to the upper 
hinge cutout. Investigation of the Model 727 airplane history revealed 
reports of 15 skin cracks having lengths up to 2 inches on 12 airplanes 
with between 23,400 and 54,600 flight cycles. Of the reported skin 
cracks, there were three reports of associated bear strap crack 
indications on three airplanes. One of the airplanes also had a cracked 
door stop fitting adjacent to the upper hinge cutout. Five cracks on 
five of the airplanes were located near the lower hinge cutout in the 
upper row of fasteners of the skin lap joint at stringer 14R. Some of 
the cracks were found on airplanes that were modified in service by 
increasing the radius of the corners of the body skin at the hinge 
cutouts, and installing doublers at the high cutouts; and airplanes on 
which the equivalent modification was done in production. These 
modifications did not prevent the cracking. This cracking, if not 
corrected, could result in reduced structural integrity and consequent 
rapid decompression of the airplane.

Other Relevant Rulemaking

    On January 16, 1990, the FAA issued AD 90-06-09, amendment 39-6488 
(55 FR 8370, March 7, 1990), applicable to certain Boeing Model 727 
series airplanes, which requires the incorporation of certain 
structural modifications specified by Boeing Document No. D6-54860, 
Revision C, dated December 11, 1989, ``Aging Airplane Service Bulletin 
Structural Modification Program--Model 727.'' That Boeing document 
references numerous Boeing service bulletins that specify various 
modification actions that are mandated by AD 90-06-09. The actions 
required by that AD are intended to prevent a degradation in the 
structural capabilities of the affected airplanes, which could result 
in structural failure. That action also reflects the FAA's decision 
that long-term continued operational safety would be ensured by actual 
modification of the airframe rather than repetitive inspection. One of 
the structural modifications in that AD is of the body skin of the mid-
galley door hinge cutouts done in accordance with Boeing Service 
Bulletin 727-53-0054, Revision 1, dated November 16, 1989. Service 
Bulletin 727-53-0054 describes procedures for inspection of the forward 
upper and lower corners at the hinge cutouts of the mid-cabin galley 
doorway for cracks in the body skin, a modification to the corners of 
the hinge cutouts, and installation of doublers at the hinge cutouts of 
the mid-cabin galley doorway. (Service Bulletin 727-53-0054 is 
referenced in Boeing Document No. D6-54860, Revision C, as one source 
of service information for accomplishing the actions.)
    On May 12, 1998, we issued AD 98-11-03, amendment 39-10530 (63 FR 
27455, May 19, 1998), applicable to all Boeing Model 727 series 
airplanes. (A correction of that AD was published in the Federal 
Register as AD 98-11-03 R1, amendment 39-10983, on December 30, 1998 
(64 FR 989, January 7, 1999).) That AD requires that the FAA-approved 
maintenance inspection program be revised to include inspections of 
Structurally Significant Items (SSI) based on damage tolerance 
analysis. That AD also allows operators not to change their programs if 
they determine that the existing inspections are effective for the new 
or affected SSI.
    On April 19, 2000, we issued AD 2000-08-19, amendment 39-11705 (65 
FR 25278, May 1, 2000), applicable to certain Boeing Model 727 and 727C 
series airplanes. That AD requires one-time inspections of the exterior 
body skin located at the forward corners of the mid-galley door hinge 
cutouts to detect cracking, and corrective actions if necessary. That 
AD also requires modification of the body skin of the mid-galley door 
hinge cutouts. Boeing Service Bulletin 727-53-0054, Revision 1, dated 
November 16, 1989, was referenced in that AD as the appropriate source 
of service information for accomplishing the required actions. The 
service bulletin describes procedures for inspection of the forward 
upper and lower corners at the hinge cutouts of the mid-cabin galley 
doorway for cracks in the body skin, a modification to the corners of 
the hinge cutouts, and installation of doublers at the hinge cutouts of 
the mid-cabin galley doorway.
    Since issuance of AD 90-06-09 and AD 2000-08-19, we have determined 
that the actions required by those ADs pertaining to the mid-galley 
door hinge cutouts are not adequate to prevent cracking in this area. 
The subject cracking of the bear strap, door stop fitting, and skin lap 
joint area is bigger than the area specified in the actions required by 
AD 90-06-09 and AD 2000-08-19; therefore, the cracks may have been 
undetected at the time a modification or repair was done. We have 
determined that additional work is necessary for airplanes on which a

[[Page 74239]]

modification or repair required by AD 90-06-09 or AD 2000-08-19 was 
done without additional inspections recommended in the service bulletin 
referenced in this proposed AD.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 727-53A0228, dated 
March 24, 2005. The service bulletin describes procedures for 
repetitive inspections for any cracks, including stop-drilled, trimmed-
out, or repaired cracks, in the body skin and bear strap at the upper 
and lower hinge cutouts of the mid-cabin galley doorway; along the 
upper fastener row of the stringer 14R lap splice; and in the doorstop 
fitting adjacent to the upper hinge cutout; and corrective action if 
necessary. The types of inspections are detailed and special detailed 
inspections'which include surface high frequency eddy current (HFEC), 
open-hole HFEC, and fluorescent dye penetrant inspections. If a 
modification or repair required by AD 90-06-09 or AD 2000-08-19 was 
done, the service bulletin describes procedures for removing the 
doublers before accomplishing the inspections. Corrective action 
includes replacing any cracked doorstop fitting with a new fitting, and 
repairing cracks in the skin or bear strap per repair instructions from 
Boeing. The service bulletin also specifies that replacement of a door 
stop fitting with a new door stop fitting made of 7075 material 
eliminates the need to repeat the inspection of that stop fitting. Door 
stop fittings having part number 65-23674-7 are made of 7075 material 
and do not need to be inspected. The service bulletin also recommends 
providing the details of any crack findings to Boeing for repair 
instructions.
    The compliance times for the inspections specified in Table 1 of 
paragraph 1.E. ``Compliance'' of the service bulletin are to be 
accomplished before the accumulation of 20,000 total flight cycles or 
within 2,000 flight cycles after the effective date of the AD, 
whichever is later; the repetitive interval is every 6,000 flight 
cycles.

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. For this reason, 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 Proposed AD and the Service Bulletin.''

Difference Between the Proposed AD and the Service Bulletin

    Paragraph 1.F. of the service bulletin specifies, ``Any cracks 
found must be repaired, before further flight, in accordance with a 
method approved by the Manager, Seattle ACO, FAA, Transport Airplane 
Directorate; or in accordance with data meeting the type certification 
basis of the airplane, approved by a Boeing Company Authorized 
Representative who has been authorized by the Manager, Seattle ACO, to 
make such findings.'' However, the Accomplishment Instructions of the 
alert service bulletin specify to contact the manufacturer for 
instructions on how to repair certain conditions. Therefore, we provide 
the following clarification: Where the Accomplishment Instructions of 
the alert service bulletin specify to provide the details of any crack 
findings to Boeing for repair instructions, this proposed AD would 
require repairing those conditions in one of the following ways:
     Using a method we approve; or
     Using data that have been approved by an Authorized 
Representative for the Boeing Commercial Airplanes Delegation Option 
Authorization Organization whom we have authorized to make those 
findings.

Interim Action

    We consider this proposed AD interim action. The manufacturer is 
currently developing a modification that will address the unsafe 
condition identified in this proposed AD. Once this modification is 
developed, approved, and available, we may consider additional 
rulemaking.

Costs of Compliance

    There are about 232 airplanes of the affected design in the 
worldwide fleet. This proposed AD would affect about 123 airplanes of 
U.S. registry. The following table provides the estimated costs for 
U.S. operators to comply with this proposed AD.

                             Estimated Costs
------------------------------------------------------------------------
                                                  Average
          Airplane group            Work hours     hourly      Cost per
                                                 labor rate    airplane
------------------------------------------------------------------------
Group 1, Configuration 1.........           10          $65         $650
Group 1, Configuration 2.........           10           65          650
Group 1, Configuration 3.........            9           65          585
Group 2..........................            9           65          585
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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,

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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 and placed it in the AD docket. 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 Federal Aviation Administration (FAA) amends Sec.  39.13 by 
adding the following new airworthiness directive (AD):

Boeing: Docket No. FAA-2005-23313; Directorate Identifier 2005-NM-
111-AD.

Comments Due Date

    (a) The FAA must receive comments on this AD action by January 
30, 2006.

Affected ADs

    (b) This AD is related to AD 98-11-03, amendment 39-10530, as 
corrected by AD 98-11-03 R1, amendment 39-10983.

Applicability

    (c) This AD applies to all Boeing Model 727, 727C, 727-100 and 
727-100C series airplanes, certificated in any category.

Unsafe Condition

    (d) This AD results from reports of skin and bear strap cracking 
at the upper and lower hinge cutout and along the upper fastener row 
of the stringer 14R lap splice, and cracking in the doorstop fitting 
adjacent to the upper hinge cutout. There are also reports of 
cracking on airplanes previously modified to prevent such cracking. 
We are issuing this AD to find and fix fatigue cracking of the 
fuselage, which could result in reduced structural integrity and 
consequent 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 ``alert service bulletin,'' as used in this AD, 
means Boeing Alert Service Bulletin 727-53A0228, dated March 24, 
2005.

Repetitive Inspections

    (g) Accomplish the applicable inspections for any cracks 
(including stop-drilled, trimmed-out, or repaired cracks) in the 
body skin and bear strap at the upper and lower hinge cutouts of the 
mid-cabin galley doorway, along the upper fastener row of the 
stringer 14R lap splice, and in the doorstop fitting adjacent to the 
upper hinge cutout, as specified in Table 1 of paragraph 1.E. 
``Compliance'' of the alert service bulletin. Accomplish the 
inspections at the applicable compliance time specified in Table 1 
of paragraph 1.E.; except, where Table 1 specifies a compliance time 
relative to the date of the release of the alert service bulletin, 
this AD requires compliance relative to the effective date of this 
AD. Accomplish the inspections by doing all the applicable actions 
specified in the Accomplishment Instructions of the alert service 
bulletin. Inspections of door stop fittings made of 7075 material 
having part number (P/N) 65-23674-7 are not required. Repeat the 
applicable inspection at the applicable repeat interval specified in 
Table 1 of paragraph 1.E. of the alert service bulletin.

Corrective Action

    (h) If any cracking is found during any inspection required by 
paragraph (g) of this AD, repair the cracking and repeat the 
inspection at the applicable compliance time specified in Table 1 of 
paragraph 1.E. ``Compliance'' of the alert service bulletin. Do the 
repair by doing all the applicable actions specified in the 
Accomplishment Instructions of the alert service bulletin. Where the 
alert service bulletin specifies to report cracking to Boeing for 
repair instructions: Before further flight, repair any cracking 
according to a method approved by the Manager, Seattle Aircraft 
Certification Office (ACO), FAA; or using a method approved in 
accordance with paragraph (j)(3) of this AD.

Optional Terminating Action

    (i) Replacement of the doorstop fitting with a fitting made of 
7075 material having P/N 65-23674-7, in accordance with the 
Accomplishment Instructions of the alert service bulletin, 
terminates the repetitive inspections of that fitting, as required 
by paragraph (g) of this AD.

Alternative Methods of Compliance (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 Figures 9 through 12 of 
the alert service bulletin, as required by paragraph (g) of this AD, 
at the thresholds and intervals specified in paragraph (g), are 
approved as a method of compliance (MOC) to paragraph (b) of AD 98-
11-03 and 98-11-03 R1, for the inspections of Structurally 
Significant Item F-16A, Supplemental Structural Inspection Document 
D6-48040-1, affected by the repair or modification. The MOC applies 
only to the areas inspected in accordance with Boeing Alert Service 
Bulletin 727-53A0228, dated March 24, 2005. All provisions of AD 98-
11-03 R1 that are not specifically referenced in this paragraph 
remain fully applicable and must be complied with.
    (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 an 
Authorized Representative for the Boeing Commercial Airplanes 
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.
    (4) Before using any AMOC approved in accordance with 14 CFR 
39.19 on any airplane to which the AMOC applies, notify the 
appropriate principal inspector in the FAA Flight Standards 
Certificate Holding District Office.

    Issued in Renton, Washington, on December 8, 2005.
Michael Zielinski,
Acting Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 05-24052 Filed 12-14-05; 8:45 am]
BILLING CODE 4910-13-P