[Federal Register Volume 71, Number 16 (Wednesday, January 25, 2006)]
[Proposed Rules]
[Pages 4069-4072]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E6-903]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2006-23672; Directorate Identifier 2005-NM-237-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 727, 727C, 727-100, 727-
100C, and 727-200 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 certain Boeing transport category airplanes. This proposed AD would 
require determining if the terminal fittings of the spars of the wings 
are made of 7079 aluminum alloy material. For any positive finding, the 
proposed AD would require doing repetitive inspections for cracks and 
corrosion of all exposed surfaces of the terminal fitting bores; doing 
repetitive inspections for cracks, corrosion, and other surface 
defects, of all exposed surfaces, including the flanges, of the 
terminal fitting; applying corrosion inhibiting compound to the 
terminal fittings; and repairing or replacing any cracked, corroded, or 
defective part with a new part. This proposed AD also provides for an 
optional terminating action for the repetitive inspections. This 
proposed AD results from reports of cracking of the terminal fittings 
of the spars of the wings. We are proposing this AD to detect and 
correct stress-corrosion cracking of the terminal fittings, which could 
result in the failure of one of the terminal fitting connections. Such 
a failure, combined with a similar failure of one of the other three 
terminal fittings, could result in the inability of the airplane 
structure to carry fail-safe loads, which could result in loss of 
structural integrity of the wing attachment points.

DATES: We must receive comments on this proposed AD by March 13, 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, 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. Send your comments to an address 
listed in the ADDRESSES section. Include the docket number ``FAA-2006-
23672; Directorate Identifier 2005-NM-237-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

[[Page 4070]]

(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 reports of cracking of the terminal fittings of 
the front and rear spars of the wings. The affected terminal fittings 
were made from a 7079-T6 aluminum forging. This material is known to be 
susceptible to stress-corrosion cracking. This condition, if not 
detected and corrected, could result in the failure of one of the 
terminal fitting connections. Such a failure, combined with a similar 
failure of one of the other three terminal fittings, could result in 
the inability of the airplane structure to carry fail-safe loads, which 
could result in loss of structural integrity of the wing attachment 
points.

Relevant Service Information

    We have reviewed Boeing Alert Service Bulletin 727-57A0185, 
Revision 1, dated November 3, 2005. The service bulletin describes 
procedures for determining if the terminal fittings of the front and 
rear spars of the wings are made of 7079 aluminum alloy material by 
either inspecting the forging number or doing a conductivity test. For 
any case where the terminal fitting is determined to be made of 7079 
aluminum alloy material or where the material cannot be determined, the 
service bulletin describes procedures for doing repetitive fluorescent 
dye penetrant inspections for cracks and corrosion of all exposed 
surfaces of the terminal fitting bores; doing repetitive detailed 
inspections for cracks, corrosion, and other surface defects, of all 
exposed surfaces, including the flanges, of the terminal fitting; 
applying corrosion inhibiting compound to the terminal fittings; and 
repairing any cracked, corroded, or defective part or contacting Boeing 
if necessary.

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 
``Differences Between the Proposed AD and Service Bulletin.'' In 
addition, the proposed AD would provide for an optional terminating 
action for the repetitive inspections. The proposed AD also would 
require sending the initial inspection results to Boeing.

Differences Between the Proposed AD and Service Bulletin

    The service bulletin specifies to contact the manufacturer for 
instructions on how to repair certain conditions, but this proposed AD 
would require repairing 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 Commercial Airplanes Delegation Option Authorization 
Organization whom we have authorized to make those findings.
    In paragraph 1.E., the service bulletins states, ``Contact Boeing 
for replacement of the fitting with a fitting not made from 7079 
aluminum alloy. Replacement of the fitting is considered terminating 
action for that fitting only.'' However, the Accomplishment 
Instructions of the service bulletin do not contain any procedures for 
accomplishing this replacement. Therefore, this proposed AD specifies 
that the optional replacement be done in accordance with a method 
approved by the Manager, Seattle Aircraft Certification Office.

Interim Action

    This proposed AD is considered to be interim action. The inspection 
reports that are required by this AD will enable the manufacturer to 
obtain better insight into the extent of the cracking and corrosion of 
the terminal fittings of the front and rear spars of the wings in the 
fleet, and to develop additional action if necessary to address the 
unsafe condition. If additional action is identified, we may consider 
further rulemaking.

Costs of Compliance

    There are about 302 airplanes of the affected design in the 
worldwide fleet. This proposed AD would affect about 157 airplanes of 
U.S. registry. The proposed determination of forging number/material 
identification would take about 4 work hours 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 $40,820, or 
$260 per airplane.
    Accomplishing the fluorescent dye penetrant and detailed 
inspections, if required, will take about 16 work hours per airplane, 
at an average labor rate of $65 per work hour. Based on these figures, 
we estimate the cost of the inspections to be $1,040 per airplane, per 
inspection cycle.

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 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:

[[Page 4071]]

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-2006-23672; Directorate Identifier 2005-NM-
237-AD.

Comments Due Date

    (a) The FAA must receive comments on this AD action by March 13, 
2006.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 727, 727C, 727-100, 727-
100C, and 727-200 series airplanes, certificated in any category; as 
identified in Boeing Alert Service Bulletin 727-57A0185, Revision 1, 
dated November 3, 2005.

Unsafe Condition

    (d) This AD results from reports of cracking of the terminal 
fittings of the front and rear spars of the wings. We are issuing 
this AD to detect and correct stress-corrosion cracking of the 
terminal fittings, which could result in the failure of one of the 
terminal fitting connections. Such a failure, combined with a 
similar failure of one of the other three terminal fittings, could 
result in the inability of the airplane structure to carry fail-safe 
loads, which could result in loss of structural integrity of the 
wing attachment points.

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.

Determination of Type of Terminal Fittings, Repetitive Inspections, and 
Corrective Actions

    (f) Within 24 months after the effective date of this AD, 
determine if the terminal fittings of the front and rear spars of 
the wings are made of 7079 aluminum alloy material by either 
inspecting the forging number or doing a conductivity test, in 
accordance with the Accomplishment Instructions of Boeing Alert 
Service Bulletin 727-57A0185, Revision 1, dated November 3, 2005.
    (1) If the forging number is that identified in Table 1 of this 
AD, or if the terminal fitting material is not made of 7079 aluminum 
alloy: No further action is required by this AD for that terminal 
fitting only.

        Table 1.--Forging Numbers Not Made of 7079 Aluminum Alloy
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     Forging No. of terminal fittings                 Location
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(i) 65-16214-3............................  Rear spar of left wing.
(ii) 65-16213-3...........................  Front spar of left wing.
(iii) 65-16214-4..........................  Rear spar of right wing.
(iv) 65-16213-4...........................  Front spar of right wing.
------------------------------------------------------------------------

    (2) If any forging number other than those identified in Table 1 
of this AD is found, or if any forging material is made of 7079 
aluminum alloy, or if the material cannot be determined: Within 24 
months after the effective date of this AD, do the inspections 
specified in Table 2 of this AD and apply corrosion inhibiting 
compound (CIC) to the terminal fittings, and before further flight, 
repair or replace any cracked, corroded, or defective part found 
during the inspections. Repeat the inspections thereafter at 
intervals not to exceed 60 months for the first two repeat 
intervals, and then thereafter at intervals not to exceed 30 months. 
Do the inspections, application of CIC, and repair in accordance 
with the service bulletin, except as provided by paragraphs (h) and 
(i) of this AD. Do the replacement in accordance with paragraph (g) 
of this AD.

                          Table 2.--Inspections
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             Do--                     For--                 Of--
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(i) A fluorescent dye           Cracks and         All exposed surfaces
 penetrant inspection.           corrosion.         of the terminal
                                                    fitting bores.
(ii) A detailed inspection....  Cracks,            All exposed surfaces,
                                 corrosion, and     including the
                                 other surface      flanges, of the
                                 defects.           terminal fitting.
------------------------------------------------------------------------

Optional Terminating Action

    (g) Replacement of any terminal fitting of the front and rear 
spars of the wings with a new terminal fitting not made of 7079 
aluminum alloy, in accordance with a method approved by the Manager, 
Seattle Aircraft Certification Office (ACO), FAA, ends the 
repetitive inspections required by paragraph (f)(2) of this AD for 
that terminal fitting only. For the replacement to be approved by 
the Manager, Seattle ACO, as required by this paragraph, the 
Manager's approval letter must specifically refer to this AD.

Exception to Service Information

    (h) Where the service bulletin specifies to contact Boeing for 
appropriate action:
    Before further flight, repair the cracked, corroded, or 
defective part using a method approved in accordance with the 
procedures specified in paragraph (l) of this AD, or replace in 
accordance with paragraph (g) of this AD.
    (i) Although the note in paragraph 3.B.7. of the service 
bulletin specifies procedures for a fluorescent dye penetrant 
inspection of the body fitting bore and repair if necessary, those 
procedures are not required by this AD.

Parts Installation

    (j) As of the effective date of this AD, no person may install 
any terminal fitting having forging number 65-16213-1/-2 or 65-
16214-1/-2, or install any terminal fitting material made of 7079 
aluminum alloy, on any airplane.

Reporting

    (k) Submit a report of the findings (both positive and negative) 
of the initial inspection required by paragraph (f)(2) of this AD to 
Boeing Commercial Airplane Group, Attention: Manager, Airline 
Support, P.O. Box 3707, Seattle, WA 98124-2207, at the applicable 
time specified in paragraph (k)(1) or (k)(2) of this AD. The report 
must include the operator's name, inspection results, a detailed 
description of any discrepancies found, the airplane serial number, 
and the number of flight cycles and flight hours on the airplane. 
Under the provisions of the Paperwork Reduction Act of 1980 (44 
U.S.C. 3501 et seq.), the Office of Management and Budget (OMB) has 
approved the information collection requirements contained in this 
AD and has assigned OMB Control Number 2120-0056.
    (1) If the inspection was done after the effective date of this 
AD: Submit the report within 30 days after the inspection.
    (2) If the inspection was accomplished prior to the effective 
date of this AD: Submit the report within 30 days after the 
effective date of this AD.

Alternative Methods of Compliance (AMOCs)

    (l)(1) The Manager, Seattle ACO, FAA, has the authority to 
approve AMOCs for this AD, if requested in accordance with the 
procedures found in 14 CFR 39.19.
    (2) Before using any AMOC approved in accordance with Sec.  
39.19 on any airplane to which the AMOC applies, notify the 
appropriate principal inspector in the FAA Flight Standards 
Certificate Holding District Office.
    (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

[[Page 4072]]

certification basis of the airplane, and the approval must 
specifically refer to this AD.

    Issued in Renton, Washington, on January 17, 2006.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. E6-903 Filed 1-24-06; 8:45 am]
BILLING CODE 4910-13-P