[Federal Register Volume 87, Number 185 (Monday, September 26, 2022)]
[Rules and Regulations]
[Pages 58259-58263]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2022-20773]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2022-0154; Project Identifier AD-2021-01153-T; 
Amendment 39-22162; AD 2022-18-11]
RIN 2120-AA64


Airworthiness Directives; The Boeing Company Airplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for all 
The

[[Page 58260]]

Boeing Company Model 777 airplanes. This AD was prompted by a report of 
a crack found in a front spar lower chord undergoing an underwing 
longeron replacement. This AD requires repetitive inspections for 
cracking of the left and right side ring chords, repair angles, front 
spar lower chords, and front spar webs (depending on configuration) 
common to the underwing longeron located at station (STA) 1035; 
modification of the front spar lower chord for some airplanes; 
repetitive post-modification inspections; and applicable on-condition 
actions. The FAA is issuing this AD to address the unsafe condition on 
these products.

DATES: This AD is effective October 31, 2022.
    The Director of the Federal Register approved the incorporation by 
reference of a certain publication listed in this AD as of October 31, 
2022.

ADDRESSES: For service information identified in this final rule, 
contact Boeing Commercial Airplanes, Attention: Contractual & Data 
Services (C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 
90740-5600; telephone 562-797-1717; internet myboeingfleet.com. You may 
view this service information at the FAA, Airworthiness Products 
Section, Operational Safety Branch, 2200 South 216th St., Des Moines, 
WA. For information on the availability of this material at the FAA, 
call 206-231-3195. It is also available at regulations.gov by searching 
for and locating Docket No. FAA-2022-0154.

Examining the AD Docket

    You may examine the AD docket at regulations.gov by searching for 
and locating Docket No. FAA-2022-0154; or in person at Docket 
Operations between 9 a.m. and 5 p.m., Monday through Friday, except 
Federal holidays. The AD docket contains this final rule, any comments 
received, and other information. The address for Docket Operations is 
U.S. Department of Transportation, Docket Operations, M-30, West 
Building Ground Floor, Room W12-140, 1200 New Jersey Avenue SE, 
Washington, DC 20590.

FOR FURTHER INFORMATION CONTACT: Luis Cortez-Muniz, Aerospace Engineer, 
Airframe Section, FAA, Seattle ACO Branch, 2200 South 216th St., Des 
Moines, WA 98198; phone and fax: 206-231-3958; email: [email protected].

SUPPLEMENTARY INFORMATION: 

Background

    The FAA issued a notice of proposed rulemaking (NPRM) to amend 14 
CFR part 39 by adding an AD that would apply to all The Boeing Company 
Model 777-200, -200LR, -300, -300ER, and 777F airplanes. The NPRM 
published in the Federal Register on March 25, 2022 (87 FR 17032). The 
NPRM was prompted by a report of a crack found in a front spar lower 
chord undergoing an underwing longeron replacement. In the NPRM, the 
FAA proposed to require repetitive inspections for cracking of the left 
and right side ring chords, repair angles, front spar lower chords, and 
front spar webs (depending on configuration) common to the underwing 
longeron located at STA 1035; modification of the front spar lower 
chord for some airplanes; repetitive post-modification inspections; and 
applicable on-condition actions. The FAA is issuing this AD to address, 
detect, and correct such cracking, which in combination with cracking 
in the front spar web, could result in a fuel leak and fire hazard, or 
in the case of more severe cracking, could also affect the structural 
integrity of the airplane.

Discussion of Final Airworthiness Directive

Comments

    The FAA received comments from two commenters, including Boeing and 
the Air Line Pilots Association, International (ALPA), who supported 
the NPRM without change.
    The FAA received additional comments from four commenters, 
including American Airlines, Delta Air Lines, FedEx Express (FedEx), 
and United Airlines. The following presents the comments received on 
the NPRM and the FAA's response to each comment.

Request To Clarify Whether Certain Modifications Terminate Certain 
Actions

    American Airlines (AAL) requested clarification on whether 
accomplishing certain modifications terminates certain inspections 
required by AD 2019-11-02, Amendment 39-19648 (84 FR 28722, June 20, 
2019) (AD 2019-11-02). AAL noted that tables 27 and 28 in paragraph 
1.E., ``Compliance,'' of Boeing Alert Requirements Bulletin 777-57A0122 
RB, dated October 8, 2021, specify modifying the left-hand and right-
hand front spar lower chord (FSLC), after which, the repeat inspections 
specified in tables 9 and 10 are terminated and new repeat inspections 
are specified. AAL noted that a related situation arises in Boeing 
Alert Service Bulletins 777-53A0081, Revision 2, dated March 29, 2019 
(required by AD 2019-11-02), in which a repeat inspection is specified 
for the underwing longerons (UWL) and then if a crack is found in that 
longeron, it is replaced and new repetitive inspections are specified. 
AAL added that Boeing confirmed that when the left-hand or right-hand 
FSLC is modified, then inspections specified in Boeing Alert Service 
Bulletins 777-53A0081, Revision 2, dated March 29, 2019; and Boeing 
Service Bulletin 777-53-0084, Revision 2, dated December 9, 2020 (which 
specifies modifying UWLs); would be satisfied for the modified side. 
AAL requested clarification on whether the proposed AD would be revised 
to state that the post-FSLC modification inspections in tables 27 and 
28 of Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 
8, 2021, would replace or supersede the post-modification inspections 
in tables 6, 7, and 8, as applicable, of Boeing Alert Service Bulletin 
777-53A0081, Revision 2, dated March 29, 2019, which is required by AD 
2019-11-02.
    The FAA agrees to clarify. Paragraph 4, ``Approval,'' of Boeing 
Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, 
states that the Manager of the FAA Seattle ACO Branch approves 
accomplishing UWL inspections, repairs, and modifications in accordance 
with Boeing Alert Requirements Bulletin 777-57A0122 RB, dated October 
8, 2021, as an alternative method of compliance (AMOC) to the 
inspection and corrective action requirements of paragraph (g) of AD 
2019-11-02, for the modified longeron on that side only. AD 2019-11-02 
would remain fully applicable to any unmodified side. The post-
modification actions required by paragraph (g) of this AD would remain 
applicable to any modified side. The FAA has not revised this AD in 
this regard.

Request To Correct the Number of Required Tables

    Delta Air Lines (Delta) requested adding a new exceptions paragraph 
to paragraph (h) of the proposed AD to correct the number of applicable 
tables specified in Boeing Alert Requirements Bulletin 777-57A0122 RB, 
dated October 8, 2021. Delta stated that in paragraph 1.E., 
``Compliance,'' of the RB, it states to accomplish the actions in 
``Tables 1 through 50,'' however, there are 54 tables that describe the 
necessary actions, not 50.
    The FAA agrees with the request. The FAA has added paragraph (h)(3) 
to this AD to specify ``Tables 1 through 54.''

[[Page 58261]]

Request To Address Formatting Issue With a Figure in Boeing Alert 
Requirements Bulletin 777-57A0122 RB, Dated October 8, 2021

    Delta requested that an exception be added to paragraph (h) of the 
proposed AD to address a formatting issue with Figure 20 in Boeing 
Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021. 
Delta stated that in Figure 20, Sheet 1 of 4, the text cuts off and 
there is no image, but the text and image continue on the next sheet.
    The FAA agrees that there appears to be a formatting issue with the 
text and image in Figure 20, Sheet 1 of 4, in Boeing Alert Requirements 
Bulletin 777-57A0122 RB, dated October 8, 2021. However, the figure 
does include all of the text and image, and contains all the required 
information. The FAA has not revised this AD in this regard.

Request To Allow a Certain Modification

    FedEx requested a revision to paragraph (h) of the proposed AD to 
allow a modification of the front spar using Section 57-10-10-2R in the 
Boeing 767 structural repair manual (SRM) as an alternate method of 
compliance for Boeing Alert Requirements Bulletin 777-57A0122 RB, dated 
October 8, 2021. FedEx explained that its review of Boeing Alert 
Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, did not 
show any difference in the post-modification inspection intervals for 
airplanes modified per the SRM section. FedEx added that the SRM repair 
has not been shown to be unsafe or unreliable, and operators and 
vendors may already have parts in stock to do the repair.
    The FAA disagrees with the commenter's request. The SRM referenced 
by FedEx is for Model 767 airplanes and would not apply to the Model 
777 airplanes referenced in this AD. The FAA infers that FedEx intended 
to refer to the Boeing 777 SRM, which has a similar repair. The FAA 
notes that Boeing Alert Requirements Bulletin 777-57A0122 RB, dated 
October 8, 2021, has configurations based in part on whether or not the 
FSLCs have been repaired using section 57-10-10 of the Boeing 777 SRM 
or similar Boeing ODA-approved repair, and that while the post-
modification intervals may be the same, certain configurations have an 
additional ultrasonic inspection. The FAA has determined that some of 
the materials specified in the SRM's repair instructions do not provide 
equivalent fatigue properties as the modification specified in Boeing 
Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021. 
However, under the provisions of paragraph (i) of this AD, the FAA will 
consider requests for alternative repairs or modification if sufficient 
data are submitted to substantiate that the alternative would provide 
an acceptable level of safety. The FAA has not changed this AD in this 
regard.

Request To Revise AMOC Statement

    FedEx requested a revision to the applicable longerons identified 
in the AMOC statement in paragraph 4, ``Approval,'' in Boeing Alert 
Requirements Bulletin 777-57A0122 RB, dated October 8, 2021. FedEx 
stated that the wording, ``only applies to modified longerons,'' is 
potentially misleading and should be revised to state ``only applies to 
underwing longerons modified by SB 777-57A0122 RB.'' FedEx noted that 
tables 39 and 40 of Boeing Alert Requirements Bulletin 777-57A0122 RB, 
dated October 8, 2021, include actions to inspect the modifications to 
the front spar, but omit any repetitive inspections of the UWL 
modification. Thus, FedEx reasoned, an operator could incorrectly 
interpret the AMOC statement as applying to airplanes previously 
modified by Boeing Service Bulletin 777-53-0084, Revision 1, dated 
March 4, 2020, and stop accomplishing the repetitive UWL inspections 
required by AD 2019-11-02.
    The FAA agrees to clarify the AMOC statement in Boeing Alert 
Requirements Bulletin 777-57A0122 RB, dated October 8, 2021. The AMOC 
statement does not extend to airplanes previously modified by Boeing 
Service Bulletin 777-53-0087 or 777-53-0084. The AMOC statement's 
applicability is limited to UWL inspections, repairs, and modifications 
accomplished in accordance with Boeing Alert Requirements Bulletin 777-
57A0122 RB, dated October 8, 2021. The AMOC does not extend to 
modifications done in accordance with any other service information. 
Further, the AMOC applies only to the actions required by paragraph (g) 
of AD 2019-11-02, which requires only Boeing Alert Service Bulletin 
777-53A0081, Revision 2, dated March 29, 2019. The FAA has not changed 
this AD in this regard.

Request To Reference Service Bulletin Instead of Requirements Bulletin

    FedEx requested revising the proposed AD to reference Boeing Alert 
Service Bulletin 777-57A0122, dated October 8, 2021, instead of Boeing 
Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021. 
FedEx noted that Boeing Alert Service Bulletin 777-57A0122, dated 
October 8, 2021, is written in a manner consistent with FAA Advisory 
Circular 20-176, and that Boeing Alert Requirements Bulletin 777-
57A0122 RB, dated October 8, 2021, duplicates the figures and tables 
from the service bulletin version to a point where it is cumbersome. 
FedEx also stated that the duplication could lead to discrepancies 
between the duplicated data. FedEx added that the RB document is only 
available as part of Boeing Alert Service Bulletin 777-57A0122, dated 
October 8, 2021, so the proposed AD would not be referencing an 
independent document.
    The FAA disagrees with the commenter's request. As noted in Note 1 
to paragraph (g) of this AD, the service bulletin may be used for 
guidance. Boeing Alert Requirements Bulletin 777-57A0122 RB, dated 
October 8, 2021, and the required for compliance (``RC'') steps 
included in Boeing Alert Service Bulletin 777-57A0122, dated October 8, 
2021, include identical information. Therefore, complying with the 
``RC'' steps in Boeing Alert Service Bulletin 777-57A0122, dated 
October 8, 2021, would also satisfy the requirements of this AD. The 
FAA notes that the requirements bulletin contains only the steps that 
are required for compliance with this AD and is posted to Docket No. 
FAA-2022-0154. The related service bulletin contains additional 
information that may be helpful when complying with the AD, but is not 
needed for compliance. Therefore, this AD specifies the requirements 
bulletin, not the service bulletin. The FAA has not changed this AD in 
this regard.

Request To Reduce Number of Groups and Configurations

    United Airlines (United) requested a revision to Boeing Alert 
Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, to reduce 
the large number of airplane groups and configurations identified in 
the service information. United stated that the large number of groups 
and configurations creates a planning challenge, and could increase the 
potential for errors and non-compliance.
    The FAA acknowledges the commenter's concerns about the relatively 
large number of airplane groups and configurations identified. However, 
the large number of airplane groups and configurations are necessary to 
address the unsafe condition in a fleet with differences in existing 
repairs and modifications in the inspected area. The FAA has not 
changed this AD in this regard.

[[Page 58262]]

Request To Extend Compliance Time

    United requested an extension to the compliance time(s) for 
accomplishing the initial inspection. United explained that the initial 
inspection involves entering the center tank, and that the current 
compliance time would require accomplishing the inspection at 
maintenance intervals that usually do not involve entering the center 
tank. United explained that adding the task of entering the center tank 
to those visits would extend the out-of-service time during those 
visits and would result in increased costs to operators.
    The FAA disagrees with the request to revise the compliance time. 
In developing an appropriate compliance time, the FAA considered the 
urgency associated with the subject unsafe condition, the availability 
of required parts, and the practical aspect of accomplishing the 
required modification within a period of time that corresponds to the 
normal scheduled maintenance for most affected operators. The FAA has 
determined that the compliance time provides an acceptable level of 
safety. However, under the provisions of paragraph (i) of this AD, the 
FAA will consider requests for an extension of the compliance time if 
sufficient data are submitted to substantiate that the change would 
provide an acceptable level of safety. The FAA has not changed this AD 
in this regard.

Conclusion

    The FAA reviewed the relevant data, considered any comments 
received, and determined that air safety requires adopting this AD as 
proposed. Except for minor editorial changes, and any other changes 
described previously, this AD is adopted as proposed in the NPRM. None 
of the changes will increase the economic burden on any operator.

Related Service Information Under 1 CFR Part 51

    The FAA reviewed Boeing Alert Requirements Bulletin 777-57A0122 RB, 
dated October 8, 2021. This service information specifies procedures 
for repetitive high frequency eddy current (HFEC), detailed, and 
ultrasonic inspections (depending on configuration) for cracking of the 
left and right side ring chords, repair angles, front spar lower 
chords, and front spar webs (depending on configuration) common to the 
underwing longeron located at STA 1035; modification of the front spar 
lower chord for some airplanes; repetitive post-modification 
inspections; and applicable on-condition actions. On-condition actions 
include repair. This service information is reasonably available 
because the interested parties have access to it through their normal 
course of business or by the means identified in ADDRESSES.

Costs of Compliance

    The FAA estimates that this AD affects 261 airplanes of U.S. 
registry. The FAA estimates the following costs to comply with this AD:

                                                 Estimated Costs
----------------------------------------------------------------------------------------------------------------
                                                                                                 Cost on U.S.
              Action                    Labor cost        Parts cost      Cost per product        operators
----------------------------------------------------------------------------------------------------------------
Inspection(s)....................  44 work-hours x $85              $0  $3,750 per           $976,140 per
                                    per hour = $3,750                    inspection cycle.    inspection cycle.
                                    per inspection
                                    cycle.
Modification *...................  137 work-hours x            $47,964  $59,609............  Up to $15,557,949.
                                    $85 per hour =
                                    $11,645.
Post-modification inspection(s) *  46 work-hours x $85              $0  $3,910 per           Up to $1,020,510
                                    per hour = $3,910                    inspection cycle.    per inspection
                                    per inspection                                            cycle.
                                    cycle.
----------------------------------------------------------------------------------------------------------------
* Number of affected airplanes that will be required to do this action is unknown

    The FAA has received no definitive data on which to base the cost 
estimates for the repairs specified in this AD.
    The FAA has included all known costs in its cost estimate. 
According to the manufacturer, however, some or all of the costs of 
this AD may be covered under warranty, thereby reducing the cost impact 
on affected operators.

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.
    The FAA is 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

    This AD will not have federalism implications under Executive Order 
13132. This 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 this AD:
    (1) Is not a ``significant regulatory action'' under Executive 
Order 12866,
    (2) Will not affect intrastate aviation in Alaska, 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.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

The Amendment

    Accordingly, under the authority delegated to me by the 
Administrator, the FAA amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

    Authority:  49 U.S.C. 106(g), 40113, 44701.

[[Page 58263]]

Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

2022-18-11 The Boeing Company: Amendment 39-22162; Docket No. FAA-
2022-0154; Project Identifier AD-2021-01153-T.

(a) Effective Date

    This airworthiness directive (AD) is effective October 31, 2022.

(b) Affected ADs

    None.

(c) Applicability

    This AD applies to all The Boeing Company Model 777-200, -200LR, 
-300, -300ER, and 777F airplanes, certificated in any category.

(d) Subject

    Air Transport Association (ATA) of America Code 57, Wings.

(e) Unsafe Condition

    This AD was prompted by a report of a crack found in a front 
spar lower chord undergoing an underwing longeron replacement. The 
FAA is issuing this AD to detect and correct such cracking, which in 
combination with cracking in the front spar web, could result in a 
fuel leak and fire hazard, or in the case of more severe cracking, 
could also affect the structural integrity of the airplane.

(f) Compliance

    Comply with this AD within the compliance times specified, 
unless already done.

(g) Required Actions

    Except as specified by paragraph (h) of this AD: At the 
applicable times specified in the ``Compliance'' paragraph of Boeing 
Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, 
do all applicable actions identified in, and in accordance with, the 
Accomplishment Instructions of Boeing Alert Requirements Bulletin 
777-57A0122 RB, dated October 8, 2021. Actions identified as 
terminating action in Boeing Alert Requirements Bulletin 777-57A0122 
RB, dated October 8, 2021, terminate the applicable required actions 
of this AD, provided the terminating action is done in accordance 
with the Accomplishment Instructions of Boeing Alert Requirements 
Bulletin 777-57A0122 RB, dated October 8, 2021.

    Note 1 to paragraph (g):  Guidance for accomplishing the actions 
required by this AD can be found in Boeing Alert Service Bulletin 
777-5A0122, dated October 8, 2021, which is referred to in Boeing 
Alert Requirements Bulletin 777-57A0122 RB, dated October 8, 2021.

(h) Exceptions to Service Information Specifications

    (1) Where the Compliance Time columns of the tables in the 
``Compliance'' paragraph of Boeing Alert Requirements Bulletin 777-
57A0122 RB, dated October 8, 2021, use the phrase ``the original 
issue date of Requirements Bulletin 777-57A0122 RB,'' this AD 
requires using ``the effective date of this AD.''
    (2) Where Boeing Alert Requirements Bulletin 777-57A0122 RB, 
dated October 8, 2021, specifies contacting Boeing for repair 
instructions: This AD requires doing the repair using a method 
approved in accordance with the procedures specified in paragraph 
(i) of this AD.
    (3) Where the ``Compliance'' paragraph of Boeing Alert 
Requirements Bulletin 777-57A0122 RB, dated October 8, 2021, uses 
the phrase ``Tables 1 through 50,'' this AD requires using ``Tables 
1 through 54.''

(i) Alternative Methods of Compliance (AMOCs)

    (1) The Manager, Seattle ACO Branch, FAA, has the authority to 
approve AMOCs for this AD, if requested using the procedures found 
in 14 CFR 39.19. In accordance with 14 CFR 39.19, send your request 
to your principal inspector or responsible Flight Standards Office, 
as appropriate. If sending information directly to the manager of 
the certification office, send it to the attention of the person 
identified in paragraph (j)(1) of this AD. Information may be 
emailed to: [email protected].
    (2) Before using any approved AMOC, notify your appropriate 
principal inspector, or lacking a principal inspector, the manager 
of the responsible Flight Standards Office.
    (3) An AMOC that provides an acceptable level of safety may be 
used for any repair, modification, or alteration required by this AD 
if it is approved by The Boeing Company Organization Designation 
Authorization (ODA) that has been authorized by the Manager, Seattle 
ACO Branch, FAA, to make those findings. To be approved, the repair 
method, modification deviation, or alteration deviation must meet 
the certification basis of the airplane, and the approval must 
specifically refer to this AD.

(j) Related Information

    (1) For more information about this AD, contact Luis Cortez-
Muniz, Aerospace Engineer, Airframe Section, FAA, Seattle ACO 
Branch, 2200 South 216th St., Des Moines, WA 98198; phone and fax: 
206-231-3958; email: [email protected].
    (2) Service information identified in this AD that is not 
incorporated by reference is available at the addresses specified in 
paragraphs (k)(3) and (4) of this AD.

(k) Material Incorporated by Reference

    (1) The Director of the Federal Register approved the 
incorporation by reference (IBR) of the service information listed 
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
    (2) You must use this service information as applicable to do 
the actions required by this AD, unless the AD specifies otherwise.
    (i) Boeing Alert Requirements Bulletin 777-57A0122 RB, dated 
October 8, 2021.
    (ii) [Reserved]
    (3) For service information identified in this AD, contact 
Boeing Commercial Airplanes, Attention: Contractual & Data Services 
(C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-
5600; telephone 562-797-1717; internet myboeingfleet.com.
    (4) You may view this service information at the FAA, 
Airworthiness Products Section, Operational Safety Branch, 2200 
South 216th St., Des Moines, WA. For information on the availability 
of this material at the FAA, call 206-231-3195.
    (5) You may view this service information that is incorporated 
by reference at the National Archives and Records Administration 
(NARA). For information on the availability of this material at 
NARA, [email protected], or go to: archives.gov/federal-register/cfr/ibr-locations.html.

    Issued on August 23, 2022.
Christina Underwood,
Acting Director, Compliance & Airworthiness Division, Aircraft 
Certification Service.
[FR Doc. 2022-20773 Filed 9-23-22; 8:45 am]
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