Airworthiness Directives; Boeing Model 757-200, -200PF, and -200CB Series Airplanes, 26875-26877 [E6-7007]

Agencies

• Federal Aviation Administration
• DEPARTMENT OF TRANSPORTATION

[Federal Register Volume 71, Number 89 (Tuesday, May 9, 2006)]
[Proposed Rules]
[Pages 26875-26877]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: E6-7007]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2006-24697; Directorate Identifier 2006-NM-045-AD]
RIN 2120-AA64


Airworthiness Directives; Boeing Model 757-200, -200PF, and -
200CB 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 Model 757-200, -200PF, and -200CB series airplanes. 
This proposed AD would require doing initial and repetitive detailed or 
high frequency eddy current inspections for cracks around the rivets at 
the upper fastener row of the skin lap splice of the fuselage, and 
repairing any crack found. This proposed AD results from a report 
indicating that certain modified rivets were incorrectly installed in 
some areas of the skin lap splices during production because they were 
drilled with a countersink that was too deep. We are proposing this AD 
to detect and correct premature fatigue cracking at certain skin lap 
splice locations of the fuselage, and consequent rapid decompression of 
the airplane.

DATES: We must receive comments on this proposed AD by June 23, 2006.

ADDRESSES: Use one of the following addresses to submit comments on 
this proposed AD.
     DOT Docket Web site: Go to https://dms.dot.gov and follow 
the instructions for sending your comments electronically.
     Government-wide rulemaking Web site: Go to https://
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: Dennis Stremick, Aerospace Engineer, 
Airframe Branch, ANM-120S, FAA, Seattle Aircraft Certification Office, 
1601 Lind Avenue, SW., Renton, Washington 98055-4056; telephone (425) 
917-6450; 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-
24697; Directorate Identifier 2006-NM-045-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 https://
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 https://dms.dot.gov.

Examining the Docket

    You may examine the AD docket on the Internet at https://
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 certain modified rivets 
were incorrectly installed in some areas of the skin lap splices of the 
fuselage during production because they were drilled with a countersink 
that was too deep. The deep countersink makes a knife edge condition in 
the skin panel. The knife edge condition can lead to cracks in the skin 
lap splices of the fuselage. This premature fatigue cracking could 
result in rapid decompression of the airplane.

Relevant Service Information

    We have reviewed Boeing Special Attention Service Bulletin 757-53-
0090, dated June 2, 2005. The service bulletin describes the following 
procedures, depending on the airplane configuration:
     Doing initial and repetitive detailed or high frequency 
eddy current (HFEC) inspections for cracks of the skin lap splice of 
the fuselage;
     Contacting Boeing for repair of cracking; and
     Sending inspection results to Boeing.
    The service bulletin recommends compliance times at the following 
intervals:

              Service Bulletin Recommended Compliance Times
------------------------------------------------------------------------
                Action                    Recommended compliance times
------------------------------------------------------------------------
Initial detailed or HFEC inspection..  Before the accumulation of 37,500
                                        total flight cycles or 3,000
                                        flight cycles after issuance of
                                        the service bulletin, whichever
                                        is later.
Repetitive detailed inspections......  Intervals not to exceed 1,200
                                        flight cycles.

[[Page 26876]]

 
Repetitive HFEC inspections..........  Intervals not to exceed 12,000
                                        flight cycles.
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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.''

Differences Between the Proposed AD and Service Bulletin

    The service bulletin specifies that you may contact the 
manufacturer for instructions on how to repair certain conditions, but 
this proposed AD would require you to repair those conditions in one of 
the following ways:
     Using a method that we approve; or
     Using data that meet the certification basis of the 
airplane, and that have been approved by an Authorized Representative 
for the Boeing Delegation Option Authorization Organization whom we 
have authorized to make those findings.
    The Accomplishment Instructions of the service bulletin specify 
reporting inspection findings to the manufacturer. This proposed AD 
would not require that action. We do not need this information from 
operators.
    These differences have been coordinated with the manufacturer.

Costs of Compliance

    There are about 294 airplanes of the affected design in the 
worldwide fleet. This proposed AD would affect about 160 airplanes of 
U.S. registry. The following tables provide the estimated costs for 
U.S. operators to comply with either the detailed or HFEC inspections 
in this proposed AD.

      Estimated Costs for Detailed Inspection, per Inspection Cycle
------------------------------------------------------------------------
                                                  Average
          Airplane group            Work hours     hourly      Cost per
                                                 labor rate    airplane
------------------------------------------------------------------------
Group 1..........................            7          $80         $560
Group 2..........................            6           80          480
Group 3..........................           12           80          960
Group 4..........................           10           80          800
------------------------------------------------------------------------


        Estimated Costs for HFEC Inspection, per Inspection Cycle
------------------------------------------------------------------------
                                                  Average
          Airplane group            Work hours     hourly      Cost per
                                                 labor rate    airplane
------------------------------------------------------------------------
Group 1..........................           12          $80         $960
Group 2..........................           11           80          880
Group 3..........................           20           80        1,600
Group 4..........................           15           80        1,200
------------------------------------------------------------------------

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.

[[Page 26877]]

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-2006-24697; Directorate Identifier 2006-NM-
045-AD.

Comments Due Date

    (a) The FAA must receive comments on this AD action by June 23, 
2006.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Boeing Model 757-200, -200PF, and -200CB 
series airplanes, certificated in any category; as identified in 
Boeing Special Attention Service Bulletin 757-53-0090, dated June 2, 
2005.

Unsafe Condition

    (d) This AD results from a report indicating that certain 
modified rivets were incorrectly installed in some areas of the skin 
lap splices during production because they were drilled with a 
countersink that was too deep. We are issuing this AD to detect and 
correct premature fatigue cracking at certain skin lap splice 
locations of the fuselage 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.

Initial and Repetitive Inspections

    (f) Do initial and repetitive detailed or high frequency eddy 
current inspections for cracking around the rivets at the upper 
fastener row of the skin lap splice of the fuselage by doing all the 
actions in accordance with the Accomplishment Instructions of Boeing 
Special Attention Service Bulletin 757-53-0090, dated June 2, 2005, 
except as provided by paragraphs (g) and (h) of this AD. Do the 
inspections at the applicable times specified in Paragraph 1.E., 
``Compliance,'' of the service bulletin; except where the service 
bulletin specifies a compliance time after the original release date 
of the service bulletin, this AD requires compliance after the 
effective date of this AD.

Repair

    (g) If any crack is found during any inspection required by this 
AD: Before further flight, repair the crack using a method approved 
in accordance with the procedures specified in paragraph (i) of this 
AD.

No Reporting Required

    (h) Although Boeing Special Attention Service Bulletin 757-53-
0090, dated June 2, 2005, recommends that inspection results be 
reported to the manufacturer, this AD does not include that 
requirement.

Alternative Methods of Compliance (AMOCs)

    (i)(1) The Manager, Seattle Aircraft Certification Office (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 certification basis 
of the airplane.

    Issued in Renton, Washington, on April 28, 2006.
Ali Bahrami,
Manager, Transport Airplane Directorate, Aircraft Certification 
Service.
 [FR Doc. E6-7007 Filed 5-8-06; 8:45 am]
BILLING CODE 4910-13-P