Revisions to Digital Flight Data Recorder Regulations for Boeing 737 Airplanes and for Part 125 Operators, 52382-52401 [06-7406]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Parts 91, 121, and 125
[Docket No.: FAA–1999–6482; Notice No.
06–12]
RIN 2120–AG87
Revisions to Digital Flight Data
Recorder Regulations for Boeing 737
Airplanes and for Part 125 Operators
Federal Aviation
Administration (FAA), DOT.
ACTION: Supplemental Notice of
Proposed Rulemaking (SNPRM).
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AGENCY:
SUMMARY: The FAA is revising a
previous proposal to increase the
number of digital flight data recorder
(DFDR) parameters required for all
Boeing 737 series airplanes. Based on
safety recommendations from the
National Transportation Safety Board
(NTSB) following the investigations of
two accidents and other incidents
involving 737s, the FAA proposed the
addition of flight recorder equipment to
monitor the rudder system on 737s.
Since that time, the FAA has mandated
significant changes to the rudder system
on these airplanes. Accordingly, this
new proposed rule would apply to a
different set of airplanes than originally
anticipated. We are requesting comment
on this change in applicability and are
requesting updated economic
information regarding installation of the
proposed monitoring equipment. The
original proposed rule also sought to
amend the flight data recorder (FDR)
requirements of part 125 that would
affect all airplanes operated under that
part or under deviation from that part;
we have included that same proposal in
this SNPRM.
DATES: Send your comments on or
before December 4, 2006.
ADDRESSES: You may send comments
identified by Docket Number FAA–
1999–6482 using any of the following
methods:
• 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–
0001.
• Fax: 1–202–493–2251.
• Hand Delivery: Room PL–401 on
the plaza level of the Nassif Building,
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400 Seventh Street, SW., Washington,
DC, between 9 a.m. and 5 p.m., Monday
through Friday, except Federal holidays.
For more information on the
rulemaking process, see the
SUPPLEMENTARY INFORMATION section of
this document.
Privacy: We will post all comments
we receive, without change, to https://
dms.dot.gov, including any personal
information you provide. For more
information, see the Privacy Act
discussion in the SUPPLEMENTARY
INFORMATION section of this document.
Docket: To read background
documents or comments received, go to
https://dms.dot.gov at any time or to
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 FURTHER INFORMATION CONTACT: For
technical issues: Timothy W. Shaver,
Avionics Systems Branch, Aircraft
Certification Service, AIR–130, Federal
Aviation Administration, 800
Independence Avenue, SW.,
Washington, DC 20591; telephone (202)
385–4686; facsimile (202) 385–4651; email tim.shaver@faa.gov. For legal
issues: Karen L. Petronis, Senior
Attorney, Regulations Division, AGC–
200, Office of the Chief Counsel, Federal
Aviation Administration, 800
Independence Ave., SW., Washington,
DC 20591; telephone (202) 267–3073;
facsimile (202) 267–7971; e-mail:
karen.petronis@faa.gov.
SUPPLEMENTARY INFORMATION:
Comments Invited
The FAA invites interested persons to
participate in this rulemaking by
submitting written comments, data, or
views. We also invite comments relating
to the economic, environmental, energy,
or federalism impacts that might result
from adopting the proposals in this
document. The most helpful comments
reference a specific portion of the
proposal, explain the reason for any
recommended change, and include
supporting data. We ask that you send
us two copies of written comments.
We will file in the docket all
comments we receive, as well as a
report summarizing each substantive
public contact with FAA personnel
concerning this proposed rulemaking.
The docket is available for public
inspection before and after the comment
closing date. If you wish to review the
docket in person, go to the address in
the ADDRESSES section of this preamble
between 9 a.m. and 5 p.m., Monday
through Friday, except Federal holidays.
You may also review the docket using
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the Internet at the Web address in the
section.
Privacy Act: Using the search function
of our docket Web site, anyone can find
and read the comments received into
any of our dockets, including the name
of the individual sending the comment
(or signing 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.
Before acting on this proposal, we
will consider all comments we receive
on or before the closing date for
comments. We will consider comments
filed late if it is possible to do so
without incurring expense or delay. We
may change this proposal in light of the
comments we receive.
If you want the FAA to acknowledge
receipt of your comments on this
proposal, include with your comments
a pre-addressed, stamped postcard on
which the docket number appears. We
will stamp the date on the postcard and
mail it to you.
ADDRESSES
Proprietary or Confidential Business
Information
Do not file in the docket information
that you consider to be proprietary or
confidential business information. Send
or deliver this information directly to
the person identified in the FOR FURTHER
INFORMATION CONTACT section of this
document. You must mark the
information that you consider
proprietary or confidential. If you send
the information on a disk or CD–ROM,
mark the outside of the disk or CD–ROM
and also identify electronically within
the disk or CD–ROM the specific
information that is proprietary or
confidential.
Under 14 CFR 11.35(b), when we are
aware of proprietary information filed
with a comment, we do not place it in
the docket. We hold it in a separate file
to which the public does not have
access, and place a note in the docket
that we have received it. If we receive
a request to examine or copy this
information, we treat it as any other
request under the Freedom of
Information Act (5 U.S.C. 552). We
process such a request under the DOT
procedures found in 49 CFR part 7.
Availability of Rulemaking Documents
You can get an electronic copy using
the Internet by:
(1) Searching the Department of
Transportation’s electronic Docket
Management System (DMS) Web page
(https://dms.dot.gov/search);
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Federal Register / Vol. 71, No. 171 / Tuesday, September 5, 2006 / Proposed Rules
(2) Visiting the FAA’s Regulations and
Polices Web page at https://www.faa.gov/
regulations_policies/; or
(3) Accessing the Government
Printing Office’s Web page at https://
www.gpoaccess.gov/fr/.
You can also get a copy by sending a
request to the Federal Aviation
Administration, Office of Rulemaking,
ARM–1, 800 Independence Avenue,
SW., Washington, DC 20591, or by
calling (202) 267–9680. Make sure to
identify the docket number, notice
number or amendment number of this
rulemaking.
Anyone is able to search the
electronic form of all comments
received into any of our dockets by the
name of the individual submitting the
comment (or signing the comment, if
submitted 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 (Volume
65, Number 70; Pages 19477–78) or you
may visit https://dms.dot.gov.
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Small Business Regulatory Enforcement
Fairness Act
The Small Business Regulatory
Enforcement Fairness Act (SBREFA) of
1996 requires FAA to comply with
small entity requests for information or
advice about compliance with statutes
and regulations within its jurisdiction. If
you are a small entity and you have a
question regarding this document, you
may contact your local FAA official, or
the person listed under FOR FURTHER
INFORMATION CONTACT. You can find out
more about SBREFA on the Internet at
https://www.faa.gov/avr/arm/sbrefa.htm,
or by e-mailing us at -AWASBREFA@faa.gov. https://www.faa.gov/
regulations_policies/rulemaking/
sbre_act/.
Authority for This Rulemaking
The FAA’s authority to issue rules
regarding aviation safety is found in
Title 49 of the United States Code.
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.
This rulemaking is promulgated
under the authority described in
Subtitle VII, Part A, Subpart III, Section
44701. Under that section, the FAA is
charged with prescribing regulations
providing minimum standards for other
practices, methods and procedures
necessary for safety in air commerce.
This regulation is within the scope of
that authority since flight data recorders
are the only means available to account
for aircraft movement and flight crew
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actions critical to finding the probable
cause of incidents or accidents,
including data that could prevent future
incidents or accidents.
I. Background
A. Statement of the Problem
Two aviation accidents in the United
States involving Boeing 737 series
airplanes (737s) appear to have been
caused by a rudder hardover with
resultant roll and sudden descent:
United Airlines flight 585, near
Colorado Springs, Colorado, on March
3, 1991, and USAir flight 427, near
Aliquippa, Pennsylvania, on September
8, 1994. Following lengthy
investigations, the NTSB determined
that the rudder on 737s may experience
sudden uncommanded movement, or
movement opposite the pilot’s input,
which may cause the airplane to roll
suddenly. Other incidents of suspected
uncommanded rudder movement have
been reported, including a 1996
incident involving Eastwind Airlines
(Eastwind) flight 517, a 737–2H5, and
five incidents in 1999 involving U.S.registered airplanes.
The 737s involved in the United
Airlines and USAir accidents, and those
in the more recent incidents, were
equipped with the flight data recorders
required by the regulations then in
effect. However, these airplanes were
not required to record, nor were they
equipped to provide, information about
the airplane’s movement about its three
axes or the position of flight control
surfaces immediately preceding the
accident or incident. While the FAA has
undertaken a series of measures
designed to address the suspected
rudder problems, our efforts have been
limited by a lack of data that focused on
the control and movement of the
components of the 737 rudder system.
Without more data, neither the FAA nor
the NTSB can definitively identify the
causes of suspected uncommanded
rudder events.
B. FAA Actions
Following piloted computer
simulations of the USAir accident and
reports of malfunctions in the yaw
damper system of 737s, the FAA
mandated design changes to the rudder
system of 737s. First, the FAA issued
Airworthiness Directive (AD) 97–14–03
(62 FR 34623, June 27, 1997), which
requires installation of a newly designed
rudder-limiting device and a newly
designed yaw damper system, in an
effort to address possible rudder
hardover situations and uncommanded
yaw damper movements. Second, in
response to the possibility of a
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secondary slide jam and rudder reversal,
the FAA issued AD 97–14–04 (62 FR
35068, June 30, 1997). That AD requires
operators to install a new vernier
control rod bolt and a new main rudder
power control unit (PCU) servo valve in
each airplane.
C. Safety Recommendations: 1995–1997
Between 1995 and 1997, while
investigating the USAir accident, the
NTSB issued 20 safety
recommendations dealing with the 737;
three of those (A–95–25, A–95–26, and
A–95–27) dealt specifically with
upgrades to the FDR for all 737s. The
NTSB stated that if either the United
Airlines or the USAir 737 had recorded
data on the flight control surface
positions, flight control inputs, and
lateral acceleration, the NTSB would
have been able to identify quickly any
abnormal control surface movements
and configuration changes or autopilot
status changes that may have been
involved in the loss of control.
At the time it made its
recommendations, the NTSB recognized
that the 737 had flown over 92 million
hours since its initial certification in
December 1967, and that the airplane’s
accident rate is comparable to that of
other airplanes of a similar type.
Nonetheless, the Board concluded that
the design changes made to the rudder
system in accordance with the issued
ADs did not eliminate the possibility of
other potential failure modes and
malfunctions.
D. FAA Response: 1997 Regulations
In response to these safety
recommendations, the FAA published
revisions to the DFDR requirements for
all airplanes (Revisions to Digital Flight
Data Recorder Rules; Final Rule (62 FR
38362, July 17, 1997)). The revised
DFDR regulations prescribe the 88
parameters that must be recorded on
DFDRs, with the exact number of
parameters required to be recorded
determined by the date of airplane
manufacture. The number of parameters
that must be recorded range from 18 for
a transport category airplane
manufactured on or before October 11,
1991, to 88 for airplanes manufactured
after August 19, 2002.
E. NTSB’s 1999 Findings and Safety
Recommendations
On March 24, 1999, the NTSB issued
the final report of its investigation into
the crash of USAir flight 427. The NTSB
determined that the probable cause of
the accident was a loss of control
resulting from the movement of the
rudder surface position to its blowdown
limit. Further, the NTSB stated that
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‘‘* * * the rudder surface most likely
deflected in a direction opposite to that
commanded by the pilots as a result of a jam
of the main rudder PCU servo valve
secondary slide to the servo valve housing
offset from its neutral position and overtravel
of the primary slide.’’
In its March 1999 report, the NTSB
concluded that the 1997 regulations for
upgrading DFDRs are inadequate for
existing 737s, because they do not
require specific flight control
information to be recorded. Because
several 737 rudder-related events have
been associated with the yaw damper
system (which moves the rudder
independent of flightcrew input), the
NTSB concluded that it is important
that yaw damper status (parameter 89),
yaw damper command (parameter 90),
standby rudder status (parameter 91),
and control wheel, control column, and
rudder pedal forces (parameter 88) be
recorded on all 737s. The NTSB also
pointed out that, for optimal
documentation, the indicated
parameters need to be sampled more
frequently than is required currently.
The NTSB stated that by recording the
yaw damper’s operation and the
resultant rudder surface movements, a
yaw damper event could be
distinguished quickly from a flightcrew
input or a rudder anomaly. The NTSB
considers this information critical to
investigating 737 incidents or accidents.
The NTSB stated that if pilot flight
control input forces had been recorded
on the United Airlines, USAir, or
Eastwind FDRs, the NTSB investigations
would have been resolved more quickly
and actions taken to prevent similar
events would have been hastened.
On April 16, 1999, the NTSB
submitted the following
recommendations to the FAA regarding
recording additional parameters on 737
DFDRs:
Recommendation No. A–99–28.
Require that all 737s operated under
part 121 or part 125 that currently have
a FDAU be equipped, by July 31, 2000,
with a flight data recorder system that
records, at a minimum, the parameters
required by the 1997 DFDR regulations
applicable to that airplane, plus the
following parameters: Pitch trim,
trailing edge flaps, leading edge flaps,
thrust reverser position (each engine),
yaw damper command, yaw damper
status, standby rudder status, and
control wheel, control column, and
rudder pedal forces. Yaw damper
command, yaw damper status, and
control wheel, control column, and
rudder pedal forces should be sampled
at a minimum rate of twice per second.
Recommendation No. A–99–29.
Require that all 737s operated under
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part 121 or part 125 that are not
equipped with a FDAU be equipped, at
the earliest time practicable, but no later
than August 1, 2001, with a flight data
recorder system that records, at a
minimum, the same parameters noted in
safety recommendation No. A–99–28.
The NTSB also noted in its final
report on the USAir accident that 737
flightcrews continue to report
anomalous rudder behavior and that the
NTSB considers it possible that another
catastrophic event related to 737 rudder
upset could occur.
F. FAA Response: Notice No. 99–19
The FAA agreed with the intent of
NTSB Safety Recommendation Nos. A–
99–28 and A–99–29 and the NTSB’s
concerns regarding continuing reports of
rudder-related incidents on 737s. On
November 9, 1999, the FAA issued
Notice No. 99–19 (64 FR 63140,
November 18, 1999), which proposed
that all 737s be required to record the
parameters listed in § 121.344(a)(1)
through (a)(22), (a)(88), plus three new
parameters, designated as (a)(89)
through (a)(91). The new parameters are
yaw damper status, yaw damper
command, and standby rudder status. In
addition, the FAA proposed increasing
the required sampling rate for the
control forces listed in current
paragraph (a)(88) for 737s. The FAA
proposed that all 737s equipped with a
FDAU of any type as of July 16, 1996,
or manufactured after July 16, 1996,
comply by August 18, 2000. For all 737s
not equipped with a FDAU of any type
as of July 16, 1996, the FAA proposed
a compliance date of August 20, 2001.
The FAA noted that if it received
sufficient data to support an extension,
the compliance period for airplanes
retrofitted to include FDAUs between
July 16, 1996, and November 18, 1999,
would be extended to August 19, 2002.
The FAA proposed corresponding
changes to part 125 for 737s operated
under that part. In addition, the FAA
proposed that no deviation authority
from the FDR requirements of part 125
would be granted for any model
airplane, and that any previously issued
deviation from the DFDR requirements
of part 125 would no longer be valid.
The FAA also proposed that § 91.609 be
amended to reflect that all airplanes
operating under part 91 under deviation
authority from part 125 must comply
with the DFDR requirements in part
125, notwithstanding such deviation
authority.
II. Continuing Need for This
Rulemaking
The original NPRM, issued by the
FAA in 1999, proposed that in addition
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to other applicable requirements, all 737
model airplanes must record certain
additional parameters of flight data,
including those specifically designed to
monitor rudder system components.
The FAA added that it planned on
issuing the final rule with an immediate
effective date to address the unresolved
issues with the airplane as soon as
possible.
In January 2001, Boeing submitted a
letter to the docket requesting that the
FAA delay the release of any final rule.
The request was based on Boeing’s 737
Rudder System Enhancement Program
(RSEP), which itself was based on an
NTSB recommendation to develop a
‘‘reliably redundant rudder system’’ for
the 737. Boeing stated that the RSEP
changes will make the 737 rudder
system functionally equivalent to the 3actuator system found on its 757 and
767 model airplanes.
Boeing’s letter states that on January
16, 2001, it presented a detailed
description of its 737 RSEP changes to
the NTSB. While noting that the
proposed rule would be applicable to
the original rudder system, not the one
being developed under the RSEP, it
attempted to minimize the value of a
final rule that applied only to airplanes
with the older system installed. Boeing
also questioned whether it would still
be appropriate to treat the 737 different
than other airplanes once the rudder
system was modified.
While the redesigned rudder control
system meets the latest FAA system
requirements, it remains a system
unique to the 737 model airplane. In
Boeing 757/767/777 model airplanes,
the rudder control system has three
separate actuators in separate power
control units (PCU) that are always
powered. The original design of the 737
rudder control system had a single input
into a valve that controlled two installed
actuators in the PCU. In the redesigned
737 system, there are three actuators,
but they are housed in two PCUs rather
than the three present in the other
Boeing model airplanes. The main PCU
has two actuators, each with its own
valve that accepts input. The third
actuator is in a standby PCU that is not
normally powered unless the main PCU
fails. Thus, the 737 rudder control
system effectively still has only two
actuators during normal flight
operations, and a single actuator when
the main PCU is inoperative.
Several events have occurred since
the NPRM was issued in 1999,
including Boeing’s RSEP. One of the
recommendations issued by the NTSB
included the formation of an
engineering test and evaluation board
(ETEB) to conduct a failure analysis of
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the rudder actuation control system of
the 737. The 737 ETEB was formed in
May 1999 and issued its final report in
July 2000.
Among the key findings of the 737
ETEB are the following:
(1) The 737 rudder control system is
susceptible to a number of failures and
jams. These failures and jams can affect
the operation of the rudder power
control units and can result in
uncommanded rudder motion.
(2) A number of failures and jams of
the 737 rudder control system were
detected in configurations on which the
FAA later issued corrective action under
one or more Airworthiness Directives
(ADs). More than two dozen of these
failures and jams (alone or in
combination) have what are considered
catastrophic failure effects.
(3) Even when 737s were in
compliance with the ADs issued at the
time, rudder control system failures and
jams were still present.
(4) Most of the failure modes were
discernable on both the older (classic)
models and the newer (next generation)
models of the 737.
(5) There were no catastrophic failure
modes identified at cruise speed and
altitude. One change to the hydraulic
pressure system mandated by AD
reduced the time an airplane was
exposed to catastrophic failure modes,
but exposure was not eliminated during
takeoffs and landings.
Among its recommended long-term
actions, the ETEB recommended that
the 737 rudder system be modified to
ensure that no single failure or single
jam of the rudder control system would
cause an uncommanded rudder motion
that has catastrophic results.
The NTSB did not withdraw or
change its recommendation regarding
further monitoring of the rudder system
on 737s, and indicated in a February
2001 letter to the FAA that it had not
changed its position regarding the need
for installation of the new FDR
equipment ‘‘at the earliest possible
opportunity regardless of any rudder
system modification.’’
In November 2001, the FAA
published a proposed AD that would
require the installation of a new rudder
control system (and accompanying
changes to nearby systems) (66 FR
56783, November 13, 2001). The FAA
determined that the inherent failure
modes in the 737 rudder system,
verified by the ETEB, result in a design
system architecture that is unsafe. The
FAA also determined that the rudder
system design architecture led to a need
for non-normal operational procedures,
which had also been implemented by
AD. The FAA concluded that the
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combination of the inherent failure
modes and the non-normal operational
procedures, considered together, present
an unsafe condition that warranted the
incorporation of a newly designed
rudder control system.
The final rule AD was published on
October 7, 2002 (67 FR 62341), with an
effective date of November 12, 2002,
and gives all operators of 737 model
airplanes 6 years to install a new rudder
control system.
Boeing has been installing the newly
designed rudder control system on 737
model airplanes manufactured since
January 2003. Boeing is also installing
the additional sensors that were
proposed in the NPRM on these newly
manufactured 737s, and those
parameters are being recorded.
When we began drafting a final rule,
we realized that the 737 fleet that would
be affected by the proposed rule—those
airplanes with the original rudder
system—had already begun to shrink in
number. The promulgation of several
Airworthiness Directives means that by
the 2008 compliance date for those ADs,
no 737 aircraft left in the U.S. fleet
would have the old rudder system.
Therefore, we no longer find it
appropriate to require the installation of
flight recorder equipment to monitor
those parts of the aircraft which became
life-limited by these ADs and will be
eliminated by 2008.
This SNPRM attempts to address the
changes in circumstances introduced by
the RSEP, the findings by the ETEB, and
the ADs issued by the FAA by revising
the fleet of airplanes affected by the
proposed rule, and by changing the
proposed compliance time to coincide
with the modifications required by the
ADs.
The FAA does not have convincing
evidence that the redesigned rudder
control system obviates the need for the
additional flight recorder parameters.
The newly designed rudder system is
unique in that the third actuator is only
activated upon the failure of the main
PCU, at which point the two main
actuators are no longer performing.
Thus, the FAA has tentatively
concluded that the information that
would be gathered by the addition of the
proposed parameters could provide
meaningful information in the event of
a rudder control failure. While the ETEB
conducted considerable testing of the
737 aircraft and its rudder system, those
tests cannot duplicate the actual flight
experience of either the original or the
new rudder system as it would be
recorded using the parameters
proposed. The only way to get this data
is by installation of equipment that will
record the movement of the rudder
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surface and the companion actions of
the yaw dampers. The ETEB did not
have this information because the
equipment to record it was not
mandatory. Since the additional
parameters have yet to be installed,
investigators of an accident or incident
remain similarly limited today.
Boeing has indicated that there have
been no reports of rudder hardover
incidents on 737s with the redesigned
rudder system. However, since the
system has only been installed as
original equipment on airplanes since
2003, and since compliance with the
retrofit is not required until 2008, only
limited historical data on the function
and reliability of this redesigned system
is available.
Additionally, as discussed above, the
redesigned rudder system does not
actively power three actuators. Rather,
the third actuator only powers up in the
event of a power failure to the two
primary actuators. Thus, while the new
design incorporates three actuators,
similar to the design of Boeing’s 757/
767/777 model airplanes, a functional
difference remains between the new 737
rudder system and that installed on
other Boeing airplanes.
We note that the rudder control
system enhancement can be split into
three separate tasks and are not
normally accomplished at once. The
first two changes can be accomplished
with the old rudder control system still
in place. As of August 2004, Boeing had
shipped 2,957 kits needed for the first
part of the installation, but only 728 kits
for the third part. The FAA assumes
these numbers have gone up; however,
since there is no reporting requirement
for compliance with the AD, we have no
way of knowing how many new
components or complete rudder control
systems have been installed. However,
the FAA understands that the wiring kit
provided by Boeing for the first part of
the redesigned rudder system includes
the wiring required for the proposed
additional sensors, making the
installation of the parameters less
burdensome than originally anticipated.
Compliance with this rule, if adopted,
would require the installation of the
sensors and their connection to the
DFDR system. These circumstances
argue for either the issuance of this rule
(to take advantage of the work yet to be
accomplished on the majority of the 737
fleet) or withdrawal, as soon as possible.
We continue to believe that unless the
proposed additional flight recorder
sensors are installed and the function of
the new system components are
monitored, there will never be any
means to eliminate the rudder system as
a possible cause of any future incident
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or accident, or to identify the particular
component or action as a source of the
problem if the rudder control system is
involved. These are the circumstances
that spurred the original NTSB
recommendations on the 737, but we are
cognizant of the significant changes in
circumstances that have occurred in the
last five years, including the mandated
changes to the original rudder system,
and the decline in reported incidence of
rudder hardover events.
We are also aware that we now need
new information on the costs and
benefits of requiring these
enhancements on a fleet of aircraft that
did not exist when we originally
proposed the rule, those with the new
rudder system installed.
The FAA originally evaluated the cost
data associated with this SNPRM nearly
five years ago, shortly after the close of
the comment period for the NPRM.
Since then, some 737s may have been
retrofitted with the new rudder, and
may be partially equipped to record the
additional flight data parameters.
Further, with the introduction of the
new Boeing 737 rudder, there is a new
class of airplane that will incur
retrofitting costs that may be different
from those costs reported by the
industry and used in the Supplemental
Preliminary Regulatory Evaluation
(Supplemental PRE) that accompanies
this rulemaking document. Because the
FAA does not have the data necessary
to evaluate the impact of, and need for,
a rule requiring the additional
parameters for those 737s equipped
with the new rudder control system, the
agency requests more current
information for the following specific
questions as well as any additional data
that the public believes needs to be
incorporated into the economic
analysis.
1. How many 737s are in your fleet?
2. How many 737s do not record the
flight parameters that we are proposing
be recorded? How many 737s currently
record these parameters?
3. How many 737s have been
retrofitted with the new Boeing rudder?
How many of those airplanes do not
record the flight data parameters that we
propose to be recorded?
4. How many 737s are expected to be
retrofitted with the new Boeing rudder
in each of the years 2006, 2007, and
2008?
5. How many 737s are expected to be
retired in each of the years 2006, 2007,
and 2008?
6. For those 737s that have already
been retrofitted under the AD but do not
record the additional flight data
parameters, how much would it cost to
install the equipment to record the
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additional flight data parameters? How
many days would it take to install the
equipment to record those additional
flight data parameters on those airplanes
if the work were done: during a major
maintenance session; an overnight
maintenance session?
7. Are the assumptions and estimates
made in Table 1 of this notice and the
accompanying Supplemental PRE, and
throughout that report, accurate? If you
are able to provide more current data,
please submit it.
8. Please provide an update on the
status of the various design changes that
would still need to be accomplished to
provide the information necessary to
install the proposed flight recorder
parameters on the fleet expected to be
retrofitted with the new rudder design.
We are issuing this SNPRM to gather
information on the need for flight
recorder parameters that monitor the
new rudder system. This proposal
represents a shift in the scope of the
rule. When the DFDR enhancements
were proposed, work was still in
progress in diagnosing the functions and
perceived weaknesses of the original
rudder system. We have modified the
original proposed regulatory text to
require that the flight recorder
parameters proposed in 1999 be
installed concurrent with the new
rudder system; we have redrafted the
rule to state that compliance would be
required no later than November 12,
2008, the date that compliance is
required with the Airworthiness
Directives mandating the installation of
the redesigned rudder system. We have
made other changes to the proposed
regulatory text based on comments to
the NPRM. These changes, which are
explained later in the document, will
not be revisited. Accordingly, we
request interested parties to direct their
attention to our requests for data, the
need for additional parameters for the
redesigned 737 rudder control system,
and the proposed November 2008
compliance date.
In summary, the FAA finds this
supplemental proposal necessary in
order to update the status of the number
and configuration of 737s in the current
fleet. Since we do not track operator
compliance with ADs, the information
requested here will tell us how many
airplanes have been retrofitted with the
new rudder system and the estimated
costs for installing the DFDR parameters
if the new rudder system has already
been installed. We expect to receive
information on the number of
retirements expected, as well as the
number of aircraft that are already in
compliance because they are new or
because the proposed DFDR rudder
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parameters may have been installed
voluntarily.
III. Summary of Comments
The FAA received 17 comments on
the proposed rule. Of the 17 comments,
the Air Transport Association of
America, Inc. (ATA), submitted three
separate comments; one of the ATA
submissions included seven comments
from member airlines. Only one
commenter, the Air Line Pilots
Association (ALPA), supports the
proposed rule as published.
Specifically, ALPA agreed that a
potentially unsafe condition has been
identified and concurs with the
proposed amendments. The other
commenters generally supported the
intent of the proposed rule; however,
these commenters expressed concern
about:
(1) The time frame for compliance
proposed in the Notice of Proposed
Rulemaking (NPRM),
(2) the availability of installation
instructions,
(3) the unavailability of parts, and
(4) the probability of considerable
airplane out-of-service time.
The amount of time that has elapsed
since comment was invited, and the
events that have occurred since
comment was invited, has caused most
of the comments to become outdated.
The proposed compliance times are no
longer applicable, nor are the costs that
were applied to them. Accordingly, we
are not including a discussion of
comments concerning compliance time,
parts availability, or out of service time
since these issues no longer exist under
current circumstances.
Comments on Specific Proposed
Requirements
The following disposition of
comments addresses those comments
that were not overtaken by intervening
events and actions. Some of the
questions and information submitted
with them remain relevant to the actions
contemplated under this modified
proposal.
Boeing stated that it typically does not
develop or commit to design changes
until the release of a final rule.
However, because of the proposed short
time frame for compliance, Boeing had
already implemented production design
changes in an attempt to accommodate
the expected compliance schedule.
Boeing noted that a typical design
change of this magnitude would require
a minimum of 18 months to allow time
to develop the design and to work with
parts suppliers, operators, and the FAA.
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A. Compliance Issues for Rudder Pedal
Forces
Proposal: The FAA stated in Notice
No. 99–19 that it had received inquiries
from the NTSB and Boeing concerning
an acceptable means of recording the
rudder pedal control input forces
required by paragraph (a)(88) of
§ 121.344; the requirement was added in
the 1997 amendment to the DFDR
regulations.
To meet the 1997 regulations, Boeing
developed a rudder pedal force
transducer that is placed ‘‘midstream’’
in the rudder control system. The
transducer is designed to identify
whether the input was coming from the
cockpit or from the rudder assembly.
The NTSB indicated informally that it
would prefer a system that measures the
rudder input force at the individual
rudder pedals. This would require the
addition of four transducers (one on
each rudder pedal) rather than the
single one designed by Boeing. The FAA
noted that the NTSB believes that only
the installation of four rudder pedal
force sensors would meet the intent of
its April 16, 1999 recommendation to
record rudder input force.
The FAA acknowledged the
difference between the data acquired
using Boeing’s already approved single
transducer system and the NTSB’s
suggested four-pedal sensor retrofit. The
FAA requested comment on the
necessity and feasibility of
instrumenting all four rudder pedals on
737s with force sensors as a means of
complying with paragraph (a)(88). The
FAA also requested comment on
whether Boeing’s single force transducer
should remain an accepted means of
compliance with parameter 88 for all
737s that do not have the transducer
installed or had not yet otherwise
complied with paragraph (a)(88). In
addition, the FAA requested cost data
for the four-pedal retrofit to determine
whether the incremental increase in
benefits that would be provided by that
configuration would be offset by the
additional time and costs involved if
such a requirement were mandated.
Comments: The FAA received two
comments on recording rudder control
inputs, one from the NTSB and one
from Boeing.
The NTSB stated that the rudder
pedal force exerted by each
crewmember is critical to its
understanding the loss of control
problems experienced in the 737. The
NTSB added that in its investigation of
a 1999 rudder incident involving
Metrojet, not knowing the amount of
rudder pedal force exerted has made it
impossible to separate pilot actions from
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(possible) rudder system anomalies. The
Board argued that a single sensor placed
midstream in the rudder control system,
as introduced by Boeing, would not
identify whether the flightcrew inputs
are in opposition to each other or
whether the nose wheel steering (NWS)
or some other system anomaly forward
of the sensor causes the inputs. In
addition, any jams in the controls
between the pedals and the sensor may
go undetected, because the amount of
force exerted by the flightcrew would
not be registered by the sensor. The
NTSB stated that, if the upgrade
required only a single force sensor in
the rudder system, the possibility would
remain that the information would not
be sufficient to identify some future
flight control problems even after the
proposed retrofit.
Boeing commented that neither the
existing rule nor the proposed rule
includes specific requirements that
support a change to the current design
to measure individual rudder pedal
force. Boeing stated that the 1997 rule
contained no requirement to measure
any disagreement between pilot inputs.
According to Boeing, the NTSB
recommendations and the proposed rule
suggested that the only issue is the
ability to quickly distinguish a yaw
damper event from a flightcrew input or
a rudder anomaly. Boeing believed the
current single transducer design meets
this intent.
Boeing claimed the current 737 NG
airplane rudder pedal design satisfies
the parameter 88 requirements defined
in the existing rule. Boeing added that
the rudder design on 737–100 through
–500 series airplanes delivered since
August 1998 is identical to that on the
737 NG airplanes, and retrofit kits are
available for this installation in
airplanes delivered before then. Boeing
noted that any change to the
requirements to which this installation
complies would require additional
retrofit.
Boeing further stated that the
proposed addition of four individual
rudder pedal force sensors would
require a significant number of design
changes in the rudder control
mechanism and to the structure of the
cockpit floor. The 737 has severely
limited space in the area these would be
placed, which limits design options. At
the time the NPRM was issued, Boeing
and its suppliers had not yet been able
to identify a design solution that could
be implemented without significant
structural and system changes that
would make retrofit complex, lengthy,
and costly. Boeing added that it
expected the design definition and
implementation of four transducers
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would take much longer than the
implementation dates proposed.
Boeing also argued that four
transducers would provide no major
incremental gain in information.
According to Boeing, a single transducer
allows investigators to determine why
the rudder moved, by pilot action or
system input, but that a single
transducer will not show whether a
pedal jammed. The four transducers
would enable Boeing to determine
whether the rudder moved and may
allow determination of which pedal was
jammed or restricted. However, the four
transducers, like the single transducer,
would not permit determination of why
a rudder pedal was jammed or
restricted, because the jam or restriction
is also ‘‘upstream’’ of the transducers.
FAA reply: Although specifically
requested, the FAA did not receive any
cost data or time estimates for a fourrudder-pedal sensor retrofit as described
in the NPRM. While the FAA
understands the NTSB’s desire for the
information that such rudder pedal
sensors might provide, general
comments from Boeing indicate that
such a retrofit would be both timeconsuming and costly. The FAA is
unaware of a sensor currently in
production that could meet the design
requirements that would be necessitated
by the NTSB’s request. Even if such a
sensor does exist, Boeing also indicated
(in its comment and in discussions with
the FAA) that major redesign of the
aircraft might be necessary, including
moving a floor beam, since there is so
little space available under the rudder
pedals of the 737. Such modifications
would take several years to design and
incorporate into the production line; the
engineering for in-service airplanes
would be more complicated, since
changes to major structural components
would mean a change to the airplane’s
original type design and the
airworthiness certification of every
affected airplane. The time that such
design and retrofit would take far
exceeds any recommendation of the
NTSB, and argues against the NTSB’s
own characterization of the
modification as time-sensitive.
Further, the FAA is unable to say with
any certainty that the information that
might be gathered by the NTSB’s
proposed pedal force sensors would
lead to a solution to the rudder problem.
The rudder pedal force sensors may
well be able to identify the amount of
force an individual pilot is placing on
a pedal, but the amount of force does
not seem to have been an issue in the
noted accidents or incidents. If there is
a problem in the rudder system, then
the amount of force exerted in an
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attempt to overcome it is less important
than finding where the malfunction is
occurring. If pilots are fighting each
other for control using the rudder
pedals, then the issue is not with the
airplane itself. It is a suspected problem
with the airplane itself that is the reason
for proposing this rule, and the FAA has
determined that continuing to allow
compliance with parameter 88 using a
single midstream transducer reflects the
best balance of cost and information to
be gained in an attempt to locate the
source of the problem in a timely
fashion.
Accordingly, the FAA has decided
against promulgating a four-pedal
sensor requirement. The agency has no
basis for concluding that a retrofit of
individual rudder pedal sensors would
be cost beneficial when the costs
themselves cannot readily be estimated
without a significant investment of time
and energy. Moreover, since the FAA is
unable to quantify the requirements
either for the equipment or the
recording rate and sensitivity, any
information on estimated costs becomes
that much less reliable and certainly
falls short of the legal requirements for
imposing the eventual cost on operators.
B. Compliance Issues for the Control
Column and Control Wheel
Proposal: Parameter (a)(88) requires
that control wheel and control column
input forces be measured and recorded.
The current rule requires that airplanes
with breakaway capability record both
left and right side control wheel forces.
The FAA noted in the preamble to the
NPRM that there also are issues of
acceptable means of measuring control
column and control wheel forces. The
FAA specifically requested comment on
the means and costs of measuring these
control forces under the requirements
proposed in this rulemaking.
Comments: The FAA received
comments from Boeing, Alaska, United
Airlines, ATA, and the NTSB on the
control column and control wheel
systems.
Boeing stated that to comply with the
existing rule for parameter (a)(88),
Boeing intended to modify the control
column and control wheel force
transducers for DFDR application to
achieve the increased force range.
Boeing would also install new flight
control computer hardware and
software to interface with the new
transducers.
Boeing stated that the retrofit for the
737–100 through –500 series airplanes
is basically the same as that for the 737
NG airplanes. However, it noted the
737–100 through –500 series airplanes
include two control column force
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transducers in the same location as the
737 NG airplanes, but that the force
applied by individual pilots cannot be
determined because the elevator control
systems of the 737–100 through –500
series airplanes do not have a jam
override device between columns.
Boeing also described the FAAapproved single-wheel force transducer
design for parameter (a)(88), and stated
that it meets the intent of the existing
rule provided that the left and right
control wheel positions also are
recorded. Boeing stated that the aileron
system measures both cockpit control
positions, but only the left side’s force.
Each pilot’s control inputs go through
the left side force transducer, except in
the event of a failure. Boeing added that
because the FAA does not typically
consider dual failures a likely event, the
proposed configuration should be
acceptable.
Boeing noted that to comply with the
existing requirements for parameter
(a)(88), the control wheel force
transducer would have to be modified
specifically for DFDR application to
achieve the increased force range. New
flight control computer hardware and
software would have to be installed to
interface with the new transducer and
the force transducer stops would have to
be modified to allow the additional
range.
Boeing further stated the control
wheel retrofit of the 737–100 through
–500 series airplanes is basically the
same as that of the 737 NG airplanes,
except that Boeing would add a (new)
second control wheel position
transducer to the first officer’s control
wheel to allow the 737–100 through
–500 series airplanes’ configurations to
be identical with that of the 737 NG
airplanes.
The NTSB stated that although it is
concerned that the current control force
sensors will not meet the range and
accuracy requirements of the proposed
rule, suitable control force sensors were
likely to be available by the then
proposed compliance dates. The NTSB
contended that separate sensors to
measure the pilot and copilot flight
control input forces must be used when
breakaway features are employed
(breakaway capability allows either
pilot to operate the airplane
independently).
Two operators of 737s and the ATA
commented that as of the date of the
NPRM, the required sensors had not yet
been developed.
FAA reply: The primary objection
raised by the commenters was that the
regulation would force early compliance
with parameter (a)(88) for control wheel
and control column forces, and that the
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sensors required to record to Appendix
M specifications were not available and
had not yet been designed. Sensor
design and availability are no longer
issues since all aircraft manufactured
after August 19, 2002 have been
required to meet Appendix M standards
for parameter (a)(88). Nor is there any
need to provide for more than one
sensor type since a sensor that records
to Appendix M standards now exists for
use in a retrofit. Accordingly, the FAA
intends to adopt the rule as originally
proposed, with the Appendix M
standards applicable to all 737s
recording all functions required by
parameter (a)(88) (±70 pounds control
wheel force and ±85 pounds control
column force).
The FAA understands that the lateral
control system on the 737 has an
override device between the two control
wheels that allows either pilot to
operate the control wheel
independently, but that the primary
control path for both pilots is through
the left cable control path. The right
control is not usually connected and is
used only in the event of a failure. A
single control wheel force transducer in
the left cable path records the inputs
from both pilots. The FAA agrees that
the single control wheel force
transducer is acceptable, provided the
left and right control wheel positions
are also recorded. The use of a single
force transducer with two position
sensors is acceptable because
comparison of the two position sensors
allows detection of a breakout of the
override between the control wheels;
this breakout allows the right cable
control path to become active.
C. Compliance Issues; Other Parameters
1. Standby Rudder Status
Proposal: In the NPRM, the FAA
proposed to add recording of the
standby rudder status. The standby
rudder system is an alternative source of
hydraulic power to the rudder that is
used when primary hydraulic power is
lost. The intent of the proposed
requirement was to record whether the
standby rudder system switch is in the
on or off position.
Comment: Boeing believed the intent
of recording the standby rudder status
was to determine the actual status of the
standby rudder system and not the
position of any particular switch.
Boeing indicated that the system should
record the state of the standby hydraulic
rudder shutoff valve, which also is
controlled by both of the standby rudder
system switches. Boeing maintained this
would provide a clearer indication of
the actual status of the standby rudder
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system than recording whether the
standby rudder switch is in the on or off
position. The ATA stated that the
sensors for the standby rudder status
parameter have not been designed for
any 737.
FAA reply: The FAA agrees with the
comments and we have revised the
proposed language in paragraph (a)(91)
to indicate that it is the valve position
that needs to be recorded for standby
rudder status, not the position of the
switch, as initially proposed.
2. Thrust Reverser
Proposal: Under the 1997 DFDR
regulations, instrumentation of the
thrust reversers (§ 121.344(a)(22)) was
not required until the year 2001 for
some airplanes and is not required at all
for older airplanes. The proposal would
require all 737s regardless of age to
record the thrust reverser position.
Comment: Boeing stated that the
requirement for recording thrust
reverser positions would require
modifications to the engine accessory
unit (EAU) to monitor the thrust
reverser. According to Boeing,
approximately 937 737–100 and –200
airplanes will require two new PC cards
and associated connectors and wiring,
and approximately 250 737–300 and
–400 airplanes will require four new PC
cards and associated connectors and
wiring if the proposal is adopted.
Boeing requested that the FAA not
require instrumentation of the thrust
reversers for the older 737–100 through
–500 series airplanes. The 737 NG
airplanes would be retrofitted to record
thrust reverser position. Boeing
suggested specific language that could
be used to codify its request.
FAA reply: The SNPRM does not
incorporate Boeing’s suggested change.
Under § 121.344(b)(1), adopted in 1997,
the only airplanes not required to record
thrust reverser position, parameter
(a)(22), are airplanes manufactured on
or before October 11, 1991, that were
not equipped with a FDAU as of July 16,
1996. All other airplanes must either be
retrofitted to record, or record at
manufacture, thrust reverser position.
The distinction made in
§ 121.344(b)(1) was introduced to
prevent the oldest airplanes from having
to be retrofitted with a FDAU to meet
the 1997 rule, not because thrust
reverser data is not important. Under
this SNPRM, the other recording
requirements for 737s necessitate the
installation of a FDAU, eliminating the
distinction made in the 1997 rule.
Further, the FAA cannot accept Boeing’s
suggested language because it is general
and would relieve not only 737s but
certain other airplanes from the 1997
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requirement to record parameter (a)(22).
This proposal would require all 737s to
record parameter (a)(22).
3. Yaw Damper Status and Yaw Damper
Command
Proposal: Proposed paragraph (a)(89)
would add the recordation of yaw
damper status. The intent of the
requirement is to determine whether the
yaw damper is on or off. Proposed
paragraph (a)(90) would add the
recordation of yaw damper command.
The intent of this requirement is to
record the amount of voltage being
received by the yaw damper system.
This determines how much rudder
movement is being commanded.
Comment: For the 737–100 through
–500 series airplanes, Boeing proposed
to record the yaw damper linear variable
displacement transducer (LVDT)
position feedback from the new yaw
damper coupler through an ARINC 429
interface, and, if the DFDR capacity
allows, the yaw damper command from
the yaw damper coupler through an
ARINC 429 interface. Boeing noted that
the 737 NG airplanes record both the
yaw damper command from the stall
management yaw damper and the yaw
damper LVDT position feedback
through an ARINC 429 interface. The
ATA stated that sensors for yaw damper
status and yaw damper command
parameters are not addressed in a
retrofit service bulletin.
FAA reply: Sensors for the yaw
damper status and yaw damper
command parameters have been
developed and have been installed in
737s manufactured since August 18,
2000. The sensors exist and the FAA
continues to believe that the parameters
should be required.
4. Other Issues
Proposal: The current DFDR
regulation allows single-source
recording for control input and control
surface positions, parameters (a)(12)
through (a)(14) or (a)(12) through (a)(17),
depending on the date of airplane
manufacture. The proposed rule
eliminated the allowance to record these
from a single source.
Comments: Boeing stated that
§ 121.344(b) and (c), as proposed,
removes the allowance to permit
recording parameters (a)(12) through
(a)(17) from a single source and applies
the full requirement of appendix M to
part 121 to recording these parameters.
However, paragraph (d) still permits
recording parameters (a)(12) through
(a)(17) from a single source.
FAA reply: Removing the allowance
for recording control and surface
positions from a single source was an
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52389
error in the proposed rule. This SNPRM
includes the single-source recording as
provided in the 1997 rule. A sentence
has been added in § 121.344(m)
indicating that single-source recording
would remain available to airplanes
otherwise subject to § 121.344(b)(1),
(c)(1), or (d)(1).
Proposal: The proposal removes 737s
from the requirements of § 121.344(b)
and (c), adds specific 737 requirements
to § 121.344(d), (e), and (f), and adds
new § 121.344(m).
Comments: Boeing indicated that
§ 121.344(d), (e), and (f), as proposed,
state that all 737s must comply with the
requirements in paragraphs (m)(1) and
(m)(2). Boeing contended this language
overlooks the requirements of paragraph
(m). Boeing also did not understand
why paragraphs (d), (e), and (f) were not
revised as paragraphs (b) and (c) to
except the 737. Boeing stated that the
addition of paragraph (m) makes it
unclear as to what is required for 737s
and that it would be much clearer to
include the additional 737 requirements
in the existing applicable paragraphs.
Boeing further stated that § 121.344(m),
as proposed, is inconsistent with
paragraphs (b), (c), and (d) in that it
requires recording parameters (a)(88)
through (a)(91), while paragraphs (b),
(c), and (d) do not.
FAA reply: The modifications to the
compliance schedule for installation of
the additional parameters have removed
the issue of compliance time;
compliance time is no longer
determined by the date of FDAU
installation.
For consistency, § 121.344(b), (c), (d),
(e), and (f) are similarly revised to
reference the 737 requirements in
§ 121.344(m). The FAA has decided
against putting the 737 requirements in
each subparagraph because it would be
cumbersome, unnecessarily repetitive,
and introduce more possibilities for
error.
Proposal: The note to parameter
(a)(88) in current Appendix M to part
121 requires airplanes that have a flight
control breakaway capability (which
allows either pilot to operate controls
independently) to record both control
force inputs; the note also discusses
sampling rates.
Comments: Boeing pointed out that
the note to parameter 88 in appendix M
to part 121 and appendix E to part 125
indicates that all the comments in the
remarks column do not apply to the 737.
Boeing believed that the note is meant
to indicate that it is only the sampling
interval remarks that do not apply to the
737s. The NTSB also stated that the
remarks section covers, in addition to
the sampling rate requirements, a
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requirement to record both control force
inputs for those airplanes that have a
flight control breakaway capability that
allows either pilot to independently
operate the airplane, which still would
apply to 737s.
FAA reply: The FAA agrees with
Boeing, and has revised footnote 18 to
clarify application of the parameter for
737s. The requirement to record both
control force inputs for systems with
breakaway capabilities does apply to the
737, but as discussed above, the FAA
has approved the use of a single control
wheel force transducer provided that
both control wheel positions are
recorded (although both pilot’s inputs
go through the left side force transducer,
except in the event of a failure). Because
the FAA historically has not considered
a dual failure a likely event, this
configuration is acceptable.
Proposal: The FAA proposed the
same changes to the digital flight data
recorder regulations in § 125.226 as
those proposed in § 121.344. In
addition, the FAA proposed the same
changes to Appendix E to part 125 as
those proposed to Appendix M to part
121. The FAA also proposed that
airplanes operating under deviation
authority from part 125 must comply
with the flight data recorder
requirements of part 125 for the
particular aircraft. The FAA specified
that this deviation requirement would
apply to all aircraft and not only the
737. The FAA specifically sought
comments on why the flight data
recorder requirements of part 125
should not be made applicable to
aircraft operated under deviation
authority. In addition, the FAA sought
comments from affected persons
operating aircraft under deviation
authority from part 125 concerning the
proposed compliance schedule.
Comments: The FAA received no
comments on the proposed changes to
part 125. Accordingly, the changes to
part 91, applicable to part 125 airplanes
operated under deviation authority, and
the changes to part 125 and Appendix
E are proposed again here without
change from the original proposal.
IV. Changes Adopted in This SNPRM
When the FAA proposed the
recordation of new flight data recorder
parameters in November 1999, the ETEB
was still in the process of conducting its
failure analysis, and other action by the
agency was not yet contemplated. The
ETEB’s finding and the FAA’s
subsequent decision to issue the AD
requiring replacement of the rudder
system mandate that this rule be
modified to account for those actions.
This proposed rule, if adopted, would
require the installation of the flight
recorder parameters proposed in the
NPRM with the following modifications.
The installation would be accomplished
simultaneously with the installation of
the redesigned rudder system in order to
minimize the costs and out-of-service
time required. The regulatory evaluation
for this proposed rule has been
significantly revised to include this
extended compliance time. This
extension of the compliance time also
addresses the majority of the comments
received in response to the proposed
rule. Specifically, this SNPRM
incorporates the following changes:
• Sections 121.344(b), (c), (d), (e), and
(f) and § 125.226(b), (c), (d), (e), and (f)
would be amended to indicate that all
737 model airplanes also must comply
with the requirements in § 121.344(m)
or § 125.226(m), respectively. Sections
121.344(m) and 125.226(m) would be
added to indicate that in addition to
other applicable requirements, all 737
model airplanes must record the
parameters listed in paragraphs (a)(1)
through (a)(22) and (a)(88) through
(a)(91) in accordance with the ranges,
accuracies, resolutions, and recording
intervals specified in Appendix M to
part 121 or Appendix E to part 125,
respectively. The proposed compliance
times have been changed to state that
the installation of the equipment
required to record these parameters
must be accomplished during the
installation of the modified rudder
system required by AD or no later than
November 2008. These sections would
also reinstate the language allowing
single-source recording, as discussed in
the disposition of comments. The
parameters that may be recorded from a
single source would be determined by
the age of the airplane and its applicable
regulations.
• Footnote 18 would be added to
parameter 88 in Appendix M to part 121
and Appendix E to part 125 and would
read ‘‘For all 737 model airplanes: The
seconds per sampling interval is 0.5 per
control input; the remarks regarding the
sampling rate do not apply; a single
control wheel force transducer installed
on the left cable control is acceptable
provided the left and right control
wheel positions also are recorded.’’
Footnote 19 would be added to
parameter 88 in Appendix M to part 121
and Appendix E to part 125 and would
read ‘‘For all 737 model airplanes
manufactured on or before January 31,
2001, Range values are: Full Range;
Control wheel ± 15 lbs.; Control column
± 40 lbs.; and Rudder pedal ± 165 lbs.’’
• Sections 121.344 (a)(91) and
125.226(a)(91) would be revised to read
‘‘standby rudder valve status’’ and in
appendix M to part 121 and appendix
E to part 125, the range for parameter 91
would be revised to read ‘‘Discrete.’’
• The range for the rudder pedal in
parameter 88 in appendix M to part 121
would be corrected to read ‘‘Rudder
pedal ± 165 lbs.’’
No 737s are exempt from this
rulemaking. Airplanes that have been
manufactured since January 2003 would
already be incompliance with this rule
because the rudder parameters proposed
here would have been installed at
manufacture.
V. Chronology
The following is a list of selected
events relevant to 737 rudder control
issues and FAA rulemaking actions:
Event
December, 1967 ...................
March 3, 1991 ......................
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Date
The Boeing 737 is type certificated.
United Airlines flight 585 crashes near Colorado Springs, CO; loss of rudder control implicated, but the flight recorder was rudimentary (5 parameters recorded as required by regulation).
NTSB Recommendation on the 737 rudder system.
Crash of USAir flight 427 near Aliquippa, PA.
Rudder hardover reported on Eastwind flight.
FAA issues AD on flight crew procedures to overcome potential system failures.
NTSB issues 20 safety recommendations on the 737, three in 1995 recommending upgrades to the DFDRs.
FAA issues two ADs on 737 rudder system components.
USAir flight 2710 reports uncommanded rudder hardover at cruise.
NTSB final report on USAir 427 indicates loss of control from uncommended rudder hardover as probable cause;
says 1997 DFDR rule changes by FAA not adequate for 737.
ETEB formed to conduct failure analysis on rudder control actuation system of the 737.
1993 .....................................
September 8, 1994 ..............
June 9, 1996 ........................
1996 .....................................
1995–1997 ...........................
June, 1997 ...........................
February 23, 1999 ................
March 24, 1999 ....................
May, 1999 ............................
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Date
Event
November 18, 1999 .............
FAA NPRM proposing three new DFDR parameters for 737s, proposing compliance in 2000 or 2001 based on installed equipment.
Comment period for NPRM closes.
Five rudder hardover incidents reported on 737s during the year.
ETEB final report finds numerous failure modes on 737 rudders, recommends modification of the entire rudder
system.
Boeing begins its Rudder System Enhancement Program (RSEP).
Boeing makes a presentation to the NTSB on its RSEP findings.
Boeing submits letter to FAA rule docket requesting delay of any final rule in anticipation of final RSEP findings
expected later that year.
In a letter to the FAA, the NTSB maintains its position on installation of new DFDR parameters on 737s as soon
as possible, and regardless of rudder system modification.
Boeing applies for a change in type design based on its RSEP.
FAA publishes NPRM AD on modified rudder system.
FAA publishes final rule AD to install modified rudder system; compliance is due in 6 years (11/11/2008); special
flight crew procedures in effect since 1996 are superseded as of installation.
New Boeing 737s are delivered with the new rudder system and the three DFDR rudder parameters as original
equipment.
December 20, 1999 .............
1999 .....................................
July, 2000 .............................
September, 2000 ..................
January 16, 2001 .................
January, 2001 ......................
February, 2001 .....................
February, 2001 .....................
November 13, 2001 .............
October 7, 2002 ...................
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January, 2003 ......................
VI. Paperwork Reduction Act
This SNPRM proposes to amend the
regulations to add a requirement for all
737s to record additional flight data
parameters. These additional parameters
are not required by the current
regulations and would provide the only
currently available means of gathering
information that the FAA and the NTSB
anticipate will help assess the cause of
incidents that appear to be related to
rudder anomalies on 737 airplanes.
The respondents are all U.S.
certificate holders operating 737
airplanes under parts 91, 121, 125, and
129.
The required information would be
electronically recorded on the DFDR
each time the airplane begins its takeoff
roll until it has completed its landing
roll and kept until the airplane has been
operated for 25 hours. The recorded
data would be overwritten on a
continuing basis and accessed only
following an accident. This requirement
would be a nominal addition to a
passive information collection activity
and therefore does not contain a
measurable additional hour burden.
As required by the Paperwork
Reduction Act of 1995 (44 U.S.C.
3507(d)), the U.S. Department of
Transportation submitted the
information collection requirements to
the Office of Management and Budget
(OMB) for its review and assignment of
an OMB control number and one was
assigned. However, when the control
number came up for reauthorization, we
decided not to renew it. If this proposed
requirement is made final, we will
reapply for the authorization.
VII. International Compatibility
In keeping with U.S. obligations
under the Convention on International
Civil Aviation, FAA policy is to comply
with International Civil Aviation
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Organization (ICAO) Standards and
Recommended Practices to the
maximum extent practicable. The FAA
has determined that there are no ICAO
Standards and Recommended Practices
that correspond to these regulations.
VIII. Economic Evaluation, Regulatory
Flexibility Determination, International
Trade Impact Assessment, and
Unfunded Mandates Assessment
Changes to Federal regulations must
undergo several economic analyses.
First, Executive Order 12866 directs
each Federal agency to propose or adopt
a regulation only if the agency makes a
reasoned determination that the benefits
of the intended regulation justify its
costs. Second, the Regulatory Flexibility
Act of 1980 requires agencies to analyze
the economic impact of regulatory
changes on small entities. Third, the
Trade Agreements Act (19 U.S.C. 2531–
2533) prohibits agencies from setting
standards that create unnecessary
obstacles to the foreign commerce of the
United States. In developing U.S.
standards, the Trade Act requires
agencies to consider international
standards. Where appropriate, agencies
are directed to use those international
standards as the basis of U.S. standards.
Fourth, the Unfunded Mandates Reform
Act of 1995 requires agencies to prepare
a written assessment of the costs,
benefits, and other effects of proposed
or final rules. This requirement applies
only to rules that include a Federal
mandate on State, local, or tribal
governments or on the private sector,
likely to result in a total expenditure of
$100 million or more in any one year
(adjusted for inflation).
Based on the available information,
the FAA believes that this proposed
rule:
(1) Would have benefits that justify its
costs and would be a ‘‘significant
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regulatory action’’ as defined in the
Executive Order and as defined in
DOT’s Regulatory Policies and
Procedures;
(2) Would have a significant impact
on a substantial number of small
entities;
(3) Would have minimal effects on
international trade; and
(4) Would not impose an unfunded
mandate on state, local or tribal
governments or on the private sector.
The FAA has placed these analyses in
the docket and summarizes them as
follows.
Data Sources
The principal data sources used are
the public comments from the ATA and
six airlines, as well as discussions with
representatives from Boeing and several
airlines that operate 737s, an ATA
survey of its members, avionics vendors,
and repair stations that will perform
some of the FDR system retrofits. In this
section, the FAA addresses the public
comments concerning the Preliminary
Regulatory Evaluation and the economic
effects of the proposed rule.
Affected Airplanes and Industries
In the November 1999 NPRM, the
FAA estimated the proposed rule would
affect 1,306 737s projected to be in
service in the year 2000, and 2,144 737s
that will be manufactured between 2001
and 2020.
In the Supplemental PRE, the FAA
estimates that this proposed rule would
affect 1,171 current 737s projected to be
active in 2008. The FAA believes this
proposal would not affect 737s in
production because Boeing voluntarily
manufacturers these airplanes to the
rule’s requirements. Currently, eight
airlines (Southwest Airlines,
Continental Airlines, United Airlines,
Delta Airlines, U.S. Airways, American
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Airlines, America West Airlines, and
Alaska Airlines) operate 80 percent of
the affected airplanes. One major airline
(Southwest Airlines) and two national
airlines (Aloha Airlines and Sun
Country Airlines) operate 737s
exclusively.
Benefits
The principal benefit from increasing
the number of recorded flight data
parameters is the increased probability
that the information gathered can be
used to determine more precisely the
causes of future 737 rudder-related
accidents. Once these causes are known,
regulatory agencies and the aviation
industry could effect corrective actions
(e.g., an airplane design modification or
changes in operating procedures) that
could prevent such future accidents.
In the NPRM, the FAA estimated the
number of these future 737 accidents
based on the assumption the historical
accident rate would remain constant.
The ATA and Continental Airlines
disagreed by noting that the FAA issued
several ADs on the 737 rudder system
since 1995, and no rudder-associated
accidents had happened since then.
(These comments, made in 2000, do not
include the 2002 AD (Number 2002–20–
07) that requires 737 rudders to be
retrofitted to prevent an uncommanded
rudder hardover event.) Continental
Airlines believed that, to the extent that
the ADs have mitigated this unknown
problem, an accident rate based on the
pre-AD 737 historical rate will
overestimate the future accident rate.
The FAA agrees the historical 737
accident rate is not appropriate for this
analysis. Given the recent ADs, there is
insufficient information to specify the
future 737 accident rate and how much
this rulemaking will reduce it. As a
result, the FAA has changed the
approach used in the NPRM in
analyzing benefits in this SNPRM
analysis. Rather than predicting a
number of future accidents, as was done
for the NPRM, the Supplemental PRE
estimates the potential quantified
benefits that would occur if recording
these flight data parameters would lead
to the prevention of an accident. Should
the FAA receive sufficient data in
response to this rulemaking notice to
permit it to predict a number of future
accidents, it may revert to the
methodology used in the preliminary
regulatory evaluation supporting the
NPRM.
In the NPRM, the FAA used the
following values to quantify the
potential benefits from a prevented 737
accident: $2.7 million for each
prevented fatality, an average of 96
passengers and crew on a 737, for a
resulting total of $259.2 million an
airplane; $20 million for a destroyed
737; $5 million for ancillary damage to
ground structures; and $31 million for
the resultant government and industry
accident investigation. Thus, the
average potential benefit from
preventing a 737 in-flight accident was
estimated to be $315.2 million in 1999
dollars. There were no comments on
this estimate.
In the Supplemental PRE, the FAA
uses the following updated values and
average 737 size to quantify the
potential benefits from a prevented 737
accident: $3 million for each prevented
fatality; an average of 113 passengers
and crew on a 737, for a resulting total
of $339 million an airplane; $17 million
for a destroyed 737; $6 million for
ancillary damage to ground structures;
and $33 million for the resultant
government and industry accident
investigation. These changes are the
result of increased costs, as well as an
increase in the average number of
passengers aboard a 737. Thus, the
average potential benefit from
preventing a 737 in-flight accident is
about $395 million in 2003 dollars.
Significant Differences in the Economic
Models Used in the Preliminary
Regulatory Evaluation and the
Supplemental Preliminary Regulatory
Evaluation
Table 1 lists the significant
differences in assumptions and values
between those used in the NPRM and
those in this analysis. The specific
impact that each value has on the
revised compliance costs is discussed in
the individual compliance cost sections.
Although there are other differences that
have changed the calculated costs, the
differences listed in Table 1 are the most
significant ones.
TABLE 1.—SIGNIFICANT DIFFERENCES IN ASSUMPTIONS AND VALUES BETWEEN THE PRELIMINARY REGULATORY
EVALUATION AND THE SUPPLEMENTAL PRELIMINARY REGULATORY EVALUATION
Assumption or value
Preliminary regulatory analysis
Supplemental preliminary regulatory analysis
Number of Airplanes ..........................................
Number of Retrofitted Airplanes .........................
Annual Increase in Flight Hours & Fuel Burn ....
Year of First Retrofits .........................................
Number of years to retrofit .................................
How scheduled retirements are handled ...........
1,306 (in Year 2000) ........................................
1,306 (by Year 2001) .......................................
4.1 percent .......................................................
2000 .................................................................
18 months ........................................................
All airplanes active on the final rule date are
retrofitted.
All individual STC holders ................................
$100; $70 .........................................................
Newer recorders in 737 ‘‘Classic’’ airplanes
can be reprogrammed at a unit cost of
$10,000..
Existing FDAUs in 737 ‘‘Classic’’ airplanes
can be reprogrammed at a unit cost of
$20,000.
No impact—no cost .........................................
1,567 (in Year 2004).
1,171 (by Year 2008).
Varies depending on number of airplanes.
2005.
4 years.
No airplane scheduled for retirement before
2008 is retrofitted.
Boeing.
$125; $85.
All recorders in 737 ‘‘Classic’’ airplanes must
be replaced at a unit cost of $20,000.
Who does initial engineering redesign ...............
Hourly Labor Rates: Engineers; Mechanics .......
How recorders are affected ................................
How FDAUs are affected ...................................
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How FCCs are affected ......................................
How many airplanes retrofitted during a ‘‘C’’ or
‘‘D’’ maintenance check.
How many out-of-service days for a retrofit not
done during a ‘‘C’’ or ‘‘D’’ maintenance check.
How many out-of-service days for a retrofit
done during a ‘‘C’’ maintenance check.
Per gallon price of aviation fuel ..........................
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All FDAUs must be replaced in 737 ‘‘Classic’’
airplanes at a unit cost of $50,000.
33 percent ........................................................
Must be reprogrammed at a cost of $10,000
per airplane.
100 percent.
4–9 ...................................................................
2–8.1
2–7 ...................................................................
0–6.
$0.61 ................................................................
$0.75.
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TABLE 1.—SIGNIFICANT DIFFERENCES IN ASSUMPTIONS AND VALUES BETWEEN THE PRELIMINARY REGULATORY
EVALUATION AND THE SUPPLEMENTAL PRELIMINARY REGULATORY EVALUATION—Continued
Assumption or value
Preliminary regulatory analysis
Future production 737s ......................................
All affected at a per airplane cost of $38,900
Supplemental preliminary regulatory analysis
No cost because parameters 89–91 would
have been installed in the absence of the
final rule.
1 In the event we receive information that some airplanes cannot be retrofitted during a ‘‘C’’ or ‘‘D’’ check, we will use an out of service time of
2 to 8 days for FDR equipment installation. We specifically request that this estimate be verified by affected operators.
Compliance Costs for the Supplemental
Rule
As summarized in Table 2, the FAA
estimated in the NPRM that the cost to
retrofit a 737 would vary between
$41,800 and $221,950 per airplane,
depending upon the 737 model, its FDR
system equipment, and whether the
retrofit would be completed during a
‘‘D’’ check, a ‘‘C’’ check, or would
require a separate dedicated scheduled
maintenance session. See also the
footnote to Table 1.
TABLE 2.—PER AIRPLANE COMPLIANCE COST BY 737 SERIES AND FDR SYSTEM ESTIMATED IN THE PRELIMINARY
REGULATORY EVALUATION
[All values in 1999 $]
Equipment and
labor costs
200 ...........................................................................................
200-Advanced (No FDAU) .......................................................
200-Advanced (FDAU) ............................................................
300 (No FDAU) ........................................................................
300 (FDAU) ..............................................................................
400 (No FDAU) ........................................................................
400 (FDAU) ..............................................................................
500 (No FDAU) ........................................................................
500 (FDAU) ..............................................................................
600 ...........................................................................................
700 ...........................................................................................
800 ...........................................................................................
900 ...........................................................................................
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737 Series
$160,200–176,400
160,200–176,400
68,800–90,000
175,200–191,400
35,100–90,000
160,200–176,400
35,100–90,000
175,200–191,400
35,100–90,000
35,100
35,100
35,100
35,100
The FAA estimated in the NPRM the
total costs of compliance with the
proposed rule between 2000 and 2020
would be about $255 million, which
had a present value of $205.4 million.
Of the $255 million total costs, the onetime costs to retrofit the existing 737
fleet (engineering plus retrofitting plus
losses from out-of-service time) would
have been $158.7 million. If the rule had
been issued on January 1, 2000, the
$158.7 million would have been spent
within 20 months or the airplanes
would have been grounded. The
increased costs to manufacture future
737s from 2000 through 2019 would
have been $86 million. Finally, the
increased annual costs of the additional
fuel burn due to the increased weight of
the airplane and the additional
maintenance of the FDR system from
2000 through 2019 would have been
$10.3 million.
In the Supplemental PRE, after
incorporating data from the comments
and updating the fleet and unit cost
data, the FAA has determined that the
cost per 737 will be between $189,320
and $201,320 for a 737–200, between
$189,320 and $209,320 for a 737–300/
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Out-ofservice days
4–7
4–7
2–4
6–9
2–4
6–9
2–4
6–9
2–4
2–4
2–4
2–4
2–4
400/500 that does not have a FDAU,
between $142,120 and $167,120 for a
737–300/400/500 that has a FDAU,
between $49,410 and $63,410 for a 737
NG that does not record parameters 89–
91, and $9,475 for a 737 NG that records
parameters 89–91.
The FAA has tentatively determined
the total cost to comply with this
SNPRM would be about $143 million
between 2004 and 2014, which has a
present value of about $126.5 million.
Of the $143 million, about $140 million
will be expended during the first 4 years
for engineering costs, retrofitting costs,
and out-of-service costs, $2 million will
be for increased fuel consumption, and
$0.7 million will be for additional FDR
system maintenance. There will be
minimal compliance costs for
production 737s because Boeing has
been voluntarily installing the
capability to record the additional data
required by the proposed rule since
August 2000.
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Out-of-service
lost net revenue
$250–800
4,900–8,600
2,450–4,900
20,375–30,550
6,800–21,550
17,350–30,350
8,675–25,250
20,150–30,200
6,700–19,100
15,375–30,750
17,350–34,675
20,800–41,575
21,950–43,875
Total costs and
lost net revenue
$160,450–177,200
160,690–185,000
71,250–94,900
195,575–221,950
41,900–111,550
177,550–206,750
43,775–107,350
195,350–221,600
41,800–109,100
50,475–65,850
52,450–69,775
55,900–76,675
57,050–76,975
Summary of Factors Creating the
Significant Differences Between the
Estimates
There are 4 major factors that create
the differences between the NPRM and
SNPRM estimates.
The first factor, which increases onetime retrofitting compliance costs, is the
FAA’s assumption that some of the
existing solid-state recorders and
existing FDAUs could be
reprogrammed. However, the ATA,
Alaska, Aloha Airlines, Continental
Airlines, Southwest Airlines, and
United Airlines commented that
retrofitting the FDR systems in the 737‘‘Classic’’ series requires purchasing
new recorders and new FDAUs; they
cannot be reprogrammed. Boeing,
American, and Aloha Airlines reported
that their 737-‘‘NG’’ series recorders and
FDAUs could be reprogrammed. The
FAA accepts both these positions. As a
new recorder costs between $10,000 and
$15,000 more than a reprogrammed
recorder, and a new FDAU costs
$30,000 more than a reprogrammed
FDAU, the impact on the total
retrofitting cost is considerable.
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A second factor, which lowers
compliance costs, is that 135 fewer 737s
will be retrofitted under the SNPRM
than would have been retrofitted under
the originally proposed rule.
A third factor, which lowers
compliance costs, is that the FAA
significantly reduces its estimated
number of labor hours to retrofit FDR
systems to record flight data parameters
(a)(19) through (a)(22) in 737s with
FDAUs. In the NPRM, the FAA
estimated it would take 400 hours while
the FAA now estimates that it takes 100
hours.
A final factor that lowers compliance
costs is that the Supplemental PRE
analysis contemplates that the flight
data parameter retrofit will be
performed when a 737 is retrofitted with
a new rudder rather than within the 20
months originally proposed in the
NPRM. Since the publication of the
proposed rule, more 737s have been
retired, reducing those estimated costs.
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Commenters’ Retrofit Cost Estimates
In the NPRM, the FAA used
retrofitting costs largely provided by the
industry. In the comments to the NPRM
estimates, Aloha Airlines estimated a
cost of $165,100 to $185,000 to retrofit
its 737–200 Advanced airplanes that did
not have a FDAU, $71,250 to $94,900 to
retrofit its 737–200 Advanced airplanes
that have a FDAU, and $52,450 to
$69,775 to retrofit its 737–700 airplanes.
American Airlines estimated a cost of
$47,250 plus lost revenue for 2+ days
out-of-service for each of its 737–800
airplanes. Continental Airlines did not
report a total cost, but was in general
agreement with the FAA estimates, if
the FAA adjusted its costs to recognize
that existing recorders and FDAUs in
737-‘‘Classic’’ airplanes cannot be
reprogrammed and must be replaced.
United Airlines estimated a total
retrofitting cost of $24,100,000 and for
its fleet of 158 737-‘‘Classics’’, for an
average airplane cost of $152,500. The
FAA has tentatively determined the
retrofitting cost of a 737-‘‘Classic’’
ranges from $142,000 to $189,000 while
the retrofitting cost of a 737-‘‘NG’’
ranges from $9,475 to $49,410.
Time to Engineer New Designs for the
Retrofitted FDR Systems
In the NPRM, the FAA assumed that
each STC holder would independently
do all the engineering redesign. Boeing,
the ATA, Alaska, Continental Airlines,
Southwest Airlines, and United Airlines
commented that such an approach
would be inefficient and lead to
duplication of effort. Industry expects
Boeing to do the initial engineering
work, which the STC holders would
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then modify for their various FDR
systems. The FAA accepts those
comments and has adjusted its analysis
accordingly.
In the NPRM, the FAA estimated that
airlines and repair stations would
redesign 40 FDR systems and it would
take 16 to 26 weeks and cost each FDR
system holder $200,000 to complete the
first FDR system redesign. As
engineering data from one STC can be
used in other STCs, the FAA assumed
that after five such FAA approvals, an
STC holder could use commonality
demonstrations to reduce this cost from
$200,000 to $25,000 per STC. Thus, the
FAA estimated a total one-time cost of
$2.95 million for the initial engineering
redesign.
Boeing indicated that the FAA
significantly underestimated the
engineering hours required for each
individual engineering analysis.
Although Boeing did not provide
specific estimates in its comments, the
FAA has assessed the engineering
analyses for the 737 series as a one-time
cost of $6.6 million, which consists of
30 engineering years.
In the NPRM, the FAA assumed that
three engineers working full-time for
four months (one engineer year) would
be needed for an FDR system redesign
STC approval, at a cost of $200,000 per
STC application. The FAA further
estimated that 32 applications would be
made for a one-time engineering cost of
$7.5 million.
Aloha Airlines, Continental Airlines,
Southwest Airlines, United, and U.S.
Airways commented that it would take
from six months to one year after Boeing
completes the initial engineering
analysis for them to complete their
design modifications and obtain FAA
approvals. They did not, however,
provide an estimate of their engineering
time or costs to complete these
applications. In the Supplemental PRE,
the FAA estimates that 15 STC
applications will require one engineer
year (at a cost of $250,000) to complete,
while 25 of the STCs will require 250
engineer hours (at a cost of $31,250) to
complete. On that basis, the calculated
total STC engineering cost is $4.6
million.
Aloha Airlines stated the FAA
underestimated the number of
engineering analyses because each
airplane ‘‘configuration’’ within a 737
series would need a separate
engineering analysis. They commented
that 13 of their 18 airplanes will need
a $200,000 analysis. The FAA agrees
that an adjustment in the cost
calculations needs to be made for the
different configurations. However,
because much of the engineering is
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identical for each configuration within a
737 series, the FAA has tentatively
determined that it will take half of the
engineering time for a commonality
demonstration STC (125 hours) for a
configuration STC. The FAA has
calculated a per configuration cost of
$16,125. Finally, the FAA has
tentatively determined that 60 of these
‘‘configuration’’ STCs will be performed
because most airlines’ fleets have fewer
configurations than the Aloha Airlines
fleet. The FAA estimates a total cost of
$967,500 for this engineering.
Alaska also noted that two of the
sensors had not been developed for any
airplane and several other sensors had
not been approved for use in many of
the 737-‘‘Classic’’ airplanes. Thus, as
well as the design STC approval, the
FAA would also need to issue Parts
Manufacturing Authorizations (PMAs)
to the new sensors manufacturers.
Alaska posited that although the
vendors will incur most of these
development costs, these costs should
be included in Boeing’s initial
engineering costs because Boeing will
be the kit supplier.
In the NPRM, the FAA estimated the
total one-time engineering costs to
modify the FDR system STCs and obtain
FAA approval would have been $9.15
million. The FAA now calculates the
total costs to modify the FDR system
STCs and obtain FAA approvals are $15
million.
Equipment and Labor Costs to Retrofit
FDR Systems
In the NPRM, the FAA estimated the
equipment and labor costs to retrofit
FDR systems for compliance with the
proposed rule would be $124.3 million.
Based on the comments and the revised
fleet, the FAA has reduced the
anticipated equipment and labor cost to
comply with the final rule, if adopted,
to $111.8 million.
In the NPRM, the FAA estimated that
156 737s would have their recorders
replaced, while the remaining 1,150
737s would have their recorders
upgraded with additional memory. The
FAA estimated that: a new recorder
would cost $25,000; upgrading the
memory of a recorder that records 18
flight data parameters would cost
$10,000; upgrading the memory of a
recorder that records 22 flight data
parameters would cost $5,000; and
upgrading the memory of a recorder that
records more than 22 parameters would
cost $1,900.
ATA, Aloha Airlines, Continental
Airlines, Southwest Airlines, and
United Airlines commented that all of
their 737-‘‘Classics’’ would have their
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recorders replaced because they cannot
be reprogrammed.
Accepting and incorporating industry
comments, and with the increased
numbers of retirements, the FAA has
tentatively determined that 605 737s
will need their recorders replaced and
279 737s will need their recorders
reprogrammed by 2008.
Finally, Continental Airlines reported
new recorder costs of $13,000 while
Aloha Airlines reported a recorder cost
of $25,000. In the Supplemental PRE,
the FAA has assessed a cost of $20,000
per recorder, the average of these two
estimates and estimates provided by
avionics manufacturers.
In the NPRM, the FAA estimated that
installing a new recorder would require
32 labor hours to remove the old
recorder and to install and test a new
recorder. Upgrading an FDR would
require 16 labor hours to remove,
reprogram, reinstall, and test. The FAA
received no comments on this estimate
and uses it in the Supplemental PRE.
In the NPRM, the FAA estimated the
cost of replaced or upgraded recorders
would be $17.2 million. Based on the
increased recorder cost estimate and the
fewer retrofitted 737s, the FAA now
calculates that the total cost of replaced
or upgraded recorders in this is $14.6
million, which has a present value of
$12.8 million.
In the NPRM, the FAA estimated that
a FDAU would be retrofitted into 496
737s that did not have one, while the
existing FDAUs in 810 737s would be
reprogrammed. The same commenters
who addressed the issue of the recorder
all agreed that, whereas the FDAUs in
their 737-‘‘NGs’’ can be reprogrammed,
every FDAU in their 737-‘‘Classics’’
would have to be replaced—those units
cannot be reprogrammed. The FAA
agrees with these comments. In the
Supplemental PRE, the FAA has
tentatively determined that by 2004
operators of 198 737–200s will have
introduced FDAUs into their airplanes;
that operators of 407 737–300/400/500s
with a FDAU will have installed new
FDAUs in their airplanes; and that
operators of 279 737–700/800/900s will
have reprogrammed their existing
FDAUs.
Continental Airlines and Aloha
Airlines reported a $50,000 cost for a
new FDAU and a cost to reprogram a
FDAU of between $7,500 and $10,000.
In the Supplemental PRE, the FAA uses
a cost of $50,000 for a new FDAU and
an average of the two estimates ($8,750)
as the cost to reprogram a FDAU.
In the NPRM, the FAA noted that
retrofitting a 737 with a FDAU would
require rerouting the FDR system wiring
because the recorder (where the wires
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formerly terminated) is located aft,
while the new FDAU would be in the
front. Relying on estimates from
Southwest Airlines and United, the
FAA estimated that retrofitting a FDAU
would take 200 labor hours, which
includes the associated labor hours to
rewire the existing FDR system. Aloha
Airlines submitted the only specific
comment on this issue and it agreed
with the FAA estimate. Thus, the FAA
continues to assume 200 labor hours to
retrofit a FDAU.
In the NPRM, the FAA estimated that
it would take 48 hours for a FDAU on
a 737-‘‘Classic’’ airplane and 40 hours
for a FDAU on a 737-‘‘NG’’ airplane to
be removed, shipped to the
manufacturer, reprogrammed,
reinstalled, and tested. Three airlines
filed comments on these estimates.
Aloha Airlines reported that it will take
the same number of labor hours (200) to
replace an existing FDAU as it will to
retrofit a FDAU in an FDR system that
did not previously have one. The FAA
disagrees. The effort to retrofit a FDAU
is greater than the effort to install one
in an airplane that did not have it.
Continental Airlines estimated a cost of
$71,500 for the equipment and labor
costs to replace a FDAU. However, that
estimate also included the cost to record
the additional flight data parameters
and the increased sampling rate for
flight data parameter (a)(88). United
Airlines similarly estimated a total labor
cost of $33,000 for the entire retrofit.
The numbers submitted by Continental
Airlines and United Airlines do not
allow the FAA to distinguish the
number of labor hours to replace a
FDAU from the total labor hours for the
retrofit. After reviewing the comments,
the FAA has increased the estimated
number of labor hours to replace a 737‘‘Classic’s’’ FDAU from 48 hours to 80
hours and reduced the number of labor
hours from 40 hours to 20 hours for a
737-‘‘NG’s’’ FDAU.
Accordingly, the FAA calculates that
the labor costs to install a FDAU in an
FDR system that did not have one is
$17,000; the labor costs to replace a
FDAU is $6,800; and the labor costs to
install a reprogrammed FDAU is $1,700.
In the NPRM, the FAA estimated the
total FDAU equipment and labor costs
to retrofit FDAUs would be $37.6
million. In the Supplemental PRE, the
FAA calculates the total equipment and
a labor cost to retrofit FDAUs at $40.9
million, which has a present value of
$35.8 million.
In the NPRM, the FAA divided the
equipment and labor costs for the
additional wiring for adding the sensors
into three components: (1) The costs to
record flight data parameters (a)(19)
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52395
through (a)(22); (2) the costs to record
flight data parameters found in (a)(88) at
the greater ranges and increased
sampling rates; and (3) the costs to
record flight data parameters (a)(89)
through (a)(91). That division is
continued in this analysis.
In the NPRM, the FAA estimated the
costs of the sensors and wiring for a 737
FDR system to record parameters (a)(19)
through (a)(22) were $20,000. The only
specific comment received on this
estimate was from Aloha Airlines,
which agreed with the estimate. As a
result, the FAA uses this value in the
Supplemental PRE.
In the NPRM, the FAA estimated that
the installation of the sensors and
wiring to record flight data parameters
(a)(19) through (a)(22) would take 200
labor hours for a 737–200, a 737–200
Advanced, or a 737–400 airplane. It
would take 400 labor hours for a 737–
300 or a 737–500 series airplane.
Boeing commented that the FAA
misclassified the labor costs for the 737–
400 because the avionics in that series
are essentially the same as the avionics
in the 737–300 and 737–500 series
airplanes. These airplanes employ
ARINC 700 systems, while the 737–200
and 737–200 Advanced are, basically,
‘‘all analog’’ airplanes. Boeing
contended the labor time (and cost) to
rewire a 737–400 airplane is similar to
the labor hours (and costs) for a 737–300
or a 737–500 airplane. The FAA accepts
Boeing’s comment and has assigned the
same number of labor hours for all the
737–300/400/500 airplanes.
As Aloha Airlines uses the same 200
labor hour estimate for its 737–200
retrofits, the FAA continues to use the
200 labor hours in the NPRM to retrofit
737–200s in the Supplemental PRE.
Boeing noted that there are minor
differences in the amount of wiring
among all of its 737- ‘‘Classics’’. The
FAA agrees and has revised its estimate
for the 737–300/400/500 series retrofit
to record flight data parameters from
400 labor hours to 200 labor hours.
Thus, the FAA calculates the sensor and
labor cost to record flight data
parameters (a)(19) through (a)(22) of
$17,000 for a 737-‘‘Classic’’. The total
anticipated cost to record flight data
parameters (a)(19) through (a)(22) is
$37,000. Boeing also commented that
the FAA had not specifically estimated
the costs for the individual sensors and
other equipment required to record
flight data parameters (a)(19) through
(a)(22). The FAA agrees; however, the
FAA notes that the airline cost estimates
were not provided on an individual
sensor basis. Consequently, the FAA
could not establish individual sensor
cost estimates.
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In the NPRM, the FAA used
preliminary industry estimates that it
would cost $12,000 to add the necessary
sensors and wiring to record flight data
parameter (a)(88) in a 737 FDR system
that does not currently record it or that
does not record it at the proposed range.
American Airlines commented that it
will cost $8,000 for the sensors to record
this flight data parameter at the
proposed range. The FAA accepts the
American Airlines estimate and has
assumed a cost of $8,000.
In the NPRM, the FAA assumed that
it would cost $12,000 to replace all
sensors currently recording flight data
parameter (a)(88) in order to comply
with the higher sampling rate
requirement. Boeing, however, reported
that the existing sensors can be
reprogrammed to transmit information
at the increased sampling rate. The FAA
agrees with Boeing and has tentatively
determined there will be no sensor costs
to comply with the higher sampling
rates for flight data parameter (a)(88).
In the NPRM, the FAA estimated that
it would take 160 labor hours to install
the sensors in a 737-‘‘Classic’’ FDR
system that was either not recording
flight data parameter (a)(88) or not
recording it at the proposed range.
Aloha Airlines reported a total of 360
labor hours to record flight data
parameters (a)(88) through (a)(91). As
three of the six flight data parameters to
be recorded are found in (a)(88), the
FAA has assumed that half of the labor
hours reported by Aloha Airlines (180)
hours will be used to install flight data
parameter (a)(88) for a labor cost of
$15,300 per airplane.
In the NPRM, the FAA estimated that
it would take 160 labor hours to replace
the sensor in a 737–‘‘NG’’ that was
recording flight data parameter (a)(88) at
the lower sampling rate. The FAA
believes that it takes fewer labor hours
to reprogram the sensor to record flight
data parameter (a)(88) than it will take
to introduce new sensors and wiring
into a FDR system that had not
previously recorded it. In the
Supplemental PRE, the FAA has
tentatively determined that it will take
80 labor hours (at a cost of $6,800) to
install new sensors for flight data
parameter (a)(88).
Boeing did not provide a labor hour
estimate to install reprogrammed
sensors to record at the higher sampling
rate. In the Supplemental PRE, the FAA
estimates that it takes one-half (40)
hours to reprogram the sensors than it
does to install new sensors at a labor
cost of $3,400 per airplane.
The FAA also estimates that the
retrofit costs to install new sensors to
record flight data parameter (a)(88) are
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$23,300 for a 737-‘‘Classic’’ and $14,800
in a 737-‘‘NG’’. The cost to install
reprogrammed sensors in a 737-‘‘NG’’ is
$3,400.
Aloha Airlines and American Airlines
provided sensor costs or the number of
labor hours to retrofit FDR systems to
record flight data parameters (a)(89),
(a)(90), and (a)(91). The American
Airlines comment provided aggregated
data and the FAA could not disaggregate
some of their costs. Aloha Airlines
reported a total wiring and sensor cost
of $12,000 to record flight data
parameters (a)(88) through (a)(91). The
FAA agrees with this estimate. As the
FAA has also determined that the
wiring and sensor cost to retrofit flight
data parameter (a)(88) is approximately
$8,000, the FAA concludes that the
wiring and sensor costs to retrofit flight
data parameters (a)(89) through (a)(91)
should be approximately $4,000.
As noted, the FAA has determined
that half of the labor time reported by
Aloha Airlines is to install flight data
parameter (a)(88) and half the time is to
install flight data parameters (a)(89),
(a)(90), and (a)(91). Thus, the FAA
calculates that 180 labor hours (at a cost
of $15,300) will be required to install
flight data parameters (a)(89), (a)(90),
and (a)(91) in a 737-‘‘Classic’’. The FAA
has also assumed that 80 labor hours (at
a cost of $6,800) will be required to
install flight data parameters (a)(89),
(a)(90), and (a)(91) in a 737-‘‘NG’’. The
FAA calculates that the retrofitting costs
to record flight data parameters (a)(89),
(a)(90), and (a)(91) is $27,300 for a 737‘‘Classic’’ and $10,800 for a 737-‘‘NG’’.
In the NPRM, the FAA estimated the
total retrofitting sensor and wiring costs
to have been: $84,000 for a 737–200 or
a 737–400 airplane without a FDAU;
$100,000 for a 737–300 or a 737–500
airplane without a FDAU; $49,000 for
an older 737 airplane with a FDAU; and
$24,000 and for a newer 737 airplane
with a FDAU.
In the Supplemental PRE, the FAA
estimates that the retrofitting sensor and
wiring costs, per 737, are: $89,600 for a
737-‘‘Classic’’ that records 18 flight data
parameters; $52,600 for a 737-‘‘Classic’’
that records 22 flight data parameters;
$25,600 for a 737-‘‘NG’’ manufactured
before August 2000: and $10,800 for a
737-‘‘NG’’ manufactured after August
2000.
In the NPRM, the FAA estimated that
the total sensor and wiring costs to
retrofit all 737 FDR systems by the
compliance date would be $69 million.
The FAA now calculates that the total
sensor and wiring costs to retrofit all
737 FDR systems by the compliance
date is $48 million, which has a present
value of $42 million.
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In the NPRM, the FAA did not
consider (and did not estimate) any cost
for reprogramming the flight control
computers (FCCs). Boeing and American
Airlines commented that recording the
additional flight data parameters would
require reprogramming the FCCs.
Boeing provided no cost estimates for
FCC reprogramming, but American
Airlines reported that it will cost $5,000
per FCC to reprogram the 2 FCCs (for a
total cost of $10,000 per airplane). The
FAA accepts the American Airlines
estimate and applies it to all 737s. The
FAA now calculates a total cost to
reprogram the FCCs of $8.8 million,
which has a present value of $7.7
million.
In the NPRM, the FAA estimated that
the equipment and labor costs to retrofit
the existing 737 fleet were $17.2 million
for recorders, $37.7 million for FDAUs,
and $69.4 million for wiring and
sensors, for a total cost of $124.3
million. In the Supplemental PRE, the
FAA calculates that the equipment and
labor costs to retrofit the existing 737
fleet are $14.7 million for recorders,
$40.9 million for FDAUs, $47.2 million
for wiring and sensors, and $8.8 million
for FCCs, for a total cost of $111.6
million, which has a present value of
$92.6 million.
Total One-Time FDR System Retrofitting
Costs
In the NPRM, the FAA estimated the
total one-time compliance costs and
losses from out-of-service time would
have been $149.6 million. Based on the
comments and updated data, the FAA
now calculates that the total one-time
compliance costs and losses from out-ofservice time would be $125.2 million,
which has a present value of $109.5
million.
Annual Costs Resulting From
Retrofitting 737 FDR Systems
The Supplemental PRE also
contemplates annual compliance costs
from: (1) Additional airplane weight due
to retrofitted FDR system; and (2)
additional maintenance costs to
annually validate the FDAU.
In the NPRM, the FAA estimated that
the proposed rule would add 40 pounds
to a 737 that does not have a FDAU and
records 18 flight data parameters and
add 10 pounds to a 737 that has a FDAU
and records at least 22 flight data
parameters. In calculating the estimated
additional fuel cost, the FAA assumed
a per-airplane average of 2,750 flight
hours per year, a price of $0.61 per
gallon of aviation fuel, and 0.23
additional gallons consumed per
additional pound per flight hour. These
assumptions resulted in per-airplane
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annual costs of $400 for a 737 that adds
40 pounds and $100 for a 737 that adds
10 pounds. On that basis, the FAA
estimated the total cost from the
increased fuel consumption during 2001
and 2020 would have been $6.1 million,
which has a present value of $3.6
million. There were no comments on
this estimate.
In the Supplemental PRE, the
underlying NPRM methodology is
maintained but certain parameters are
updated (from 2,750 to 3,360 flight
hours per year and from $0.61 to $0.75
per gallon cost of aviation fuel).
However, the FAA has revised the
weight added by the retrofitted sensors
and wiring for 737–300/400/500s from
10 pounds to 20 pounds. On that basis,
the FAA now calculates that adding 40
pounds to a 737 would increase its
annual fuel costs by $584, adding 20
pounds would increase its annual fuel
costs by $292, and adding 10 pounds
would increase its annual fuel costs by
$146. These revised calculations result
in a total fuel cost increase of $2 million
between 2005–2014, which has a
present value of $1.4 million.
In the NPRM, the FAA estimated that
the incremental annual inspection and
validation of a FDAU would cost $750.
On that basis, the FAA estimated the
total cost from the increased
maintenance during 2001 and 2020
would have been $4.2 million, which
has a present value of $2.7 million. As
there were no comments on this
estimate, the FAA has decided to retain
it. Based on the number of 737s that
would have had FDAUs introduced into
the airplane and on the number that
would have been retired between 2005
to 2014, the FAA calculates a total
maintenance cost increase of $700,000,
which has a present value of $535,000.
In the NPRM, the FAA estimated that
the increased annual operational and
maintenance costs between 2001 and
2020 would have been $10.3 million,
which has a present value of $6.3
million. In the Supplemental PRE, the
FAA calculates that the increased
annual operational and maintenance
costs between 2005 and 2014 are $2.7
million, which has a present value of
$1.9 million.
Compliance Costs for Production 737s
In the NPRM, the FAA estimated a
total cost for 737s manufactured
between 2000 and 2020 of $86 million,
which has a present value of $40.4
million, to install the equipment to
record proposed flight data parameters
(a)(89), (a)(90), and (a)(91). As
previously discussed, the Supplemental
PRE has taken into account Boeing’s
voluntary installation of this equipment
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on all its 737s since August 2000,
indicating that the SNPRM would
impose no compliance costs on
production 737s.
Benefit-Cost Comments
In the NPRM, the FAA estimated that
the expected present value of the
benefits ($156 million) would have been
less than the present value of the
quantifiable total compliance costs
($214 million). However, the FAA noted
there is considerable uncertainty about
the potential number of future
accidents. As a result, the FAA
concluded that it was in general
agreement with the NTSB
recommendations that this information
is needed.
Boeing disagreed with an aggregated
benefit-cost approach and commented
that an appropriate analysis should be
based on an individual provision-byprovision (or, in this case, flight data
parameter by flight data parameter)
evaluation. In principle, the FAA agrees
with the Boeing comment. However, the
FAA has no data that can support a
parameter-by-parameter cost
calculation. All of the submitted
retrofitting cost data were block costs in
which no individual flight data
parameter costs were provided. In
practice, such a detailed benefits
analysis presupposes the existence of an
objective probability function based on
an engineering analysis for each flight
data parameter of the potential for the
additional information to lead accident
investigators to the cause of an accident.
It is precisely because engineering
analyses have been unable to determine
the causes of these accidents that such
individual probabilities cannot be
determined. At best, current engineering
analyses have established that one of
this group of several flight data
parameters, if recorded, may help to
determine the causes of future
accidents. As a result, the FAA has
decided against reevaluating its benefitcost analysis in the Supplemental PRE
based on the individual flight data
parameters.
Finally, Boeing commented that the
FAA should analyze the proposed rule
for individual airplanes based on their
expected remaining service life with a
possible view of exempting older 737s.
The justification is that the potential
benefits to any individual 737 airplane
would be lower the shorter its
remaining service life while the costs
would not be similarly reduced.
Although the FAA agrees that, for an
individual 737, the incremental benefits
received from a dollar of cost are lower
for older airplanes, the FAA disagrees
that this is an appropriate framework to
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analyze the recording requirements. The
primary benefits attributable to this
proposed rule do not accrue to the 737
that would have an accident, but, rather,
to every other 737 that would not have
a similar accident because engineering
or operational changes that would
prevent such future accidents would be
developed from the flight data recorded
from the accident or incident. The FAA
is not able to correlate the potential
probability of such an accident to the
age of a 737. Accordingly, in any year,
the FAA assumes that all 737s face an
equal probability that an accident may
occur to any one of them. If some 737s
were exempted from the rule and if an
uncontrolled rudder movement accident
were to happen to one of those
exempted airplanes, then no such future
accident would be prevented for the 737
fleet because the necessary flight data
would not have been recorded and no
appropriate engineering or operational
changes could have been made.
However, in recognition of the potential
economic impact, the FAA agrees with
Boeing’s suggestion that it is appropriate
to limit the applicability of this rule to
not include those 737s that have a
limited remaining service life. Thus,
this proposed rule would apply only to
737s that would be in service 4 years
after the promulgation of the final rule.
Regulatory Flexibility Determination
The Regulatory Flexibility Act of
19805 U.S.C. 601–612, directs the FAA
to fit regulatory requirements to the
scale of the businesses, organizations,
and governmental jurisdictions subject
to the regulation. The FAA is required
to determine whether a proposed or
final action will have a ‘‘significant
economic impact on a substantial
number of small entities’’ as defined in
the ACT. If the FAA finds that the
action will have a significant impact,
the FAA must perform a ‘‘regulatory
flexibility analysis.’’ However, if an
agency determines that a proposed or
final rule is not expected to have a
significant economic impact on a
substantial number of small entities,
section 605(b) of the Act provides that
the head of the agency may so certify,
and a regulatory flexibility analysis is
not required. The certification must
include a statement providing the
factual basis for this determination, and
the reasoning should be clear.
In the NPRM, the FAA prepared a
Preliminary Regulatory Flexibility
Analysis because the proposed rule
might have had a significant economic
impact upon a substantial number of
small entities. The FAA had concluded,
after that preliminary analysis, that the
proposed rule may not have met that
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criterion, but it reported its analysis and
requested public comments. The FAA
received no comments about the
Preliminary Regulatory Flexibility
Analysis.
However, subsequent to publication
of the NPRM, the Office of Advocacy of
the Small Business Administration
published new guidelines that defined a
small airline as one that has fewer than
1,500 employees. In 2003, the FAA
performed a new Regulatory Flexibility
Analysis for this SNPRM. In that
analysis, of the 20 airlines that would be
affected by the SNPRM, 12 have fewer
than 1,500 employees and are small
entities. Of these 12 airlines, one had a
positive net operating income, seven
had negative net operating income, and
net operating income data were not
available for four airlines. Twelve
airlines is a substantial number of
airlines and the cost per airplane is
significant—particularly when the
airline has negative net operating
income.
Therefore, based on that information
available at that time and the definition
of a small business, the FAA
Administrator has determined that the
proposed rule could have a significant
economic effect on a substantial number
of small entities. Under the new
definition, our preliminary conclusion
is that it will have a significant
economic impact.
This determination is explained in
more detail in the Regulatory Flexibility
Section of the Supplemental PRE.
However, since the results of that
evaluation are based on data that are not
current, we are requesting that affected
operators provide us with more current
data to be used to update the Regulatory
Flexibility Evaluation before any final
rule is issued.
Trade Impact Assessment
The Trade Agreement Act of 1979
prohibits Federal agencies from
establishing any standards or engaging
in related activities that create
unnecessary obstacles to the foreign
commerce of the United States.
Legitimate domestic objectives, such as
safety, are not considered unnecessary
obstacles. The statute also requires
consideration of international standards
and, where appropriate, that they be the
basis for U.S. standards. The FAA has
assessed the potential effect of this
rulemaking and determined that it
would have only a domestic impact and,
therefore, no affect on any tradesensitive activity.
Unfunded Mandates Assessment
The Unfunded Mandates Reform Act
of 1995 (the Act) is intended, among
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other things, to curb the practice of
imposing unfunded Federal mandates
on State, local, and tribal governments
or on the private sector.
Section 202(a) (2 U.S.C. 1532) of Title
II of the Act requires that each Federal
agency, to the extent permitted by law,
prepare a written statement assessing
the effects of any Federal mandate in a
proposed or final agency rule that may
result in the expenditure by State, local,
and tribal governments, in the aggregate,
or by the private sector, of $100 million
or more (adjusted annually for inflation)
in any one year; such a mandate is
deemed to be a ‘‘significant regulatory
action.’’ The FAA currently uses an
inflation-adjusted value of $128.1
million in lieu of $100 million. Section
203(a) of the Act (2 U.S.C. 1533)
provides that before establishing any
regulatory requirements that might
significantly or uniquely affect small
governments, an agency shall have
developed a plan under which the
agency shall:
(1) Provide notice of the requirements
to potentially affected small
governments, if any;
(2) Enable officials of affected small
governments to provide meaningful and
timely input in the development of
regulatory proposals containing
significant Federal intergovernmental
mandates; and,
(3) Inform, educate, and advise small
governments on compliance with the
requirements.
With respect to (2), Section 204(a) of
the Act (2 U.S.C. 1534) requires the
Federal agency to develop an effective
process to permit elected officers of
State, local, and tribal governments (or
their designees) to provide the input
described.
This rulemaking does not contain a
significant Federal intergovernmental or
private sector mandate because the
compliance costs to the private sector
would be about $48 million in each of
the years 2005, 2006, and 2007, and no
more than $3 million in any following
year. Therefore, the requirements of
Title II do not apply.
Executive Order 13132, Federalism
The FAA has analyzed this
rulemaking under the principles and
criteria of Executive Order 13132,
Federalism. We determined that this
action will not have a substantial direct
effect on the States, or the relationship
between the national Government and
the States, or on the distribution of
power and responsibilities among the
various levels of government, and
therefore does not have federalism
implications.
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IX. Environmental Analysis
FAA Order 1050.1E identifies FAA
actions that are categorically excluded
from preparation of an environmental
assessment or environmental impact
statement under the National
Environmental Policy Act in the
absence of extraordinary circumstances.
The FAA has determined this
rulemaking action qualifies for the
categorical exclusion identified in
paragraph 312d and involves no
extraordinary circumstances.
X. Regulations That Significantly Affect
Energy Supply, Distribution, or Use
The FAA has analyzed this SNPRM
under Executive Order 13211, Actions
Concerning Regulations that
Significantly Affect Energy Supply,
Distribution, or Use (May 18, 2001). We
have determined that it is not a
‘‘significant energy action’’ under the
executive order because it is not a
‘‘significant regulatory action’’ under
Executive Order 12866, and it is not
likely to have a significant adverse effect
on the supply, distribution, or use of
energy.
List of Subjects
14 CFR Part 91
Aircraft, Aviation safety, Reporting
and recordkeeping requirements.
14 CFR Part 121
Air carriers, Aircraft, Aviation safety,
Reporting and recordkeeping
requirements, Safety, Transportation.
14 CFR Part 125
Aircraft, Aviation safety, Reporting
and recordkeeping requirements.
The Amendment
In consideration of the foregoing, the
Federal Aviation Administration
proposes amending Chapter I of Title
14, Code of Federal Regulations as
follows:
PART 91—GENERAL OPERATING AND
FLIGHT RULES
1. The authority citation for part 91
continues to read as follows:
Authority: 49 U.S.C. 106(g), 1155, 40103,
40113, 40120, 44101, 44111, 44701, 44709,
44711, 44712, 44715, 44716, 44717, 44722,
46306, 46315, 46316, 46504, 46506–46507,
47122, 47508, 47528–47531, articles 12 and
29 of the Convention on International Civil
Aviation (61 stat. 1180).
2. Amend § 91.609 by adding a new
paragraph (h) as follows:
§ 91.609 Flight recorders and cockpit
voice recorders.
*
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(h) An aircraft operated under this
part under deviation authority from part
125 of this chapter must comply with all
of the applicable flight data recorder
requirements of part 125 applicable to
the aircraft, notwithstanding such
deviation authority.
PART 121—OPERATING
REQUIREMENTS: DOMESTIC, FLAG,
AND SUPPLEMENTAL OPERATIONS
3. The authority citation for part 121
continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 40119,
41706, 44101, 44701–44702, 44705, 44709–
44711, 44713, 44716–44717, 44722, 44901,
44903–44904, 44912, 45101–45105, 46105,
46301.
4. Amend § 121.344 by removing the
word ‘‘and’’ after paragraph (a)(87); by
removing the period after paragraph
(a)(88) and adding a semicolon in its
place; by adding new paragraphs (a)(89),
(90) and (91), (b)(4), (c)(4), (d)(3), (e)(3)
and (m); and by revising paragraph (f) to
read as follows:
§ 121.344 Digital flight data recorders for
transport category airplanes.
(a) * * *
(89) Yaw damper status;
(90) Yaw damper command; and
(91) Standby rudder valve status.
(b) * * *
(4) In addition to the requirements of
paragraphs (b)(1) through (b)(3) of this
section, all Boeing 737 model airplanes
must comply with the requirements of
paragraph (m) of this section, as
applicable.
(c) * * *
(4) In addition to the requirements of
paragraphs (c)(1) through (c)(3) of this
section, all Boeing 737 model airplanes
must comply with the requirements of
paragraph (m) of this section, as
applicable.
(d) * * *
(3) In addition to the requirements of
paragraphs (d)(1) and (d)(2) of this
section, all Boeing 737 model airplanes
also must comply with the requirements
of paragraph (m) of this section, as
applicable.
(e) * * *
(3) In addition to the requirements of
paragraphs (e)(1) and (e)(2) of this
section, all Boeing 737 model airplanes,
also must comply with the requirements
of paragraph (m) of this section, as
applicable.
(f) For all turbine-engine-powered
transport category airplanes
manufactured after August 19, 2002—
(1) The parameters listed in
paragraphs (a)(1) through (a)(88) of this
section must be recorded within the
ranges, accuracies, resolutions, and
recording intervals specified in
appendix M to this part.
Seconds per
sampling
interval
Parameter
Range
Accuracy
(sensor input)
88. All cockpit flight
control input
forces (control
wheel, control
column, rudder
pedal).18 19
Full range ..............
Control wheel ±70
lbs.
Control column ±85
lbs.
Rudder pedal ±165
lbs.
±5% ..................
1
89. Yaw damper
status.
90. Yaw damper
command.
91. Standby rudder
valve status.
Discrete (on/off) .....
...........................
As installed .......
0.5
Discrete .................
...........................
(2) In addition to the requirements of
paragraphs (f)(1) of this section, all
Boeing 737 model airplanes must also
comply with the requirements of
paragraph (m) of this section.
*
*
*
*
*
(m) In addition to all other applicable
requirements of this section, all Boeing
737 model airplanes must record the
parameters listed in paragraph (a)(1)
through (a)(22) and (a)(88) through
(a)(91) of this section within the ranges,
accuracies, resolutions, and recording
intervals specified in Appendix M to
this part. The approved recorder and all
equipment necessary to record the
parameters required by this paragraph
must be installed no later than the
installation of the redesigned rudder
system required by one or more
Airworthiness Directives issued under
part 39 of this chapter. The singlesource recording provisions of
paragraphs (b)(1)(ii), (c)(1), and (d)(1) of
this section may be used for airplanes
otherwise subject to those paragraphs.
5. Amend Appendix M to part 121 by
revising item 88 and adding items 89
through 91 to read as follows:
Appendix M to Part 121—Airplane
Flight Recorder Specifications—
Continued
*
*
*
*
*
0.5
Full range ..............
52399
0.5
Resolution
Remarks
0.2% of full range ........
For fly-by-wire flight control systems,
where flight control surface position
is a function of the control input device only, it is not necessary to
record this parameter. For airplanes
that have a flight control break away
capability that allows either pilot to
operate the control independently,
record both control force inputs. The
control force inputs may be sampled
alternately once per 2 seconds to
produce the sampling interval of 1.
1% of full range.
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18 For all 737 model airplanes: the seconds per sampling interval is 0.5 per control input; the remarks regarding the sampling rate do not apply;
a single control wheel force transducer installed on the left cable control is acceptable provided the left and right control wheel positions also are
recorded.
19 For all 737 model airplanes manufactured on or before January 31, 2001, Range values are: Full Range; Control wheel ±15 lbs.; Control column ±40 lbs.; and Rudder pedal ±165 lbs.
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Federal Register / Vol. 71, No. 171 / Tuesday, September 5, 2006 / Proposed Rules
PART 125—CERTIFICATION AND
OPERATIONS: AIRPLANES HAVING A
SEATING CAPACITY OF 20 OR MORE
PASSENGERS OR A MAXIMUM
PAYLOAD CAPACITY OF 6,000
POUNDS OR MORE
6. The authority citation for part 125
continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701–
44702, 44705, 44710–44711, 44713, 44716–
44717, 44722.
7. Amend § 125.3 by adding a new
paragraph (d) to read as follows:
§ 125.3
Deviation authority.
*
*
*
*
*
(d) No deviation authority from the
flight data recorder requirements of this
part will be granted. Any previously
issued deviation from the flight data
recorder requirements of this part is no
longer valid.
8. Amend § 125.226 by removing the
word ‘‘and’’ after paragraph (a)(87); by
removing the period after paragraph
(a)(88) and adding a semicolon in its
place; by adding new paragraphs (a)(89),
(90), and (91), (b)(4), (d)(3), (e)(3), and
(m); and by revising paragraph (f) to
read as follows:
§ 125.226
Digital flight data recorders.
(a) * * *
(89) Yaw damper status;
(90) Yaw damper command; and
(91) Standby rudder valve status.
(b) * * *
(4) In addition to the requirements of
paragraphs (b)(1) through (b)(3) of this
section, all Boeing 737 model airplanes
also must comply with the requirements
of paragraph (m) of this section.
(c) * * *
(4) In addition to the requirements of
paragraphs (c)(1) through (c)(3) of this
section, all Boeing 737 model airplanes
must comply with the requirements of
paragraph (m) of this section, as
applicable.
(d) * * *
(3) In addition to the requirements of
paragraphs (d)(1) and (d)(2) of this
section, all Boeing 737 model airplanes
also must comply with the requirements
of paragraph (m) of this section, as
applicable.
(e) * * *
(3) In addition to the requirements of
paragraphs (e)(1) and (e)(2) of this
section, all Boeing 737 model airplanes,
also must comply with the requirements
of paragraph (m) of this section, as
applicable.
(f) For all turbine-engine-powered
transport category airplanes
manufactured after August 19, 2002—
(1) The parameters listed in
paragraphs (a)(1) through (a)(88) of this
section must be recorded within the
ranges, accuracies, resolutions and
recording intervals specified in
appendix E to this part.
Seconds per
sampling
interval
Parameter
Range
Accuracy
(sensor input)
88. All cockpit flight
control input
forces (control
wheel, control
column, rudder
pedal).18 19
Full range ..............
Control wheel ±70
lbs.
Control column ±85
lbs.
Rudder pedal ±65
lbs.
±5% ..................
1
89. Yaw damper
status.
90. Yaw damper
command.
91. Standby rudder
valve status.
Discrete (on/off) .....
...........................
As installed .......
0.5
Discrete .................
...........................
Appendix E to Part 125—Airplane
Flight Recorder Specifications—
Continued
*
*
*
*
*
0.5
Full range ..............
(2) In addition to the requirements of
paragraph (f)(1) of this section, all
Boeing 737 model airplanes must also
comply with the requirements of
paragraph (m) of this section.
*
*
*
*
*
(m) In addition to all other applicable
requirements of this section, all Boeing
737 model airplanes must record the
parameters listed in paragraph (a)(1)
through (a)(22) and (a)(88) through
(a)(91) of this section within the ranges,
accuracies, resolutions, and recording
intervals specified in Appendix E to this
part. The approved recorder and all
equipment necessary to record the
parameters required by this paragraph
must be installed no later than the
installation of the redesigned rudder
system required by one or more
Airworthiness Directives issued under
part 39 of this chapter. The singlesource recording provisions of
paragraphs (b)(1)(ii), (c)(1), and (d)(1) of
this section may be used for airplanes
otherwise subject to those paragraphs.
9. Amend Appendix E to part 125 by
revising item 88, and adding items 89
through 91 to read as follows:
0.5
Resolution
Remarks
0.2% of full range ........
For fly-by-wire flight control systems,
where flight control surface position
is a function of the displacement of
the control input device only, it is not
necessary to record this parameter.
For airplanes that have a flight control break away capability that allows
either pilot to operate the control
independently, record both control
force inputs. The control force inputs
may be sampled alternately once per
2 seconds to produce the sampling
interval of 1.
1% of full range.
jlentini on PROD1PC65 with PROPOSAL2
18 For all 737 model airplanes: the seconds per sampling interval is 0.5 per control input; the remarks regarding the sampling rate do not apply;
a single control wheel force transducer installed on the left cable control is acceptable provided the left and right control wheel positions also are
recorded.
19 For all 737 model airplanes manufactured on or before January 31, 2001, Range values are: Full Range; Control wheel ±15 lbs.; Control column ±40 lbs.; and Rudder pedal ±165 lbs.
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Federal Register / Vol. 71, No. 171 / Tuesday, September 5, 2006 / Proposed Rules
*
*
*
*
*
Issued in Washington, DC, on August 25,
2006.
John J. Hickey,
Director, Aircraft Certification Service.
[FR Doc. 06–7406 Filed 9–1–06 8:45 am]
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BILLING CODE 4910–13–P
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Agencies
[Federal Register Volume 71, Number 171 (Tuesday, September 5, 2006)]
[Proposed Rules]
[Pages 52382-52401]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 06-7406]
[[Page 52381]]
-----------------------------------------------------------------------
Part II
Department of Transportation
-----------------------------------------------------------------------
Federal Aviation Administration
-----------------------------------------------------------------------
14 CFR Parts 91, 121, and 125
Revisions to Digital Flight Data Recorder Regulations for Boeing 737
Airplanes and for Part 125 Operators; Proposed Rule
Federal Register / Vol. 71, No. 171 / Tuesday, September 5, 2006 /
Proposed Rules
[[Page 52382]]
-----------------------------------------------------------------------
DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Parts 91, 121, and 125
[Docket No.: FAA-1999-6482; Notice No. 06-12]
RIN 2120-AG87
Revisions to Digital Flight Data Recorder Regulations for Boeing
737 Airplanes and for Part 125 Operators
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Supplemental Notice of Proposed Rulemaking (SNPRM).
-----------------------------------------------------------------------
SUMMARY: The FAA is revising a previous proposal to increase the number
of digital flight data recorder (DFDR) parameters required for all
Boeing 737 series airplanes. Based on safety recommendations from the
National Transportation Safety Board (NTSB) following the
investigations of two accidents and other incidents involving 737s, the
FAA proposed the addition of flight recorder equipment to monitor the
rudder system on 737s. Since that time, the FAA has mandated
significant changes to the rudder system on these airplanes.
Accordingly, this new proposed rule would apply to a different set of
airplanes than originally anticipated. We are requesting comment on
this change in applicability and are requesting updated economic
information regarding installation of the proposed monitoring
equipment. The original proposed rule also sought to amend the flight
data recorder (FDR) requirements of part 125 that would affect all
airplanes operated under that part or under deviation from that part;
we have included that same proposal in this SNPRM.
DATES: Send your comments on or before December 4, 2006.
ADDRESSES: You may send comments identified by Docket Number FAA-1999-
6482 using any of the following methods:
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 20590-0001.
Fax: 1-202-493-2251.
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 more information on the rulemaking process, see the
SUPPLEMENTARY INFORMATION section of this document.
Privacy: We will post all comments we receive, without change, to
https://dms.dot.gov, including any personal information you provide. For
more information, see the Privacy Act discussion in the SUPPLEMENTARY
INFORMATION section of this document.
Docket: To read background documents or comments received, go to
https://dms.dot.gov at any time or to 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 FURTHER INFORMATION CONTACT: For technical issues: Timothy W.
Shaver, Avionics Systems Branch, Aircraft Certification Service, AIR-
130, Federal Aviation Administration, 800 Independence Avenue, SW.,
Washington, DC 20591; telephone (202) 385-4686; facsimile (202) 385-
4651; e-mail tim.shaver@faa.gov. For legal issues: Karen L. Petronis,
Senior Attorney, Regulations Division, AGC-200, Office of the Chief
Counsel, Federal Aviation Administration, 800 Independence Ave., SW.,
Washington, DC 20591; telephone (202) 267-3073; facsimile (202) 267-
7971; e-mail: karen.petronis@faa.gov.
SUPPLEMENTARY INFORMATION:
Comments Invited
The FAA invites interested persons to participate in this
rulemaking by submitting written comments, data, or views. We also
invite comments relating to the economic, environmental, energy, or
federalism impacts that might result from adopting the proposals in
this document. The most helpful comments reference a specific portion
of the proposal, explain the reason for any recommended change, and
include supporting data. We ask that you send us two copies of written
comments.
We will file in the docket all comments we receive, as well as a
report summarizing each substantive public contact with FAA personnel
concerning this proposed rulemaking. The docket is available for public
inspection before and after the comment closing date. If you wish to
review the docket in person, go to the address in the ADDRESSES section
of this preamble between 9 a.m. and 5 p.m., Monday through Friday,
except Federal holidays. You may also review the docket using the
Internet at the Web address in the ADDRESSES section.
Privacy Act: Using the search function of our docket Web site,
anyone can find and read the comments received into any of our dockets,
including the name of the individual sending the comment (or signing
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.
Before acting on this proposal, we will consider all comments we
receive on or before the closing date for comments. We will consider
comments filed late if it is possible to do so without incurring
expense or delay. We may change this proposal in light of the comments
we receive.
If you want the FAA to acknowledge receipt of your comments on this
proposal, include with your comments a pre-addressed, stamped postcard
on which the docket number appears. We will stamp the date on the
postcard and mail it to you.
Proprietary or Confidential Business Information
Do not file in the docket information that you consider to be
proprietary or confidential business information. Send or deliver this
information directly to the person identified in the FOR FURTHER
INFORMATION CONTACT section of this document. You must mark the
information that you consider proprietary or confidential. If you send
the information on a disk or CD-ROM, mark the outside of the disk or
CD-ROM and also identify electronically within the disk or CD-ROM the
specific information that is proprietary or confidential.
Under 14 CFR 11.35(b), when we are aware of proprietary information
filed with a comment, we do not place it in the docket. We hold it in a
separate file to which the public does not have access, and place a
note in the docket that we have received it. If we receive a request to
examine or copy this information, we treat it as any other request
under the Freedom of Information Act (5 U.S.C. 552). We process such a
request under the DOT procedures found in 49 CFR part 7.
Availability of Rulemaking Documents
You can get an electronic copy using the Internet by:
(1) Searching the Department of Transportation's electronic Docket
Management System (DMS) Web page (https://dms.dot.gov/search);
[[Page 52383]]
(2) Visiting the FAA's Regulations and Polices Web page at https://
www.faa.gov/regulations_policies/; or
(3) Accessing the Government Printing Office's Web page at https://
www.gpoaccess.gov/fr/.
You can also get a copy by sending a request to the Federal
Aviation Administration, Office of Rulemaking, ARM-1, 800 Independence
Avenue, SW., Washington, DC 20591, or by calling (202) 267-9680. Make
sure to identify the docket number, notice number or amendment number
of this rulemaking.
Anyone is able to search the electronic form of all comments
received into any of our dockets by the name of the individual
submitting the comment (or signing the comment, if submitted 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 (Volume 65, Number 70; Pages 19477-78) or you may visit
https://dms.dot.gov.
Small Business Regulatory Enforcement Fairness Act
The Small Business Regulatory Enforcement Fairness Act (SBREFA) of
1996 requires FAA to comply with small entity requests for information
or advice about compliance with statutes and regulations within its
jurisdiction. If you are a small entity and you have a question
regarding this document, you may contact your local FAA official, or
the person listed under FOR FURTHER INFORMATION CONTACT. You can find
out more about SBREFA on the Internet at https://www.faa.gov/avr/arm/
sbrefa.htm, or by e-mailing us at -AWA-SBREFA@faa.gov. https://
www.faa.gov/regulations_policies/rulemaking/sbre_act/.
Authority for This Rulemaking
The FAA's authority to issue rules regarding aviation safety is
found in Title 49 of the United States Code. 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.
This rulemaking is promulgated under the authority described in
Subtitle VII, Part A, Subpart III, Section 44701. Under that section,
the FAA is charged with prescribing regulations providing minimum
standards for other practices, methods and procedures necessary for
safety in air commerce. This regulation is within the scope of that
authority since flight data recorders are the only means available to
account for aircraft movement and flight crew actions critical to
finding the probable cause of incidents or accidents, including data
that could prevent future incidents or accidents.
I. Background
A. Statement of the Problem
Two aviation accidents in the United States involving Boeing 737
series airplanes (737s) appear to have been caused by a rudder hardover
with resultant roll and sudden descent: United Airlines flight 585,
near Colorado Springs, Colorado, on March 3, 1991, and USAir flight
427, near Aliquippa, Pennsylvania, on September 8, 1994. Following
lengthy investigations, the NTSB determined that the rudder on 737s may
experience sudden uncommanded movement, or movement opposite the
pilot's input, which may cause the airplane to roll suddenly. Other
incidents of suspected uncommanded rudder movement have been reported,
including a 1996 incident involving Eastwind Airlines (Eastwind) flight
517, a 737-2H5, and five incidents in 1999 involving U.S.-registered
airplanes.
The 737s involved in the United Airlines and USAir accidents, and
those in the more recent incidents, were equipped with the flight data
recorders required by the regulations then in effect. However, these
airplanes were not required to record, nor were they equipped to
provide, information about the airplane's movement about its three axes
or the position of flight control surfaces immediately preceding the
accident or incident. While the FAA has undertaken a series of measures
designed to address the suspected rudder problems, our efforts have
been limited by a lack of data that focused on the control and movement
of the components of the 737 rudder system. Without more data, neither
the FAA nor the NTSB can definitively identify the causes of suspected
uncommanded rudder events.
B. FAA Actions
Following piloted computer simulations of the USAir accident and
reports of malfunctions in the yaw damper system of 737s, the FAA
mandated design changes to the rudder system of 737s. First, the FAA
issued Airworthiness Directive (AD) 97-14-03 (62 FR 34623, June 27,
1997), which requires installation of a newly designed rudder-limiting
device and a newly designed yaw damper system, in an effort to address
possible rudder hardover situations and uncommanded yaw damper
movements. Second, in response to the possibility of a secondary slide
jam and rudder reversal, the FAA issued AD 97-14-04 (62 FR 35068, June
30, 1997). That AD requires operators to install a new vernier control
rod bolt and a new main rudder power control unit (PCU) servo valve in
each airplane.
C. Safety Recommendations: 1995-1997
Between 1995 and 1997, while investigating the USAir accident, the
NTSB issued 20 safety recommendations dealing with the 737; three of
those (A-95-25, A-95-26, and A-95-27) dealt specifically with upgrades
to the FDR for all 737s. The NTSB stated that if either the United
Airlines or the USAir 737 had recorded data on the flight control
surface positions, flight control inputs, and lateral acceleration, the
NTSB would have been able to identify quickly any abnormal control
surface movements and configuration changes or autopilot status changes
that may have been involved in the loss of control.
At the time it made its recommendations, the NTSB recognized that
the 737 had flown over 92 million hours since its initial certification
in December 1967, and that the airplane's accident rate is comparable
to that of other airplanes of a similar type. Nonetheless, the Board
concluded that the design changes made to the rudder system in
accordance with the issued ADs did not eliminate the possibility of
other potential failure modes and malfunctions.
D. FAA Response: 1997 Regulations
In response to these safety recommendations, the FAA published
revisions to the DFDR requirements for all airplanes (Revisions to
Digital Flight Data Recorder Rules; Final Rule (62 FR 38362, July 17,
1997)). The revised DFDR regulations prescribe the 88 parameters that
must be recorded on DFDRs, with the exact number of parameters required
to be recorded determined by the date of airplane manufacture. The
number of parameters that must be recorded range from 18 for a
transport category airplane manufactured on or before October 11, 1991,
to 88 for airplanes manufactured after August 19, 2002.
E. NTSB's 1999 Findings and Safety Recommendations
On March 24, 1999, the NTSB issued the final report of its
investigation into the crash of USAir flight 427. The NTSB determined
that the probable cause of the accident was a loss of control resulting
from the movement of the rudder surface position to its blowdown limit.
Further, the NTSB stated that
[[Page 52384]]
``* * * the rudder surface most likely deflected in a direction
opposite to that commanded by the pilots as a result of a jam of the
main rudder PCU servo valve secondary slide to the servo valve
housing offset from its neutral position and overtravel of the
primary slide.''
In its March 1999 report, the NTSB concluded that the 1997
regulations for upgrading DFDRs are inadequate for existing 737s,
because they do not require specific flight control information to be
recorded. Because several 737 rudder-related events have been
associated with the yaw damper system (which moves the rudder
independent of flightcrew input), the NTSB concluded that it is
important that yaw damper status (parameter 89), yaw damper command
(parameter 90), standby rudder status (parameter 91), and control
wheel, control column, and rudder pedal forces (parameter 88) be
recorded on all 737s. The NTSB also pointed out that, for optimal
documentation, the indicated parameters need to be sampled more
frequently than is required currently. The NTSB stated that by
recording the yaw damper's operation and the resultant rudder surface
movements, a yaw damper event could be distinguished quickly from a
flightcrew input or a rudder anomaly. The NTSB considers this
information critical to investigating 737 incidents or accidents. The
NTSB stated that if pilot flight control input forces had been recorded
on the United Airlines, USAir, or Eastwind FDRs, the NTSB
investigations would have been resolved more quickly and actions taken
to prevent similar events would have been hastened.
On April 16, 1999, the NTSB submitted the following recommendations
to the FAA regarding recording additional parameters on 737 DFDRs:
Recommendation No. A-99-28. Require that all 737s operated under
part 121 or part 125 that currently have a FDAU be equipped, by July
31, 2000, with a flight data recorder system that records, at a
minimum, the parameters required by the 1997 DFDR regulations
applicable to that airplane, plus the following parameters: Pitch trim,
trailing edge flaps, leading edge flaps, thrust reverser position (each
engine), yaw damper command, yaw damper status, standby rudder status,
and control wheel, control column, and rudder pedal forces. Yaw damper
command, yaw damper status, and control wheel, control column, and
rudder pedal forces should be sampled at a minimum rate of twice per
second.
Recommendation No. A-99-29. Require that all 737s operated under
part 121 or part 125 that are not equipped with a FDAU be equipped, at
the earliest time practicable, but no later than August 1, 2001, with a
flight data recorder system that records, at a minimum, the same
parameters noted in safety recommendation No. A-99-28.
The NTSB also noted in its final report on the USAir accident that
737 flightcrews continue to report anomalous rudder behavior and that
the NTSB considers it possible that another catastrophic event related
to 737 rudder upset could occur.
F. FAA Response: Notice No. 99-19
The FAA agreed with the intent of NTSB Safety Recommendation Nos.
A-99-28 and A-99-29 and the NTSB's concerns regarding continuing
reports of rudder-related incidents on 737s. On November 9, 1999, the
FAA issued Notice No. 99-19 (64 FR 63140, November 18, 1999), which
proposed that all 737s be required to record the parameters listed in
Sec. 121.344(a)(1) through (a)(22), (a)(88), plus three new
parameters, designated as (a)(89) through (a)(91). The new parameters
are yaw damper status, yaw damper command, and standby rudder status.
In addition, the FAA proposed increasing the required sampling rate for
the control forces listed in current paragraph (a)(88) for 737s. The
FAA proposed that all 737s equipped with a FDAU of any type as of July
16, 1996, or manufactured after July 16, 1996, comply by August 18,
2000. For all 737s not equipped with a FDAU of any type as of July 16,
1996, the FAA proposed a compliance date of August 20, 2001. The FAA
noted that if it received sufficient data to support an extension, the
compliance period for airplanes retrofitted to include FDAUs between
July 16, 1996, and November 18, 1999, would be extended to August 19,
2002.
The FAA proposed corresponding changes to part 125 for 737s
operated under that part. In addition, the FAA proposed that no
deviation authority from the FDR requirements of part 125 would be
granted for any model airplane, and that any previously issued
deviation from the DFDR requirements of part 125 would no longer be
valid. The FAA also proposed that Sec. 91.609 be amended to reflect
that all airplanes operating under part 91 under deviation authority
from part 125 must comply with the DFDR requirements in part 125,
notwithstanding such deviation authority.
II. Continuing Need for This Rulemaking
The original NPRM, issued by the FAA in 1999, proposed that in
addition to other applicable requirements, all 737 model airplanes must
record certain additional parameters of flight data, including those
specifically designed to monitor rudder system components. The FAA
added that it planned on issuing the final rule with an immediate
effective date to address the unresolved issues with the airplane as
soon as possible.
In January 2001, Boeing submitted a letter to the docket requesting
that the FAA delay the release of any final rule. The request was based
on Boeing's 737 Rudder System Enhancement Program (RSEP), which itself
was based on an NTSB recommendation to develop a ``reliably redundant
rudder system'' for the 737. Boeing stated that the RSEP changes will
make the 737 rudder system functionally equivalent to the 3-actuator
system found on its 757 and 767 model airplanes.
Boeing's letter states that on January 16, 2001, it presented a
detailed description of its 737 RSEP changes to the NTSB. While noting
that the proposed rule would be applicable to the original rudder
system, not the one being developed under the RSEP, it attempted to
minimize the value of a final rule that applied only to airplanes with
the older system installed. Boeing also questioned whether it would
still be appropriate to treat the 737 different than other airplanes
once the rudder system was modified.
While the redesigned rudder control system meets the latest FAA
system requirements, it remains a system unique to the 737 model
airplane. In Boeing 757/767/777 model airplanes, the rudder control
system has three separate actuators in separate power control units
(PCU) that are always powered. The original design of the 737 rudder
control system had a single input into a valve that controlled two
installed actuators in the PCU. In the redesigned 737 system, there are
three actuators, but they are housed in two PCUs rather than the three
present in the other Boeing model airplanes. The main PCU has two
actuators, each with its own valve that accepts input. The third
actuator is in a standby PCU that is not normally powered unless the
main PCU fails. Thus, the 737 rudder control system effectively still
has only two actuators during normal flight operations, and a single
actuator when the main PCU is inoperative.
Several events have occurred since the NPRM was issued in 1999,
including Boeing's RSEP. One of the recommendations issued by the NTSB
included the formation of an engineering test and evaluation board
(ETEB) to conduct a failure analysis of
[[Page 52385]]
the rudder actuation control system of the 737. The 737 ETEB was formed
in May 1999 and issued its final report in July 2000.
Among the key findings of the 737 ETEB are the following:
(1) The 737 rudder control system is susceptible to a number of
failures and jams. These failures and jams can affect the operation of
the rudder power control units and can result in uncommanded rudder
motion.
(2) A number of failures and jams of the 737 rudder control system
were detected in configurations on which the FAA later issued
corrective action under one or more Airworthiness Directives (ADs).
More than two dozen of these failures and jams (alone or in
combination) have what are considered catastrophic failure effects.
(3) Even when 737s were in compliance with the ADs issued at the
time, rudder control system failures and jams were still present.
(4) Most of the failure modes were discernable on both the older
(classic) models and the newer (next generation) models of the 737.
(5) There were no catastrophic failure modes identified at cruise
speed and altitude. One change to the hydraulic pressure system
mandated by AD reduced the time an airplane was exposed to catastrophic
failure modes, but exposure was not eliminated during takeoffs and
landings.
Among its recommended long-term actions, the ETEB recommended that
the 737 rudder system be modified to ensure that no single failure or
single jam of the rudder control system would cause an uncommanded
rudder motion that has catastrophic results.
The NTSB did not withdraw or change its recommendation regarding
further monitoring of the rudder system on 737s, and indicated in a
February 2001 letter to the FAA that it had not changed its position
regarding the need for installation of the new FDR equipment ``at the
earliest possible opportunity regardless of any rudder system
modification.''
In November 2001, the FAA published a proposed AD that would
require the installation of a new rudder control system (and
accompanying changes to nearby systems) (66 FR 56783, November 13,
2001). The FAA determined that the inherent failure modes in the 737
rudder system, verified by the ETEB, result in a design system
architecture that is unsafe. The FAA also determined that the rudder
system design architecture led to a need for non-normal operational
procedures, which had also been implemented by AD. The FAA concluded
that the combination of the inherent failure modes and the non-normal
operational procedures, considered together, present an unsafe
condition that warranted the incorporation of a newly designed rudder
control system.
The final rule AD was published on October 7, 2002 (67 FR 62341),
with an effective date of November 12, 2002, and gives all operators of
737 model airplanes 6 years to install a new rudder control system.
Boeing has been installing the newly designed rudder control system
on 737 model airplanes manufactured since January 2003. Boeing is also
installing the additional sensors that were proposed in the NPRM on
these newly manufactured 737s, and those parameters are being recorded.
When we began drafting a final rule, we realized that the 737 fleet
that would be affected by the proposed rule--those airplanes with the
original rudder system--had already begun to shrink in number. The
promulgation of several Airworthiness Directives means that by the 2008
compliance date for those ADs, no 737 aircraft left in the U.S. fleet
would have the old rudder system. Therefore, we no longer find it
appropriate to require the installation of flight recorder equipment to
monitor those parts of the aircraft which became life-limited by these
ADs and will be eliminated by 2008.
This SNPRM attempts to address the changes in circumstances
introduced by the RSEP, the findings by the ETEB, and the ADs issued by
the FAA by revising the fleet of airplanes affected by the proposed
rule, and by changing the proposed compliance time to coincide with the
modifications required by the ADs.
The FAA does not have convincing evidence that the redesigned
rudder control system obviates the need for the additional flight
recorder parameters. The newly designed rudder system is unique in that
the third actuator is only activated upon the failure of the main PCU,
at which point the two main actuators are no longer performing. Thus,
the FAA has tentatively concluded that the information that would be
gathered by the addition of the proposed parameters could provide
meaningful information in the event of a rudder control failure. While
the ETEB conducted considerable testing of the 737 aircraft and its
rudder system, those tests cannot duplicate the actual flight
experience of either the original or the new rudder system as it would
be recorded using the parameters proposed. The only way to get this
data is by installation of equipment that will record the movement of
the rudder surface and the companion actions of the yaw dampers. The
ETEB did not have this information because the equipment to record it
was not mandatory. Since the additional parameters have yet to be
installed, investigators of an accident or incident remain similarly
limited today.
Boeing has indicated that there have been no reports of rudder
hardover incidents on 737s with the redesigned rudder system. However,
since the system has only been installed as original equipment on
airplanes since 2003, and since compliance with the retrofit is not
required until 2008, only limited historical data on the function and
reliability of this redesigned system is available.
Additionally, as discussed above, the redesigned rudder system does
not actively power three actuators. Rather, the third actuator only
powers up in the event of a power failure to the two primary actuators.
Thus, while the new design incorporates three actuators, similar to the
design of Boeing's 757/767/777 model airplanes, a functional difference
remains between the new 737 rudder system and that installed on other
Boeing airplanes.
We note that the rudder control system enhancement can be split
into three separate tasks and are not normally accomplished at once.
The first two changes can be accomplished with the old rudder control
system still in place. As of August 2004, Boeing had shipped 2,957 kits
needed for the first part of the installation, but only 728 kits for
the third part. The FAA assumes these numbers have gone up; however,
since there is no reporting requirement for compliance with the AD, we
have no way of knowing how many new components or complete rudder
control systems have been installed. However, the FAA understands that
the wiring kit provided by Boeing for the first part of the redesigned
rudder system includes the wiring required for the proposed additional
sensors, making the installation of the parameters less burdensome than
originally anticipated. Compliance with this rule, if adopted, would
require the installation of the sensors and their connection to the
DFDR system. These circumstances argue for either the issuance of this
rule (to take advantage of the work yet to be accomplished on the
majority of the 737 fleet) or withdrawal, as soon as possible.
We continue to believe that unless the proposed additional flight
recorder sensors are installed and the function of the new system
components are monitored, there will never be any means to eliminate
the rudder system as a possible cause of any future incident
[[Page 52386]]
or accident, or to identify the particular component or action as a
source of the problem if the rudder control system is involved. These
are the circumstances that spurred the original NTSB recommendations on
the 737, but we are cognizant of the significant changes in
circumstances that have occurred in the last five years, including the
mandated changes to the original rudder system, and the decline in
reported incidence of rudder hardover events.
We are also aware that we now need new information on the costs and
benefits of requiring these enhancements on a fleet of aircraft that
did not exist when we originally proposed the rule, those with the new
rudder system installed.
The FAA originally evaluated the cost data associated with this
SNPRM nearly five years ago, shortly after the close of the comment
period for the NPRM. Since then, some 737s may have been retrofitted
with the new rudder, and may be partially equipped to record the
additional flight data parameters. Further, with the introduction of
the new Boeing 737 rudder, there is a new class of airplane that will
incur retrofitting costs that may be different from those costs
reported by the industry and used in the Supplemental Preliminary
Regulatory Evaluation (Supplemental PRE) that accompanies this
rulemaking document. Because the FAA does not have the data necessary
to evaluate the impact of, and need for, a rule requiring the
additional parameters for those 737s equipped with the new rudder
control system, the agency requests more current information for the
following specific questions as well as any additional data that the
public believes needs to be incorporated into the economic analysis.
1. How many 737s are in your fleet?
2. How many 737s do not record the flight parameters that we are
proposing be recorded? How many 737s currently record these parameters?
3. How many 737s have been retrofitted with the new Boeing rudder?
How many of those airplanes do not record the flight data parameters
that we propose to be recorded?
4. How many 737s are expected to be retrofitted with the new Boeing
rudder in each of the years 2006, 2007, and 2008?
5. How many 737s are expected to be retired in each of the years
2006, 2007, and 2008?
6. For those 737s that have already been retrofitted under the AD
but do not record the additional flight data parameters, how much would
it cost to install the equipment to record the additional flight data
parameters? How many days would it take to install the equipment to
record those additional flight data parameters on those airplanes if
the work were done: during a major maintenance session; an overnight
maintenance session?
7. Are the assumptions and estimates made in Table 1 of this notice
and the accompanying Supplemental PRE, and throughout that report,
accurate? If you are able to provide more current data, please submit
it.
8. Please provide an update on the status of the various design
changes that would still need to be accomplished to provide the
information necessary to install the proposed flight recorder
parameters on the fleet expected to be retrofitted with the new rudder
design.
We are issuing this SNPRM to gather information on the need for
flight recorder parameters that monitor the new rudder system. This
proposal represents a shift in the scope of the rule. When the DFDR
enhancements were proposed, work was still in progress in diagnosing
the functions and perceived weaknesses of the original rudder system.
We have modified the original proposed regulatory text to require that
the flight recorder parameters proposed in 1999 be installed concurrent
with the new rudder system; we have redrafted the rule to state that
compliance would be required no later than November 12, 2008, the date
that compliance is required with the Airworthiness Directives mandating
the installation of the redesigned rudder system. We have made other
changes to the proposed regulatory text based on comments to the NPRM.
These changes, which are explained later in the document, will not be
revisited. Accordingly, we request interested parties to direct their
attention to our requests for data, the need for additional parameters
for the redesigned 737 rudder control system, and the proposed November
2008 compliance date.
In summary, the FAA finds this supplemental proposal necessary in
order to update the status of the number and configuration of 737s in
the current fleet. Since we do not track operator compliance with ADs,
the information requested here will tell us how many airplanes have
been retrofitted with the new rudder system and the estimated costs for
installing the DFDR parameters if the new rudder system has already
been installed. We expect to receive information on the number of
retirements expected, as well as the number of aircraft that are
already in compliance because they are new or because the proposed DFDR
rudder parameters may have been installed voluntarily.
III. Summary of Comments
The FAA received 17 comments on the proposed rule. Of the 17
comments, the Air Transport Association of America, Inc. (ATA),
submitted three separate comments; one of the ATA submissions included
seven comments from member airlines. Only one commenter, the Air Line
Pilots Association (ALPA), supports the proposed rule as published.
Specifically, ALPA agreed that a potentially unsafe condition has been
identified and concurs with the proposed amendments. The other
commenters generally supported the intent of the proposed rule;
however, these commenters expressed concern about:
(1) The time frame for compliance proposed in the Notice of
Proposed Rulemaking (NPRM),
(2) the availability of installation instructions,
(3) the unavailability of parts, and
(4) the probability of considerable airplane out-of-service time.
The amount of time that has elapsed since comment was invited, and
the events that have occurred since comment was invited, has caused
most of the comments to become outdated. The proposed compliance times
are no longer applicable, nor are the costs that were applied to them.
Accordingly, we are not including a discussion of comments concerning
compliance time, parts availability, or out of service time since these
issues no longer exist under current circumstances.
Comments on Specific Proposed Requirements
The following disposition of comments addresses those comments that
were not overtaken by intervening events and actions. Some of the
questions and information submitted with them remain relevant to the
actions contemplated under this modified proposal.
Boeing stated that it typically does not develop or commit to
design changes until the release of a final rule. However, because of
the proposed short time frame for compliance, Boeing had already
implemented production design changes in an attempt to accommodate the
expected compliance schedule. Boeing noted that a typical design change
of this magnitude would require a minimum of 18 months to allow time to
develop the design and to work with parts suppliers, operators, and the
FAA.
[[Page 52387]]
A. Compliance Issues for Rudder Pedal Forces
Proposal: The FAA stated in Notice No. 99-19 that it had received
inquiries from the NTSB and Boeing concerning an acceptable means of
recording the rudder pedal control input forces required by paragraph
(a)(88) of Sec. 121.344; the requirement was added in the 1997
amendment to the DFDR regulations.
To meet the 1997 regulations, Boeing developed a rudder pedal force
transducer that is placed ``midstream'' in the rudder control system.
The transducer is designed to identify whether the input was coming
from the cockpit or from the rudder assembly.
The NTSB indicated informally that it would prefer a system that
measures the rudder input force at the individual rudder pedals. This
would require the addition of four transducers (one on each rudder
pedal) rather than the single one designed by Boeing. The FAA noted
that the NTSB believes that only the installation of four rudder pedal
force sensors would meet the intent of its April 16, 1999
recommendation to record rudder input force.
The FAA acknowledged the difference between the data acquired using
Boeing's already approved single transducer system and the NTSB's
suggested four-pedal sensor retrofit. The FAA requested comment on the
necessity and feasibility of instrumenting all four rudder pedals on
737s with force sensors as a means of complying with paragraph (a)(88).
The FAA also requested comment on whether Boeing's single force
transducer should remain an accepted means of compliance with parameter
88 for all 737s that do not have the transducer installed or had not
yet otherwise complied with paragraph (a)(88). In addition, the FAA
requested cost data for the four-pedal retrofit to determine whether
the incremental increase in benefits that would be provided by that
configuration would be offset by the additional time and costs involved
if such a requirement were mandated.
Comments: The FAA received two comments on recording rudder control
inputs, one from the NTSB and one from Boeing.
The NTSB stated that the rudder pedal force exerted by each
crewmember is critical to its understanding the loss of control
problems experienced in the 737. The NTSB added that in its
investigation of a 1999 rudder incident involving Metrojet, not knowing
the amount of rudder pedal force exerted has made it impossible to
separate pilot actions from (possible) rudder system anomalies. The
Board argued that a single sensor placed midstream in the rudder
control system, as introduced by Boeing, would not identify whether the
flightcrew inputs are in opposition to each other or whether the nose
wheel steering (NWS) or some other system anomaly forward of the sensor
causes the inputs. In addition, any jams in the controls between the
pedals and the sensor may go undetected, because the amount of force
exerted by the flightcrew would not be registered by the sensor. The
NTSB stated that, if the upgrade required only a single force sensor in
the rudder system, the possibility would remain that the information
would not be sufficient to identify some future flight control problems
even after the proposed retrofit.
Boeing commented that neither the existing rule nor the proposed
rule includes specific requirements that support a change to the
current design to measure individual rudder pedal force. Boeing stated
that the 1997 rule contained no requirement to measure any disagreement
between pilot inputs. According to Boeing, the NTSB recommendations and
the proposed rule suggested that the only issue is the ability to
quickly distinguish a yaw damper event from a flightcrew input or a
rudder anomaly. Boeing believed the current single transducer design
meets this intent.
Boeing claimed the current 737 NG airplane rudder pedal design
satisfies the parameter 88 requirements defined in the existing rule.
Boeing added that the rudder design on 737-100 through -500 series
airplanes delivered since August 1998 is identical to that on the 737
NG airplanes, and retrofit kits are available for this installation in
airplanes delivered before then. Boeing noted that any change to the
requirements to which this installation complies would require
additional retrofit.
Boeing further stated that the proposed addition of four individual
rudder pedal force sensors would require a significant number of design
changes in the rudder control mechanism and to the structure of the
cockpit floor. The 737 has severely limited space in the area these
would be placed, which limits design options. At the time the NPRM was
issued, Boeing and its suppliers had not yet been able to identify a
design solution that could be implemented without significant
structural and system changes that would make retrofit complex,
lengthy, and costly. Boeing added that it expected the design
definition and implementation of four transducers would take much
longer than the implementation dates proposed.
Boeing also argued that four transducers would provide no major
incremental gain in information. According to Boeing, a single
transducer allows investigators to determine why the rudder moved, by
pilot action or system input, but that a single transducer will not
show whether a pedal jammed. The four transducers would enable Boeing
to determine whether the rudder moved and may allow determination of
which pedal was jammed or restricted. However, the four transducers,
like the single transducer, would not permit determination of why a
rudder pedal was jammed or restricted, because the jam or restriction
is also ``upstream'' of the transducers.
FAA reply: Although specifically requested, the FAA did not receive
any cost data or time estimates for a four-rudder-pedal sensor retrofit
as described in the NPRM. While the FAA understands the NTSB's desire
for the information that such rudder pedal sensors might provide,
general comments from Boeing indicate that such a retrofit would be
both time-consuming and costly. The FAA is unaware of a sensor
currently in production that could meet the design requirements that
would be necessitated by the NTSB's request. Even if such a sensor does
exist, Boeing also indicated (in its comment and in discussions with
the FAA) that major redesign of the aircraft might be necessary,
including moving a floor beam, since there is so little space available
under the rudder pedals of the 737. Such modifications would take
several years to design and incorporate into the production line; the
engineering for in-service airplanes would be more complicated, since
changes to major structural components would mean a change to the
airplane's original type design and the airworthiness certification of
every affected airplane. The time that such design and retrofit would
take far exceeds any recommendation of the NTSB, and argues against the
NTSB's own characterization of the modification as time-sensitive.
Further, the FAA is unable to say with any certainty that the
information that might be gathered by the NTSB's proposed pedal force
sensors would lead to a solution to the rudder problem. The rudder
pedal force sensors may well be able to identify the amount of force an
individual pilot is placing on a pedal, but the amount of force does
not seem to have been an issue in the noted accidents or incidents. If
there is a problem in the rudder system, then the amount of force
exerted in an
[[Page 52388]]
attempt to overcome it is less important than finding where the
malfunction is occurring. If pilots are fighting each other for control
using the rudder pedals, then the issue is not with the airplane
itself. It is a suspected problem with the airplane itself that is the
reason for proposing this rule, and the FAA has determined that
continuing to allow compliance with parameter 88 using a single
midstream transducer reflects the best balance of cost and information
to be gained in an attempt to locate the source of the problem in a
timely fashion.
Accordingly, the FAA has decided against promulgating a four-pedal
sensor requirement. The agency has no basis for concluding that a
retrofit of individual rudder pedal sensors would be cost beneficial
when the costs themselves cannot readily be estimated without a
significant investment of time and energy. Moreover, since the FAA is
unable to quantify the requirements either for the equipment or the
recording rate and sensitivity, any information on estimated costs
becomes that much less reliable and certainly falls short of the legal
requirements for imposing the eventual cost on operators.
B. Compliance Issues for the Control Column and Control Wheel
Proposal: Parameter (a)(88) requires that control wheel and control
column input forces be measured and recorded. The current rule requires
that airplanes with breakaway capability record both left and right
side control wheel forces. The FAA noted in the preamble to the NPRM
that there also are issues of acceptable means of measuring control
column and control wheel forces. The FAA specifically requested comment
on the means and costs of measuring these control forces under the
requirements proposed in this rulemaking.
Comments: The FAA received comments from Boeing, Alaska, United
Airlines, ATA, and the NTSB on the control column and control wheel
systems.
Boeing stated that to comply with the existing rule for parameter
(a)(88), Boeing intended to modify the control column and control wheel
force transducers for DFDR application to achieve the increased force
range. Boeing would also install new flight control computer hardware
and software to interface with the new transducers.
Boeing stated that the retrofit for the 737-100 through -500 series
airplanes is basically the same as that for the 737 NG airplanes.
However, it noted the 737-100 through -500 series airplanes include two
control column force transducers in the same location as the 737 NG
airplanes, but that the force applied by individual pilots cannot be
determined because the elevator control systems of the 737-100 through
-500 series airplanes do not have a jam override device between
columns.
Boeing also described the FAA-approved single-wheel force
transducer design for parameter (a)(88), and stated that it meets the
intent of the existing rule provided that the left and right control
wheel positions also are recorded. Boeing stated that the aileron
system measures both cockpit control positions, but only the left
side's force. Each pilot's control inputs go through the left side
force transducer, except in the event of a failure. Boeing added that
because the FAA does not typically consider dual failures a likely
event, the proposed configuration should be acceptable.
Boeing noted that to comply with the existing requirements for
parameter (a)(88), the control wheel force transducer would have to be
modified specifically for DFDR application to achieve the increased
force range. New flight control computer hardware and software would
have to be installed to interface with the new transducer and the force
transducer stops would have to be modified to allow the additional
range.
Boeing further stated the control wheel retrofit of the 737-100
through -500 series airplanes is basically the same as that of the 737
NG airplanes, except that Boeing would add a (new) second control wheel
position transducer to the first officer's control wheel to allow the
737-100 through -500 series airplanes' configurations to be identical
with that of the 737 NG airplanes.
The NTSB stated that although it is concerned that the current
control force sensors will not meet the range and accuracy requirements
of the proposed rule, suitable control force sensors were likely to be
available by the then proposed compliance dates. The NTSB contended
that separate sensors to measure the pilot and copilot flight control
input forces must be used when breakaway features are employed
(breakaway capability allows either pilot to operate the airplane
independently).
Two operators of 737s and the ATA commented that as of the date of
the NPRM, the required sensors had not yet been developed.
FAA reply: The primary objection raised by the commenters was that
the regulation would force early compliance with parameter (a)(88) for
control wheel and control column forces, and that the sensors required
to record to Appendix M specifications were not available and had not
yet been designed. Sensor design and availability are no longer issues
since all aircraft manufactured after August 19, 2002 have been
required to meet Appendix M standards for parameter (a)(88). Nor is
there any need to provide for more than one sensor type since a sensor
that records to Appendix M standards now exists for use in a retrofit.
Accordingly, the FAA intends to adopt the rule as originally proposed,
with the Appendix M standards applicable to all 737s recording all
functions required by parameter (a)(88) (70 pounds control
wheel force and 85 pounds control column force).
The FAA understands that the lateral control system on the 737 has
an override device between the two control wheels that allows either
pilot to operate the control wheel independently, but that the primary
control path for both pilots is through the left cable control path.
The right control is not usually connected and is used only in the
event of a failure. A single control wheel force transducer in the left
cable path records the inputs from both pilots. The FAA agrees that the
single control wheel force transducer is acceptable, provided the left
and right control wheel positions are also recorded. The use of a
single force transducer with two position sensors is acceptable because
comparison of the two position sensors allows detection of a breakout
of the override between the control wheels; this breakout allows the
right cable control path to become active.
C. Compliance Issues; Other Parameters
1. Standby Rudder Status
Proposal: In the NPRM, the FAA proposed to add recording of the
standby rudder status. The standby rudder system is an alternative
source of hydraulic power to the rudder that is used when primary
hydraulic power is lost. The intent of the proposed requirement was to
record whether the standby rudder system switch is in the on or off
position.
Comment: Boeing believed the intent of recording the standby rudder
status was to determine the actual status of the standby rudder system
and not the position of any particular switch. Boeing indicated that
the system should record the state of the standby hydraulic rudder
shutoff valve, which also is controlled by both of the standby rudder
system switches. Boeing maintained this would provide a clearer
indication of the actual status of the standby rudder
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system than recording whether the standby rudder switch is in the on or
off position. The ATA stated that the sensors for the standby rudder
status parameter have not been designed for any 737.
FAA reply: The FAA agrees with the comments and we have revised the
proposed language in paragraph (a)(91) to indicate that it is the valve
position that needs to be recorded for standby rudder status, not the
position of the switch, as initially proposed.
2. Thrust Reverser
Proposal: Under the 1997 DFDR regulations, instrumentation of the
thrust reversers (Sec. 121.344(a)(22)) was not required until the year
2001 for some airplanes and is not required at all for older airplanes.
The proposal would require all 737s regardless of age to record the
thrust reverser position.
Comment: Boeing stated that the requirement for recording thrust
reverser positions would require modifications to the engine accessory
unit (EAU) to monitor the thrust reverser. According to Boeing,
approximately 937 737-100 and -200 airplanes will require two new PC
cards and associated connectors and wiring, and approximately 250 737-
300 and -400 airplanes will require four new PC cards and associated
connectors and wiring if the proposal is adopted. Boeing requested that
the FAA not require instrumentation of the thrust reversers for the
older 737-100 through -500 series airplanes. The 737 NG airplanes would
be retrofitted to record thrust reverser position. Boeing suggested
specific language that could be used to codify its request.
FAA reply: The SNPRM does not incorporate Boeing's suggested
change. Under Sec. 121.344(b)(1), adopted in 1997, the only airplanes
not required to record thrust reverser position, parameter (a)(22), are
airplanes manufactured on or before October 11, 1991, that were not
equipped with a FDAU as of July 16, 1996. All other airplanes must
either be retrofitted to record, or record at manufacture, thrust
reverser position.
The distinction made in Sec. 121.344(b)(1) was introduced to
prevent the oldest airplanes from having to be retrofitted with a FDAU
to meet the 1997 rule, not because thrust reverser data is not
important. Under this SNPRM, the other recording requirements for 737s
necessitate the installation of a FDAU, eliminating the distinction
made in the 1997 rule. Further, the FAA cannot accept Boeing's
suggested language because it is general and would relieve not only
737s but certain other airplanes from the 1997 requirement to record
parameter (a)(22). This proposal would require all 737s to record
parameter (a)(22).
3. Yaw Damper Status and Yaw Damper Command
Proposal: Proposed paragraph (a)(89) would add the recordation of
yaw damper status. The intent of the requirement is to determine
whether the yaw damper is on or off. Proposed paragraph (a)(90) would
add the recordation of yaw damper command. The intent of this
requirement is to record the amount of voltage being received by the
yaw damper system. This determines how much rudder movement is being
commanded.
Comment: For the 737-100 through -500 series airplanes, Boeing
proposed to record the yaw damper linear variable displacement
transducer (LVDT) position feedback from the new yaw damper coupler
through an ARINC 429 interface, and, if the DFDR capacity allows, the
yaw damper command from the yaw damper coupler through an ARINC 429
interface. Boeing noted that the 737 NG airplanes record both the yaw
damper command from the stall management yaw damper and the yaw damper
LVDT position feedback through an ARINC 429 interface. The ATA stated
that sensors for yaw damper status and yaw damper command parameters
are not addressed in a retrofit service bulletin.
FAA reply: Sensors for the yaw damper status and yaw damper command
parameters have been developed and have been installed in 737s
manufactured since August 18, 2000. The sensors exist and the FAA
continues to believe that the parameters should be required.
4. Other Issues
Proposal: The current DFDR regulation allows single-source
recording for control input and control surface positions, parameters
(a)(12) through (a)(14) or (a)(12) through (a)(17), depending on the
date of airplane manufacture. The proposed rule eliminated the
allowance to record these from a single source.
Comments: Boeing stated that Sec. 121.344(b) and (c), as proposed,
removes the allowance to permit recording parameters (a)(12) through
(a)(17) from a single source and applies the full requirement of
appendix M to part 121 to recording these parameters. However,
paragraph (d) still permits recording parameters (a)(12) through
(a)(17) from a single source.
FAA reply: Removing the allowance for recording control and surface
positions from a single source was an error in the proposed rule. This
SNPRM includes the single-source recording as provided in the 1997
rule. A sentence has been added in Sec. 121.344(m) indicating that
single-source recording would remain available to airplanes otherwise
subject to Sec. 121.344(b)(1), (c)(1), or (d)(1).
Proposal: The proposal removes 737s from the requirements of Sec.
121.344(b) and (c), adds specific 737 requirements to Sec. 121.344(d),
(e), and (f), and adds new Sec. 121.344(m).
Comments: Boeing indicated that Sec. 121.344(d), (e), and (f), as
proposed, state that all 737s must comply with the requirements in
paragraphs (m)(1) and (m)(2). Boeing contended this language overlooks
the requirements of paragraph (m). Boeing also did not understand why
paragraphs (d), (e), and (f) were not revised as paragraphs (b) and (c)
to except the 737. Boeing stated that the addition of paragraph (m)
makes it unclear as to what is required for 737s and that it would be
much clearer to include the additional 737 requirements in the existing
applicable paragraphs. Boeing further stated that Sec. 121.344(m), as
proposed, is inconsistent with paragraphs (b), (c), and (d) in that it
requires recording parameters (a)(88) through (a)(91), while paragraphs
(b), (c), and (d) do not.
FAA reply: The modifications to the compliance schedule for
installation of the additional parameters have removed the issue of
compliance time; compliance time is no longer determined by the date of
FDAU installation.
For consistency, Sec. 121.344(b), (c), (d), (e), and (f) are
similarly revised to reference the 737 requirements in Sec.
121.344(m). The FAA has decided against putting the 737 requirements in
each subparagraph because it would be cumbersome, unnecessarily
repetitive, and introduce more possibilities for error.
Proposal: The note to parameter (a)(88) in current Appendix M to
part 121 requires airplanes that have a flight control breakaway
capability (which allows either pilot to operate controls
independently) to record both control force inputs; the note also
discusses sampling rates.
Comments: Boeing pointed out that the note to parameter 88 in
appendix M to part 121 and appendix E to part 125 indicates that all
the comments in the remarks column do not apply to the 737. Boeing
believed that the note is meant to indicate that it is only the
sampling interval remarks that do not apply to the 737s. The NTSB also
stated that the remarks section covers, in addition to the sampling
rate requirements, a
[[Page 52390]]
requirement to record both control force inputs for those airplanes
that have a flight control breakaway capability that allows either
pilot to independently operate the airplane, which still would apply to
737s.
FAA reply: The FAA agrees with Boeing, and has revised footnote 18
to clarify application of the parameter for 737s. The requirement to
record both control force inputs for systems with breakaway
capabilities does apply to the 737, but as discussed above, the FAA has
approved the use of a single control wheel force transducer provided
that both control wheel positions are recorded (although both pilot's
inputs go through the left side force transducer, except in the event
of a failure). Because the FAA historically has not considered a dual
failure a likely event, this configuration is acceptable.
Proposal: The FAA proposed the same changes to the digital flight
data recorder regulations in Sec. 125.226 as those proposed in Sec.
121.344. In addition, the FAA proposed the same changes to Appendix E
to part 125 as those proposed to Appendix M to part 121. The FAA also
proposed that airplanes operating under deviation authority from part
125 must comply with the flight data recorder requirements of part 125
for the particular aircraft. The FAA specified that this deviation
requirement would apply to all aircraft and not only the 737. The FAA
specifically sought comments on why the flight data recorder
requirements of part 125 should not be made applicable to aircraft
operated under deviation authority. In addition, the FAA sought
comments from affected persons operating aircraft under deviation
authority from part 125 concerning the proposed compliance schedule.
Comments: The FAA received no comments on the proposed changes to
part 125. Accordingly, the changes to part 91, applicable to part 125
airplanes operated under deviation authority, and the changes to part
125 and Appendix E are proposed again here without change from the
original proposal.
IV. Changes Adopted in This SNPRM
When the FAA proposed the recordation of new flight data recorder
parameters in November 1999, the ETEB was still in the process of
conducting its failure analysis, and other action by the agency was not
yet contemplated. The ETEB's finding and the FAA's subsequent decision
to issue the AD requiring replacement of the rudder system mandate that
this rule be modified to account for those actions.
This proposed rule, if adopted, would require the installation of
the flight recorder parameters proposed in the NPRM with the following
modifications. The installation would be accomplished simultaneously
with the installation of the redesigned rudder system in order to
minimize the costs and out-of-service time required. The regulatory
evaluation for this proposed rule has been significantly revised to
include this extended compliance time. This extension of the compliance
time also addresses the majority of the comments received in response
to the proposed rule. Specifically, this SNPRM incorporates the
following changes:
Sections 121.344(b), (c), (d), (e), and (f) and Sec.
125.226(b), (c), (d), (e), and (f) would be amended to indicate that
all 737 model airplanes also must comply with the requirements in Sec.
121.344(m) or Sec. 125.226(m), respectively. Sections 121.344(m) and
125.226(m) would be added to indicate that in addition to other
applicable requirements, all 737 model airplanes must record the
parameters listed in paragraphs (a)(1) through (a)(22) and (a)(88)
through (a)(91) in accordance with the ranges, accuracies, resolutions,
and recording intervals specified in Appendix M to part 121 or Appendix
E to part 125, respectively. The proposed compliance times have been
changed to state that the installation of the equipment required to
record these parameters must be accomplished during the installation of
the modified rudder system required by AD or no later than November
2008. These sections would also reinstate the language allowing single-
source recording, as discussed in the disposition of comments. The
parameters that may be recorded from a single source would be
determined by the age of the airplane and its applicable regulations.
Footnote 18 would be added to parameter 88 in Appendix M
to part 121 and Appendix E to part 125 and would read ``For all 737
model airplanes: The seconds per sampling interval is 0.5 per control
input; the remarks regarding the sampling rate do not apply; a single
control wheel force transducer installed on the left cable control is
acceptable provided the left and right control wheel positions also are
recorded.'' Footnote 19 would be added to parameter 88 in Appendix M to
part 121 and Appendix E to part 125 and would read ``For all 737 model
airplanes manufactured on or before January 31, 2001, Rang