Rule2021-26393
Airworthiness Directives; The Boeing Company Airplanes
Primary source
Metadata and text below are from the Federal Register, a public-domain U.S. government work. Always verify the official published version before relying on it for any legal matter.
Published
December 6, 2021
Effective
January 10, 2022
Issuing agencies
Transportation DepartmentFederal Aviation Administration
Abstract
The FAA is adopting a new airworthiness directive (AD) for certain The Boeing Company Model 787-8 and 787-9 airplanes. This AD was prompted by reports that shimming requirements were not met during the assembly of certain structural joints, which can result in reduced fatigue thresholds of the affected structural joints. This AD requires repetitive inspections for cracking of certain areas of the front spar pickle fork and front spar outer chord and repair of any cracking found. The FAA is issuing this AD to address the unsafe condition on these products.
Full Text
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<title>Federal Register, Volume 86 Issue 231 (Monday, December 6, 2021)</title>
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[Federal Register Volume 86, Number 231 (Monday, December 6, 2021)]
[Rules and Regulations]
[Pages 68902-68905]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2021-26393]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2021-0332; Project Identifier AD-2020-01414-T;
Amendment 39-21819; AD 2021-23-20]
RIN 2120-AA64
Airworthiness Directives; The Boeing Company Airplanes
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule.
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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for
certain The Boeing Company Model 787-8 and 787-9 airplanes. This AD was
prompted by reports that shimming requirements were not met during the
assembly of certain structural joints, which can result in reduced
fatigue thresholds of the affected structural joints. This AD requires
repetitive inspections for cracking of certain areas of the front spar
pickle fork and front spar outer chord and repair of any cracking
found. The FAA is issuing this AD to address the unsafe condition on
these products.
DATES: This AD is effective January 10, 2022.
The Director of the Federal Register approved the incorporation by
reference of certain publications listed in this AD as of January 10,
2022.
ADDRESSES: For service information identified in this final rule,
contact Boeing Commercial Airplanes, Attention: Contractual & Data
Services (C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA
90740-5600; telephone 562-797-1717; internet <a href="https://www.myboeingfleet.com">https://www.myboeingfleet.com</a>. You may view this service information at the
FAA, Airworthiness Products Section, Operational Safety Branch, 2200
South 216th St., Des Moines, WA. For information on the availability of
this material at the FAA, call 206-231-3195. It is also available at
<a href="https://www.regulations.gov">https://www.regulations.gov</a> by searching for and locating Docket No.
FAA-2021-0332.
Examining the AD Docket
You may examine the AD docket at <a href="https://www.regulations.gov">https://www.regulations.gov</a> by
searching for and locating Docket No. FAA-2021-0332; or in person at
Docket Operations between 9 a.m. and 5 p.m., Monday through Friday,
except Federal holidays. The AD docket contains this final rule, any
comments received, and other information. The address for Docket
Operations is U.S. Department of Transportation, Docket Operations, M-
30, West Building Ground Floor, Room W12-140, 1200 New Jersey Avenue
SE, Washington, DC 20590.
FOR FURTHER INFORMATION CONTACT: Greg Rutar, Aerospace Engineer,
Airframe Section, FAA, Seattle ACO Branch, 2200 South 216th St., Des
Moines, WA 98198; phone and fax: 206-231-3529; email:
<a href="/cdn-cgi/l/email-protection#13546176743d4166677261537572723d747c65"><span class="__cf_email__" data-cfemail="2c6b5e494b027e59584d5e6c4a4d4d024b435a">[email protected]</span></a>.
SUPPLEMENTARY INFORMATION:
Background
The FAA issued a notice of proposed rulemaking (NPRM) to amend 14
CFR part 39 by adding an AD that would apply to certain The Boeing
Company Model 787-8 and 787-9 airplanes. The NPRM published in the
Federal Register on May 7, 2021 (86 FR 24551). The NPRM was prompted by
reports that shimming requirements were not met during the assembly of
certain structural joints, which can result in reduced fatigue
thresholds of the affected structural joints. In the NPRM, the FAA
proposed to require repetitive inspections for cracking of certain
areas of the front spar pickle fork and front spar outer chord and
repair of any cracking found. The FAA is issuing this AD to address
undetected fatigue cracking, which could weaken primary structure so it
cannot sustain limit load, and could result in reduced structural
integrity of the airplane.
Discussion of Final Airworthiness Directive
Comments
The FAA received comments from American Airlines (AAL) who
supported the NPRM.
The FAA received additional comments from four commenters,
including Boeing, United Airlines (UAL), Avianca Airlines (AVA), and
AAL. The following presents the comments received on the NPRM and the
FAA's response to each comment.
Request To Clarify Applicability
Boeing asked that the applicability specified in paragraph (c) of
the proposed AD be clarified, as follows: ``This AD applies to The
Boeing Company Model 787-8 and 787-9 airplanes, certificated in any
category, as identified in Boeing Alert Requirements Bulletins B787-
81205-SB530075-00 RB and B787-81205-SB530076-00 RB, both Issue 001,
both dated September 8, 2020.'' Boeing stated that, although the
applicability is the same in each bulletin, identifying both will avoid
confusion for operators.
The FAA agrees with the commenter for the reason provided.
Paragraph (c) of
[[Page 68903]]
the proposed AD only identifies Boeing Alert Requirements Bulletin
B787-81205-SB530075-00 RB, Issue 001, dated September 8, 2020;
therefore, the FAA has changed paragraph (c) of this AD to identify
both bulletins, as requested by the commenter.
Request To Remove Certain Thresholds
AAL asked that the FAA remove the flight length sensitive (FLS)
threshold requirements in paragraph (g) of the proposed AD. AAL stated
that the ``Compliance'' paragraph specified in Boeing Alert
Requirements Bulletins B787-81205-SB530075-00 RB and B787-81205-
SB530076-00 RB, both Issue 001, both dated September 8, 2020, includes
the formulas to calculate the FLS threshold, and these formulas are
based on aircraft cycles and hours. AAL added that its internal
tracking process can only use flight-cycles, flight-hours, and days,
its systems cannot use formulas to take full advantage of the FLS
threshold. AAL noted that the current compliance data would require the
use of the most conservative values or constant monitoring of aircraft
utilization. AAL suggested that the FAA include simplified limits in
this paragraph, allowing operators to maximize the hours and cycle
threshold.
UAL also asked that the FAA remove the formula for the threshold
requirements in paragraph (g) of the proposed AD. UAL suggested
incorporating simplified flight-hour and flight-cycle limits that can
be easily tracked in its existing system. UAL added that its system is
not able to accommodate the existing formula.
The FAA does not agree with the commenter's request. FLS threshold
requirements were developed with the flexibility to take advantage of
individual aircraft utilization. An operator may choose to develop
simplified thresholds, provided they are at or below the required
compliance times. As stated in paragraph (g) of this AD, guidance for
accomplishing the actions required by this AD can be found in Boeing
Alert Service Bulletins B787-81205-SB530075-00 and B787-81205-SB530076-
00, both Issue 001, dated both September 8, 2020. Appendix A of these
documents is particularly instructive regarding compliance times. The
FAA has not changed this AD in this regard.
Request To Use Alternative Repair Method
AVA asked that the FAA change the following language used in
paragraph (h)(2) of the proposed AD ``This AD requires doing the repair
using a method approved in accordance with the procedures specified in
paragraph (i) of this AD.'' AVA stated that this means submitting a
request for an alternative method of compliance (AMOC) is required in
accordance with paragraph (i)(3) of the proposed AD. AVA added that the
proposed repair is based on the time delay required to obtain an AMOC
letter, which affects the operational return to service of the affected
aircraft, and noted that a Form 8100-9 is already an approved document
that certifies compliance with the airworthiness standard. AVA proposed
that only an 8100-9 approval form be required for doing a repair after
contacting Boeing.
The FAA does not agree with the commenter's request. An FAA Form
8100-9, which is both a repair data approval and AMOC approval, may be
issued by the Boeing Company Organization Designation Authorization
(ODA), provided it has been authorized by the Manager, Seattle ACO
Branch, FAA, as required by paragraph (i)(3) of this AD. Therefore, the
FAA has not changed this AD in this regard.
Request To Use Later Revision of the Service Information
AVA asked that the FAA include a paragraph in this AD that approves
any further revision or issue of Boeing Alert Requirements Bulletins
B787-81205-SB530075-00 RB and B787-81205-SB530076-00 RB, both Issue
001, both dated September 8, 2020, for compliance with this AD.
The FAA does not agree with the commenter's request. The FAA may
not in an AD refer to any document that does not yet exist. In general
terms, the FAA is required by Office of the Federal Register (OFR)
regulations for approval of materials incorporated by reference, as
specified in 1 CFR 51.1(f), to either publish the service document
contents as part of the actual AD language; or submit the service
document to the OFR for approval as referenced material, in which case
the FAA may only refer to such material in the text of an AD. The AD
may refer to the service document only if the OFR approved it for
incorporation by reference. See 1 CFR part 51.
To allow operators to use later revisions of the referenced
document (issued after publication of the AD), either the FAA must
revise the AD to reference specific later revisions, or operators must
request approval to use later revisions as an alternative method of
compliance with this AD under the provisions of paragraph (i) of this
AD.
Conclusion
The FAA reviewed the relevant data, considered any comments
received, and determined that air safety requires adopting this AD as
proposed. Except for minor editorial changes, and any other changes
described previously, this AD is adopted as proposed in the NPRM. None
of the changes will increase the economic burden on any operator.
Related Service Information Under 1 CFR Part 51
The FAA reviewed Boeing Alert Requirements Bulletin B787-81205-
SB530075-00 RB, Issue 001, dated September 8, 2020. The service
information describes procedures for repetitive high frequency eddy
current (HFEC) inspections for cracking around all the fasteners common
to the front spar pickle fork outer chord surface between stringer S-22
and stringer S-24 at station (STA) 873 on the left and right sides, and
along the entire forward edge of the front spar pickle fork outer chord
covered by the body chord splice angle between stringer S-24 and
stringer S-25 at STA 873 on the left and right sides, and repair of any
cracking found. The service information also describes procedures for
repetitive ultrasonic (UT) inspections for cracking of the front spar
pickle fork outer chord along the upper, lower and aft edges of the end
fittings at stringer S-23 at STA 873, on the left and right sides, and
repair of any cracking found.
The FAA also reviewed Boeing Alert Requirements Bulletin B787-
81205-SB530076-00 RB, Issue 001, dated September 8, 2020. The service
information describes procedures for repetitive HFEC inspections for
cracking along the entire forward edge of the front spar body chord in
the area covered by the body chord splice angle at stringer S-25 on the
left and right sides, and the splice fitting at BL 0, STA 873, and
repair of any cracking found. The service information also describes
procedures for repetitive detailed inspections of the front spar body
chord horizontal flange surface between stringer S-26 to stringer S-40
at STA 873 on the left and right sides and repair of any cracking
found. The service information also describes procedures for repetitive
UT inspections for cracking of the of the front spar body chord
horizontal flange along the upper and lower edges of the end fittings
at stringer S-27, at STA 873 on the left and right sides, and repair of
any cracking found.
This service information is reasonably available because the
interested parties
[[Page 68904]]
have access to it through their normal course of business or by the
means identified in the ADDRESSES section.
Costs of Compliance
The FAA estimates that this AD affects 79 airplanes of U.S.
registry. The FAA estimates the following costs to comply with this AD:
Estimated Costs for Required Actions
--------------------------------------------------------------------------------------------------------------------------------------------------------
Action Labor cost Parts cost Cost per product Cost on U.S. operators
--------------------------------------------------------------------------------------------------------------------------------------------------------
Repetitive inspections........... 14 work-hours x $85 $0 $1,190 per inspection cycle............. $94,010 per inspection cycle.
per hour = $1,190
per inspection
cycle.
--------------------------------------------------------------------------------------------------------------------------------------------------------
The FAA has received no definitive data on which to base the cost
estimates for the on-condition repairs specified in this AD.
Authority for This Rulemaking
Title 49 of the United States Code specifies the FAA's authority to
issue rules on aviation safety. Subtitle I, section 106, describes the
authority of the FAA Administrator. Subtitle VII: Aviation Programs,
describes in more detail the scope of the Agency's authority.
The FAA is issuing this rulemaking under the authority described in
Subtitle VII, Part A, Subpart III, Section 44701: General requirements.
Under that section, Congress charges the FAA with promoting safe flight
of civil aircraft in air commerce by prescribing regulations for
practices, methods, and procedures the Administrator finds necessary
for safety in air commerce. This regulation is within the scope of that
authority because it addresses an unsafe condition that is likely to
exist or develop on products identified in this rulemaking action.
Regulatory Findings
This AD will not have federalism implications under Executive Order
13132. This AD will not have a substantial direct effect on the States,
on the relationship between the national government and the States, or
on the distribution of power and responsibilities among the various
levels of government.
For the reasons discussed above, I certify that this AD:
(1) Is not a ``significant regulatory action'' under Executive
Order 12866,
(2) Will not affect intrastate aviation in Alaska, and
(3) Will not have a significant economic impact, positive or
negative, on a substantial number of small entities under the criteria
of the Regulatory Flexibility Act.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.
The Amendment
Accordingly, under the authority delegated to me by the
Administrator, the FAA amends 14 CFR part 39 as follows:
PART 39--AIRWORTHINESS DIRECTIVES
0
1. The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
Sec. 39.13 [Amended]
0
2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive:
2021-23-20 The Boeing Company: Amendment 39-21819; Docket No. FAA-
2021-0332; Project Identifier AD-2020-01414-T.
(a) Effective Date
This airworthiness directive (AD) is effective January 10, 2022.
(b) Affected ADs
None.
(c) Applicability
This AD applies to The Boeing Company Model 787-8 and 787-9
airplanes, certificated in any category, as identified in Boeing
Alert Requirements Bulletins B787-81205-SB530075-00 RB and B787-
81205-SB530076-00 RB, both Issue 001, both dated September 8, 2020.
(d) Subject
Air Transport Association (ATA) of America Code 53, Fuselage.
(e) Unsafe Condition
This AD was prompted by reports that shimming requirements were
not met during the assembly of certain areas of the front spar
pickle fork and front spar outer chord structural joints, which can
result in reduced fatigue thresholds of the affected structural
joints. The FAA is issuing this AD to address undetected fatigue
cracking, which could weaken primary structure so it cannot sustain
limit load, and could result in reduced structural integrity of the
airplane.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Required Actions
Except as specified by paragraph (h) of this AD: At the
applicable times specified in the ``Compliance'' paragraph of Boeing
Alert Requirements Bulletins B787-81205-SB530075-00 RB and B787-
81205-SB530076-00 RB, both Issue 001, both dated September 8, 2020,
do all applicable actions identified in, and in accordance with, the
Accomplishment Instructions of Boeing Alert Requirements Bulletins
B787-81205-SB530075-00 RB and B787-81205-SB530076-00 RB, both Issue
001, both dated September 8, 2020.
Note 1 to paragraph (g): Guidance for accomplishing the actions
required by this AD can be found in Boeing Alert Service Bulletins
B787-81205-SB530075-00 and B787-81205-SB530076-00, both Issue 001,
dated both September 8, 2020, which are referred to in Boeing Alert
Requirements Bulletins B787-81205-SB530075-00 RB and B787-81205-
SB530076-00 RB, both Issue 001, both dated September 8, 2020.
(h) Exceptions to Service Information Specifications
(1) Where Boeing Alert Requirements Bulletin B787-81205-
SB530076-00 RB, Issue 001, dated September 8, 2020, uses the phrase
``the issue 001 date of the Requirements Bulletin B787-81205-
SB530076-00 RB,'' this AD requires using ``the effective date of
this AD.''
(2) Where Boeing Alert Requirements Bulletins B787-81205-
SB530075-00 RB and B787-81205-SB530076-00 RB, both Issue 001, both
dated September 8, 2020, specify contacting Boeing for repair
instructions: This AD requires doing the repair using a method
approved in accordance with the procedures specified in paragraph
(i) of this AD.
(i) Alternative Methods of Compliance (AMOCs)
(1) The Manager, Seattle ACO Branch, FAA, has the authority to
approve AMOCs for this AD, if requested using the procedures found
in 14 CFR 39.19. In accordance with 14 CFR 39.19, send your request
to your principal inspector or responsible Flight Standards Office,
as appropriate. If sending information directly to the manager of
the certification office, send it to the attention of the person
identified in paragraph (j) of this AD. Information may be emailed
to: <a href="/cdn-cgi/l/email-protection#ebd2c6aaa5a6c6b88e8a9f9f878ec6aaa8a4c6aaa6a4a8c6b98e9a9e8e989f98ab8d8a8ac58c849d"><span class="__cf_email__" data-cfemail="d2ebff939c9fff81b7b3a6a6beb7ff93919dff939f9d91ff80b7a3a7b7a1a6a192b4b3b3fcb5bda4">[email protected]</span></a>.
(2) Before using any approved AMOC, notify your appropriate
principal inspector, or lacking a principal inspector, the manager
of the responsible Flight Standards Office.
[[Page 68905]]
(3) An AMOC that provides an acceptable level of safety may be
used for any repair, modification, or alteration required by this AD
if it is approved by The Boeing Company Organization Designation
Authorization (ODA) that has been authorized by the Manager, Seattle
ACO Branch, FAA, to make those findings. To be approved, the repair
method, modification deviation, or alteration deviation must meet
the certification basis of the airplane, and the approval must
specifically refer to this AD.
(j) Related Information
For more information about this AD, contact Greg Rutar,
Aerospace Engineer, Airframe Section, FAA, Seattle ACO Branch, 2200
South 216th St., Des Moines, WA 98198; phone and fax: 206-231-3529;
email: <a href="/cdn-cgi/l/email-protection#b1f6c3d4d69fe3c4c5d0c3f1d7d0d09fd6dec7"><span class="__cf_email__" data-cfemail="c88fbaadafe69abdbca9ba88aea9a9e6afa7be">[email protected]</span></a>.
(k) Material Incorporated by Reference
(1) The Director of the Federal Register approved the
incorporation by reference (IBR) of the service information listed
in this paragraph under 5 U.S.C. 552(a) and 1 CFR part 51.
(2) You must use this service information as applicable to do
the actions required by this AD, unless the AD specifies otherwise.
(i) Boeing Alert Requirements Bulletin B787-81205-SB530075-00
RB, Issue 001, dated September 8, 2020.
(ii) Boeing Alert Requirements Bulletin B787-81205-SB530076-00
RB, Issue 001, dated September 8, 2020.
(3) For service information identified in this AD, contact
Boeing Commercial Airplanes, Attention: Contractual & Data Services
(C&DS), 2600 Westminster Blvd., MC 110-SK57, Seal Beach, CA 90740-
5600; telephone 562-797-1717; internet <a href="https://www.myboeingfleet.com">https://www.myboeingfleet.com</a>.
(4) You may view this service information at the FAA,
Airworthiness Products Section, Operational Safety Branch, 2200
South 216th St., Des Moines, WA. For information on the availability
of this material at the FAA, call 206-231-3195.
(5) You may view this service information that is incorporated
by reference at the National Archives and Records Administration
(NARA). For information on the availability of this material at
NARA, <a href="/cdn-cgi/l/email-protection#abcdd985c2c5d8dbcec8dfc2c4c5ebc5cad9ca85ccc4dd"><span class="__cf_email__" data-cfemail="167064387f7865667375627f7978567877647738717960">[email protected]</span></a>, or go to: <a href="https://www.archives.gov/federal-register/cfr/ibr-locations.html">https://www.archives.gov/federal-register/cfr/ibr-locations.html</a>.
Issued on November 5, 2021.
Lance T. Gant,
Director, Compliance & Airworthiness Division, Aircraft Certification
Service.
[FR Doc. 2021-26393 Filed 12-3-21; 8:45 am]
BILLING CODE 4910-13-P
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