Rule2024-13015
Airworthiness Directives; The Boeing Company Airplanes
Primary source
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Published
June 14, 2024
Effective
July 19, 2024
Issuing agencies
Transportation DepartmentFederal Aviation Administration
Abstract
The FAA is adopting a new airworthiness directive (AD) for all The Boeing Company Model 757 airplanes. This AD was prompted by potential cracks starting in hidden areas underneath the scuff plates in the fuselage skin and bear strap of certain doors. This AD requires a general visual inspection or a maintenance records check for repairs in the areas around the fuselage skin door cutout lower corners of certain doors, applicable on-condition actions, and inspections for airplanes modified to a cargo configuration. The FAA is issuing this AD to address the unsafe condition on these products.
Full Text
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<title>Federal Register, Volume 89 Issue 116 (Friday, June 14, 2024)</title>
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[Federal Register Volume 89, Number 116 (Friday, June 14, 2024)]
[Rules and Regulations]
[Pages 50510-50513]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 2024-13015]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. FAA-2023-0017; Project Identifier AD-2022-01418-T;
Amendment 39-22753; AD 2024-10-07]
RIN 2120-AA64
Airworthiness Directives; The Boeing Company Airplanes
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final rule.
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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for all
The Boeing Company Model 757 airplanes. This AD was prompted by
potential cracks starting in hidden areas underneath the scuff plates
in the fuselage skin and bear strap of certain doors. This AD requires
a general visual inspection or a maintenance records check for repairs
in the areas around the fuselage skin door cutout lower corners of
certain doors, applicable on-condition actions, and inspections for
airplanes modified to a cargo configuration. The FAA is issuing this AD
to address the unsafe condition on these products.
DATES: This AD is effective July 19, 2024.
The Director of the Federal Register approved the incorporation by
reference of a certain publication listed in this AD as of July 19,
2024.
ADDRESSES:
AD Docket: You may examine the AD docket at <a href="http://regulations.gov">regulations.gov</a> under
Docket No. FAA-2023-0017; 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.
Material Incorporated by Reference:
<bullet> For service information, 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; website <a href="http://myboeingfleet.com">myboeingfleet.com</a>.
<bullet> 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="http://regulations.gov">regulations.gov</a> under Docket No. FAA-2023-0017.
FOR FURTHER INFORMATION CONTACT: Wayne Ha, Aviation Safety Engineer,
FAA, 2200 South 216th Street, Des Moines, WA 98198; phone: 562-627-
5238; email: <a href="/cdn-cgi/l/email-protection#c1b6a0b8afa4efa9a081a7a0a0efa6aeb7"><span class="__cf_email__" data-cfemail="3a4d5b43545f14525b7a5c5b5b145d554c">[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 all The Boeing Company
Model 757 airplanes. The NPRM published in the Federal Register on
January 26, 2023 (88 FR 4920). The NPRM was prompted by the potential
for cracks to start in hidden areas underneath the scuff plates in the
fuselage skin and bear strap of certain doors. In the NPRM, the FAA
proposed to require an inspection or a maintenance records check for
repairs in the areas around the fuselage skin door cutout lower corners
of certain doors, and applicable on-condition actions. The FAA is
issuing this AD to address the unsafe condition on these products.
The FAA issued a supplemental notice of proposed rulemaking (SNPRM)
to amend 14 CFR part 39 by adding an AD that would apply to all The
Boeing Company Model 757 airplanes. The SNPRM published in the Federal
Register on September 6, 2023 (88 FR 60904). The SNPRM was prompted by
additional inspections for Model 757-200 series airplanes that have
been modified from a passenger configuration to a cargo configuration
under supplemental type certificate (STC) ST04242AT, ST03562AT, or
ST03952AT. The SNPRM proposed to require Model 757-200 series airplanes
with STC ST04242AT, ST03562AT, or ST03952AT, only the No. 1, No. 2, and
No. 4 passenger entry doors, and the No. 1, No. 2, and No. 3 cargo
doors, would have to be inspected. The SNPRM proposed to require that
for those airplanes, the crew entry door and main deck cargo door, as
applicable, would also have to be inspected. The FAA is issuing this AD
to address cracks caused by higher fatigue stresses at the fuselage
skin door cutout lower corners, which could adversely affect the
structural integrity of the airplane.
Discussion of Final Airworthiness Directive
Comments
The FAA received comments from an individual commenter, Air Line
Pilots Association, International (ALPA), and Boeing, who supported the
SNPRM without change.
The FAA received additional comments from three commenters, FedEx
Express, VT Mobile Aerospace Engineering (VT MAE), and United Parcel
Service (UPS). The following presents the comments received on the
SNPRM and the FAA's response to each comment.
Request for Change to Applicability Requirements
FedEx stated that it cannot fully comply with paragraph (g)(3) of
this proposed AD. FedEx stated it plans to complete the inspect
procedures for Group 1, Group 2, and Group 3 aircraft due to multiple
door configurations throughout their 757-200 fleet. In addition to
Group 1, Group 2, and Group 3 aircraft inspection requirements, FedEx
requested the main deck cargo door inspection area from Group 6
aircraft be included for our VT MAE STC ST03562AT converted aircraft.
Therefore, FedEx stated it plans to comply with Group 1, Group 2, and
Group 3 aircraft inspection requirements and Group 6 main deck cargo
door area only.
The FAA agrees to clarify the requirements. Paragraph (g)(3) of
this AD was added to the SNPRM to include the inspections at the main
deck cargo door for Model 757-200 series airplanes that have been
modified from a passenger to cargo configuration under VT MAE STC
ST03562AT or ST03952AT. Paragraph (g)(1) already requires the
inspections for Group 1, Group 2, and Group 3 for all airplanes, as
applicable. Therefore, this AD captures FedEx's requested change. The
FAA has not changed this AD in this regard.
Request for Change to Compliance Requirements
Two commenters requested that the initial compliance time be
extended for certain airplanes. FedEx and VT MAE requested initial
inspections for the main deck cargo door (MDCD) start 30,000 flight
cycles from installation or 3,000 flight cycles from the original issue
date of Boeing Requirements Bulletin 757-53A0119 RB (October 12, 2022).
FedEx stated main deck cargo doors were installed during passenger-
[[Page 50511]]
to-freighter conversion per VT MAE STC ST03562AT. VT MAE noted that for
airplanes modified from a passenger to a freighter configuration per VT
MAE STC ST03562AT or ST03952AT, the skin and bear strap at the main
deck cargo door area is newly installed.
The FAA disagrees because the compliance times specified in this AD
address the unsafe condition initiating at all of the affected lower
door corner cutouts. In addition, although VT MAE provided data showing
the skin and bear strap is newly installed during their passenger to
freighter conversion, it did not provide a fatigue test report or a
fatigue and damage tolerance analysis to substantiate an alternative
inspection threshold to what is required by this AD for the main deck
cargo door area. The FAA will consider alternative methods of
compliance (AMOCs) for extensions to the compliance times if sufficient
FedEx needs to supply additional data is submitted to show the proposed
compliance time adequately addresses the unsafe condition at this
specific location. The FAA has not changed this AD in this regard.
Request Consideration for Damage Tolerance and Allowable Limits
UPS requested that paragraph (h)(2) of the proposed AD be revised
to change ``any existing repair'' to ``any existing reinforcing
repair.''
UPS also requested that an exception be added in paragraph (h)(4)
of the proposed AD to specify ``where Boeing Alert Requirements
Bulletin 757-53A0119 RB, dated October 12, 2022, uses the phrase ``any
repair,'' this AD requires using ``any reinforcing repair.''
UPS stated that structural repair manual (SRM) procedure 53-00-15-
1A-2 allows for dents common to the main and lower cargo door lower
scuff plates and the fuselage outer skin to have a maximum depth of
0.010'' without further inspection of the underlying skin or repetitive
supplemental inspections. Additionally, UPS stated that SRM procedure
53-00-01-1A-1 allows for the fuselage skin to have smooth dents, edge,
surface blends up to 15% of any cross-sectional area, and SRM procedure
53-00-01-2R-6 allows for rivet plugging of lightning-strike or small-
hole damage. UPS stated that rivet plugs using solid rivets are noted
as a category A repair with no supplemental inspections. UPS stated
that the repairs within the SRM allowable limits and small damage
repair do not appreciably affect damage tolerance of the fuselage skin
at the door cutouts and surrounding structure. Furthermore, UPS noted
the potential for non-reinforcing repairs (dents, blends, etc.) that
are beyond SRM-allowable limits but approved by Boeing authorization to
remain with no supplemental inspections. UPS considered the intent of
the general visual inspection (GVI) or maintenance records review is to
identify and report existing reinforcing repairs that may affect damage
tolerance of the fuselage skin.
The FAA disagrees. The unsafe condition identified in this AD has
an impact on the damage tolerance of all repairs in the affected areas.
These repairs need to be evaluated in conjunction with the unsafe
condition identified in this AD to determine whether they still provide
an acceptable level of safety. The FAA has not changed this AD in this
regard.
Conclusion
The FAA reviewed the relevant data, considered any comments
received, and determined that air safety requires adopting this AD as
proposed. Accordingly, the FAA is issuing this AD to address the unsafe
condition on these products. Except for minor editorial changes, and
any other changes described previously, this AD is adopted as proposed
in the SNPRM. 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 757-53A0119 RB,
dated October 12, 2022. This service information specifies procedures
for either a general visual inspection or a maintenance records check
for repairs in the areas around the fuselage skin door cutout lower
corners of the No. 1, No. 2, and No. 4 passenger entry doors; crew
entry door; No. 1, No. 2, and No. 3 cargo doors; and main deck cargo
door; and applicable on-condition actions, including repetitive low
frequency and high frequency eddy current inspections for cracks in the
skin or bear strap in the unrepaired areas, and crack repair.
This service information is reasonably available because the
interested parties have access to it through their normal course of
business or by the means identified in ADDRESSES.
Costs of Compliance
The FAA estimates that this AD affects 482 airplanes of U.S.
registry. The FAA estimates the following costs to comply with this AD:
Estimated Costs
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Cost per Cost on U.S.
Action Labor cost Parts cost product operators
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General visual inspection for repairs. 1 work-hour x $85 per $0 $85 $40,970
hour = $85.
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The FAA estimates the following costs to do any necessary on-
condition actions that would be required based on the results of the
proposed inspection. The agency has no way of determining the number of
airplanes that might need these on-condition actions:
On-Condition Costs
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Action Labor cost Parts cost Cost per product
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Inspections for cracks................. Up to 27 work-hours x $85 per $0 Up to $2,295 per
hour = Up to $2,295 per inspection cycle.
inspection cycle.
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The extent of cracking found during the on-condition inspection
could vary significantly from airplane to airplane. The FAA has no way
of determining the extent of cracking that may be found on each
airplane, the cost to repair the cracking on each airplane, or the
number of airplanes that may require repair.
[[Page 50512]]
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:
2024-10-07 The Boeing Company: Amendment 39-22753; Docket No. FAA-
2023-0017; Project Identifier AD-2022-01418-T.
(a) Effective Date
This airworthiness directive (AD) is effective July 19, 2024.
(b) Affected ADs
None.
(c) Applicability
(1) This AD applies to all The Boeing Company Model 757-200, -
200PF, -200CB, and -300 series airplanes, certificated in any
category.
(2) Installation of Supplemental Type Certificate (STC)
ST01518SE does not affect the ability to accomplish the actions
required by this AD. Therefore, for airplanes on which STC ST01518SE
is installed, a ``change in product'' alternative method of
compliance (AMOC) approval request is not necessary to comply with
the requirements of 14 CFR 39.17.
(d) Subject
Air Transport Association (ATA) of America Code 53, Fuselage.
(e) Unsafe Condition
This AD was prompted by the potential for cracks to start in
hidden areas underneath the scuff plates in the fuselage skin and
bear strap of certain doors. The FAA is issuing this AD to address
cracks caused by higher fatigue stresses at the fuselage skin door
cutout lower corners. This unsafe condition, if not addressed, could
adversely affect the structural integrity of the airplane.
(f) Compliance
Comply with this AD within the compliance times specified,
unless already done.
(g) Required Actions
(1) For all airplanes: Except as specified by paragraph (h) of
this AD, at the applicable times specified in the ``Compliance''
paragraph of Boeing Alert Requirements Bulletin 757-53A0119 RB,
dated October 12, 2022, do all applicable actions identified in, and
in accordance with, the Accomplishment Instructions of Boeing Alert
Requirements Bulletin 757-53A0119 RB, dated October 12, 2022.
(2) For Model 757-200 series airplanes that have been modified
from a passenger to cargo configuration under VT Mobile Aerospace
Engineering (VT MAE) STC ST04242AT: Except as specified by paragraph
(h) of this AD, at the applicable times specified in Table 4 and
Table 5 of the ``Compliance'' paragraph of Boeing Alert Requirements
Bulletin 757-53A0119 RB, dated October 12, 2022, do all applicable
actions for Group 4 identified in, and in accordance with, Table 4
and Table 5 of the Accomplishment Instructions of Boeing Alert
Requirements Bulletin 757-53A0119 RB, dated October 12, 2022.
(3) For Model 757-200 series airplanes that have been modified
from a passenger to cargo configuration under VT MAE STC ST03562AT
or ST03952AT: Except as specified by paragraph (h) of this AD, at
the applicable times specified in Table 5 of the ``Compliance''
paragraph of Boeing Alert Requirements Bulletin 757-53A0119 RB,
dated October 12, 2022, do all applicable actions for Group 6
identified in, and in accordance with, Table 5 of the Accomplishment
Instructions of Boeing Alert Requirements Bulletin 757-53A0119 RB,
dated October 12, 2022.
Note 1 to paragraph (g): Guidance for accomplishing the actions
required by this AD can be found in Boeing Alert Service Bulletin
757-53A0119, dated October 12, 2022, which is referred to in Boeing
Alert Requirements Bulletin 757-53A0119 RB, dated October 12, 2022.
(h) Exceptions to Service Information Specifications
(1) Where the Compliance Time columns of the tables in the
``Compliance'' paragraph of Boeing Alert Requirements Bulletin 757-
53A0119 RB, dated October 12, 2022, use the phrase ``the original
issue date of Requirements Bulletin 757-53A0119 RB,'' this AD
requires using ``the effective date of this AD.''
(2) Where Boeing Alert Requirements Bulletin 757-53A0119RB,
dated October 12, 2022, specifies performing a general visual
inspection (GVI) or a maintenance records check for any existing
repair, if only a maintenance records check is accomplished with no
GVI, then any initial high frequency eddy current (HFEC) or low
frequency eddy current (LFEC) inspection with a compliance time of
before further flight must be done prior to the accumulation of
30,000 total flight cycles, or within 3,000 flight cycles after the
effective date of this AD, whichever occurs later.
(3) Where Boeing Alert Requirements Bulletin 757-53A0119 RB,
dated October 12, 2022, specifies contacting Boeing for repair
instructions or for alternative inspections: This AD requires doing
the repair, or doing the alternative inspections and applicable on-
condition actions, before further flight 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, AIR-520, Continued Operational Safety 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 Continued Operational
Safety Branch, 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#d594989a9695b3b4b4fbb2baa3"><span class="__cf_email__" data-cfemail="db9a9694989bbdbabaf5bcb4ad">[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.
(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
[[Page 50513]]
(ODA) that has been authorized by the Manager, AIR-520, Continued
Operational Safety Branch, to make those findings. To be approved,
the repair method, modification deviation, or alteration deviation
must meet the certification basis of the airplane, and the approval
must specifically refer to this AD.
(j) Related Information
(1) For more information about this AD, contact Wayne Ha,
Aviation Safety Engineer, FAA, 2200 South 216th Street, Des Moines,
WA 98198; phone: 562-627-5238; email: <a href="/cdn-cgi/l/email-protection#92e5f3ebfcf7bcfaf3d2f4f3f3bcf5fde4"><span class="__cf_email__" data-cfemail="097e6870676c276168496f6868276e667f">[email protected]</span></a>.
(2) Service information identified in this AD that is not
incorporated by reference is available at the address specified in
paragraph (k)(3) of this AD.
(k) Material Incorporated by Reference
(1) The Director of the Federal Register approved the
incorporation by reference 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 757-53A0119 RB, dated
October 12, 2022.
(ii) [Reserved]
(3) For service information, 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; website <a href="http://myboeingfleet.com">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 material at the National Archives and
Records Administration (NARA). For information on the availability
of this material at NARA, visit <a href="http://www.archives.gov/federal-register/cfr/ibr-locations.html">www.archives.gov/federal-register/cfr/ibr-locations.html</a> or email <a href="/cdn-cgi/l/email-protection#bed8cc90d7d0cdcedbddcad7d1d0fed0dfccdf90d9d1c8"><span class="__cf_email__" data-cfemail="a6c0d488cfc8d5d6c3c5d2cfc9c8e6c8c7d4c788c1c9d0">[email protected]</span></a>.
Issued on May 14, 2024.
James D. Foltz,
Deputy Director, Compliance & Airworthiness Division, Aircraft
Certification Service.
[FR Doc. 2024-13015 Filed 6-13-24; 8:45 am]
BILLING CODE 4910-13-P
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