Airworthiness directives: McDonnell Douglas,
[Federal Register: November 23, 1998 (Volume 63, Number 225)]
[Proposed Rules]
[Page 64664-64667]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr23no98-33]
DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 39
[Docket No. 98-NM-228-AD]
RIN 2120-AA64
Airworthiness Directives; McDonnell Douglas Model DC-10-10, -15, -30, and -40 Series Airplanes, and KC-10A (Military) Airplanes
AGENCY: Federal Aviation Administration, DOT.
ACTION: Notice of proposed rulemaking (NPRM).
SUMMARY: This document proposes the supersedure of an existing airworthiness directive (AD), applicable to certain McDonnell Douglas Model DC-10 series airplanes and KC-10A (military) airplanes, that currently requires repetitive inspections to detect failure of the attachment fasteners located in the banjo No. 4 fitting of the vertical stabilizer. That AD also requires a one-time inspection to detect cracking of the flanges and bolt holes of the banjo No. 4 fitting, and repair or replacement of the attachment fasteners with new, improved fasteners. This action would add a new one-time inspection to determine whether certain fasteners are installed in the banjo No. 4 fitting of the vertical stabilizer, and follow-on actions, if necessary. This proposal is prompted by reports of failure of certain fasteners installed in the banjo No. 4 fitting of the vertical stabilizer. The actions specified by the proposed AD are intended to prevent cracking of the attachment fasteners of the vertical stabilizer, which could result in loss of fail-safe capability of the vertical stabilizer and reduced controllability of the airplane.
DATES: Comments must be received by January 7, 1999.
ADDRESSES: Submit comments in triplicate to the Federal Aviation Administration (FAA), Transport Airplane Directorate, ANM-114, Attention: Rules Docket No. 98-NM-228-AD, 1601 Lind Avenue, SW., Renton, Washington 98055-4056. Comments may be inspected at this location between 9:00 a.m. and 3:00 p.m., Monday through Friday, except Federal holidays.
The service information referenced in the proposed rule may be obtained from The Boeing Company, Douglas Products Division, 3855 Lakewood Boulevard, Long Beach, California 90846, Attention: Technical Publications Business Administration, Dept. C1-L51 (2-60). This information may be examined at the FAA, Transport Airplane Directorate, 1601 Lind Avenue, SW., Renton, Washington; or at the FAA, Transport Airplane Directorate, Los Angeles Aircraft Certification Office, 3960 Paramount Boulevard, Lakewood, California.
FOR FURTHER INFORMATION CONTACT: Ron Atmur, Aerospace Engineer, Airframe Branch, ANM-120L, FAA, Transport Airplane Directorate, Los Angeles Aircraft Certification Office, 3960 Paramount Boulevard, Lakewood, California 90712-4137; telephone (562) 627-5224; fax (562) 627-5210.
SUPPLEMENTARY INFORMATION:
Comments Invited
Interested persons are invited to participate in the making of the proposed rule by submitting such written data, views, or arguments as they may desire. Communications shall identify the Rules Docket number and be submitted in triplicate to the address specified above. All communications received on or before the closing date for comments, specified above, will be considered before taking action on the proposed rule. The proposals contained in this notice may be changed in light of the comments received.
Comments are specifically invited on the overall regulatory, economic, environmental, and energy aspects of the proposed rule. All comments submitted will be available, both before and after the closing date for comments, in the Rules Docket for examination by interested persons. A report summarizing each FAA-public contact concerned with the substance of this proposal will be filedin the Rules Docket.
Commenters wishing the FAA to acknowledge receipt of their comments submitted in response to this notice must submit a self-addressed, stamped postcard on which the following statement is made: ``Comments to Docket Number 98-NM-228-AD.'' The postcard will be date stamped and returned to the commenter.
Availability of NPRMs
Any person may obtain a copy of this NPRM by submitting a request to the FAA, Transport Airplane Directorate, ANM-114, Attention: Rules Docket No. 98-NM-228-AD, 1601 Lind Avenue, SW., Renton, Washington 98055-4056.
Discussion
On March 18, 1996, the FAA issued AD 96-07-01, amendment 39-9549 (61 FR 12015, March 25, 1996), applicable
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to certain McDonnell Douglas Model DC-10 series airplanes and KC-10A (military) airplanes, to require repetitive visual inspections to detect failure of the attachment fasteners located in the banjo No. 4 fitting of the vertical stabilizer. That AD also requires a one-time eddy current inspection to detect cracking of the flanges and bolt holes of the banjo No. 4 fitting, and repair or replacement of the attachment fasteners. That action was prompted by reports indicating that attachment fasteners of the vertical stabilizer failed due to fatigue. The requirements of that AD are intended to prevent loss of fail-safe capability of the vertical stabilizer due to cracking of its attachment fasteners.
Actions Since Issuance of Previous Rule
Since the issuance of that AD, the FAA has received reports indicating that, on two airplanes, certain second oversize fasteners that were approved for use as replacement fasteners in the banjo No. 4 fitting of the vertical stabilizer have failed due to fatigue cracking.
Explanation of Relevant Service Information
The FAA has reviewed and approved McDonnell Douglas Service Bulletin DC10-55-023, Revision 02, dated October 30, 1996, and Revision 03, dated March 25, 1998. These revised service bulletins are essentially similar to McDonnell Douglas DC-10 Service Bulletin 55-23, Revision 1, dated December 17, 1993, which was referenced as the appropriate source of service information in AD 96-07-01. However, among other things, Revision 02 of the service bulletin provides instructions for gaining access to perform the eddy current inspection of the aft flange, instructions for repair of cracks in the banjo No. 4 fitting, and an additional preventive modification for uncracked banjo fittings; and Revision 03 revises the part number of second oversize fasteners to be used as replacements for the attachment fasteners in the banjo No. 4 fitting. Revision 03 also describes procedures for an external visual inspection to detect failure of the attachment fasteners of the banjo No. 4 fitting, and follow-on actions. Those follow-on actions include performing the external visual inspections on a repetitive basis; inspecting using an eddy current technique to detect cracking of the forward and aft flanges and bolt holes of the banjo No. 4 fitting, and repair, if necessary; and replacing the attachment fasteners of the banjo No. 4 fitting with new, improved attachment fasteners made from a higher strength and more corrosion- resistant material. Accomplishment of the actions specified in the service bulletins is intended to adequately address the identified unsafe condition.
Explanation of Requirements of Proposed Rule
Since an unsafe condition has been identified that is likely to exist or develop on other products of this same type design, the proposed AD would supersede AD 96-07-01 to continue to require repetitive inspections to detect any failure of the attachment fasteners located in the banjo No. 4 fitting of the vertical stabilizer, a one-time inspection to detect cracking of the flanges and bolt holes of the banjo No. 4 fitting, and repair or replacement of the attachment fasteners with new, improved fasteners. This proposed AD also would add a new one-time inspection to determine whether certain fasteners are installed in the banjo No. 4 fitting of the vertical stabilizer, and follow-on actions, if necessary. The actions would be required to be accomplished in accordance with the service bulletin described previously, except as discussed below.
Differences Between Proposed Rule and Service Bulletin
Operators should note that, although the service bulletin specifies that the manufacturer may be contacted for disposition of certain repair conditions, this proposal would require the repair of those conditions to be accomplished in accordance with a method approved by the FAA.
Cost Impact
There are approximately 420 airplanes of the affected design in the worldwide fleet. The FAA estimates that 242 airplanes of U.S. registry would be affected by this proposed AD.
Since the issuance of AD 96-07-01, the manufacturer has revised its estimate of the work hours necessary to perform the actions that are currently required by that AD. McDonnell Douglas Service Bulletin DC10- 55-023, Revision 03, reflects the manufacturer's revised estimates; and the cost information, below, also has been revised to refer to the new estimates.
The visual inspection that is currently required by AD 96-07-01, and retained in this AD, takes approximately 1 work hour per airplane to accomplish, at an average labor rate of $60 per work hour. Based on these figures, the cost impact of the visual inspection currently required by that AD on U.S. operators is estimated to be $14,520, or $60 per airplane, per inspection cycle.
The eddy current inspection that is currently required by AD 96-07- 01, and retained in this AD, takes approximately 4 work hours per airplane to accomplish, at an average labor rate of $60 per work hour. Based on these figures, the cost impact of the eddy current inspection currently required by this AD on U.S. operators is estimated to be $58,080, or $240 per airplane.
The replacement of the 12 attachment fasteners of the banjo No. 4 fitting that is currently required by AD 96-07-01, and retained in this AD, takes approximately 14 work hours per airplane to accomplish, at an average labor rate of $60 per work hour. Required parts cost approximately $250 per airplane. Based on these figures, the cost impact of the replacement currently required by this AD on U.S. operators is estimated to be $263,780, or $1,090 per airplane.
The new inspection that is proposed in this AD action would take approximately 1 work hour per airplane to accomplish, at an average labor rate of $60 per work hour. Based on these figures, the cost impact of the inspection proposed by this AD on U.S. operators is estimated to be $14,520, or $60 per airplane.
The cost impact figures discussed above are based on assumptions that no operator has yet accomplished any of the current or proposed requirements of this AD action, and that no operator would accomplish those actions in the future if this AD were not adopted.
Should an operator that has already completed the replacement of the attachment fasteners of the banjo No. 4 fitting in accordance with AD 96-07-01 be required to repeat the replacement, it would take approximately 14 additional work hours, at an average labor rate of $60 per work hour. Additional parts would cost $150 per airplane. Based on these figures, the cost impact of any necessary repetition of the replacement is estimated to be $990 per airplane.
Regulatory Impact
The regulations proposed herein would not have substantial direct effects 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. Therefore, in accordance with Executive Order 12612, it is determined that this proposal would not have sufficient federalism implications to warrant the preparation of a Federalism Assessment.
For the reasons discussed above, I certify that this proposed regulation (1) is not a ``significant regulatory action'' under Executive Order 12866; (2) is not
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a ``significant rule'' under the DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); and (3) if promulgated, 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. A copy of the draft regulatory evaluation prepared for this action is contained in the Rules Docket. A copy of it may be obtained by contacting the Rules Docket at the location provided under the caption ADDRESSES.
List of Subjects in 14 CFR Part 39
Air transportation, Aircraft, Aviation safety, Safety.
The Proposed Amendment
Accordingly, pursuant to the authority delegated to me by the Administrator, the Federal Aviation Administration proposes to amend part 39 of the Federal Aviation Regulations (14 CFR part 39) as follows:
PART 39--AIRWORTHINESS DIRECTIVES
-
The authority citation for part 39 continues to read as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701.
Sec. 39.13 [Amended]
-
Section 39.13 is amended by removing amendment 39-9549 (61 FR 12015, March 25, 1996), and by adding a new airworthiness directive (AD), to read as follows:
McDonnell Douglas: Docket 98-NM-228-AD. Supersedes AD 96-07-01, Amendment 39-9549.
Applicability: Model DC-10-10, -15, -30, and -40 series airplanes; and KC-10A (military) airplanes; as listed in McDonnell Douglas DC-10 Service Bulletin 55-23, Revision 1, dated December 17, 1993; certificated in any category.
Note 1: This AD applies to each airplane identified in the preceding applicability provision, regardless of whether it has been modified, altered, or repaired in the area subject to the requirements of this AD. For airplanes that have been modified, altered, or repaired so that the performance of the requirements of this AD is affected, the owner/operator must request approval for an alternative method of compliance in accordance with paragraph (e) of this AD. The request should include an assessment of the effect of the modification, alteration, or repair on the unsafe condition addressed by this AD; and, if the unsafe condition has not been eliminated, the request should include specific proposed actions to address it.
Compliance: Required as indicated, unless accomplished previously.
To prevent cracking of the attachment fasteners of the vertical stabilizer, which could result in loss of fail-safe capability of the vertical stabilizer and reduced controllability of the airplane, accomplish the following:
(a) Except as required by paragraph (c)(3) of this AD, within 1,500 landings after April 24, 1996 (the effective date of AD 96-07- 01, amendment 39-9549): Perform an external visual inspection, using a minimum 5X power magnifying glass, to detect any failure of the 12 attachment fasteners located in the banjo No. 4 fitting of the vertical stabilizer (as specified in McDonnell Douglas DC-10 Service Bulletin 55-23, Revision 1, dated December 17, 1993; or McDonnell Douglas Service Bulletin DC10-55-023, Revision 02, dated October 30, 1996, or Revision 03, dated March 25, 1998). Perform this inspection in accordance with procedures specified in McDonnell Douglas Nondestructive Testing Manual, Chapter 20-10-00, or McDonnell Douglas Nondestructive Testing Standard Practice Manual, Part 09.
(1) If no failure is detected, repeat the external visual inspection thereafter at intervals not to exceed 1,500 landings until the requirements of paragraph (b) of this AD are accomplished.
(2) If any failure is detected, prior to further flight, accomplish the requirements of paragraph (b) of this AD.
(b) Except as required by paragraphs (a)(2) and (c)(3)(ii) of this AD, within 5 years after April 24, 1996: Perform an eddy current surface inspection to detect cracking of the forward and aft flanges; and an eddy current bolt hole inspection of the bolt holes of the banjo No. 4 fitting; in accordance with McDonnell Douglas DC- 10 Service Bulletin 55-23, Revision 1, dated December 17, 1993; or McDonnell Douglas Service Bulletin DC10-55-023, Revision 02, dated October 30, 1996, or Revision 03, dated March 25, 1998.
Note 2: Paragraph (b) of this AD does not require that eddy current bolt hole inspections be accomplished for the bolt holes of the banjo No. 4 fitting if the attachment fasteners were replaced prior to April 24, 1996, in accordance with McDonnell Douglas DC-10 Service Bulletin 55-23, dated December 17, 1992.
(1) If no cracking is detected, prior to further flight, replace the 12 attachment fasteners located on the banjo No. 4 fitting with new, improved attachment fasteners, in accordance with McDonnell Douglas DC-10 Service Bulletin 55-23, dated December 17, 1992, or Revision 1, dated December 17, 1993; or McDonnell Douglas Service Bulletin DC10-55-023, Revision 02, dated October 30, 1996, or Revision 03, dated March 25, 1998. After the effective date of this AD, only Revision 03 of the service bulletin shall be used.
(i) Accomplishment of the replacement in accordance with the original issue of the service bulletin constitutes terminating action for the requirements of paragraph (a) of this AD, provided that the eddy current surface inspection of the forward and aft flanges is accomplished in accordance with McDonnell Douglas DC-10 Service Bulletin 55-23, Revision 1, dated December 17, 1993; or McDonnell Douglas Service Bulletin DC10-55-023, Revision 02, dated October 30, 1996, or Revision 03, dated March 25, 1998.
(ii) Accomplishment of the replacement in accordance with McDonnell Douglas DC-10 Service Bulletin 55-23, Revision 1, dated December 17, 1993; or McDonnell Douglas Service Bulletin DC10-55- 023, Revision 02, dated October 30, 1996, or Revision 03, dated March 25, 1998; constitutes terminating action for the requirements of paragraph (a) of this AD, provided that the eddy current surface inspection of the forward and aft flanges, and the eddy current bolt hole inspection of the bolt holes of the banjo No. 4 fitting, are accomplished in accordance with Revision 1, Revision 02, or Revision 03 of the service bulletin.
(2) If any cracking is detected, prior to further flight, repair either in accordance with Figure 6 or Figure 7, as applicable, of Chapter 55-20-00, Volume 1, of the DC-10 Structural Repair Manual; or in accordance with a method approved by the Manager, Los Angeles Aircraft Certification Office (ACO), FAA, Transport Airplane Directorate.
(c) Within 1,500 landings after the effective date of this AD, perform a one-time visual inspection to determine whether second oversize fasteners having part number (P/N) S4931917-8Y are installed in the banjo No. 4 fitting of the vertical stabilizer.
(1) If second oversize fasteners having P/N S4931917-8Y are not installed, and the actions required by paragraph (b) of this AD have been accomplished, no further action is required by this AD.
(2) If second oversize fasteners having P/N S4931917-8Y are not installed, and the actions required by paragraph (b) of this AD have not been accomplished: Within 1,500 landings after the last inspection performed in accordance with paragraph (a) of this AD, repeat that inspection, and perform the follow-on actions specified by paragraph (a) of this AD.
(3) If second oversize fasteners having P/N S4931917-8Y are installed, prior to further flight, perform an external visual inspection to detect any failure of the 12 attachment fasteners located in the banjo No. 4 fitting of the vertical stabilizer in accordance with paragraph (a) of this AD.
(i) If no failure is detected, repeat the external visual inspection thereafter at intervals not to exceed 1,500 landings until the requirements of paragraph (b) of this AD are accomplished.
(ii) If any failure is detected, prior to further flight, accomplish the requirements of paragraph (b) of this AD.
(d) As of the effective date of this AD, no person shall install a second oversize fastener having part number (P/N) S4931917-8Y in the banjo No. 4 fitting of the vertical stabilizer on any airplane.
(e) An alternative method of compliance or adjustment of the compliance time that provides an acceptable level of safety may be used if approved by the Manager, Los Angeles ACO. Operators shall submit their requests through an appropriate FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, Los Angeles ACO.
Note 3: Information concerning the existence of approved alternative methods of compliance with this AD, if any, may be obtained from the Los Angeles ACO.
(f) Special flight permits may be issued in accordance with sections 21.197 and 21.199
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of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate the airplane to a location where the requirements of this AD can be accomplished.
Issued in Renton, Washington, on November 16, 1998. Darrell M. Pederson, Acting Manager, Transport Airplane Directorate, Aircraft Certification Service.
[FR Doc. 98-31172Filed11-20-98; 8:45 am]
BILLING CODE 4910-13-U
