2005-08-01 Boeing: Docket No. FAA-2005-20915; Directorate Identifier 2005-NM-042-AD; Amendment 39-14053. \n\nEffective Date \n\n\t(a) This AD becomes effective April 26, 2005. \n\nAffected ADs \n\n\t(b) This AD supersedes AD 91-11-01, amendment 39-6997, and AD 2005-04-51, amendment 39-13995. \n\nApplicability \n\n\t(c) This AD applies to Boeing Model 747-100, -100B, -100B SUD, - 200B, -200C, -200F, and -300 series airplanes; and Model 747SP and 747SR series airplanes; certificated in any category; as identified in Boeing Alert Service Bulletin 747-53A2265, Revision 9, dated February 17, 2005. \n\nUnsafe Condition \n\n\t(d) This AD was prompted by reports of large cracks common to fuselage frames in the upper deck area, and severed or nearly severed adjacent frames. We are issuing this AD to detect and correct fatigue cracks in the body frames, skin and other internal structure in fuselage section 41, which could lead to rapid decompression and loss of the structural integrity of the airplane. \n\nCompliance \n\n\t(e) You are responsible for having the actions required by this AD performed within the compliance times specified, unless the actions have already been done. \n\nRequirements of AD 91-11-01 \n\nExisting Repetitive Inspections and Corrective Actions \n\n\t(f) Within the next 500 flight cycles after June 24, 1991 (the effective date of AD 91-11-01), or prior to accumulating the flight limit specified in Boeing Drawing 624U0001, Sheet 3, Revision A, dated December 14, 1989, whichever occurs later, accomplish the flight limit inspection contained in Boeing Service Bulletin 747- 53A2265, Revision 7, dated January 25, 1990. The inspections required by this paragraph consist of flight limit inspections at 8,000, 10,000, 13,000, 16,000, and 19,000 total flight cycles and repetitive inspections after the flight limit inspections. Do these inspections at intervals not to exceed those specified in the drawing, except as provided by paragraph (g) of this AD. As of the effective date of this AD, the inspections identified in Revision 7 of the service bulletin must be done in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 747- 53A2265, Revision 9, dated February 17, 2005. \n\n\t(g) For Model 747SR series airplanes: Based on continued mixed operation of lower cabin differentials, the flight limit and repetitive inspection intervals specified in paragraph (f) of this AD may be multiplied by a 1.2 adjustment factor for the next inspection required by that paragraph after the effective date of this AD. Subsequent inspections identified in Boeing Service Bulletin 747-53A2265, Revision 7, dated January 25, 1990, must be done at the intervals specified in Revision 9 of Boeing Alert Service Bulletin 747-53A2265, dated February 17, 2005 (the 1.2 adjustment factor is not allowed in any subsequent inspections). \n\n\t(h) If any cracking is found during any inspection required by paragraph (f) of this AD: Prior to further flight, repair in accordance with FAA-approved procedures. Concurrent with performing any repair, visually inspect adjacent structures in accordance with Section III of Boeing Service Bulletin 747-53A2265, Revision 7, dated January 25, 1990; and before further flight, repair any cracks in accordance with FAA-approved procedures. After the effective date of this AD, the actions must be done in accordance with paragraph (q) of this AD. \n\n\t(i) For structure that has been replaced with new structure during previous airplane modification/repair, the inspection thresholds referenced in paragraph (f) of this AD are measured from the time of replacement of that structure. \n\nRequirements of AD 2005-04-51 \n\nRepetitive External Detailed Inspections \n\n\t(j) For Boeing Model 747-100B SUD, -200C, -200F, and -300 series airplanes, line numbers 1 through 685 inclusive; and Boeing Model 747-200B series airplanes, line numbers 271, 276, 336, 344, 369, 389, 397, 474, 491, 518, 521, and 539: Before the accumulation of 8,000 total flight cycles, or within 10 flight cycles after March 9, 2005 (the effective date of AD 2005-04-51), whichever occurs later, do an external detailed inspection for cracked skin or loose or missing fasteners of the body skin between BS 420 and 460 inclusive and between stringers S-8 and S-12 inclusive on the left and right sides of the airplane. Repeat the external detailed inspection thereafter at intervals not to exceed 25 flight cycles until the initial high frequency eddy current (HFEC) inspection required by paragraph (k), (n), or (o) of this AD is done. \n\n\tNote 1: For the purposes of this AD, a detailed inspection is: "An intensive examination of a specific item, installation, or assembly to detect damage, failure, or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirror, magnifying lenses, etc., may be necessary. Surface cleaning and elaborate procedures may be required." \n\nCorrective Actions \n\n\t(k) If any cracked skin or loose or missing fastener is detected during any external detailed inspection required by paragraph (j) of this AD, before further flight, do an internal surface HFEC inspection for cracks in the frames between BS 420 and 460 inclusive and between stringers S-8 and S-12 inclusive on the left and right sides of the airplane, in accordance with paragraph 2. and Notes 2 and 3 of Figure 17 of the Accomplishment Instructions of Boeing Alert Service Bulletin 747-53A2265, Revision 9, dated February 17, 2005, except as provided by Note 1 of Figure 17 of the service bulletin. Accomplishing the surface HFEC inspection ends the repetitive inspections required by paragraph (j) of this AD. \n\n\t(1) If no cracked frame is found, before further flight, repair the cracked skin and replace the loose or missing fasteners with new fasteners, as applicable, in accordance with a method approved by the Manager, Seattle Aircraft Certification Office (ACO), FAA; or in accordance with data meeting the certification basis of the airplane approved by an Authorized Representative (AR) for the Boeing Delegation Option Authorization (DOA) Organization who has been authorized by the Manager, Seattle ACO, to make those findings. For a repair method to be approved, the repair must meet the certification basis of the airplane, and the approval must specifically reference this AD. \n\n\t(2) If any cracked frame is found, before further flight, repair the cracked frame and skin and replace the loose or missing fasteners with new fasteners, as applicable, in accordance with a method approved by the Manager, Seattle ACO, FAA; or in accordance with data meeting the certification basis of the airplane approved by an AR for the Boeing DOA Organization who has been authorized by the Manager, Seattle ACO, to make those findings. For a repair method to be approved, the repair must meet the certification basis of the airplane, and theapproval must specifically reference this AD. \n\nNew Requirements of This AD \n\n8,000 Total Flight-Cycle (Flight Limit) Detailed Inspection Between BS 420 and 460 Inclusive \n\n\t(l) For Group 1 through 11 airplanes identified in Boeing Alert Service Bulletin 747-53A2265, Revision 9, dated February 17, 2005: At the time specified in paragraph (l)(1), (l)(2), or (l)(3) of this AD, as applicable; do an internal detailed inspection for cracks of the left and right side body frames and adjacent skin between BS 420 and 460 inclusive and between stringers S-8 and S-12 inclusive, in accordance with the Figures 11 through 16, as applicable, of the Accomplishment Instructions of the service bulletin. Accomplishment of the 10,000 total flight-cycle (flight limit) inspection required by paragraphs (f) and (m) of this AD, or the initial inspection required by paragraph (o) of this AD, as applicable, is considered acceptable for compliance with the requirements of this paragraph. \n\n\tNote 2: ForGroups 1, 3 through 6, and 8 through 11 airplanes, the 8,000 total flight-cycle detailed inspection in paragraph (l) of this AD is a new flight limit inspection in addition to those inspections specified in paragraph (f) of this AD. For Groups 2 and 7 airplanes, the 8,000 total flight-cycle inspection in paragraph (l) of this AD is an addition to the existing 8,000 total flight- cycle (flight limit) inspection. \n\n\t(1) For Group 1 through 6 airplanes: Before the accumulation of 8,000 total flight cycles, or within 2,000 flight cycles after the effective date of this AD, whichever occurs later. \n\n\t(2) For Group 7 through 11 airplanes that have accumulated less than 8,000 total flight cycles as of the effective date of this AD: Before the accumulation of 8,000 total flight cycles, or within 750 flight cycles after the effective date of this AD, whichever occurs later. \n\n\t(3) For Group 7 through 11 airplanes that have accumulated 8,000 or more total flight cycles as of the effectivedate of this AD: Before the accumulation of 8,750 total flight cycles, or within 50 flight cycles after the effective date of this AD, whichever occurs later. \n\n10,000 Total Flight-Cycle (Flight Limit) Detailed Inspection Between BS 440 and 520 Inclusive \n\n\t(m) For Group 1 through 11 airplanes identified in Boeing Alert Service Bulletin 747-53A2265, Revision 9, dated February 17, 2005: At the time specified in paragraph (m)(1) or (m)(2) of this AD, as applicable, do an internal detailed inspection for cracks of the left and right side body frames and adjacent skin/tear straps between BS 440 and 520 inclusive and between stringers S-6 and S-12 inclusive, in accordance with Figures 11 through 16, as applicable, of the Accomplishment Instructions of the service bulletin. Accomplishment of the 13,000 total flight-cycle (flight limit) inspection required by paragraph (f) of this AD is considered acceptable for compliance with the requirements of this paragraph. \n\n\tNote 3: For Group 1through 11 airplanes, the 10,000 total flight-cycle detailed inspection in paragraph (m) of this AD is in addition to the existing 10,000 total flight-cycle (flight limit) inspection. \n\n\t(1) For Group 1 through 6 airplanes: Before the accumulation of 10,000 total flight cycles, or within 1,000 flight cycles after the effective date of this AD, whichever occurs later. \n\n\t(2) For Group 7 through 11 airplanes: Before the accumulation of 10,000 total flight cycles, or within 50 flight cycles after the effective date of this AD, whichever occurs later. \n\nRepetitive HFEC Inspections Between BS 420 and 460 Inclusive \n\n\t(n) For Group 7 through 11 airplanes identified in Boeing Alert Service Bulletin 747-53A2265, Revision 9, dated February 17, 2005: At the time specified in paragraph (n)(1) or (n)(2) of this AD, as applicable; do an internal surface HFEC inspection for cracks of the left and right side body frames between BS 420 and 460 inclusive and between stringers S-8 and S-12 inclusive, in accordance with Figures 12 through 16, as applicable, of the Accomplishment Instructions of the service bulletin. Repeat the inspection thereafter at intervals not to exceed the applicable flight limits specified in the Accomplishment Instructions of the service bulletin. Accomplishment of the initial inspection required by paragraph (o) of this AD is considered acceptable for compliance with the initial inspection required by this paragraph. \n\n\tNote 4: For Group 7 through 11 airplanes, the HFEC inspection in paragraph (n) of this AD is an addition to each of the flight limit inspections. \n\n\t(1) For airplanes that have accumulated less than 8,000 total flight cycles as of the effective date of this AD: Do the inspection prior to the accumulation of 8,000 total flight cycles, or within 750 flight cycles after the effective date of this AD, whichever occurs later. \n\n\t(2) For airplanes that have accumulated 8,000 or more total flight cycles as of the effective date of thisAD: Do the inspection prior to the accumulation of 8,750 total flight cycles, or within 50 flight cycles after the effective date of this AD, whichever occurs later. \n\nRepetitive Supplemental Detailed and HFEC Inspections Between BS 420 and 460 Inclusive \n\n\t(o) For Group 7 through 11 airplanes identified in Boeing Alert Service Bulletin 747-53A2265, Revision 9, dated February 17, 2005: At the applicable times specified in paragraphs (o)(1) and (o)(2) of this AD, do internal detailed and surface HFEC inspections for cracks of the body frames and adjacent skin between BS 420 and 460 inclusive and between stringers S-8 and S-12 inclusive, in accordance with Figure 17 of the Accomplishment Instructions of the service bulletin. Repeat the inspections thereafter at intervals not to exceed 1,000 flight cycles until the next flight limit inspection required by paragraph (n) of this AD; and after each flight limit inspection, repeat the inspections required by this paragraph thereafter atintervals not to exceed 1,000 flight cycles until the next flight limit inspection; except as provided by paragraph (p) of this AD. \n\n\tNote 5: For Group 7 through 11 airplanes, the supplemental detailed and HFEC inspections in paragraph (o) of this AD are inspections to be done in between the flight limit inspections. \n\n\t(1) For airplanes on which any inspection required by paragraph (f) of this AD has been done as of the effective date of this AD: Do the inspections at the later of the times specified in paragraphs (o)(1)(i) and (o)(1)(ii) of this AD. \n\n\t(i) Within 750 flight cycles after the last inspection required by paragraph (f) of this AD. \n\n\t(ii) Within 50 flight cycles after the effective date of this AD. \n\n\t(2) For airplanes on which any inspection required by paragraph (f) of this AD has not been done as of the effective date of this AD: Within 1,000 flight cycles after doing any inspection required by paragraph (l) of this AD. \n\n\t(p) In lieu of performing the repetitive detailed and surface HFEC inspections required by paragraph (o) of this AD at intervals not to exceed 1,000 flight cycles: Perform an internal detailed inspection for cracks of the body frame and adjacent skin between BS 420 and 460 inclusive and between stringers S-8 and S-12 inclusive, in accordance with Figure 17 of the Accomplishment Instructions of the service bulletin, at intervals not to exceed 750 flight cycles. Operators may alternate the inspection methods provided that the corresponding repetitive inspection interval is not exceeded. \n\nCorrective Action \n\n\t(q) If any crack is found during any inspection required by paragraph (l) through (p) of this AD, before further flight, do the related investigative and corrective actions in accordance with the Accomplishment Instructions of Boeing Alert Service Bulletin 747- 53A2265, Revision 9, dated February 17, 2005, except as provided by paragraph (r) of this AD. \n\n\t(r) Where Boeing Alert Service Bulletin 747-53A2265,Revision 9, dated February 17, 2005, specifies to contact Boeing for appropriate action: Before further flight, repair the cracked part in accordance with a method approved by the Manager, Seattle ACO, FAA; or in accordance with data meeting the certification basis of the airplane approved by an AR for the Boeing DOA who has been authorized by the Manager, Seattle ACO, to make those findings. For a repair method to be approved, the repair must meet the certification basis of the airplane, and the approval must specifically reference this AD. \n\nTerminating Action for Modified Structure Only \n\n\t(s) Modification in accordance with Boeing Service Bulletin 747- 53-2272, dated January 12, 1987, through Revision 18, dated May 16, 2002, prior to the effective date of this AD, constitutes terminating action for the requirements of paragraphs (f), (j), and (l) through (p) of this AD for modified structure only. As of the effective date of this AD, the modification must be done in accordancewith Boeing Service Bulletin 747-53-2272, Revision 18, dated May 16, 2002. \n\n\tNote 6: Paragraph H of AD 91-11-01, amendment 39-6997, refers to Boeing Service Bulletin 747-53-2272, dated January 12, 1987, as the appropriate source of service information for accomplishing the optional terminating action in that AD. AD 90-06-06, amendment 39- 6490, refers to Boeing Service Bulletin 747-53-2272, Revision 12, dated December 22, 1988; or earlier revisions; as an appropriate source of service information for accomplishing the mandatory terminating action in that AD. \n\nAlternative Methods of Compliance (AMOCs) \n\n\t(t)(1) The Manager, Seattle ACO, FAA, has the authority to approve AMOCs for this AD, if requested in accordance with the procedures found in 14 CFR 39.19. \n\n\t(2) An AMOC that provides an acceptable level of safety may be used for any repair required by this AD, if it is approved by an AR for the Boeing DOA Organization who has been authorized by the Manager, Seattle ACO, tomake those findings. For a repair method to be approved, the repair must meet the certification basis of the airplane, and the approval must specifically refer to this AD. \n\n\t(3) AMOCs approved previously according to ADs 91-11-01 or 2005- 04-51 are approved as AMOCs for the corresponding requirements of this AD. \n\nMaterial Incorporated by Reference \n\n\t(u) You must use Boeing Service Bulletin 747-53A2265, Revision 7, dated January 25, 1990; and Boeing Alert Service Bulletin 747- 53A2265, Revision 9, dated February 17, 2005; as applicable; to perform the actions that are required by this AD, unless the AD specifies otherwise. \n\n\t(1) The incorporation by reference of Boeing Service Bulletin 747-53A2265, Revision 7, dated January 25, 1990, is approved by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. \n\n\t(2) The incorporation by reference of Boeing Alert Service Bulletin 747-53A2265, Revision 9, dated February 17, 2005, was approved previously by the Director of the Federal Register as of March 9, 2005 (70 FR 10485, March 4, 2005). \n\n\t(3) To get copies of the service information, contact Boeing Commercial Airplanes, P.O. Box 3707, Seattle, Washington 98124-2207. To view the AD docket, go to the Docket Management Facility, U.S. Department of Transportation, 400 Seventh Street SW., room PL-401, Nassif Building, Washington, DC. To review copies of the service information, go to the National Archives and Records Administration (NARA). For information on the availability of this material at the NARA, call (202) 741-6030, or go to http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html .