Airworthiness Directives; McDonnell Douglas Model DC-9, DC-9-80, and C-9 (Military) Series Airplanes and Model MD-88 Airplanes

DEPARTMENT OF TRANSPORTATION

14 CFR Part 39

[Docket No. 94-NM-172-AD]

Airworthiness Directives; McDonnell Douglas Model DC-9, DC-9-80,

and C-9 (Military) Series Airplanes and Model MD-88 Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: This document proposes the adoption of a new airworthiness

directive (AD) that is applicable to certain McDonnell Douglas Model

DC-9, DC-9-80, and C-9 (military) series airplanes and Model MD-88

airplanes. This proposal would require a visual inspection to verify

proper installation of the wire termination lugs on the ignition

selector switch, and removal and correct installation of any improperly

installed wire termination lugs. This proposal would also require

application of sealant to the wire termination lugs and the attachment

screws. This proposal is prompted by a report that, during the

manufacturer's production flight testing, an abnormal engine start

valve open annunciation for engine No. 2 occurred and resulted in an

uncontained failure of the engine starter. The actions specified by the

proposed AD are intended to prevent damage to the engine cowling,

damage to adjacent engine components, and possible fire in the cowling,

due to an uncontained failure of the engine starter.

DATES: Comments must be received by January 19, 1995.

ADDRESSES: Submit comments in triplicate to the Federal Aviation

Administration (FAA), Transport Airplane Directorate, ANM-103,

Attention: Rules Docket No. 94-NM-172-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 McDonnell Douglas Corporation, P.O. Box 1771, Long Beach,

California 90801-1771, Attention: Business Unit Manager, Technical

Administrative Support, Dept. LS1, M.C. 2-98. 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: Robert Baitoo, Aerospace Engineer,

Propulsion Branch, ANM-140L, FAA, Transport Airplane Directorate, Los

Angeles Aircraft Certification Office, 3960 Paramount Boulevard,

Lakewood, California 90712; telephone (310) 627-5245; fax (310) 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 filed in 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 94-NM-172-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-103, Attention: Rules

Docket No. 94-NM-172-AD, 1601 Lind Avenue, SW., Renton, Washington

98055-4056.

Discussion

The FAA has received a report that, during the manufacturer's

production flight testing, an abnormal engine start valve open

annunciation for engine No. 2 occurred on a Model DC-9 series airplane.

After the airplane landed, inspection revealed that an uncontained

failure of the engine starter on engine No. 2 had occurred.

Investigation revealed that a wire termination lug in the ignition

selector switch was installed barrel down, and consequently, contacted

an adjacent terminal, causing an electrical short. This electrical

short at the ignition selector switch caused the engine start valve to

stay open and resulted in an uncontained failure of the engine starter.

This condition, if not corrected, could result in damage to the engine

cowling, damage to adjacent engine components, and possible fire in the

cowling.

The FAA has reviewed and approved McDonnell Douglas DC-9 Service

Bulletin 24-121, dated February 24, 1992, which describes procedures

for visual inspection to verify proper installation of the wire

termination lugs on the ignition selector switch. This service bulletin

also describes procedures for removal and proper installation of the

wire termination lug if it is found to be installed incorrectly.

Additionally, the service bulletin describes procedures for the

application of a sealant to the termination lugs and attachment screws.

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 require a one-time visual inspection to verify proper

installation of the wire termination lugs on the ignition selector

switch. The proposed AD would also require removal of the wire

termination lugs and reinstallation, if they are installed improperly.

Additionally, the proposed AD would require the application of a

sealant to the termination lugs and attachment screws. The actions

would be required to be accomplished in accordance with the service

bulletin described previously.

[Note: As a result of recent communications with the Air Transport

Association (ATA) of America, the FAA has learned that, in general,

some operators may misunderstand the legal effect of AD's on

airplanes that are identified in the applicability provision of the

AD, but that have been altered or repaired in the area addressed by

the AD. Under these circumstances, at least one operator appears to

have incorrectly assumed that its airplane was not subject to an AD.

On the contrary, all airplanes identified in the applicability

provision of an AD are legally subject to the AD. If an airplane has

been altered or repaired in the affected area in such a way as to

affect compliance with the AD, the owner or operator is required to

obtain FAA approval for an alternative method of compliance with the

AD, in accordance with the paragraph of each AD that provides for

such approvals. A note has been included in this notice to clarify

this requirement.]

There are approximately 1,954 Model DC-9, DC-9-80, and C-9 series

airplanes, and Model MD-88 airplanes of the affected design in the

worldwide fleet. The FAA estimates that 1,097 airplanes of U.S.

registry would be affected by this proposed AD, that it would take

approximately 2 work hours per airplane to accomplish the proposed

actions, and that the average labor rate is $60 per work hour. The cost

of required parts would be nominal. Based on these figures, the total

cost impact of the proposed AD on U.S. operators is estimated to be

$131,640 or $120 per airplane.

The total cost impact figure discussed above is based on

assumptions that no operator has yet accomplished any of the proposed

requirements of this AD action, and that no operator would accomplish

those actions in the future if this AD were not adopted.

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 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

1. The authority citation for part 39 continues to read as follows:

Authority: 49 U.S.C. App. 1354(a), 1421 and 1423; 49 U.S.C.

106(g); and 14 CFR 11.89.

Sec. 39.13 [Amended]

2. Section 39.13 is amended by adding the following new

airworthiness directive:

McDonnell Douglas: Docket 94-NM-172-AD.

Applicability: Model DC-9 and C-9 (Military) series airplanes,

and Model MD-88 airplanes, as listed in McDonnell Douglas DC-9

Service Bulletin 24-121, dated February 24, 1992, 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 use the authority

provided in paragraph (c) to request approval from the FAA. This

approval may address either no action, if the current configuration

eliminates the unsafe condition; or different actions necessary to

address the unsafe condition described in this AD. Such a request

should include an assessment of the effect of the changed

configuration on the unsafe condition addressed by this AD. In no

case does the presence of any modification, alteration, or repair

remove any airplane from the applicability of this AD.

Compliance: Required as indicated, unless accomplished

previously.

To prevent an engine start valve uncontained failure, which

could cause damage to the engine cowling, damage to adjacent engine

components, and possible fire in the cowling, accomplish the

following:

(a) Within 8 months after the effective date of this AD, perform

a visual inspection of the wire termination lugs on the ignition

selector switch located in the forward overhead switch panel in the

flight compartment to determine if the lugs are installed correctly,

in accordance with McDonnell Douglas DC-9 Service Bulletin 24-121,

dated February 24, 1992.

(1) If any wire termination lug is improperly installed, prior

to further flight, remove and reinstall the wire terminations with

the barrel up, and encapsulate the wire termination lugs and

attachment screws with sealant, in accordance with the service

bulletin.

(2) If all wire termination lugs are properly installed, prior

to further flight, encapsulate the termination lugs and attachment

screws with sealant in accordance with the service bulletin.

(b) Within 10 days after removing and reinstalling any wire

terminations with the barrel up, as required by paragraph (a)(1),

submit a report of that action to the FAA, Transport Airplane

Directorate, Los Angeles Aircraft Certification Office, 3960

Paramount Boulevard, Lakewood, California 90712, Attention: Robert

Baitoo, ANM-140L; fax (310) 627-5210. Information collection

requirements contained in this regulation have been approved by the

Office of Management and Budget (OMB) under the provisions of the

Paperwork Reduction Act of 1980 (44 U.S.C. 3501 et seq.) and have

been assigned OMB Control Number 2120-0056.

(c) 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 Aircraft Certification

Office (ACO), FAA, Transport Airplane Directorate. 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 2: Information concerning the existence of approved

alternative methods of compliance with this AD, if any, may be

obtained from the Los Angeles ACO.

(d) Special flight permits may be issued in accordance with

Secs. 21.197 and 21.199 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, 1994.

Darrell M. Pederson,

Acting Manager, Transport Airplane Directorate, Aircraft Certification

Service.

[FR Doc. 94-28744 Filed 11-21-94; 8:45 am]

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