Airworthiness Directives; McDonnell Douglas Model DC-10 Series Airplanes and Model MD-11F (Freighter) Airplanes

[[Page 29009]]

DEPARTMENT OF TRANSPORTATION

14 CFR Part 39

[Docket No. 95-NM-120-AD; Amendment 39-9661; AD 96-12-18]

RIN 2120-AA64

Airworthiness Directives; McDonnell Douglas Model DC-10 Series

Airplanes and Model MD-11F (Freighter) Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment adopts a new airworthiness directive (AD) that

is applicable to all McDonnell Douglas Model DC-10 series airplanes and

Model MD-11F airplanes. Among other things, this amendment requires

repetitive leak checks of the lavatory drain system and repair, if

necessary; provides for the option of revising the FAA-approved

maintenance program to include a schedule of leak checks; and requires

the installation of a cap on the flush/fill line. This amendment is

prompted by continuing reports of damage to engines and airframes,

separation of engines from airplanes, and damage to property on the

ground, caused by ``blue ice'' that forms from leaking lavatory drain

systems on transport category airplanes and subsequently dislodges from

the airplane fuselage. The actions specified by this AD are intended to

prevent such damage associated with the problems of ``blue ice.''

EFFECTIVE DATE: July 12, 1996.

ADDRESSES: Information related to this rulemaking action may be

examined at the FAA, Transport Airplane Directorate, 1601 Lind Avenue,

SW., Renton, Washington; or at the FAA, Los Angeles Aircraft

Certification Office, Transport Airplane Directorate, 3960 Paramount

Boulevard, Lakewood, California.

FOR FURTHER INFORMATION CONTACT: Walter Eierman, Aerospace Engineer,

Systems and Equipment Branch, ANM-130L, FAA, Los Angeles Aircraft

Certification Office, 3960 Paramount Boulevard, Lakewood, California

90712; telephone (310) 627-5336; fax (310) 627-5210.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal

Aviation Regulations (14 CFR part 39) to include an airworthiness

directive (AD) that is applicable to all Model DC-10 series airplanes

and MD-11F airplanes was published in the Federal Register on November

2, 1995 (60 FR 55668). That action proposed to require repetitive leak

checks of the lavatory drain system and repair, if necessary; to

provide for the option of revising the FAA-approved maintenance program

to include a schedule of leak checks; and to require the installation

of a cap on the flush/fill line.

Interested persons have been afforded an opportunity to participate

in the making of this amendment. Due consideration has been given to

the comments received.

Support for the Proposal

One commenter supports the proposal.

Request To Exclude All-Cargo Configured Airplanes From Applicability

One commenter requests that the applicability of the proposal be

revised to exclude airplanes operating in an all-cargo configuration,

where lavatories and lavatory fill/drain systems have been removed.

The FAA concurs. This final rule requires leak checks of the

lavatory/fill drain system. However, if no such system is installed on

the airplane then, obviously, the requirements of the AD cannot be

performed and, likewise, should not be required. Although the commenter

states that, for all-cargo configurations of the affected airplanes,

lavatory systems may be removed, the FAA is aware that most cases of

all-cargo-configured Model DC-10's have at least one (forward) lavatory

installed near the flightcrew deck. As long as there is one lavatory

drainage system installed on the airplane, the requirements of this AD

would still apply. To make this eminently clear to affected operators,

the FAA has revised the applicability of the final rule to clarify that

the AD applies to airplanes that are equipped with a lavatory drainage

system.

Request To Revise Dump Valve Leak Check Procedure

One commenter requests that the dump valve leak check procedures,

specified throughout the proposal, be revised to permit the check to be

performed using less fluid. The proposal states that the check is to be

performed by filling the toilet tank with fluid to a level such that

the bowl is approximately half full (at least 2 inches above the

flapper in the bowl). However, this commenter states that the check can

be accomplished and the same intent can be achieved with the use of

less fluid. This commenter, a U.S. operator, indicates that use of less

fluid would be more effective in terms of both time and cost. As an

example, the commenter states that many Model DC-10 airplanes are

equipped with aft waste tanks with a 90-gallon capacity; if the

proposed check procedures are accomplished, over 120 gallons of fluid

would be required to fill the toilet tanks to a level such that each of

the four toilet bowls are half full. The commenter requests that this

leak check on these airplanes be revised to require a maximum of only

50 gallons of fluid to be used. The commenter asserts that this

revision to the test procedures would still accomplish the same intent

and would decrease the time required to test the system.

The FAA does not concur. The procedure to fill the toilet bowl to

approximately \1/2\ full is also meant to check the tank and the rinse

line check valves. The FAA finds that performing the test using less

fluid does not do as complete and adequate a job as is necessary to

meet the intent of this AD.

Request To Delete the Method for Conducting Leak Checks

One commenter requests that the proposal be revised to delete the

defined method of conducting the leak check. The commenter suggests

that, in lieu of requiring the aircraft to be pressurized, the proposal

should merely stipulate that operators are to ``apply 3 psi [sic]

across the valve'' and then allow operators to determine the most

economical means of verifying the integrity of the seals. The commenter

contends that requiring pressurization of the airplane causes

unnecessary expenses to be incurred.

The FAA does not consider that any revision to the final rule is

necessary based on the commenter's request. The wording of the final

rule (and proposal) simply states that the check must be performed with

``a minimum of 3 PSID applied across the valve.'' To do this does not

require that the airplane be pressurized. The FAA acknowledges that the

NOTE contained in the proposal referred operators to the procedures

specified in chapter 38-30-00 of the DC-10 Maintenance Manual procedure

as one source of guidance for performing the check procedures, and

those particular procedures do call for pressurizing the airplane.

However, the reference to the Maintenance Manual procedure is merely

informational; it is not a requirement and, likewise, pressurizing the

airplane is not a requirement. The only requirement of the AD is that a

minimum of 3 PSID be applied across the valve when the check is

performed.

[[Page 29010]]

Request for Clarification of Check Requirements for Valves With Outer

Seals and Inner Caps

One commenter requests that proposed paragraphs (a)(3)(i) and

(a)(3)(ii) be revised to define more clearly which types of valves

require the outer seal to be pressure checked for leakage.

The FAA agrees that some clarification is warranted. Some valves

have an inner seal that is closed when the outer cap is closed. For

this type of valve, leakage from the outer cap could only be checked if

the inner seal were removed since, when the inner seal is correctly in

place, it will prevent any fluid from reaching the outer cap seal. For

this type of valve, paragraph (a)(3)(ii) of the final rule provides an

alternative to allow operators to inspect the seal and seal surface of

the outer cap seal in lieu of performing a leak check of the outer

seal. The FAA has included a new NOTE in paragraph (a)(3) to provide

this information.

Request To Increase Leak Check Interval for Certain Shaw Aero

Valves

One commenter requests that proposed paragraph (a)(1) and (b)(2)(i)

be revised to allow the following Shaw Aero valves to be leak checked

at 1,000-hour intervals:

331 series, all serial numbers;

332 series, all serial numbers;

10101000BA2, having serial numbers 130 and higher; and

10101000BB2, all serial numbers.

The commenter states that these valves have been accepted previously by

the FAA for a 1,000-hour leak check interval either in accordance with

AD 94-23-10, amendment 39-9073 (59 FR 59124, November 16, 1994), which

is applicable to Boeing Model 727 series airplanes; or a similar

proposed rule applicable to Boeing Model 737 series airplanes

(reference Docket No. 95-NM-111-AD; 60 FR 55673, November 2, 1995).

The FAA concurs in part. The FAA finds that the 1,000-hour leak

check interval is acceptable for most of the valves requested by the

commenter. However, based on data received, only 10101000BB2 series

valves having serial number 0011 and higher are acceptable for this

leak check interval. The final rule has been revised accordingly.

Request for Increase in Leak Check Interval for All Shaw Aero

Valves

This same commenter requests that proposed paragraph (a)(1) and

(b)(2)(i) be revised to permit the leak check interval of 1,000 hours

for specified Shaw Aero valves to be increased to 2,000 hours upon the

revision of an operator's maintenance procedures in accordance with the

proposal and the submittal of data to substantiate the longer interval.

The FAA does not consider that any change to the rule is necessary

based on this commenter's request. Paragraph (c) of the final rule

provides a procedure for collecting and submitting data to substantiate

an increase in the leak check interval for any valve. The procedure

specified in that paragraph is the appropriate one to follow for

requesting any such increase in the leak check interval.

Request To Increase Leak Check Interval for Certain Kaiser Valves

One commenter requests that proposed paragraphs (a)(1) and

(b)(2)(i) be revised to increase the 1,000-hour leak check interval for

Kaiser valves having part numbers 0218-0026 and 0218-0032. The

commenter requests that the interval be increased to 2,500 hours based

on qualification and test report data submitted.

The FAA cannot concur with the commenter's request since

insufficient data was submitted to support a longer inspection

interval.

Request for Special Procedures for Systems With ``Interlock''

Mechanisms

One commenter requests that proposed paragraph (b)(2)(ii) be

revised to include different requirements for systems that incorporate

an ``interlock'' mechanism that prevents the closure of the outer cap

if the ``donut'' is not installed. This commenter states that if the

functioning of the interlock mechanism is verified, the requirement for

pressure leak checks should be similar to the checks of other valves

that have both an inner and an outer seal.

The FAA does not concur. Though the interlock mechanism ensures

that the donut is installed, it does not ensure that the donut is in

good condition. This type of valve, therefore, should be inspected at

the same interval as other ``donut valves,'' unless data to

substantiate a longer inspection interval can be provided. For this

type of valve, the inner seal (the ``donut'') can be leak checked and

the outer cap seal and seal surface can be inspected for wear in

accordance with the procedures specified in paragraph (b)(2)(ii)(B) of

the final rule.

Request To Allow Installation of an Alternative Lock Cap

One commenter requests that proposed paragraph (d) be revised to

allow the installation of a \1/4\-turn ball lock cap as an alternative

to the proposed lever lock cap. This commenter, a non-U.S. operator,

states that its fleet is already equipped with these lock caps and the

commenter considers them equivalent to the caps that would be required

by the AD.

The FAA does not concur. Service experience has shown that, on many

occasions, caps have been missing from the airplane. The lever lock cap

installation required by this final rule secures the cap to the

airplane better than other types of cap installations that the FAA

currently knows of. However, under the provisions of paragraph (f) of

this final rule, the FAA would consider approval of the use of other

types of caps as an alternative method of compliance if sufficient data

are presented to justify the use of a different type of cap.

Request To Address Need for Heaters on Flush/Fill Lines

This same commenter indicates that the proposed installation of

caps on the flush/fill lines, as would be required by paragraph (d) of

the proposal, also may require the installation of heaters. Without

such heaters, residual water will collect at the flush/fill nipples and

freeze, thus hindering maintenance. This will increase the costs

associated with the proposed rule.

The FAA does not concur with the commenter's observation.

Typically, caps already are installed on airplanes; this AD will

require the installation of only a particular style of cap, and may not

change the possible need for heaters on some airplanes. If the lines

are allowed to drain thoroughly before the cap is closed, the need for

heaters also would be minimized or eliminated.

Request for Permission To Use Alternative Check Valves on Flush/

Fill Line

Several commenters request that proposed paragraph (d) be revised

to permit the use of Monogram 4803-86 series check valves on flush/fill

lines as an alternative to the proposed lever/lock caps. These

commenters point out that Monogram check valves with similar design

characteristics were approved previously by the FAA as an acceptable

alternative item for compliance with a similar proposed AD that is

applicable to Boeing Model 737 series airplanes (reference Docket No.

95-NM-111-AD).

The FAA concurs with the commenters' request. Paragraph (d) of the

final rule has been revised to specify that installation of Monogram

4803-86 series check valves on the flush/fill lines is an acceptable

action for compliance.

[[Page 29011]]

Additionally, paragraphs (a)(4) and (b)(3) of the final rule have

been revised to provide the necessary instructions for replacing the O-

rings associated with the Monogram 4803-86 series check valve, and for

testing the check valve for proper operation.

Request for Revision of Cost Impact Information

One commenter states that the cost impact information, as explained

in the preamble to the proposal, indicated that required parts for

installing a cap on the flush/fill line would cost $275 per airplane.

The commenter states that the cost of parts is $275 per unit; based on

an average of 8 units per airplane, the cost per airplane is $2,200.

The FAA concurs. The cost information presented in the proposal

inadvertently indicated the cost per unit, rather than the total cost

per airplane. The commenter's figures are correct and the cost impact

discussion, below, has been revised accordingly.

Conclusion

After careful review of the available data, including the comments

noted above, the FAA has determined that air safety and the public

interest require the adoption of the rule with the changes previously

described. The FAA has determined that these changes will neither

increase the economic burden on any operator nor increase the scope of

the AD.

Cost Impact

There are approximately 435 Model DC-10 series airplanes and Model

MD-11F airplanes of the affected design in the worldwide fleet. The FAA

estimates that 285 airplanes of U.S. registry, and 18 U.S. operators,

will be affected by this proposed AD.

For airplanes in the passenger configuration, the estimated costs

associated with the requirements of this AD are as follows:

1. Leak checks. It will take approximately 4 work hours per

airplane lavatory drain to accomplish each leak check, at an average

labor cost of $60 per work hour. There normally are two drains per

airplane. Depending upon the type of valve installed and the flight

utilization rate of the airplane, airplanes will be required to be

inspected as few as 3 times per year or as many as 15 times per year.

Based on these figures, the cost impact of the proposed leak check

requirement on U.S. operators is expected to be between $1,440 and

$7,200 per airplane per year.

2. Inspections. Should an operator elect to perform the inspection

of the service panel drain valve cap/door seal and seal mating surface,

the inspection will take approximately 2 work hours to accomplish, at

an average labor cost of $60 per work hour. Depending upon the type of

valves installed and the flight utilization rate of the airplane,

airplanes will be required to be inspected as few as 3 times per year

or as many as 15 times per year. Based on these figures, the cost

impact of the inspection requirements on U.S. operators will be between

$360 and $1,800 per airplane per year.

3. Installation of cap on flush/fill line. This installation will

take approximately 2 work hours to accomplish, at an average labor cost

of $60 per work hour. The cost of required parts is estimated to be

$2,200 per airplane. (There are 8 flush/fill lines per airplane, and

parts for each line will cost approximately $275.) There currently are

175 passenger-configured airplanes of U.S. registry that will be

subject to this requirement. Based on these figures, the cost impact of

the installation requirement on U.S. operators is expected to be

$553,000, or $3,160 per airplane.

For airplanes in the freighter configuration, the estimated costs

associated with the requirements of this AD are as follows:

1. Leak checks. It will take approximately 4 work hours per

airplane lavatory drain to accomplish each leak check, at an average

labor cost of $60 per work hour. There normally is one drain per

airplane. Depending upon the type of valve installed and the flight

utilization rate of the airplane, airplanes will be required to be

inspected as few as 3 times per year or as many as 15 times per year.

Based on these figures, the cost impact of the leak check requirement

on U.S. operators of these airplanes is expected to be between $720 and

$3,600 per airplane per year.

2. Inspections. Should an operator elect to perform the inspection

of the service panel drain valve cap/door seal and seal mating surface,

the inspection will take approximately 1 work hour to accomplish, at an

average labor cost of $60 per work hour. Depending upon the type of

valves installed and the flight utilization rate of the airplane,

airplanes will be required to be inspected as few as 3 times per year

or as many as 15 times per year. Based on these figures, the cost

impact of the inspection requirements on U.S. operators of these

airplanes will be between $180 and $900 per airplane per year.

3. Installation of cap on flush/fill line. This installation will

take approximately 2 work hours to accomplish, at an average labor cost

of $60 per work hour. The cost of required parts is estimated to be

$275 per airplane. (There is 1 flush/fill line per airplane.) There

currently are 110 freighter-configured airplanes of U.S. registry that

will be subject to this requirement. Based on these figures, the cost

impact of the installation requirement on U.S. operators of these

airplanes is expected to be $43,450, or $395 per airplane.

The number of required work hours, as indicated above, is presented

as if the accomplishment of the actions required by this AD were to be

conducted as ``stand alone'' actions. However, in actual practice,

these actions could be accomplished coincidentally or in combination

with normally scheduled airplane inspections and other maintenance

program tasks. Therefore, the actual number of necessary ``additional''

work hours will be minimal in many instances. Additionally, any costs

associated with special airplane scheduling should be minimal.

In addition to the costs discussed above, for those operators who

elect to comply with paragraph (b) of this AD action, the FAA estimates

that it will take approximately 40 work hours per operator to

incorporate the lavatory drain system leak check procedures into the

maintenance programs, at an average labor cost of $60 per work hour.

Based on these figures, the total cost impact of the maintenance

revision requirement of this AD on the 18 affected U.S. operators is

estimated to be $43,200, or $2,400 per operator.

The cost impact figures discussed above are based on assumptions

that no operator has yet accomplished any of the requirements of this

AD action, and that no operator would accomplish those actions in the

future if this AD were not adopted.

The FAA recognizes that the obligation to maintain aircraft in an

airworthy condition is vital, but sometimes expensive. Because AD's

require specific actions to address specific unsafe conditions, they

appear to impose costs that would not otherwise be borne by operators.

However, because of the general obligation of operators to maintain

aircraft in an airworthy condition, this appearance is deceptive.

Attributing those costs solely to the issuance of this AD is

unrealistic because, in the interest of maintaining safe aircraft,

prudent operators would accomplish the required actions even if they

were not required to do so by the AD.

A full cost-benefit analysis has not been accomplished for this AD.

As a matter of law, in order to be airworthy, an aircraft must conform

to its type

[[Page 29012]]

design and be in a condition for safe operation. The type design is

approved only after the FAA makes a determination that it complies with

all applicable airworthiness requirements. In adopting and maintaining

those requirements, the FAA has already made the determination that

they establish a level of safety that is cost-beneficial. When the FAA,

as in this AD, makes a finding of an unsafe condition, this means that

the original cost-beneficial level of safety is no longer being

achieved and that the required actions are necessary to restore that

level of safety. Because this level of safety has already been

determined to be cost-beneficial, a full cost-benefit analysis for this

AD would be redundant and unnecessary.

Regulatory Impact

The regulations adopted herein will 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 final

rule does not have sufficient federalism implications to warrant the

preparation of a Federalism Assessment.

For the reasons discussed above, I certify that this action (1) is

not a ``significant regulatory action'' under Executive Order 12866;

(2) is not a ``significant rule'' under DOT Regulatory Policies and

Procedures (44 FR 11034, February 26, 1979); 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. A final evaluation has been prepared for this action

and it is contained in the Rules Docket. A copy of it may be obtained

from 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.

Adoption of the Amendment

Accordingly, pursuant to the authority delegated to me by the

Administrator, the Federal Aviation Administration amends 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. 106(g), 40113, 44701.

Sec. 39.13 [Amended]

2. Section 39.13 is amended by adding the following new

airworthiness directive:

96-12-18 McDonnell Douglas: Amendment 39-9661. Docket 95-NM-120-AD.

Applicability: Model DC-10 series airplanes and Model MD-11F

series airplanes; equipped with a lavatory drainage system, forward

or aft; 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 (f) 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 previously

accomplished.

To prevent engine damage, airframe damage, and/or a hazard to

persons or property on the ground as a result of ``blue ice'' that

has formed from leakage of the lavatory drain system and dislodged

from the airplane, accomplish the following:

Note 2: The toilet dump valve leak checks required by this AD

may be performed by filling the toilet tank with water/rinsing fluid

to a level such that the bowl is approximately half full (at least 2

inches above the flapper in the bowl) and checking for leakage after

a period of 5 minutes.

(a) Except as provided in paragraph (b) of this AD, accomplish

the applicable procedures specified in paragraphs (a)(1), (a)(2),

(a)(3), (a)(4), and (a)(5) of this AD. If the individual waste drain

system panel incorporates more than one type of valve, the

inspection interval that applies to that panel is determined by the

component with the longest inspection interval allowed. Each of the

components must be inspected or tested at that time at each service

panel location.

(1) Within 1,000 flight hours after the effective date of this

AD, and thereafter at intervals not to exceed 1,000 flight hours,

accomplish the applicable procedures specified in paragraphs

(a)(1)(i) and (a)(1)(ii) of this AD for each lavatory drain system

with a service panel drain valve installed that is listed in Table

1, below:

Table 1.--Valves Requiring Leak Checks at 1,000-Flight-Hour Intervals

------------------------------------------------------------------------

Manufacturer- Part No. Serial No.

------------------------------------------------------------------------

Kaiser Electroprecision......... 0218-0032 series.. All serial

numbers.

Shaw Aero Devices............... 1010100C-N (or All serial

higher dash numbers.

number).

Shaw Aero Devices............... 1010100B-A-1...... 0115 through 0121,

0146 through

0164, 0180 and

higher.

Shaw Aero Devices -............. 10101000BA2-...... 130 and higher.

Shaw Aero Devices -............. 10101000BB2-...... 0011 and higher.

Shaw Aero Devices -............. 331 series -...... All serial

numbers.

Shaw Aero Devices -............. 332 series -...... All serial

numbers.

Pneudraulics -.................. 9527 series-...... All serial

numbers.

------------------------------------------------------------------------

(i) Conduct a leak check of the dump valve and drain valve. The

service panel drain valve leak check must be performed with a

minimum of 3 PSID applied across the valve. Both the inner door/

closure device and the outer cap/door must be leak checked.

(ii) For service panel valves that have an inner seal: In lieu

of pressure testing, the outer cap seal and seal surface may be

visually inspected for damage or wear. Any damaged parts must be

replaced or repaired prior to further flight, or the affected

lavatory(s) must be drained and placarded inoperative until repairs

can be accomplished.

(2) Within 600 flight hours after the effective date of this AD,

and thereafter at intervals not to exceed 600 flight hours,

accomplish the applicable procedures specified in paragraphs

(a)(2)(i) and (a)(2)(ii) of this AD for each lavatory drain system

with a service panel drain valve installed that is listed in Table

2, below:

Table 2.--Valves Requiring Leak Checks at 600-Flight Hour Intervals

------------------------------------------------------------------------

Manufacturer- Part No.- Serial No.

------------------------------------------------------------------------

Kaiser Electroprecision -....... 0218-0026 series-. All serial

numbers.

[[Page 29013]]

Shaw Aero Devices -............. 1010100C series,

except as called

out in Table 1,

above,.

Shaw Aero Devices -............. 1010100B series,

except as called

out in Table 1,

above.

------------------------------------------------------------------------

(i) Conduct a leak check of the dump valve and the service panel

drain valve. The service panel drain valve leak check must be

performed with a minimum 3 PSID applied across the valve. Both the

inner door/closure device and the outer cap/door must be leak

checked.

(ii) For service panel valves that have an inner seal: In lieu

of pressure testing, the outer cap seal and seal surface may be

visually inspected for damage or wear. Any damaged parts must be

replaced or repaired prior to further flight, or the affected

lavatory(s) must be drained and placarded inoperative until repairs

can be accomplished.

(3) For each lavatory drain system not addressed in paragraph

(a)(1) or (a)(2) of this AD: Within 200 flight hours after the

effective date of this AD, and thereafter at intervals not to exceed

200 flight hours, accomplish the following procedures:

(i) Conduct a leak check of the dump valve and the service panel

drain valve. The service panel drain valve leak check must be

performed with a minimum 3 PSID applied across the valve. If the

service panel drain valve has an inner door with a second positive

seal, both the inner door and the outer cap/door must be leak

checked.

(ii) For service panel valves that have an inner seal: In lieu

of pressure testing, the outer cap seal and seal surface may be

visually inspected for damage or wear. Any damaged parts must be

replaced or repaired prior to further flight, or the affected

lavatory(s) must be drained and placarded inoperative until repairs

can be accomplished.

Note 3: Some service panel valves have an inner seal that is

closed when the outer cap is closed. For this type of valve, the

fluid leakage from the outer cap can be checked only if the inner

seal is removed; when the inner seal is in place, it prevents any

fluid from reaching the outer cap seal. For this type of valve, the

actions specified in paragraph (a)(3)(ii) are provided to allow

inspection of the seal and seal surface of the outer cap seal as an

alternative to leak checking the outer seal itself.

(4) For flush/fill lines: Within 5,000 flight hours after the

effective date of this AD, and thereafter at intervals not to exceed

5,000 flight hours, accomplish either of the procedures specified in

paragraphs (a)(4)(i) or (a)(4)(ii) of this AD, as appropriate for

the airplane's flush/fill line installation:

(i) For airplanes equipped with a flush/fill line cap,

accomplish either paragraph (a)(4)(i)(A) or (a)(4)(i)(B) of this AD:

(A) Conduct a leak check of the flush/fill line cap. This leak

check must be made with a minimum of 3 PSID applied across the cap.

Or

(B) Replace the seals on the toilet tank anti-siphon (check)

valve and the flush/fill line cap. Additionally, perform a leak

check of the toilet tank anti-siphon (check) valve with a minimum of

3 PSID across the valve.

Note 4: The Inspection/Check procedure specified in DC-10

Maintenance Manual, chapter 38-30-00, pages 601 and 602, dated June

1, 1993, may be referred to as guidance for the procedures required

by this paragraph.

(ii) For airplanes equipped with a check valve vacuum breaker,

Monogram part number series 4803-86: Replace the O-rings /seals in

the valve and test the check valve and vacuum breaker sections of

the valve for proper operation, in accordance with the

manufacturer's component maintenance/overhaul manual.

(5) If a leak is discovered during any leak check required by

paragraph (a) of this AD, prior to further flight, accomplish either

of the procedures specified in paragraph (a)(5)(i) or (a)(5)(ii) of

this AD:

(i) Repair the leak and retest. Or

(ii) Drain the affected lavatory system and placard the lavatory

inoperative until repairs can be accomplished.

(b) As an alternative to the requirements of paragraph (a) of

this AD: Within 180 days after the effective date of this AD, revise

the FAA-approved maintenance program to include the requirements

specified in paragraphs (b)(1), (b)(2), (b)(3), (b)(4), (b)(5), and

(b)(6) of this AD.

(1) For each lavatory drain system: Within 5,000 flight hours

after revision of the maintenance program in accordance with

paragraph (b) of this AD, and thereafter at intervals not to exceed

18 months, replace the valve seals. Any revision to this replacement

schedule must be approved by the Manager, Los Angeles Aircraft

Certification Office (ACO), FAA, Transport Airplane Directorate.

(2) Conduct periodic leak checks of the lavatory drain systems

in accordance with the applicable schedule specified in paragraphs

(b)(2)(i), (b)(2)(ii), and (b)(2)(iii) of this AD. If the individual

waste drain system panel incorporates more than one type of valve,

the inspection interval that applies to that panel is determined by

the component with the longest inspection interval allowed. Each of

the components must be inspected/tested at that time at each service

panel location. Any revision to the leak check schedule must be

approved by the Manager, Los Angeles ACO, FAA, Transport Airplane

Directorate.

(i) Within 1,000 flight hours after revising the maintenance

program in accordance with paragraph (b) of this AD, and thereafter

at intervals not to exceed 1,000 flight hours, accomplish the

applicable procedures specified in paragraphs (b)(2)(i)(A) and

(b)(2)(i)(B) of this AD for each lavatory drain system with a

service panel drain valve installed that is listed in Table 3,

below:

Table 3.--Valves Requiring Leak Checks at 1,000-Flight Hour Intervals

------------------------------------------------------------------------

Manufacturer Part No. Serial No.

------------------------------------------------------------------------

Kaiser Electroprecision......... 0218-0032 series.. All serial

numbers.

Kaiser Electroprecision......... 0218-0026 series.. All serial

numbers.

Shaw Aero Devices............... 1010100C series... All serial

numbers.

Shaw Aero Devices............... 1010100B series... All series

numbers.

Shaw Aero Devices............... 10101000BA2....... 130 and higher.

Shaw Aero Devices............... 10101000BB2....... 0011 and higher.

Shaw Aero Devices............... 331 series........ All serial

numbers.

Shaw Aero Devices............... 332 series........ All serial

numbers.

Pneudraulics.................... 9527 series....... All serial

numbers.

------------------------------------------------------------------------

(A) Conduct leak checks of the dump valve and service panel

drain valve. The service panel drain leak must be performed with a

minimum of 3 PSID applied across the valve. Only the inner door/

closure device of the service panel drain valve must be leak

checked. And

(B) Visually inspect the service panel drain valve outer cap/

door seal and seal mating surface for wear or damage that may cause

leakage. Any worn or damaged seal must be replaced, and any damaged

seal mating surface must be repaired or replaced, prior to further

flight, in accordance with the valve manufacturer's maintenance

manual.

(ii) Within 200 flight hours after revising the maintenance

program in accordance with paragraph (b) of this AD, and thereafter

at intervals not to exceed 200 flight hours, accomplish the

applicable procedures in

[[Page 29014]]

paragraph (b)(2)(ii)(A) and (b)(2)(ii)(B) of this AD for each

lavatory drain system with a lavatory drain system valve that

incorporates one of the valves listed in Table 4, below:

Table 4.--Valves Requiring Leak Checks at 200-Flight Hour Intervals

------------------------------------------------------------------------

Manufacturer Part No. Serial No.

------------------------------------------------------------------------

Kaiser Electroprecision -....... 4259-20 or 4259-31 All serial

``donut'' numbers.

assemblies -(or

substitute

assemblies from

another

manufacturer).

Kaiser Roylyn................... 2651-231..........

Kaiser Roylyn................... 2651-259..........

------------------------------------------------------------------------

(A) Conduct leak checks of the dump valve and the service panel

drain valve. The service panel drain valve leak check must be

performed with a minimum 3 PSID applied across the valve. Both the

donut and the outer cap/door must be leak checked.

(B) For service panel valves that have an inner seal: In lieu of

pressure testing, visually inspect the outer cap seal and seal

surface for damage or wear. Any damaged parts must be replaced or

repaired prior to further flight, or the affected lavatory(s) must

be drained and placarded inoperative until repairs can be

accomplished.

(iii) For each lavatory drain system that incorporates any other

type of approved valves: Within 400 flight hours after revising the

maintenance program in accordance with paragraph (b) of this AD, and

thereafter at intervals not to exceed 400 flight hours accomplish

both of the following procedures:

(A) Conduct leak checks of the dump valve and the service panel

drain valve. The service panel drain valve leak check must be

performed with a minimum 3 PSID applied across the valve. If the

service panel drain valve has an inner door/closure device with a

second positive seal, only the inner door must be leak checked. And

(B) If the valve has an inner door/closure device with a second

positive seal: Visually inspect the service panel drain valve outer

door/cap seal and seal mating surface for wear or damage that may

cause leakage. Any worn or damaged seal must be replaced and any

damaged seal mating surface must be repaired or replaced, prior to

further flight, in accordance with the valve manufacturer's

maintenance manual.

(3) For flush/fill lines: Within 5,000 flight hours after the

effective date of this AD, and thereafter at intervals not to exceed

5,000 flight hours, accomplish the procedure specified in either

paragraph (b)(3)(i) or (b)(3)(ii) of this AD, as appropriate for the

airplane's flush/fill line installation:

(i) For airplanes equipped with a flush/fill line cap,

accomplish either paragraph (b)(3)(i)(A) or (b)(3)(i)(B) of this AD:

(A) Conduct a leak check of the flush/fill line cap. This leak

check must be made with a minimum of 3 PSID applied across the cap.

Or

(B) Replace the seals on the toilet tank anti-siphon (check)

valve and the flush/fill line cap. Additionally, perform a leak

check of the toilet tank anti-siphon (check) valve with a minimum of

3 PSID across the valve.

Note 5: The Inspection/Check procedure specified in DC-10

Maintenance Manual, chapter 38-30-00, pages 601 and 602, dated June

1, 1993, may be referred to as guidance for the procedures required

by this paragraph.

(ii) For airplanes equipped with a check valve vacuum breaker,

Monogram part number series 4803-86: Replace the O-rings/seals in

the valve and test the check valve and vacuum breaker sections of

the valve for proper operation, in accordance with the

manufacturer's component maintenance/overhaul manual.

(4) Provide procedures for accomplishing visual inspections to

detect leakage, to be conducted by maintenance personnel at

intervals not to exceed 4 calendar days or 45 flight hours,

whichever occurs later.

(5) Provide procedures for reporting leakage. These procedures

shall provide that any ``horizontal blue streak'' findings must be

reported to maintenance and that, prior to further flight, the

leaking system shall either be repaired, or be drained and placarded

inoperative.

(6) Provide training programs for maintenance and servicing

personnel that include information on ``Blue Ice Awareness'' and the

hazards of ``blue ice.''

(c) For operators who elect to comply with paragraph (b) of this

AD: Any revision to (i.e., extension of) the leak check intervals

required by paragraph (b) of this AD must be approved by the

Manager, Los Angeles ACO, FAA, Transport Airplane Directorate.

Requests for such revisions must be submitted to the Manager of the

Los Angeles ACO through the FAA Principal Maintenance Inspector

(PMI), and must include the following information:

(1) The operator's name;

(2) A statement verifying that all known cases/indications of

leakage or failed leak tests are included in the submitted material;

(3) The type of valve (make, model, manufacturer, vendor part

number, and serial number);

(4) The period of time covered by the data;

(5) The current FAA leak check interval;

(6) Whether or not seals have been replaced between the seal

replacement intervals required by this AD;

(7) Whether or not leakage has been detected between leak check

intervals required by this AD, and the reason for leakage (i.e.,

worn seals, foreign materials on sealing surface, scratched or

damaged sealing surface or valve, etc.);

(8) Whether or not any leak check was conducted without first

inspecting or cleaning the sealing surfaces, changing the seals, or

repairing the valve. [If such activities have been accomplished

prior to conducting the periodic leak check, that leak check shall

be recorded as a ``failure'' for purposes of the data required for

this request submission. The exception to this is the normally

scheduled seal change in accordance with paragraph (b)(1) of this

AD. Performing this scheduled seal change prior to a leak check will

not cause that leak check to be recorded as a failure.]

Note 6: Requests for approval of revised leak check intervals

may be submitted in any format, provided that the data give the same

level of assurance specified in paragraph (c) of this AD.

Note 7: For the purposes of expediting resolution of requests

for revisions to the leak check intervals, the FAA suggests that the

requester summarize the raw data; group the data gathered from

different airplanes (of the same model) and drain systems with the

same kind of valve; and provide a recommendation from pertinent

industry group(s) and/or the manufacturer specifying an appropriate

revised leak check interval.

(d) For all airplanes: Within 5,000 flight hours after the

effective date of this AD, accomplish the requirements of either

paragraph (d)(1) or (d)(2) of this AD:

(1) Install a lever/lock cap on the flush/fill lines for all

lavatory service panels. The cap must be either an FAA-approved

lever/lock cap; or a lever/lock cap installed in accordance with

McDonnell Douglas Service Bulletin 38-65 (for Model DC-10 series

airplanes) or Service Bulletin 38-39 [for Model MD-11F series

airplanes (freighter)], as applicable. Or

(2) Install a Monogram 4803-86 series check valve on the flush/

fill lines for all lavatory service panels.

(e) For any affected airplane acquired after the effective date

of this AD: Before any operator places into service any airplane

subject to the requirements of this AD, a schedule for the

accomplishment of the leak checks required by this AD shall be

established in accordance with either paragraph (e)(1) or (e)(2) of

this AD, as applicable. After each leak check has been performed

once, each subsequent leak check must be performed in accordance

with the new operator's schedule, in accordance with either

paragraph (a) or (b) of this AD as applicable.

(1) For airplanes previously maintained in accordance with this

AD, the first leak check to be performed by the new operator must be

accomplished in accordance with the previous operator's schedule or

with the new operator's schedule, whichever would result in the

earlier accomplishment date for that leak check.

(2) For airplanes that have not been previously maintained in

accordance with this AD, the first leak check to be performed by the

new operator must be accomplished prior to further flight, or in

accordance with a schedule approved by the FAA PMI, but within a

period not to exceed 200 flight hours.

(f) 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, FAA, Transport

Airplane Directorate. Operators shall submit their requests through

an appropriate FAA PMI, who may add comments and then send it to the

Manager, Los Angeles ACO.

Note 8: Information concerning the existence of approved

alternative methods of

[[Page 29015]]

compliance with this AD, if any, may be obtained from the Los

Angeles ACO.

Note 9: For any valve that is not eligible for the extended leak

check intervals of this AD: To be eligible for the leak check

interval specified in paragraphs (a)(1) and (b)(2)(i), the service

history data of the valve must be submitted to the Manager, Los

Angeles ACO, FAA, Transport Airplane Directorate, with a request for

an alternative method of compliance with this AD. The request should

include an analysis of known failure modes for the valve, if it is

an existing design, and known failure modes of similar valves.

Additionally, the request should include an explanation of how

design features will preclude these failure modes, results of

qualification tests, and approximately 25,000 flight hours or 25,000

flight cycles of service history data, including a winter season,

collected in accordance with the requirements of paragraph (c) of

this AD or a similar program.

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

sections 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.

(h) This amendment becomes effective on July 12, 1996.

Issued in Renton, Washington, on June 3, 1996.

Darrell M. Pederson,

Acting Manager, Transport Airplane Directorate, Aircraft Certification

Service.

[FR Doc. 96-14386 Filed 6-6-96; 8:45 am]

BILLING CODE 4910-13-U