Note the actions resulting from SFAR 88 fuel system safety reviews

Action & Date Posted on Federal Register

June 22

Final rule

FR Doc 05-12000

Docket no. FAA-2004-19754

AD 2005-13-02

Hydraulics and pressurization (admittedly, a unique combination, but read on)

Summary of Situation

Bombardier Model CL-600 regional jet, series -700, -701 and -900 airplanes.

AD is issued to prevent loss of hydraulic pressure, which could result in reduced controllability, and cracks around feed-through holes in aft pressure bulkhead, which could result in reduced structural integrity.

Action Date & Comments

AD effective July 27.

Based on reports of hydraulic pressure loss due to breakage or leakage of hydraulic lines in the aft equipment bay, and reports of cracks in the aft pressure bulkhead around feed through holes.

Cost for repetitive inspections $65 per inspection. Cost of terminating action not specified.

Affects 116 airplanes in U.S. registry.

Action & Date Posted on Federal Register

June 24

Final rule

FR Doc 05-12311

Docket No. FAA-2004-18787

AD 2005-13-20

Fuel system safety

Summary of Situation

Boeing B747-400, B767-200 and -300, and B777-200 and -300 airplanes.

Requires installing a jumper wire between fire extinguisher and the fuel shutoff switch, to prevent the fuel shutoff valve from being partially open when the engine fire switch is activated, which could lead to fuel feeding an uncontrolled fire in the engine or strut.

Action Date & Comments

AD effective July 29.

Accomplish within 60 months.

Cost per airplane varies between $130 to $1,700.

About 1,880 airplanes in worldwide service affected, of which 579 are in U.S. registry.

Action & Date Posted on Federal Register

June 24

Final rule

FR Doc 05-12315

Docket No. FAA-2004-19567

AD 2005-13-15

Fuel system safety

Summary of Situation

Boeing Model B737 (all except the -100 model).

Requires inspection and corrective action to prevent fuel vapors from leaking into the cargo or passenger compartment, and coming into contact with a possible ignition source, which could result in fire or explosion.

Action Date & Comments

AD effective July 29.

Another fuel system fire hazard.

Cost to rectify: $325 to $900 per airplane.

About 3,380 airplanes of affected design in worldwide use, of which 1,520 are in U.S. registry.

Action & Date Posted on Federal Register

June 24

Final rule

FR Doc 05-12312

Docket No. FAA-2005-20166

AD 2005-12-19

Fire protection

Summary of Situation

Airbus Model A319, A320 and A321 series airplanes.

AD requires replacing the cargo ventilation extraction duct with a new duct to prevent air leakage around the temperature sensor, which, in the event of a fire, could cause insufficient concentration of fire suppressant and consequent inability of fire extinguishing system to suppress a fire.

Action Date & Comments

AD effective July 29.

Based on test of the fire extinguishing system in the aft cargo compartment (ASW comment: points to need for oxygen sensor to determine if fire suppressant is in sufficient concentration to suppress fire).

FAA holds to 24-month compliance time because of the "high degree of urgency" surrounding the action.

Cost between $9,200 and $13,800 per airplane.

Affects 643 airplanes in U.S. registry.

Action & Date Posted on Federal Register

June 24

Final rule

FR Doc 05-12304

Docket No. FAA-2005-21053

AD 2005-15-24

Fuel system safety

Summary of Situation

Dornier Model 328-100 series airplanes.

AD requires modifying electrical wiring of fuel pumps and other actions to reduce the potential for ignition sources inside fuel tanks, which could result in fuel tank explosion and loss of the airplane.

Action Date & Comments

AD effective July 29.

Based on fuel system review conducted by the manufacturer under the aegis of SFAR 88.

Costs estimated at $18,600 per airplane.

Affects 6 airplanes in U.S. registry (ASW note: the significance is not in the number of aircraft affected but in the amount of work needed to address fuel system safety concerns).

Action & Date Posted on Federal Register

June 24

Final rule

FR Doc 05-12313

Docket No. FAA-2004-19867

AD 2005-13-14

Braking system safety

Summary of Situation

McDonnell Douglas (now Boeing) MD-90-30 series airplanes.

AD issued to prevent metallic contamination of anti-skid system, consequent tire failure during high speed/high energy braking, and possible departure of aircraft from the runway.

Action Date & Comments

AD effective July 29.

AD prompted by multiple incidents of blown tires on landing.

Cost ranges from a modest $8,500 per airplane to a whopping $241,000 per airplane.

Affects 115 airplanes worldwide, of which some 24 are in U.S. registry.

Action & Date Posted on Federal Register

June 27

Supplemental notice of proposed rulemaking, reopening of comment period

FR Doc 05-12637

Docket No. 2003-NM-163-AD

Electrical system safety

Summary of Situation

Bombardier CL-600 (regional jet, series 100 and 440) airplanes.

To detect and correct chafing of the electrical cables of the spoiler and brake pressure sensor on both sides of the wing root, which could result in loss of flight control system.

Action Date & Comments

Comments due July 22.

Calls for repairing or replacing any chafed harness or wiring. Action is now expanded to cover additional aircraft serial numbers.

Cost of proposed modification is $325 per airplane.

About 709 airplanes in U.S. registry.

Action & Date Posted on Federal Register

June 27

Final rule

FR Doc 05-12513

Docket No. FAA-2004-19809

AD 2005-13-18

Battery safety

Summary of Situation

McDonnell Douglas DC-9 and MD-80 series airplanes (but not the B717, which is a derivative).

Requires inspection and corrective action to prevent shearing off of battery screws, internal shorting and arcing, which could compromise emergency power in the event of primary electrical power loss.

Action Date & Comments

AD effective Aug. 1.

One commenter requests a better way of identifying the modification than with a sticker. Stickers have come unglued in the presence of water, acid and heat, all of which exist around batteries. Commentator suggests changing the data plate by adding a letter to the existing part number.

FAA disagrees, saying the sticker is "merely a secondary indication of compliance."

Cost about $65 per airplane.

About 1,828 airplanes in worldwide service, of which 1,087 are in U.S. registry.

Action & Date Posted on Federal Register

June 27

Final rule

FR Doc 05-12510

Docket No. 2001-NM-89-AD

AD 2005-13-28

Center stowage bins and electrical racks

Summary of Situation

Boeing Model 777-200 and -300 series airplanes.

Requires inspection of tie rods for stowage bins and electrical racks, corrective action and placards if electrical racks carry too much installed weight, to prevent racks and center stowage bins from falling onto passengers during an emergency landing.

Action Date & Comments

AD effective Aug. 1.

Collapsing overhead bins is a frequent problem in crash landings.

Cost $260 to $3,400 per airplane, depending upon extent of work required.

About 282 airplanes in worldwide service, of which 84 are in U.S. registry.

Action & Date Posted on Federal Register

June 27

Final rule

FR Doc 05-12514

Docket No. FAA-2004-19533

AD 2005-13-27

Structural integrity

Summary of Situation

Boeing Model 737-300, -400 and -500 series airplanes.

Requires repetitive inspections and corrective action to correct fatigue cracking of the fuselage skin, the failure of which could lead to rapid decompression.

Action Date & Comments

AD effective Aug. 1.

Prompted by fuselage structure tests and fatigue analysis.

Cost $6,100 per inspection cycle.

About 579 airplanes in worldwide service, of which 175 are in U.S. registry.

Action & Date Posted on Federal Register

June 27

Final rule

FR Doc 05-12509

Docket No. FAA-2005-20660

AD 2005-13-29

Wiring system safety

Summary of Situation

Boeing Model 777-200 and -300 series airplanes.

Inspect wire bundles routed into the central control stand in flight deck for chafing, which could result in the loss of flight control, communications, navigation and engine fire control systems.

Action Date & Comments

AD effective Aug. 1.

AD talks about erosion of safety margins, which errs on the side of understatement.

Cost about $75 per airplane.

About 289 airplanes in worldwide service, of which 130 are in U.S. registry.

Action & Date Posted on Federal Register

June 27

Final rule

FR Doc 05-12512

Docket No. FAA-2005-20079

AD 2005-13-26

Safety of doors

Summary of Situation

Airbus A300 B2 and B4, and A310-200 and -300 airplanes.

Requires installing safety signs on all doors to ensure that crew members do not forcibly open the door before the fuselage is fully depressurized.

Action Date & Comments

AD effective Aug. 1.

Recall the flight attendant who was killed opening the L1 door on an A300 before the airplane was fully depressurized (see ASW, Aug. 19, 2002).

Cost about $325 per airplane.

About 182 airplanes in U.S. registry.

Action & Date Posted on Federal Register

June 27

Final rule

FR Doc05-12505

Docket No. FAA-2005-20861

AD 2005-13-33

Pitch trim

Summary of Situation

Airbus Model A300 B2 and B4 series airplanes.

Modify wiring to prevent trim loss when flight crew tries to override the autopilot pitch control, which could result in uncontrolled flight.

Action Date & Comments

AD effective Aug. 1.

Action based on several reports of pitch trim disconnect based on insufficient length of the wiring.

Cost about $2,360 to $5,000 per airplane.

Affects 20 airplanes in U.S. registry.

Action & Date Posted on Federal Register

June 28

Notice of update of Advisory Circular (AC) No. 150/5345-53B to ?53C

FR Doc 05-12723

Airport lighting certification program

Summary of Situation

Federal Aviation Administration (FAA) issues draft of the new AC to clarify the means by which third parties can certify airport lighting systems to the FAA. A third party can be a testing laboratory. According to the AC, the lighting system manufacturer is issued a Certificate of Conformance by the third party that attests to the lighting system meeting FAA standards.

Action Date & Comments

Comments due Aug. 12.

Lighting includes beacons, runway, taxiway, precision approach path indicator and other lights, cabling, controls, etc.

Testing will be of a minimum of 10 randomly selected lights installed in the fixture being tested. Testing will continue until 90 percent of all lamps have reached the end of their useful life.

Action & Date Posted on Federal Register

June 29

Notice of proposed rulemaking

FR Doc 05-12838

Docket No. FAA-2005-21683

Fuel system safety

Summary of Situation

Fokker F27 Mark 200, 400, 500 and 600 airplanes.

Requires inspection and corrective action to ensure that rotary knobs for the fuel tank isolation valves are not inadvertently moved to the shut position, which could result in fuel starvation to the engines.

Action Date & Comments

Comments due July 29.

Based on an accident in the Netherlands where both engines were starved of fuel shortly after takeoff.

Cost about $130. One airplane in U.S. registry. The case is listed here to show a means of fuel starvation.

Action & Date Posted on Federal Register

June 29

Notice of proposed rulemaking

FR Doc 05-12839

Docket No. FAA-2005-21702

Fuel system safety

Summary of Situation

Airbus model A330 and A340 airplanes.

Requires repetitive inspections and replacement of all float valves in left and right trim tanks to mitigate the effects of a lightning strike.

Action Date & Comments

Comments due July 29.

Based on comparable SFAR 88 design review.

Cost estimated at $450 per airplane.

About 25 airplanes (A330s) in U.S. registry. No A340s in U.S. service, but if they're imported they'll need the work done.

Action & Date Posted on Federal Register

June 29

Notice of proposed rulemaking

FR Doc 05-12840

Docket No. FAA-2005-21701

Fuel system safety

Summary of Situation

Boeing 747 and 767 airplanes.

Requires reworking the electrical bonding to prevent a fuel tank explosion.

Action Date & Comments

Comments due Aug. 15.

Results from a design review of the fuel pump installation based on SFAR 88.

Cost estimated at $650 for 747 and $585 for 767.

About 3,400 airplanes in worldwide service, of which some 2,036 are in U.S. registry.

Action & Date Posted on Federal Register

June 30

Final rule

FR Doc 05-12844

Docket No. FAA-2005-20355

AD 2005-13-40

Fuel system safety

Summary of Situation

Boeing 727 airplanes equipped with auxiliary fuel tank having a fuel pump installed.

Requires pump switches to be turned off immediately when the low-pressure light illuminates, to prevent a possible ignition source in the tank and consequent fire or explosion of the auxiliary fuel tank.

Action Date & Comments

Effective Aug. 4.

Results from a design review of the fuel pump installation based on SFAR 88.

Cost estimated at $65 per aircraft.

About 300 airplanes in worldwide service, of which 200 are in U.S. registry.

Action & Date Posted on Federal Register

July 5

Notice of proposed rulemaking

FR Doc 05-13136

Docket No. FAA-2005-21712

Flight control system safety

Summary of Situation

Boeing 737-100, -200, -300, -400, -500, -600, -700, -800 and -900 series airplanes.

Requires modifying the elevator input torque tube assembly to prevent a restriction in the pilot's elevator control system, to prevent a loss of elevator control.

Action Date & Comments

Comments due Aug. 19.

Based on restricted movement on a 737-700 aircraft. Design review indicates that "a single broken bolt or backed-off nut, and subsequent migration of the fastener, could jam the torque tube."

Cost estimated at $50 to $1,290 per plane.

About 2,971 airplanes in service worldwide, of which 1,573 are in U.S. registry.

Action & Date Posted on Federal Register

July 5

Notice of proposed rulemaking

FR Doc 05-13141

Docket No. FAA-2005-21714

Fuel system safety

Summary of Situation

Boeing model 737-600, -700, -800 and -900 series airplanes.

Requires modification of wire bundles above the center fuel tank, to prevent chafing and electrical arcing through the tank wall, which could result in a fuel tank explosion.

Action Date & Comments

Comments due Aug. 19.

Results from design review based on SFAR 88. Note, the NTSB commented in its report of the TWA Flight 800 fuel tank explosion involving a 747, on the wire separation standards, noting that Boeing called for only 1/4 inch separation in pressurized areas and 1/2 inch in unpressurized areas (as opposed to McDonnell Douglas, which called for 3 inches separation).

Cost estimated at $1,700 per airplane.

Affects 1,636 airplanes in worldwide service, of which 650 are in U.S. registry.

Action & Date Posted on Federal Register

July 5

Notice of proposed rulemaking

FR Doc 05-13139

Docket No. FAA-2005-21713

Fire protection

Summary of Situation

Boeing Model 767-400ER and 777-200 and -300 series airplanes.

Proposed AD requires replacement of fire extinguishing bottles, prompted by failure of safety fittings due to corrosion, which could result in leakage of agent and, if a fire occurs in the cargo bay, insufficient agent to control the fire.

Action Date & Comments

Comments due Aug. 19.

Involves spraying corrosion inhibiting compound as well as replacing the fire-extinguishing bottle.

This is another example of the need for oxygen sensors in the cargo bay to measure the efficacy of fire-extinguishing agent.

Note that this action affects ETOPS airplanes, which must be able to suppress a cargo fire long enough to get to a divert airfield (plus 15 minutes).

Cost $265 to $325 per testing cycle for the leak test. $3,320 to $4,000 for replacement.

About 322 airplanes in worldwide service, of which as many as 131 planes are in U.S. registry.

Source: U.S. Federal Register