AD 2022-03-21 Airworthiness Directives; The Boeing Company Airplanes

Models named: 787-8, 787-9, 787-10. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to The Boeing Company Model 787-8, 787-9, and 787-10 airplanes, certificated in any category, having line numbers (L/Ns) 6 through 871 inclusive, excluding L/N 688; and L/Ns 873, 875, 877, 878, 879, 881, and 883.

Comply with this AD within the compliance times specified, unless already done.

Within 180 days after the effective date of this AD, revise the existing maintenance or inspection program, as applicable, to incorporate the information specified in Sections C through F of Boeing 787 Special Compliance Items/Airworthiness Limitations, D011Z009-03-04, dated August 2018. The initial compliance time for doing the airworthiness limitation instruction (ALI) tasks specified in Sections C through F of Boeing 787 Special Compliance Items/Airworthiness Limitations, D011Z009-03-04, dated August 2018, as applicable for each airplane, is at the times specified in paragraphs (g)(1) through (14) of this AD. (1) For AWL No. 28-AWL-89, “Fuel Quantity Data Concentrator (FQDC) Bracket Inspections,” at the applicable time in paragraph (g)(1)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 28-AWL-89: Within 5 years or 10,000 flight cycles, whichever occur first after the most recent inspection was performed as specified in AWL No. 28-AWL-89. (ii) For airplanes on which no initial inspection was performed: Within 5 years or 10,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (2) For AWL No. 57-AWL-01, “Edge and Fillet Seals at Stringer and Spar Locations (Zone 2),” at the applicable time in paragraph (g)(2)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-01: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-01. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (3) For AWL No. 57-AWL-02, “Fasteners on Bare Carbon Fiber Reinforced Plastic (CFRP) Stripes,” at the applicable time in paragraph (g)(3)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-02: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-02. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (4) For AWL No. 57-AWL-03, “Head-in-tank Thin-Sleeved Interference-Fit Fasteners with Heads in the Fuel Tank” at the applicable time in paragraph (g)(4)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-03: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-03. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (5) For AWL No. 57-AWL-05, “Titanium Collars—BACC30CT Fasteners (Clearance Fit).” at the applicable time in paragraph (g)(5)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-05: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-05. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (6) For AWL No. 57-AWL-06, “Titanium Collars—BACC30CY Collars (Interference-Fit with Swaged Collars)” at the applicable time in paragraph (g)(6)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-06: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-06. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (7) For AWL No. 57-AWL-07, “Tension-rated Bolt Locations at Side of Body (SOB) and Nacelle Fittings” at the applicable time in paragraph (g)(7)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-07: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-07. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (8) For AWL No. 57-AWL-08, “Dielectric Top on Wing Surface,” at the applicable time in paragraph (g)(8)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-08: Within 6 years or 12,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-08. (ii) For airplanes on which no initial inspection was performed: Within 6 years or 12,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (9) For AWL No. 57-AWL-09, “Inspection Requirements for Class 1A Seal Installations created as a result of Boeing Material Review Board,” at the applicable time in paragraph (g)(9)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-09: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-09. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (10) For AWL No. 57-AWL-10, “Inspection Requirements for In-Tank Fasteners near Side of Body (SOB) Rib and between Ribs 7 and 18,” at the applicable time in paragraph (g)(10)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-10: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-10. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (11) For AWL No. 57-AWL-13, “Inspection Requirements for In-Tank Fasteners and Edge Seal near Disbond Arrestment (DBA) Fastener Installations in Lightning Zone 2,” at the applicable time in paragraph (g)(11)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-13: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-13. (ii) For airplanes on which no initial inspection was performed: At the applicable time in paragraph (g)(11)(ii)(A) or (B) of this AD. (A) For airplanes on which Boeing Service Bulletin B787-81205-SB570030-00 is applicable: Within 12 years or 24,000 flight cycles, whichever occurs first after the incorporation of Boeing Service Bulletin B787-81205-SB570030-00. (B) For airplanes having line numbers 10, 13, and 15 through 19 inclusive: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (12) For AWL No. 57-AWL-14, “Supplemental Inspection Requirements for Pre-cured Sealant Caps, Fillet Seals, and Edge Seals associated Stringer Splice Fitting Installation located at Right Wing Upper Panel Stringer No. 3, just Outboard of the Side of Body Rib,” at the applicable time in paragraph (g)(12)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-14: Within 12 years or 24,000 flight cycles whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-14. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (13) For AWL No. 57-AWL-15, “Inspection Requirements for Pre-cured Sealant Caps, Injection Seals, Fillet Seals, and Edge Seals associated with the Wing Lower Panel Stringer Attachments to the Lower Side of Body (SOB) Chord,” at the applicable time in paragraph (g)(13)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-15: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-15. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness. (14) For AWL No. 57-AWL-16, “Supplemental Inspection Requirements for Edge Seals located at Left Wing Upper Panel Stringer No. 19, Between Ribs 8 and 9,” at the applicable time in paragraph (g)(14)(i) or (ii) of this AD. (i) For airplanes on which an inspection was performed as specified in AWL No. 57-AWL-16: Within 12 years or 24,000 flight cycles, whichever occurs first after the most recent inspection was performed as specified in AWL No. 57-AWL-16. (ii) For airplanes on which no initial inspection was performed: Within 12 years or 24,000 flight cycles, whichever occurs first after the date of issuance of the original standard airworthiness certificate or the date of issuance of the original export certificate of airworthiness.

This AD was prompted by significant changes, including new and more restrictive requirements, made to the airworthiness limitations (AWLs) related to fuel tank ignition prevention and the nitrogen generation system. The FAA is issuing this AD to address ignition sources inside the fuel tanks and increased flammability exposure of the fuel tanks caused by latent failures, alterations, repairs, or maintenance actions, which could result in a fuel tank explosion and consequent loss of an airplane.

This AD affects AD 2018-11-13, Amendment 39-19301 (83 FR 25894, June 5, 2018) (AD 2018-11-13).