Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE
- ANGLE 5910130
BULKHEAD TEE FWD
• VISUA
INSPECTION INBD AREA CRACX
- EB 70° OR 90° ENDOSCOPE
DETAIL A - ENDOSCOPE VISUAL IMSPECTION ANGLE CRACK 5910130 • VISUAL INSPECTIOM
BULKHEAD AREA TEE - WEB
IMSPECTION MIRROR
FLASHLIGHT
DETAIL B - MIRROR FLASHLIGHT VISUAL INSPECTION SEQUENCE 1 VISUAL AND ENDSCOPE INSPECTION OF BULKHEAD TEE
AFT PRESSURE BULKHEAD TEE - INSPECTION FIGURE 3 (SHEET 5 OF 14) March 28/90 Bulletin XX-XXX Page 17
AG 43-204 8/14/97 Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE
LOOKING FORWARD TEE SPLICE PLATE• CRACK CRACK WEB WEB OUT8D FWD ANGLE
SECTION A-A SECTION B-B DC-9 VENTRAL AFT PRESSURE BULKHEAD. TEE CAP CRACKS
AFT PRESSURE BULKHEAD TEE - INSPECTION FIGURE 3 (SHEET 6 OF 14) Bulletin XX-XXX March 28/90 Page 18
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE C. The basis for the following tooling data is per operator.
NOTE: CAGE indicates Commercial and Government Entity code for Manufacturers/Distributors.
(1) Option I - Test equipment to be procured from operator's stock or sources indicated.
Test Equipment Type Qty CAGE Supplier Endoscope 70 Degree Model 54341 Expanded Optics.
(Fore oblique) Angle 10320D Incorporated 19-Inch (482.6 MM) Long 301-C West Dyer Road
0.217-Inch Santa Ana, California Diameter 92702-3427 or Equivalent NOTE: One 70 or 90 degree endoscope of any diameter with 18-inch (457.2 MM) minimum length and matching light source may be used.
Fiber Optic Model 1 54341 Expanded Optics, Light Bundle 1F8D3 Incorporated 301-C West Dyer Road Santa Ana, California 92702-3427 and Endoscope Light Source No. 00482 54341 Expanded Optics, 110 or 220 Volt OI Incorporated No. E0590 301-C West Dyer Road Santa Ana, California 92702-3427 and Sylvania Projector Lamp 1 54341 Expanded Optics, 150 Watt, 120 Volt Incorporated 301-C West Dyer Road Santa Ana, California 92702-3427 NOTE: Similar or equivalent endoscopes and illuminators may be obtained from the following sources.
March 28/90 Bulletin XX-XXX Page 19
Appendix E
SAMPLE VISUAL INSPECTION PROCEDURE Test Equipment Type Qtr CAGE Supplier Alva Ingenieros Velazquez 121 Madrid 6, Spain or Automation Instruments Service 47 Birch Street Bankston 2200, Australia or 3 G Electronics Sede Commercial 20135 Milano Via Perugino 9, Italy or 50958 Richard Wolf Medical Instrument Corporation 7046 Lyndon Avenue Rosemont, minois 60018-3410 or Inspection Instruments NDT Limited 32 Duncan Terrace London N188R, England or Karl Storz KG D 7200 Tuttlingen West Germany Flexible Borescope Model 1 32212 Olympus Corporation
29.8-Inch (757 MM) Long 1F8D3 Scientific Products Group
0.315-Inch 4 Nevada Drive Diameter Lake Success, New York 11040-1114 Cold Light Supply No. 1LK-4 32212 Olympus Corporation 100 to 230 Volt Scientific Products Group 4 Nevada Drive Lake Success, New York 11040-1114 Or Equivalent Bulletin XX-XXX March 28/90 Page 20
8/14/97 AC 43-204 Appendix F APPENDIX F. BOEING 747 SERVICE BULLETIN
SAMPLE INSPECTION PROCEDURE Excerpts of Boeing Service Bulletin 747-53-2307, Dec 21/89.
Retyped with permission of Boeing Commercial Airplane Group.
Page
A043-204 8/14/97 Appendix F
SAMPLE VISUAL INSPECTION PROCEDURE
SERVICE BULLETIN
SUMMARY BOEING COMVERCIAL AIRPLANES POST OFFICE BOX 3707 SEATTLE, WASHINGTON 88124-2207
BACKGROUND This inspection will detect corrosion and fatigue cracks in upper body skin longitudinal lap joints caused by-disbonding of the cold bond at the joint. Continued operation of an airplane that has corrosion or fatigue cracking in lap joints could lead to separation of the skin at the lap joint causing rapid decompression of the airplane.
Several operators have reported corrosion, and associated bulging of skin at upper body lap joints para on airplanes with 26,733 to 70.000 flight-hours. One operator reported cracking and corrosion of the lap joint at Stringer 12 from Station 1515 to 1735 and Stringer 4L at Station 1710 on an airplane with 35,134 flight-hours. One other operator reported corrosion and cracking at the lap joint at Stringer 4R, Station 1500 on an airplane with 49,024 flight-hours. Another operator reported a one-inch crack at Stringer O, Station 738 suspected to have been caused by corrosion from disbonding at the cold-bonded lap joint. There have been numerous additional instances of corrosion reported at the Stringer 23 lap joint.
This bulletin supersedes that portion of Service Bulletin 747-53-2157 which addresses the upper body skin longitudinal lap joints.
Airplanes previously inspected per Service Bulletin 747-53-2157 require additional inspection of lap joint areas as described herein.
Any lap joint areas repaired per Service bulletin 747-53-2157 do not require further repair or Lospection.
This bulletin does not supersede Service Bulletin 747-53-2253 or Service Bulletin 747-53A2303 which address the upper body skin longitudinal lap joints at Stringer 6 in Section 41.
This service bulletin is the subject of Federal Aviation Administration (FAA) Notice of Proposed Rulemaking 88-NM-194-AD dated February 9, 1989.
ACTION Within 1,000 flight-cycles after receipt of this bulletin, conduct a detailed external visual inspection of the upper body longitudinal lap joints at Stringers 23 and above from Station 140 to 2360 (except Stringer 7 from Station 340 to 520). Visually inspect all lap joints for evidence of corrosion or cracking. Evidence of corrosion includes missing or distressed fasteners, white powder protruding from the lap joint, or bulging or pillowing of the lap joint between fasteners. Repair any corrosion beyond allowable limits or cracking, as specified herein, prior to further flight.
Repeat these visual inspections at intervals not to exceed 1,000 flight-cycles for the lap joints in Sections 41. 42. and 46. Repeat the visual inspections at 2,000 flight-cycle intervals for the lap joints in Section 44.
Dec 21/89 747-53-2307 Page 2
8/14/97 A043-204 Appendix F BOEING SERVICE BULLETIN 747-53-2307
SECTION STA 2360
LAP JOINT S-12 (TYPICAL) STA 1480 S-6 S-19 S -0 S-14 STA 4 4 1000 STA RIGHT SIDE SHOWN 42 520
LEFT SIDE OPPOSITS STA 4 1 140
SECTIONS
INSPECT LAP JOINTS FOR CORRORSION, CRACKS OR PILLOWING
OF SKIN, AND MISSING OR DISTRESSED FASTENERS Dec 21/89 747-53-2307 Page 3
Appendix F BOEING SERVICE BULLETIN 747-53-2307 In lieu of continued reinspections, terminating action may be accomplished. Terminating action is accomplished when an uncorroded lap joint area is separated between adjacent circumferential splices, adhesive removed, faying surface sealant is applied, and joint is refastened per 747 Structural Repair Manual Subject 43-30-03. Terminating action in a corroded or cracked lap joint area may be accomplished when the area is repaired per 747 Structural Repair Manual Subject 53-
EFFECTIVITY 747 Airplanes line position 001 through 200
MANPOWER Visual Inspection:
Total Manhours - 152 per Airplane Elapsed Time - 38 Hours
MATERIAL INFORMATION None.
Dec 21/89 747-53-2307 Page 4
8/14/97 AC 43-204 Appendix F BOEING SERVICE BULLETIN 747-53-2307 BOEING COMMERCIAL AIRPLANES BOEING SEATTLE. WASHINGTON 88124-2207
SERVICE BULLETIN Л4₴ ATA SYSTEM: 5310 NUMBER: 747-53-2307 DATE: December 21, 1989 5331 SUBJECT: FUSELAGE - SKIN - UPPER BODY SKIN LONGITUDINAL LAP JOINT (STRINGERS 23 AND ABOVE) INSPECTION AND REPAIR
PLANNING INFORMATION A Effectivity
1. Airplanes Affected See Service Bulletin Index Part 3 for cross reference of Variable Number to Airplane Serial Number.
This change is applicable only to airplanes listed below.
CODE VARIABLE NUMBER ACN RA743 AFA RA251-RA259 AIN RA722-RA724 ARL RA203 RA501-RA502 BAB RA217 RA301-RA308 RA310 RA312 RA702 CAL RA51-RA552 CLX RA023 RA025 Dec 21/89 747-53-2307 Page 5
Appendix F BOEING SERVICE BULLETIN 747-53-2307
CODE VARIABLE NUMBER (CONTINUED) ELA RA781-RA782 RB043 EVR RA003-RA004 RA022 RA113 FTL RA026 RA029 RA033 RA632 RA634-RA635 RA741 RA916 RB041 IBE RA585 IRN RA101-RA103 RA112 RA161-RA163 JAL RA521-RA527 RA532-RA534 RA537-RA540 KAL RA216 RA245 RA201 KLM RA671-RA675 RA677 MNR RA701 NAS RA908 NWA RA351-RA360 RA369-RA373 RA601-RA602 ORI RA020 PAA RA002 RA005-RA007 RA009 RA012-RA019 RA027-RA028 RA030-RA032 RA034 RA631 RA633 RA910 RA914 PEX RA559 RA561 RB003-RB005 QAN RA909 RB001-RB002 SAA RB071-RB075 SAB RB101-RB102 TWO RA024 RA201 RA761 RB042 TWA RA104-RA110 RA311 RA581-RA582 RA651-RA652 RD001-RD002 RA114-RA115 RA164 RA309 VAL RA406-RA414 RA903-RA907 UPS RA901-RA902 RA911-RA913 RA915 VAA RA560 WDA RA742 RA762 RB044 Dec 21/89 747-53-2307 Page 6
Appendix F BOEING SERVICE BULLETIN 747-53-2307
CODE VARIABLE NUMBER (CONTINUED)
LISTING BY VARIABLE NUMBER RA002-RA034 RA101-RA115 RA161-RA164 RA201-RA203 RA216-RA217 RA245-RA246 RA251-RA259 RA301-RA312 RA351-RA360 RA369-RA373 RA401-RA414 RA501-RA502 RA521-RA527 RA532-RA540 RA551-RA552 RA559-RA561 RA581-RA582 RA585 RA601-RA602 RA631-RA635 RA651-RA652 RA671-RA677 RA701-RA702 RA721-RA724 RA741-RA743 RA761-RA762 RA781-RA782 RA901-RA916 RB001-RB005 RB041-RB044 RB071-RB075 RB101-RB102 RD001-RD002 RR201
2. Spares Affected None B. Reason This inspection will detect corrosion or cracking in upper body skin longitudinal lap joints caused by disbonding of the cold bond at the lap joint. Continued operation of an airplane that has corrosion or cracking in lap joints could lead to separation of the skin at the lap joint causing rapid decompression of the airplane.
Several operators have reported corrosion, and associated bulging of skin at upper body lap joints on airplanes with 26,733 to 70,000 flight-hours.
One operator reported corrosion of one to three lap joint rivets and bulging of the skin at Stringer 12 near Station 1694 on an airplane with 34,827 flight-hours. This operator also reported cracked and corroded fuselage skin with separation at the lap joint at Stringer 12 L and R at six locations each side from Station 1515 to 1735 and Stringer 4L at Station 1710 on the same airplane with 35,134 flight-hours.
Another operator reported a one-inch skin crack emanating from the lap joint at Stringer 0 near Station 738 on an airplane with 49,800 flight-hours which was suspected to have been caused by corrosion from disbonding at the cold-bonded lap joint (Ref. SILA 747-71). This operator also reported two airplanes with skin corrosion of lap joint at Stringer 4L. On one airplane, with 35,985 flight-hours, this corrosion was found at four locations between Stations 1482 and 1676. On the other airplane, corrosion was found near Stations 1510 and 1615 on an airplane with 36,461 flight-hours.
Also an operator has reported skin corrosion in the lap joint at Stringer 23R near Station 1400 on an airplane with 26,733 flight-hours and skin corrosion with bulging skin involving the lap joint at Stringer 23L between Station 1720 and 1820 There have been numerous additional instances of corrosion reported at the Stringer 23 lap joint.
Dec 21/89 747-53-2307 Page 7
Appendix F BOEING SERVICE BULLETIN 747-53-2307 B. (Continued) This bulletin supersedes that portion of Service Bulletin 747-53-2157 which addresses the upper body skin longitudinal lap joints.
Airplanes previously inspected per Service Bulletin 747-53-2157 require additional inspection of lap joint areas as described herein.
Any lap joint areas repaired per Service Bulletin 747-53-2157 do not require further repair or inspection.
This bulletin does not supersede Service Bulletin 747-53-2253 or Service Bulletin 747-53A2303 which address the upper body skin longitudinal lap joints at Stringer 6 in Section 41.
This service bulletin is the subject of Federal Aviation Administration (FAA) Notice of Proposed Rulemaking 88-NM-1954-AD dated February 9, 1989.
Description Within 1,000 flight-cycles after receipt of this bulletin, conduct a detailed external visual inspection of the upper body longitudinal lap joints at Stringers 23 and above from Station 340 to 520). Visually inspect all lap joints for evidence of corrosion or cracking. Evidence of corrosion includes missing or distressed fasteners, white powder protruding from the lap joint, or bulging or pillowing of the lap joint between fasteners. Repair any corrosion beyond allowable limits or cracking, as specified herein, prior to further flight. Repeat these visual inspections at intervals not to exceed 1,000 flight-cycles for the lap joints in Sections 41 (Station 140-520), 42 (Station 520-1000), and 46 (Station 1480-2360). Repeat the visual inspections at 2,000 flight-cycle intervals for the lap joints in Section 44 (Station 1000-1480).
In lieu of continued reinspections, terminating action may be accomplished.
Terminating action is accomplished when an uncorroded lap joint area is separated between adjacent circumferential splices, adhesive removed, faying surface sealant is applied, and joint is refastened per 747 Structural Repair Manual Subject 53-30-
03. Terminating action in a corroded or cracked lap joint area may be accomplished when the area is repaired per 747 Structural Repair Manual Subject 53-30-03.
It is recommended that this service bulletin be accomplished concurrently with service bulletins 747-53A2265 and 747-53A2279 due to common access.
This service bulletin is the subject of Federal Aviation Administration (FAA) Notice of Proposed Rule Making, FAA Docket Number 88-NM-194-AD. issued February 9, D. Approval This service bulletin has been reviewed by the Federal Aviation Administration (FAA) and the repairs and modifications herein comply with the applicable Federal Aviation Regulations (FAR's) and are FAA approved.
Dec 21/89 747-53-2307 Page 8