Airbus All Operators Transmission A57N020-22

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Page 1Open in PDF

CUSTOMER SERVICES DIRECTORATE 2 ROND POINT EMILE DEWOITINE 31700 BLAGNAC FRANCE TELEPHONE + 33 (0)5 61 93 33 33

ALERT OPERATORS TRANSMISSION - AOT AOT ref: A57N020-22 Rev 00 Page 1 of 21 Date: 07-DEC-2022 C80_AOT_FM1104649_v8.0 © AIRBUS S.A.S. 2022. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT SUBJECT: ATA 57 – Inspection of CWB rear lower spar and slanted beam areas AIRCRAFT TYPE: A321 OUR REF.: A57N020-22 Rev 00 dated 07-DEC-2022 EFFECTIVITY DATE: 16-Dec-2022

1. AIRCRAFT AFFECTED A321 CEO Aircraft (A/C) A/C Models: A321-111, A321-112, A321-131, A321-211, A321-212, A321-213, A321-231, A321-232.

2. REFERENCED DOCUMENTATION

2.1 APPENDIX Appendix 1: AOT instructions flowchart Appendix 2: AOT embodiment reporting form

2.2 REFERENCES Ref.[1] Aircraft Maintenance Manual (AMM) TASK 28-10-00-910-002-A – "Access to the Fuel Tanks and the Work Areas" Ref.[2] Aircraft Maintenance Manual (AMM) TASK 33-42-11-000-001-A – "Removal of the Landing Light" Ref.[3] Structural Repair Manual (SRM) 53-35-11-07-A - FAIRING DOORS, FR40-FR42 Ref.[4] Illustrated Parts Catalog (IPC) FIG. 29-22-83-07 - HYDRAULIC INSTL-BLUE SYSTEM Zone(s) 190 Ref.[5] Structural Repair Manual (SRM) 51-42-11 - FASTENER INSTALLATION AND REMOVAL -

METALLIC STRUCTURE Ref.[6] Non-destructive Testing Manual (NTM) 51-10-08 - HFEC Inspection for Surface Breaking Cracks" Ref.[7] Non-destructive Testing Manual (NTM) 51-10-01 – "Rotating Probe Testing – General" Ref.[8] Structural Repair Manual (SRM) 51-44-11 - FASTENERS - HOLE AND DRILL DATA -

METALLIC STRUCTURE Ref.[9] Structural Repair Manual (SRM) 51-43 – FASTENER OVERSIZE AND ALTERNATIVE Ref.[10] Structural Repair Manual (SRM) 51-23-11 – PAINT COATINGS Ref.[11] Structural Repair Manual (SRM) 51-76-12 – REPAIR OF FUEL TANK SEALING Ref.[12] Aircraft Maintenance Manual (AMM) TASK 33-42-11-400-003-A – "Installation of the Landing Light" Ref.[13] Structural Repair Manual (SRM) 51-76-11 – REPAIR OF SEALING EXCLUDING FUEL TANK Ref.[14] Technical Follow-Up (TFU) 57.11.00020 – "A321 - CWB rear lower spar junction area" Ref.[15] OIT 999.0018/16 – ATA 00 – PROCEDURE TO REPORT RESULTS OF INSPECTION

SERVICE BULLETINS AND ALERT OPERATORS TRANSMISSIONS

Page 2Open in PDF

3. REASON

3.1 FACTS In the frame of A321 XLR certification, it has been highlighted high fatigue stress affecting 2 areas:

- the A321 CEO Center Wing Box (CWB) rear lower spar junction area at Fr42

- the A321 CEO FR42 slanted beam connection with rear spar and lower panel Area A. CWB rear lower spar junction area at Fr42 Rear Spar CWB Figure 1: CWB rear spar fitting component description (LH shown - RH symmetrical)

Page 3Open in PDF

ALERT OPERATORS TRANSMISSION - AOT AOT ref: A57N020-22 Rev 00 Page 3 of 21 Date: 07-DEC-2022 C80_AOT_FM1104649_v8.0 © AIRBUS S.A.S. 2022. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT Figure 2: Overview of lower corner fitting location inside and outside CWB (LH shown - RH symmetrical) Figure 3: Lower corner fitting location inside CWB - Zoom view looking backward & forward (LH shown - RH symmetrical)

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ALERT OPERATORS TRANSMISSION - AOT AOT ref: A57N020-22 Rev 00 Page 4 of 21 Date: 07-DEC-2022 C80_AOT_FM1104649_v8.0 © AIRBUS S.A.S. 2022. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT Area B. FR42 slanted beam connection area Figure 4: Overview of Fr42 slanted beam junction location after CWB rear Figure 5: Location of Fr42 slanted at connection with CWB rear spar and lower panel (LH shown - RH symmetrical)

Page 5Open in PDF

3.2 HISTORY/BACKGROUND In the frame of Fatigue and Damage Tolerance harmonization of the Single Aisle family, new stress calculation has been done in the CWB and slanted junction areas at FR42, leading to updated margins.

3.3 ROOT CAUSE Stress analyses have highlighted high fatigue stress in the areas of the FR42 front fitting rear spar and slanted junction.

3.4 INVESTIGATION Following margin update, investigation has revealed that cracks may appear:

- in the CWB area at FR 42

- at slanted junction area at FR42

3.5 CONSEQUENCES In case of unrepaired crack(s), the CWB residual strength may be reduced.

As a consequence, an inspection for potential findings on the two (2) following items is required:

Item 1. CWB rear lower spar junction area at Fr42 Cracks may appear on the Left (LH) and Right (RH) sides of the rear spar lower flange and/or on the LH and RH side of Frame 42 front fitting:

- 1a/ Rear spar lower flange (XY plan) Figure 6: Critical rear spar edge at FR42

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- 1b/ Frame 42 front fitting at junction with rear spar (YZ plan) Figure 7: Critical rear spar fastener hole at FR42 Item 2. FR42 slanted beam connection area Cracks may appear on the Left (LH) and Right (RH) side of FR42 slanted beam connection:

Figure 8: Critical fastener hole at slanted beam junction per A/C side

Page 7Open in PDF

4. OBJECTIVES OF THIS AOT This AOT requests a one-time inspection of both below areas:

- the A321 CEO CWB rear lower spar junction area through rototest and High Frequency Eddy Current (HFEC)

- the A321 CEO FR42 slanted beam connection through rototest

5. MAINTENANCE PROCEDURE NOTE: This AOT is classified mandatory or expected to be classified mandatory by an Airworthiness Directive (AD). If the instructions of this AOT are marked as Required for Compliance (RC), the operator must follow the instructions as indicated. These instructions are introduced by “in accordance with”.

NOTE: The instructions of this AOT include procedures given in other documents or in other sections of the AOT. If the instructions of this AOT are NOT marked as Required for Compliance (RC), the operator can use an alternative procedure accepted by his/her local authority. These instructions are introduced by “refer to”.

NOTE: When this AOT gives the access or close-up instructions with no return to service tests, the operator can adapt these instructions to add flexibility to the maintenance operations. The technical intent of this AOT must comply with the set parameters.

5.1 PLANNING (RC) For A/C having accumulated less than 31000 Flight Cycles (FC), do the actions in accordance with paragraphs 5.4 to 5.7 before exceeding 31000FC from A/C Entry Into Service or no later than 6 months from the AOT effective date whichever occurs later.

For A/C having already exceeded 31000FC at the time of AOT effective date, a compliance time is granted to do the actions in accordance with paragraphs 5.4 to 5.7:

- 6 months or 2FC whichever occurs later from AOT effective date for A/C having cumulated between 31000 & 49000FC

- 3 months or 2FC whichever occurs later from AOT effective date for A/C having accumulated more than 49000FC Note: Inspection threshold and related compliance time are built based on A/C landing cases accumulation. Consequently, inspection values are driven by A/C FC, Flight Hours (FH) is not relevant.

Page 8Open in PDF

5.2 MANPOWER WARNING:

TWO PERSONS ARE NECESSARY FOR THIS PROCEDURE:

- ONE PERSON IN THE TANK TO DO THE PROCEDURE, AND

- A SECOND PERSON OUT OF THE TANK TO MONITOR THE SAFETY CONDITIONS.

IF YOU DO NOT OBEY THIS PRECAUTION, THERE IS A RISK OF INJURY OR DEATH.

Estimated required man-hours to do the required actions are:

- Access: 4 hours x 2 people = 8 Man-Hours (time for venting of the tank not taken into account)

- CWB sealant and fastener removal = 0.5 hours x 2 people = 1 Man-Hour per A/C side

- CWB NDT inspection (rototest and HFEC) = 0.5 hours x 2 people = 1 Man-Hour per A/C side

- CWB Reaming oversize, fastener wet installation and sealant application = 0.5 hours x 2 people = 1 Man-Hour per A/C side

- Slanted sealant and fastener removal = 0.5 hour x 1 people = 0.5 Man-Hour per A/C side

- Slanted rototest inspection = 0.5 hour x 1 people = 0.5 Man-Hour per A/C side

- Slanted sealant and fastener installation = 0.5 hour x 1 people = 0.5 Man-Hour per A/C side

- Close-up: 4 hours x 2 people = 8 Man-Hours Elapsed time: 11 hours per A/C side Total Man-hours: 25 Man-Hours NOTE: The estimation does not take into account the time to vent the CWB after defueling nor the time to embody a repair in case of finding.

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5.3 ACCESS

5.3.1: To get access to areas to be inspected:

Area A. CWB rear lower spar junction area at Fr42 WARNING:

TWO PERSONS ARE NECESSARY FOR THIS PROCEDURE:

- ONE PERSON IN THE TANK TO DO THE PROCEDURE, AND

- A SECOND PERSON OUT OF THE TANK TO MONITOR THE SAFETY CONDITIONS.

IF YOU DO NOT OBEY THIS PRECAUTION, THERE IS A RISK OF INJURY OR DEATH.

CAUTION:

DO NOT USE THE FUEL PIPES AND THE EQUIPMENT AS HANDHOLDS WHEN YOU DO WORK IN A FUEL TANK. THIS WILL PREVENT DAMAGE TO THEM.

(1) Access the working area. Refer to Ref.[1]

(2) If necessary, remove the landing lights 7LB and 8LB to ease access. Refer to Ref.[2].

Area B. FR42 slanted beam connection area

(1) Access the working area. Open the access fairing doors, refer to Ref.[3] items 1 & 5 for door identification.

(2) For LHS side, if necessary remove the upper RAT access covers. Refer to Ref.[4] for part identification.

5.3.2: To close access to areas to be inspected:

Area A. CWB rear lower spar junction area at Fr42

(1) Close access. Refer to Ref.[1]

(2) If removed, re-install landing lights 7LB and 8LB, refer to Ref.[12] Area B. FR42 slanted beam connection area

(1) If removed, re-install RAT access covers

(2) Close access fairing doors refer to Ref.[3] items 1 & 5 for door identification.

Page 10Open in PDF

5.4 INSPECTION (RC) Item 1. CWB rear lower spar junction area at Fr42 WARNING:

TWO PERSONS ARE NECESSARY FOR THIS PROCEDURE:

- ONE PERSON IN THE TANK TO DO THE PROCEDURE, AND

- A SECOND PERSON OUT OF THE TANK TO MONITOR THE SAFETY CONDITIONS.

IF YOU DO NOT OBEY THIS PRECAUTION, THERE IS A RISK OF INJURY OR DEATH.

CAUTION:

DO NOT USE THE FUEL PIPES AND THE EQUIPMENT AS HANDHOLDS WHEN YOU DO WORK IN A FUEL TANK. THIS WILL PREVENT DAMAGE TO THEM.

The same procedure is to be applied on the Left (LH) and Right (RH) sides of the A/C:

(1) Remove the sealant around the nut identified in Figure 7 and in the rear spar lower flange.

(2) Remove the affected fastener identified in Figure 7. Refer to Ref.[5].

(3) Measure affected hole diameter and report associated value in APPENDIX 2: AOT embodiment reporting form.

(4) Do the HFEC inspection of the rear spar lower flange as defined in Figure 9 in accordance with Ref.[6], ensuring that the whole free edge is inspected from the internal rod fitting from one side and until the second fastener head from the other side.

Figure 9: rear spar edge HFEC inspection at FR42

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(5) Do the rototest inspection on all layers of the circled hole defined in Figure 10 in accordance with Ref.[7].

Figure 10: Critical rear spar fastener hole at FR42 Item 2. FR42 slanted beam connection area The same procedure is to be applied on the Left (LH) and Right (RH) sides of the A/C:

(1) Remove the sealant and the affected fastener identified in Figures 12. Refer to Ref.[5].

(2) Do the rototest inspection on all layers of the hole located at the closest position near wing junction per A/C side, in accordance with Ref.[7].

Figure 11: Slanted beam fastener hole at FR42

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ALERT OPERATORS TRANSMISSION - AOT AOT ref: A57N020-22 Rev 00 Page 12 of 21 Date: 07-DEC-2022 C80_AOT_FM1104649_v8.0 © AIRBUS S.A.S. 2022. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT Figure 12: Slanted beam fastener hole identification per A/C side

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