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Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1355 Original Issue: March 10, 2017 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Station 1016 Aft Pressure Bulkhead - Gore Webs Inspection and Repair Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 300-774). An export license may be required before it is used for development, production or use by foreign persons from specific countries. The controller of this data has the individual responsibility to abide by all export laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET Copyright © 2017 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing.
Original Issue: March 10, 2017 737-53A1355 1 of 100
2.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 2 of 100 BOEING SERVICE BULLETIN 737-53A1355
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BLANK PAGE
Table of Contents
S u m m a r y5
1. PLANNING INFORMATION ........................................ 1 1 A . E f f e c t i v i t y ............................................... 1 1
1. Airplanes ............................................ 1 1 2 . S p a r e s A f f e c t e d ........................................ 2 3 B. Concurrent Requirements ...................................... 2 3 C. Reason ................................................ 2 3 D. Description .............................................. 2 4 E. Compliance .............................................. 2 6 F . A p p r o v a l ............................................... 4 1 G. Manpower .............................................. 4 2 H. Weight and Balance Changes .................................... 4 4 I. Electrical Load Data ......................................... 4 4 J . R e f e r e n c e s .............................................. 4 4
1. Existing Data: ......................................... 4 4
2. Data Supplied with this Service Bulletin: ........................... 4 4
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 5 K. Publications Affected ........................................ 4 5 L. Interchangeability and Intermixability of Parts ........................... 4 5 M. Software Accomplishment Summary ................................ 4 5
2. MATERIAL INFORMATION ........................................ 4 7 A. Material - Price and Availability ................................... 4 7 B. Industry Support Information .................................... 4 7 C. Parts Necessary for Each Airplane ................................. 4 7 1 . K i t s / P a r t s ............................................ 4 7
2. Parts and Materials Supplied by the Operator ........................ 4 7
3. Parts Modified and Reidentified ................................ 4 7
4. Parts Removed and Not Replaced .............................. 4 7 D. Parts Necessary to Change Spares ................................. 4 7 E. Special Tooling - Price and Availability ............................... 4 7 F. Special Tooling Necessary to do this Service Bulletin ....................... 4 7
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 4 9 A. GENERAL INFORMATION ..................................... 4 9 B. WORK INSTRUCTIONS ....................................... 5 1 FIGURE 1: STA 1016 - AFT PRESSURE BULKHEAD - AFT SIDE - DETAILED, HFEC AND LFEC INSPECTIONS OF THE GORE WEBS - ZONE 1 [Group 2] ................. 5 6 FIGURE 2: STA 1016 - AFT PRESSURE BULKHEAD - AFT SIDE - DETAILED, HFEC AND LFEC INSPECTIONS OF THE GORE WEB LAP SPLICES - ZONE 2 [Group 2] ......... 6 1 FIGURE 3: STA 1016 - AFT PRESSURE BULKHEAD - AFT SIDE - DETAILED, HFEC AND LFEC
INSPECTIONS OF THE GORE WEBS AND REPAIR WEBS OF THE SRM SINGLE GORE WEB REPAIR [Group 2] .................................... 6 8 FIGURE 4: STA 1016 - AFT PRESSURE BULKHEAD - AFT SIDE - DETAILED, HFEC AND LFEC INSPECTIONS OF THE REPAIR WEBS OF THE SRM ALL GORE WEB REPAIR [Group 2] .................................................. 7 3 APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 1 [Group 2, Configuration 1 ] ................................................ 7 7 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 3 of 100 BOEING SERVICE BULLETIN 737-53A1355
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APPENDIX B: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 2 [Group 2, Configuration 2 ] ................................................ 8 2 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 3 [Group 2] ...... 8 7 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 4 [Group 2] ...... 9 4 APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE TABLE 5 [Group 2] ...... 9 9 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 4 of 100 BOEING SERVICE BULLETIN 737-53A1355
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Commercial Airplanes 737 Service Bulletin ALERT SummaryNumber: 737-53A1355Original Issue: March 10, 2017 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Station 1016 Aft Pressure Bulkhead - Gore Webs Inspection and Repair
THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None.
BACKGROUND This service bulletin gives instructions to do detailed inspections, High Frequency Eddy Current (HFEC) inspections, and Low Frequency Eddy Current (LFEC) inspections for any crack in the gore webs, in the lap splices and in some fastener locations in the apex area outside the lap splices, of the aft pressure bulkhead at Station (STA) 1016 from the center of the aft pressure bulkhead to the second tear strap, not including the fastener locations under the second tear strap. This service bulletin also gives instructions to do detailed, HFEC, and LFEC inspections for any crack in the gore webs and repair webs, in the lap splices and in some fastener locations in the apex area outside the lap splices, common to existing Structural Repair Manual (SRM) single gore web repair or SRM all gore web repair. Accomplishment of this service bulletin will mitigate the safety issue associated with the cracking in the gore webs, in the lap splices and in some fastener locations in the apex area outside the lap splices, of the aft pressure bulkhead and make sure that any crack is found and repaired before the crack grows to a critical length. If not corrected, cracking in the gore web lap splices of the aft pressure bulkhead can result in possible rapid decompression and loss of structural integrity.
The inspection of the gore webs in the apex area of the aft pressure bulkhead was added to Revision 3 of Boeing Service Bulletin (SB) 737-53A1214. Since the release of Revision 3 of SB 737-53A1214, operators have reported cracks in the aft pressure bulkhead at STA 1016, in the critical fastener rows of the gore web lap splices, outside the apex area. These cracks were found during Supplemental Structural Inspection Document (SSID) inspections of Structural Significant Item (SSI) F-30C (LFEC inspection of the hidden gore web critical fastener rows) and SSI F-30D (HFEC inspection of the visible gore web critical fastener rows). Cracks were also found during accomplishment of repair in accordance with SB 737-53A1214. The cracks found in the gore web lap splices of the aft pressure bulkhead are due to fatigue caused by cyclic pressure loading of the fuselage. Boeing determined that the existing inspection programs are not sufficient to find such cracks before they could lead to a decompression event.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 5 of 100
Boeing received reports of a total of ten airplanes on which cracks were found in critical fastener rows of the gore web lap splices that are not included in the inspection area of SB 737-53A1214, which extends approximately seven inches radially outboard from the center of the aft pressure bulkhead. Cracks in the critical lap splice fastener rows of the hidden forward gore web were found on eight airplanes between approximately 37,000 and 66,000 total flight cycles, and the maximum reported tip-to-tip crack length was 0.766 inch, growing from opposite sides of a fastener hole. Cracks in the critical lap splice fastener rows of the visible aft gore web were found on four airplanes between approximately 42,000 and 62,000 total flight cycles, but crack lengths were not reported.
This service bulletin supersedes the inspection of the aft pressure bulkhead gore webs in the apex area addressed by PART IV - NDT INSPECTION OF THE DOME CAP AT THE CENTER OF THE BULKHEAD of SB 737-53A1214, Revision 5.
The gore web lap splices of the aft pressure bulkhead have been determined to be structure that is susceptible to Widespread Fatigue Damage (WFD).
This service bulletin provides alternative inspections for SSIs F-30C and F-30D for some areas that are affected by the SRM repairs. For the remaining areas affected by the SRM repairs, the alternative inspections for SSIs F-30C and F-30D are contained in the SRM repairs.
SRM single gore web repairs:
– 737-100/200 SRM 53-10-11, Figure 13, for 737-200 and 737-200C airplanes – 737-300/400/500 SRM 53-80-08, Repair 9, for 737-300/400/500 airplanes SRM all gore web repairs:
– 737-100/200 SRM 53-10-11, Figure 14, for 737-200 and 737-200C airplanes – 737-300/400/500 SRM 53-80-08, Repair 10, for 737-300/400/500 airplanes Boeing Service Related Problem (SRP) 737-SRP-53-0500 is related to this service bulletin.
Boeing Fleet Team Digest (FTD) 737 FTD 53-15002 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
ReferenceAffectedPlanning Data Paragraph 1.A.2., Spares AffectedNoSpares Affected Paragraph 1.E., Compliance and Paragraph
1.F., Approval YesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedYesPublications Affected Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/PartsNoKits/Parts Required Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 6 of 100 BOEING SERVICE BULLETIN 737-53A1355
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ReferenceAffectedPlanning Data Paragraph 2.C.2., Parts and Materials Supplied by the Operator NoOperator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Group 1:
Boeing endorses the FAA rules related to Limit of Validity (LOV) and recommends immediate and permanent removal from service of any airplanes upon reaching the LOV, whether or not it is operated under FAA jurisdiction.
As such, Boeing no longer provides maintenance instructions for airplanes that have accumulated flight cycles beyond the LOV. Airplanes in Group 1 (line numbers 1-291) have accumulated flight cycles beyond the LOV of the maintenance program. 14 CFR 121.1115 and 129.115 prohibit operation of an airplane beyond its LOV.
Group 2:
1. Get access to the aft side of the aft pressure bulkhead at Station (STA) 1016 and do the actions that follow:
2. Do detailed inspections, High Frequency Eddy Current (HFEC) inspections, and Low Frequency Eddy Current (LFEC) inspections for any crack in the gore webs (lap splices and outside the lap splices) of the aft pressure bulkhead in Zone 1. If any crack is found in Zone 1, do the repair in accordance with this service bulletin. If no crack is found, repeat the inspections.
NOTE: Zone 1 includes all fastener locations within 7 inches from the center of the aft pressure bulkhead, measured radially outboard. This includes the first six fastener rows of the gore web lap splices and the fastener locations on the gore web within the first 7 inches that are outside the gore web lap splices. Zone 1 of this service bulletin is the same as the inspection area of PART IV of SB 737-53A1214 at the center of the aft pressure bulkhead.
3. Do detailed inspections, High Frequency Eddy Current (HFEC) inspections, and Low Frequency Eddy Current (LFEC) inspections for any crack in the gore webs (lap splices only) of the aft pressure bulkhead in Zone 2. If any crack is found in Zone 2, contact The Boeing Company for repair instructions and do the repair. If no crack is found, repeat the inspections.
NOTE: Zone 2 includes all fastener locations of the gore web radial lap splices from the seventh fastener row to the second tear strap (thirty-ninth fastener row), counted radially outboard from the center of the aft pressure bulkhead. Some airplane configurations have two fastener rows common to the first (inner) tear strap and some airplane configurations have three fastener rows common to the first tear strap. It is required to inspect the gore web lap splices common to all fastener rows under the first tear strap.
4. For airplanes with any SRM single gore web repair or a SRM all gore web repair, do detailed inspections, HFEC inspections, and LFEC inspections for any crack in the gore webs (lap splices only) and in the repair webs (lap splices and outside the lap splices), of each SRM single gore web repair or a SRM all gore web repair. If any crack is found, contact The Boeing Company for repair instructions and do the repair. If no crack is found, repeat the inspections.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 7 of 100 BOEING SERVICE BULLETIN 737-53A1355
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EFFECTIVITY All 737-100/200/200C/300/400/500 Airplanes. Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 98-11-04 R1, AD 2008-08-23, AD 2008-09-13 and AD 2012-18-13 R1 are related to this service bulletin.
The Federal Aviation Administration (FAA) will possibly release an additional Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 8 of 100 BOEING SERVICE BULLETIN 737-53A1355
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BOEING SERVICE BULLETIN 737-53A1355
ALERT ALERT STA 1016
DO DETAILED, HFEC AND LFEC
INSPECTIONS FOR ANY CRACK IN THE
GORE WEBS (LAP SPLICES AND OUTSIDE THE LAP SPLICES) IN ZONE 1 AND LAP SPLICES IN ZONE 2. IF ANY
CRACK IS FOUND, DO THE REPAIR IN
ACCORDANCE WITH THIS SERVICE
BULLETIN, IF NO CRACK IS FOUND, REPEAT THE INSPECTIONS.
BL 0
GORE WEB LAP SPLICE (7 LOCATIONS) DO DETAILED, HFEC AND S-7L S-7R
LFEC INSPECTIONS FOR
ANY CRACK IN THE GORE
WEBS (LAP SPLICES ONLY)
AND REPAIR WEBS (LAP SPLICES AND OUTSIDE THE ZONE 2
LAP SPLICES) OF EACH SRM
SINGLE GORE WEB REPAIR
OR A SRM ALL GORE WEB REPAIR. IF ANY CRACK IS
FOUND, DO THE REPAIR IN
ACCORDANCE WITH THIS SERVICE BULLETIN. IF NO
CRACK IS FOUND, REPEAT THE INSPECTIONS.
S-15L - • S-15R ZONE 1 S-23L S-23R AFT PRESSURE BULKHEAD (AFT SIDE) 2481363 A-A Original Issue: March 10, 2017 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1355 Work - See page 1 for details. 9 of 100
BOEING SERVICE BULLETIN 737-53A1355
ALERT ALERT
- ZONE 1
TYPICAL CRACK IN
VISIBLE AFT GORE WEB (LAP SPLICE AND OUTSIDE
LAP SPLICE)
- TYPICAL CRACK IN
HIDDEN FWD GORE WEB (LAP SPLICE ONLY)
TYPICAL CRACKS IN GORE WEBS (AFT SIDE) 2534523 Original Issue: March 10, 2017 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 737-53A1355 Work - See page 1 for details. 10 of 100
Commercial Airplanes 737 Service Bulletin ALERT Number: 737-53A1355 Original Issue: March 10, 2017 ATA System: 5311 SUBJECT: FUSELAGE - Frames and Bulkheads - Station 1016 Aft Pressure Bulkhead - Gore Webs Inspection and Repair
THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to all 737-100/200/200C/300/400/500 Airplanes, in 2 Groups.
The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D6-19567 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
DESCRIPTIONCONFIGURATIONGROUP 737-100/200/200C Airplanes, line numbers 1 thru 291.-1 737-200/200C/300/400/500 Airplanes, line numbers 292 thru 3132.-2 Airplanes on which an inspection of the gore webs in the apex area at the center of the bulkhead was done in accordance with PART IV of Boeing Service Bulletin (SB) 737-53A1214.
1 Airplanes on which an inspection of the gore webs in the apex area at the center of the bulkhead was not done in accordance with PART IV of Boeing Service Bulletin (SB) 737-53A1214.
2 Airplane Models:
737-100, 737-200, 737-200C, 737-300, 737-400, 737-500 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 11 of 100
GroupVariable Number 1PA001 - PA022 1PA099 1PA231 - PA232 1PC001 - PC005 1PG001 - PG075 1PG199 1PG201 - PG230 1PG251 - PG255 1PG271 - PG279 1PG301 - PG314 1PG331 - PG332 1PG351 - PG356 1PG375 1PG401 - PG403 1PG431 - PG442 1PG471 - PG475 1PG501 - PG505 1PG571 - PG583 2PG584 - PG586 1PG621 - PG630 1PG651 - PG652 1PG701 - PG705 2PH001 2PH011 - PH013 2PH021 - PH024 1PH701 - PH715 1PH731 - PH732 1PH741 - PH742 2PH743 1PJ001 - PJ002 2PJ003 - PJ009 1PJ031 - PJ032 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: March 10, 2017 737-53A1355 12 of 100 BOEING SERVICE BULLETIN 737-53A1355