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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-53A2452 Original Issue: April 03, 2003 Revision 1: July 16, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Upper Chord 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 © 2003 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Unpublished Work.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, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8A, 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. BOEING is a trademark of Boeing Management Company.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 1 of 142
4.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 2 of 142 BOEING SERVICE BULLETIN 747-53A2452
ALERTALERT
BLANK PAGE
Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 2 0 B. Concurrent Requirements ...................................... 2 0 C. Reason ................................................ 2 0 D. Description .............................................. 2 1 E. Compliance .............................................. 2 2 F. Approval ............................................... 4 5 G. Manpower .............................................. 4 6 H. Weight and Balance Changes .................................... 4 8 I. Electrical Load Data ......................................... 4 8 J. References .............................................. 4 8
1. Existing Data: ......................................... 4 8
2. Data Supplied with this Service Bulletin: ........................... 4 8
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 4 8 K. Publications Affected ........................................ 4 8 L. Interchangeability and Intermixability of Parts ........................... 4 9 M. Software Accomplishment Summary ................................ 4 9
2. MATERIAL INFORMATION ........................................ 5 1 A. Material - Price and Availability ................................... 5 1 B. Industry Support Information .................................... 5 1 C. Parts Necessary for Each Airplane ................................. 5 1
1. Kits/Parts: ........................................... 5 1
2. Parts and Materials Supplied by the Operator: ........................ 5 1
3. Parts Modified and Reidentified: ............................... 5 4
4. Parts Removed and Not Replaced: .............................. 5 4 D. Parts Necessary to Change Spares ................................. 5 4 E. Special Tooling - Price and Availability ............................... 5 4 F. Special Tooling Necessary to do this Service Bulletin ....................... 5 4
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 5 5 A. GENERAL INFORMATION ..................................... 5 5 B. WORK INSTRUCTIONS ....................................... 5 7 FIGURE 1: THIS FIGURE IS DELETED .................................. 6 4 FIGURE 2: INSPECTION AREA DEFINITIONS .............................. 6 5 FIGURE 3: OPEN-HOLE HFEC INSPECTION AT FLOOR PANEL ATTACHMENT FASTENER LOCATIONS .................................................. 8 1 FIGURE 4: FLOOR PANEL ATTACHMENT FASTENER - HOLE MODIFICATION ........... 8 3 FIGURE 5: CLIPNUT MODIFICATION AND SURFACE HFEC INSPECTION .............. 8 5 FIGURE 6: HOLE MEASUREMENTS AFTER CRACK REMOVAL ................... 8 9 FIGURE 7: REPAIR STRAP INSTALLATION ............................... 9 1 FIGURE 8: UPPER CHORD TRIM ..................................... 9 6 FIGURE 9: UPPER CHORD TRIM REPAIR WITH STRAP (REPAIR #7) ............... 1 0 0 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 3 of 142 BOEING SERVICE BULLETIN 747-53A2452
ALERTALERT
FIGURE 10: UPPER CHORD TRIM REPAIR WITH STRAP AND CLIP (REPAIR #6) ......... 1 0 5 FIGURE 11: UPPER CHORD THICK FLANGE REPAIR WITH STRAP (REPAIR #8) ......... 1 1 0 FIGURE 12: UPPER CHORD THICK FLANGE REPAIR WITH ANGLE (REPAIR #9) ......... 1 1 5 FIGURE 13: UPPER CHORD THIN FLANGE REPAIR WITH STRAP (REPAIR #11) .......... 1 2 0 FIGURE 14: UPPER CHORD THIN FLANGE REPAIR WITH ANGLE (REPAIR #12) ......... 1 2 5 FIGURE 15: AFTER-REPAIR INSPECTION FOR LOCATIONS WITH THE STRAP REPAIR ..... 1 3 0 FIGURE 16: AFTER-REPAIR INSPECTIONS FOR LOCATIONS WITH UPPER CHORD TRIM REPAIR WITH STRAP OR ANGLE .................................. 1 3 2 FIGURE 17: OPEN-HOLE HFEC INSPECTION OF AREA 3 ....................... 1 3 4 FIGURE 18: SURFACE HIGH FREQUENCY EDDY CURRENT (HFEC) INSPECTION AT PERMANENT FASTENER LOCATIONS .................................. 1 3 8 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 4 of 142 BOEING SERVICE BULLETIN 747-53A2452
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT Revision Transmittal SheetNumber: 747-53A2452Original Issue: April 03, 2003 Revision 1: July 16, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Upper Chord Inspection and Repair This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION More work is necessary on the airplane(s) inspected in accordance with the original issue of this service bulletin.
Inspection of permanent fastener locations in Area 1 and Area 2 have been added. Also, initial inspection compliance times have been reduced for all inspection areas. Refer to Paragraph 1.E., Compliance, for details.
Federal Aviation Administration (FAA) Airworthiness Directives AD 2005-20-29 and AD 2004-07-22 R1 are related to this service bulletin.
REASON FOR REVISION This revision is sent to reduce initial inspection compliance times, add replacement requirements for upper deck floor beam upper chords, and add inspection requirements at all permanent fastener locations common to the affected upper deck floor beam upper and lower chords.
These sections were changed:
1. In Summary: Updated the Background section. Added Planning Data table. Revised Action section to reflect new inspection requirements. Revised Effectivity description. Added related Airworthiness Directive (AD) statement. Revised Manpower estimates. Updated Summary Illustration.
2. In Paragraph 1.C., Reason: Updated reason information and changed Airworthiness Directive reference.
3. In Paragraph 1.D., Description: A surface HFEC inspection at permanent fastener locations is added.
Maintenance zone tables are added. "Permanent" fastener locations are defined as all fastener locations, except floor panel attachment fastener locations.
4. In Paragraph 1.E., Compliance: New AD references are added. New compliance times and new compliance tables have been added.
5. In Paragraph 1.F., Approval: Updated approval statement and added Alternative Method of Compliance (AMOC) statements.
6. In Paragraph 1.G., Manpower: Manpower estimates are revised.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 5 of 142
7. In Paragraph 1.H., Weight and Balance Changes: Added explanation of possible weight and balance changes.
8. In Paragraph 1.J., References: Reference to new Airworthiness Directives and Structural Repair Manual are added.
9. In Paragraph 1.K., Publications Affected: Structural Repair Manual references are added to the publications list and a damage tolerance based structural inspection statement is added.
10. In Paragraph 3.A., General Information: The notes section is updated.
11. In Paragraph 3.B., Work Instructions: Existing work instructions have been re-organized and revised for clarification. Repair options for floor panel attachment holes are clarified and numbered. Also, new inspection requirements at permanent fastener locations is added.
12. FIGURE 1: This Figure is deleted. In the original issue of this service bulletin, Figure 1 was a logic diagram. The information previously contained in Figure 1 is now included in Paragraph 1.E., Compliance.
13. FIGURE 2: The inspection area definitions are updated.
14. FIGURE 4: The edge margin measurement is clarified.
15. FIGURE 6: The edge margin measurement is clarified.
16. FIGURE 7: The FWD arrow is corrected in view B-B. A note is added.
17. FIGURE 8: Revised footnote to clarify trim depth measurement.
18. FIGURE 9: The FWD arrow is corrected in view B-B. A note is added. The figure title is changed.
19. FIGURE 10: The FWD arrow is corrected in view B-B. A note is added. The figure title is changed.
20. FIGURE 11: The Figure title is changed. A note for clarification of flange thickness is added.
21. FIGURE 12: The Figure title is changed. A note for clarification of flange thickness is added.
22. FIGURE 13: The Figure title is changed. A note for clarification of flange thickness is added.
23. FIGURE 14: The Figure title is changed. A note for clarification of flange thickness is added.
24. FIGURE 15: A note is added.
25. FIGURE 16: A note is added.
26. FIGURE 18: A new inspection figure is added.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location of important changes.
Pages with no vertical lines have no important changes.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 6 of 142 BOEING SERVICE BULLETIN 747-53A2452
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REVISION HISTORY April 03, 2003Original Issue:
July 16, 2012Revision 1:
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 7 of 142 BOEING SERVICE BULLETIN 747-53A2452
ALERTALERT
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 8 of 142 BOEING SERVICE BULLETIN 747-53A2452
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-53A2452Original Issue: April 03, 2003 Revision 1: July 16, 2012 ATA System: 5321 SUBJECT: FUSELAGE - Floors - Upper Deck Floor Beam Upper Chord Inspection and Repair
THIS BULLETIN 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 SERVICE BULLETIN TO THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO THE NEW OWNER.
CONCURRENT REQUIREMENTS None
BACKGROUND Accomplishment of the inspections shown in this service bulletin will ensure the structural integrity of the upper chords of the upper deck floor beams. Cracks in these chords that are not found and repaired could become large and cause the floor beam to become severed. This can lead to large deflection or deformation of the floor and of the body skin, frames, and stringers. This deflection or deformation could result in damage to wire bundles and unintended inputs to the flight control cables which could affect airplane controllability. Multiple adjacent severed floor beams could result in rapid decompression of the airplane.
Flight critical wire bundles and control cables are routed through cutouts in the upper deck floor beams.
Upper deck floor beam upper chord cracks were found on Boeing's 747-SR Fatigue Test airplane, which accumulated 20,000 full pressure flight-cycles and an additional 20,000 test cycles. Numerous upper chord cracks were also reported by several operators accomplishing the inspections in accordance with Boeing Service Bulletin 747-53A2349, "Fuselage - Inspections Based on Fatigue Test Results."
A structural reassessment of the 747 airplane was conducted under the requirements of Federal Aviation Administration (FAA) Advisory Circular 91-56, in accordance with Federal Aviation Regulation (FAR) 25.571 as amended in 1978, to ensure safe operation of 747 airplanes throughout their operational life. From this requirement, the Section 41 upper deck floor beam upper chords were determined to be significant, in that they are critical to airplane structural integrity. Therefore, a flight safety inspection program which will continue throughout the operational life of the airplane is specified in this service bulletin.
The inspections shown in this service bulletin were previously included in Revision 1 of Boeing Service Bulletin 747-53A2349, "Fuselage - Inspections Based on Fatigue Test Results." Upper chord HFEC inspections are required by FAA Airworthiness Directive (AD) AD 2005-20-29.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 9 of 142
The initial inspection compliance time to start High Frequency Eddy Current (HFEC) inspections of upper deck floor beam upper chords that were previously in Service Bulletin 747-53A2349, Revision 1 was reduced for the original issue of this service bulletin because of the critical nature of the header floor beams that reinforce the upper deck floor stairway cutouts. The Area 3 inspections were included to address a location where cracks were found on Boeing's 747SR Fatigue Test airplane, but was not included in Service Bulletin 747-53A2349.
The initial inspection compliance times have been further reduced in Revision 1 of this service bulletin to align with the initial inspection compliance times for Supplemental Structural Inspection Document (SSID) D6-35022 requirements for the same structure.
Boeing Service Related Problem (SRP) 747-SRP-53-0122 is related to this service bulletin.
Subsequent to the original issue of this service bulletin, Boeing has determined that upper deck floor beam upper chords are susceptible to Widespread Fatigue Damage (WFD). Ongoing inspection of this structure is not sufficient to maintain an acceptable level of safety. Therefore, Boeing plans to issue another service bulletin that will recommend replacement of the upper chords. Accomplishment of the upper chord replacement service bulletin will terminate the inspection requirements of this service bulletin.
For more information on WFD, refer to Boeing Service Letter 747-SL-53-088A.
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., ComplianceYesAD Related Paragraph 1.H., Weight and Balance ChangesYesWeight and Balance Change Paragraph 1.I., Electrical Load DataNoElectrical Load Changed Paragraph 1.K., Publications AffectedNoPublications 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 Paragraph 2.C.2., Parts and Materials Supplied by the Operator YesOperator Supplied Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION Get access from above or below to the upper chord of the upper deck floor beams from STA 380 aft. If access is gained from above, do open-hole HFEC inspections for cracks at floor panel attachment fastener holes in the upper chords. If access is gained from below, modify the clipnuts for the floor panel attachment fasteners in accordance with this service bulletin and do surface HFEC inspections of the forward and aft horizontal flanges of the upper chord. If any crack is found, do a repair as shown in this service bulletin. If no cracks are found, do the inspection again at the time shown in Paragraph 1.E., Compliance.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 10 of 142 BOEING SERVICE BULLETIN 747-53A2452
ALERTALERT
Get access to the upper and lower chord of the upper deck floor beams at the location in accordance with this service bulletin. Do surface HFEC inspection for cracks in the upper and lower chords of the upper deck floor beams at permanent fastener locations. If any crack is found, contact Boeing for repair instructions, and do the repair. If no cracks are found, do the inspection again at the time in accordance with Paragraph 1.E., Compliance .
For areas repaired as shown in this service bulletin, start to do repeat inspections at repaired locations as shown in this service bulletin at the times shown in Paragraph 1.E., Compliance. For any locations that have a repair that is different from those shown in this service bulletin, contact Boeing for an after-repair inspection plan.
EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-300, 747SP, and 747SR airplanes. Refer to Paragraph
1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directives AD 2005-20-29 and AD 2004-07-22 R1 are related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection and repair procedures given in this service bulletin.
MANPOWER Elapsed Time (Hours) Total Man-Hours Airplanes
106.25670.00Group 1
89.75538.00Group 2
118.75720.00Group 3
92.25548.00Group 4
158.00884.00Group 5
94.75558.00Group 6
MATERIAL INFORMATION None Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 03, 2003 747-53A2452Revision 1: July 16, 2012 11 of 142 BOEING SERVICE BULLETIN 747-53A2452
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BOEING SERVICE BULLETIN 747-53A2452
ALERT ALERT SEE A GROUPS 1-4: INSPECT STA 380-800 GROUP 5: INSPECT STA 380-1100 GROUP 6: INSPECT STA 380-860 FWD < (TYPICAL)
FLOOR PANEL
DO HFEC INSPECTION OF THE UPPER
CHORDS OF THE UPPER DECK FLOOR
BEAMS FOR CRACKS AT THE FLOOR
PANEL ATTACHMENT FASTENER HOLES
AND DO SURFACE HFEC INSPECTION
UPPER CHORD AT PERMANENT FASTENER LOCATIONS WEB
FLOOR PANEL ATTACHEMENT HOLES
TYPICAL UPPER
CHORD CRACK ›PERMANENT FASTENER LOCATIONS
LOWER CHORD
ALSO DO SURFACE HFEC
INSPECTIONS AT PERMANENT
• INBD FASTENER LOCATIONS ON TYPICAL UPPER DECK FLOOR BEAM SOME LOWER CHORDS V67425 Original Issue: April 03, 2003 Revision 1: July 16, 2012 PROPRIETARY - Copyright © Unpublished Export Controlled ECCN: 9E991 - BOEING 747-53A2452 Work - See page 1 for details. 12 of 142