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Commercial Airplanes 747 Service Bulletin ALERT Number: 747-54A2246 Original Issue: February 05, 2016 ATA System: 5461 SUBJECT: NACELLES/PYLONS - No. 1 and No. 4 Engines Aft Strut Fairings - Vapor Seal, Block Seal, and Heat Shield Seal Inspection and Replacement 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 © 2016 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Unpublished Work.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: February 05, 2016 747-54A2246 1 of 55
3.0
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 2 of 55 BOEING SERVICE BULLETIN 747-54A2246
ALERTALERT
BLANK PAGE
Table of Contents
Summary5
1. PLANNING INFORMATION11
A. Effectivity11
1. Airplanes11
2. Spares Affected12
B. Concurrent Requirements12
C. Reason12
D. Description13
E. Compliance14
F. Approval16
G. Manpower16
H. Weight and Balance Changes17
I. Electrical Load Data17
J. References18
1. Existing Data:18
2. Data Supplied with this Service Bulletin:18
3. Installation Drawings Used in the Preparation of this Service Bulletin:18
K. Publications Affected18
L. Interchangeability and Intermixability of Parts19
M. Software Accomplishment Summary19
2. MATERIAL INFORMATION21
A. Material - Price and Availability21
B. Industry Support Information21
C. Parts Necessary for Each Airplane21
1. Kits/Parts21
2. Parts and Materials Supplied by the Operator21
3. Parts Modified and Reidentified22
4. Parts Removed and Not Replaced22
D. Parts Necessary to Change Spares22
E. Special Tooling - Price and Availability22
F. Special Tooling Necessary to do this Service Bulletin22
3. ACCOMPLISHMENT INSTRUCTIONS23
A. GENERAL INFORMATION23
B. WORK INSTRUCTIONS25
FIGURE 1: NO. 1 STRUT - VAPOR SEAL DETAILED INSPECTION29
FIGURE 2: NO. 4 STRUT - VAPOR SEAL DETAILED INSPECTION32
FIGURE 3: NO. 1 STRUT - VAPOR SEAL, BLOCK SEAL, AND HEAT SHIELD SEAL - REMOVAL . 35 FIGURE 4: NO. 4 STRUT - VAPOR SEAL, BLOCK SEAL, AND HEAT SHIELD SEAL - REMOVAL . 37 FIGURE 5: NO. 1 STRUT - STRUCTURAL INSPECTION FOR HEAT DAMAGE - DETAILED INSPECTION
AND EDDY CURRENT CONDUCTIVITY MEASUREMENT39
FIGURE 6: NO. 4 STRUT - STRUCTURAL INSPECTION FOR HEAT DAMAGE - DETAILED INSPECTION
AND EDDY CURRENT CONDUCTIVITY MEASUREMENT42
FIGURE 7: NO. 1 STRUT - VAPOR SEAL, BLOCK SEAL, AND HEAT SHIELD SEAL - INSTALLATION
.45
FIGURE 8: NO. 4 STRUT - VAPOR SEAL, BLOCK SEAL, AND HEAT SHIELD SEAL - INSTALLATION
.49
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 3 of 55 BOEING SERVICE BULLETIN 747-54A2246
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APPENDIX A: LOGIC DIAGRAM FOR PARAGRAPH 1.E. COMPLIANCE: TABLE 1: NO. 1 AND NO. 4 STRUT
AFT FAIRING - SAFETY RELATED - INITIAL AND REPEAT VAPOR SEAL INSPECTIONS
AND SEAL REPLACEMENT53
APPENDIX B: PART DEMAND INTENT55
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 4 of 55 BOEING SERVICE BULLETIN 747-54A2246
ALERTALERT
Commercial Airplanes 747 Service Bulletin ALERT SummaryNumber: 747-54A2246Original Issue: February 05, 2016 ATA System: 5461 SUBJECT: NACELLES/PYLONS - No. 1 and No. 4 Engines Aft Strut Fairings - Vapor Seal, Block Seal, and Heat Shield Seal Inspection and Replacement
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 this service bulletin will detect heat damage on the vapor seal between the strut and aft fairing. If any heat damaged seals are not found and replaced, in the event of flammable fluid leakage in the aft fairing, this could lead to an uncontained engine strut fire.
Boeing has received reports from operators of damaged vapor seals, block seals, and heat shield seals on number 1 and number 4 engines aft strut fairings. These reports from the operators show vapor seal damage on the outboard pylons occurring at 1468 flight cycles and fully compromised vapor seals at 2768 flight cycles and 3626 flight cycles.
The aft fairing vapor seals, block seals, and heat shield seals prevent hot exhaust gases from entering the aft fairing. Boeing analysis has found that hot exhaust gases leaking past the heat shield seal can cause heat damage to the block seals and vapor seals. Boeing has determined that this issue only affects outboard pylons because in these pylons the vapor seal is located directly above the heat shield seal. If the vapor seal has heat damage, and if there is a hydraulic leak that sprays onto the strut bulkhead, fluid could drain across the worn seal and contact heat shield surfaces below the seals. The heat shield could then ignite the fluid and the fire could extend to the aft fairing. In addition, Boeing has determined that extended operation of the airplane with degraded seals can likely cause heat damage to secondary structure and structure within the strut and aft fairing.
This service bulletin gives instructions to inspect for heat damage on the vapor seals between the strut and aft fairing. If the vapor seal is found with any heat damage, this service bulletin gives instructions to replace vapor seals, block seals, and heat shield seals to reduce risk of potential fire due to a heat damaged vapor seal. Boeing has determined that inspection and replacement of the seals are safety related.
In addition, this service bulletin gives inspection and repair instructions for heat damage on adjacent structure of the seals. Boeing has determined that the inspection and repair of the structure are economic related. Boeing recommends to do the inspection and repair of the adjacent structure during the seal replacement, before installation of new seals, to prevent possible operational disruptions.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 5 of 55
A future service bulletin will be released to give instructions to install new and improved parts including block seals, and heat shield seals. The accomplishment of the future service bulletin will be terminating action for the inspection requirements, both safety and economic related, given in this service bulletin.
Boeing Service Related Problem (SRP) 747-8-SRP-54-0153 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 ChangesNoWeight 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 Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin NoSpecial Tooling Required ACTION
SAFETY RELATED - INITIAL AND REPEAT INSPECTIONS AND REPLACEMENT OF SEALS
1. Get access between the strut and aft fairing on Engine No. 1 and Engine No. 4.
2. Do a detailed inspection of the vapor seal for heat damage.
a. If no heat damage is found on the vapor seals, repeat the detailed inspection of the vapor seal for heat damage at the time given in the service bulletin.
b. If any heat damage is found on the vapor seals, remove the aft fairing. Replace the vapor seals, block seals, and heat shield seals and repeat the detailed inspection of the vapor seal for heat damage at the time given in the service bulletin.
NOTE: Boeing recommends to do a detailed inspection and eddy current conductivity measurement of the specified structure for heat damage and do the necessary repairs during the seal replacement, before installation of new seals. This is given as an economic consideration to prevent possible operational disruptions. Refer to ECONOMIC RELATED
- STRUCTURAL INSPECTION AND REPAIR FOR HEAT DAMAGE.
3. Put the airplane back to a serviceable condition.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 6 of 55 BOEING SERVICE BULLETIN 747-54A2246
ALERTALERT
ECONOMIC RELATED - STRUCTURAL INSPECTION AND REPAIR FOR HEAT DAMAGE
1. Remove and keep the aft strut fairing on Engine No. 1 and Engine No. 4.
2. Do a detailed inspection and eddy current conductivity measurement of the specified structure for heat damage and do the necessary repairs.
NOTE: Boeing recommends to do a detailed inspection and eddy current conductivity measurement of the specified structure for heat damage and do the necessary repairs during the seal replacement, before installation of new seals. This is given as an economic consideration to prevent possible operational disruptions.
3. Install kept aft strut fairing on Engine No. 1 and Engine No. 4.
4. Put the airplane back to a serviceable condition.
A future service bulletin will be released to give instructions to install new and improved parts including block seals, and heat shield seals. The accomplishment of the future service bulletin will be terminating action for the inspections, both safety and economic related, given in this service bulletin.
EFFECTIVITY All 747-8 and 747-8F Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplanes.
COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to this service bulletin. The Airworthiness Directive will make the compliance tasks and times, that are safety related, given in this service bulletin mandatory.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of February 12, 2015. Please refer to Paragraph 2.B., Industry Support Information. The warranty remedies will expire eight years from the original issue date of this service bulletin.
MANPOWER Table 1: SAFETY RELATED - INITIAL AND REPEAT VAPOR SEAL INSPECTIONS Elapsed HoursTotal Task HoursAirplanes
3.403.40All Airplanes Table 2: SAFETY RELATED - SEAL REPLACEMENT Elapsed HoursTotal Task HoursAirplanes
19.8131.8All Airplanes Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 7 of 55 BOEING SERVICE BULLETIN 747-54A2246
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Table 3: ECONOMIC RELATED - STRUCTURAL INSPECTION AND REPAIR FOR
HEAT DAMAGE Elapsed HoursTotal Task HoursAirplanes
17.2129.2All Airplanes (a)
(a) Estimated Task Hours includes detailed inspection only. This estimate does not include the task time to do the High Frequency Eddy Current (HFEC) conductivity measurement.
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 8 of 55 BOEING SERVICE BULLETIN 747-54A2246
ALERTALERT
BOEING SERVICE BULLETIN 747-54A2246
ALERT ALERT SAFETY RELATED:
DO A DETAILED INSPECTION OF THE VAPOR SEALS FOR HEAT DAMAGE. IF NO HEAT DAMAGE IS FOUND,
REPEAT THE DETAILED INSPECTION AT THE TIME GIVEN IN THE SERVICE BULLETIN. IF ANY HEAT
DAMAGE IS FOUND, REPLACE THE VAPOR SEALS, BLOCK SEALS. AND HEAT SHIELD SEALS AND
REPEAT THE DETAILED INSPECTION OF THE VAPOR SEAL AT THE TIME GIVEN IN THE SERVICE BULLETIN.
ECONOMIC RELATED:
DO A DETAILED INSPECTION AND EDDY
CURRENT CONDUCTIVITY MEASUREMENT OF
THE SPECIFIED STRUCTURE FOR HEAT DAMAGE AND DO THE NECESSARY REPAIRS.
NO. 1 AND NO. 4 STRUT AFT FAIRING 2461791 Original Issue: February 05, 2016 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished 747-54A2246 Work - See page 1 for details. 9 of 55
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 10 of 55 BOEING SERVICE BULLETIN 747-54A2246
ALERTALERT
BLANK PAGE
Commercial Airplanes 747 Service Bulletin ALERT Number: 747-54A2246 Original Issue: February 05, 2016 ATA System: 5461 SUBJECT: NACELLES/PYLONS - No. 1 and No. 4 Engines Aft Strut Fairings - Vapor Seal, Block Seal, and Heat Shield Seal Inspection and Replacement
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.
1. PLANNING INFORMATION A. Effectivity
1. Airplanes This service bulletin is applicable to all 747-8 and 747-8F Airplanes line numbers 1420 and on in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below.
Refer to Service Bulletin Index D6-30300 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1539.
Affected airplanes after Line Number 1539 will be added to the service bulletin's MyBoeingFleet.com (MBF) "get effectivity" result when they are added to the MBF Fleet Profile Page.
DESCRIPTIONCONFIGURATIONGROUP All 747-8 and 747-8F Airplanes line numbers 1420 and on.-1 Airplane Models:
747-8, 747-8F GroupVariable Number 1RC001 - RC009 1RC021 - RC040 1RC051 - RC060 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 11 of 55
GroupVariable Number 1RC066 - RC072 1RC076 - RC077 1RC501 - RC514 1RC521 - RC528 1RC541 1RC546 - RC566 1RC571 - RC582 1RC601 - RC605 1RC641 - RC644 1RC651 - RC652 1RC661 1RC671 - RC674
2. Spares Affected None.
B. Concurrent Requirements None.
C. Reason Accomplishment of this service bulletin will detect heat damage on the vapor seal between the strut and aft fairing. If any heat damaged seals are not found and replaced, in the event of flammable fluid leakage in the aft fairing, this could lead to an uncontained engine strut fire.
Boeing has received reports from operators of damaged vapor seals, block seals, and heat shield seals on number 1 and number 4 engines aft strut fairings. These reports from the operators show vapor seal damage on the outboard pylons occurring at 1468 flight cycles and fully compromised vapor seals at 2768 flight cycles and 3626 flight cycles.
The aft fairing vapor seals, block seals, and heat shield seals prevent hot exhaust gases from entering the aft fairing. Boeing analysis has found that hot exhaust gases leaking past the heat shield seal can cause heat damage to the block seals and vapor seals. Boeing has determined that this issue only affects outboard pylons because in these pylons the vapor seal is located directly above the heat shield seal. If the vapor seal has heat damage, and if there is a hydraulic leak that sprays onto the strut bulkhead, fluid could drain across the worn seal and contact heat shield surfaces below the seals. The heat shield could then ignite the fluid and the fire could extend to the aft fairing. In addition, Boeing has determined that extended operation of the airplane with degraded seals can likely cause heat damage to secondary structure and structure within the strut and aft fairing.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: February 05, 2016 747-54A2246 12 of 55 BOEING SERVICE BULLETIN 747-54A2246