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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0078 Original Issue: December 05, 2014 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - Station 2150 - Aft Pressure Bulkhead Web Lap Splice Inspection 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 © 2014 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Unpublished Work.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: December 05, 2014 777-53A0078 1 of 30
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 05, 2014 777-53A0078 2 of 30 BOEING SERVICE BULLETIN 777-53A0078
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 5 B. Concurrent Requirements ...................................... 1 5 C. Reason ................................................ 1 5 D. Description .............................................. 1 5 E. Compliance .............................................. 1 6 F. Approval ............................................... 1 7 G. Manpower .............................................. 1 8 H. Weight and Balance Changes .................................... 1 8 I. Electrical Load Data ......................................... 1 8 J. References .............................................. 1 9
1. Existing Data: ......................................... 1 9
2. Data Supplied with this Service Bulletin: ........................... 1 9
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 9 K. Publications Affected ........................................ 1 9 L. Interchangeability and Intermixability of Parts ........................... 2 0 M. Software Accomplishment Summary ................................ 2 0
2. MATERIAL INFORMATION ........................................ 2 1 A. Material - Price and Availability ................................... 2 1 B. Industry Support Information .................................... 2 1 C. Parts Necessary for Each Airplane ................................. 2 1
1. Kits/Parts ............................................ 2 1
2. Parts and Materials Supplied by the Operator ........................ 2 1
3. Parts Modified and Reidentified ................................ 2 1
4. Parts Removed and Not Replaced .............................. 2 1 D. Parts Necessary to Change Spares ................................. 2 1 E. Special Tooling - Price and Availability ............................... 2 1 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 1
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 3 A. GENERAL INFORMATION ..................................... 2 3 B. WORK INSTRUCTIONS ....................................... 2 4 FIGURE 1: AFT PRESSURE BULKHEAD RADIAL WEB LAP SPLICES INSPECTIONS ........ 2 6 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 05, 2014 777-53A0078 3 of 30 BOEING SERVICE BULLETIN 777-53A0078
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-53A0078Original Issue: December 05, 2014 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - Station 2150 - Aft Pressure Bulkhead Web Lap Splice Inspection
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 This service bulletin gives instructions to provide a through the thickness examination of the aft web of the radial lap splices using Medium Frequency Eddy Current (MFEC) for fatigue cracks, and to install repairs if any crack is found. If these inspections and repairs are not done, fatigue cracks can develop in the bulkhead webs. If this Wide Spread Fatigue cracking is not found and repaired, the cracks can rapidly coalesce and can result in possible rapid decompression and loss of structural integrity Widespread Fatigue Damage (WFD) analysis of the 777, as required by 14 CFR 26.21(b), has resulted in the conclusion that existing MPD Section 9, Airworthiness Limitation Instruction (ALI) inspection program is not sufficient to preclude the occurrence of WFD in the aft webs of the aft pressure bulkhead lap splices as the airplane ages. The pressure bulkhead lap splices have multiple adjacent identical details which have the potential for Multi-Site Damage (MD) and the potential for WFD. 14 CFR 26.21 requires evaluation of such designs for the potential for WFD and implementation of the appropriate Service Actions to ensure that WFD is precluded before the Limit of Validity (LOV). The aft pressure bulkhead web lap splices affected by this service bulletin have been determined to be structure that is susceptible to WFD. Boeing has not received any reports of cracks in the pressure bulkhead lap splices. Fatigue cracking was found in the pressure bulkhead aft webs of the radial lap splices common to the full scale fatigue test article.
Accomplishment of the inspections and repairs in this service bulletin will ensure that the aft web of the aft pressure bulkhead web lap splices are free of detectable cracks and maintain the structural integrity of the aft pressure bulkhead.
Boeing Service Related Problem (SRP) 777-SRP-53-0463 is related to this service bulletin.
This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 05, 2014 777-53A0078 5 of 30
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 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 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 Get access to the aft side of the aft pressure bulkhead.
Do the Medium Frequency Eddy Current (MFEC) inspections around fasteners in the aft webs at the aft pressure bulkhead radial lap splices.
If cracks are found, repair in accordance with the 777 Structural Repair Manual (SRM) or contact Boeing for repair instructions and do the repair.
EFFECTIVITY All 777-200, 777-200LR, 777 -300, 777 -300ER and 777F Airplane(s), Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s).
COMPLIANCE Federal Aviation Administration (FAA) Airworthiness Directive AD 2012-07-06 is related to this service bulletin.
The effective date of AD 2012-07-06 is May 15, 2012.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are not available for the inspection(s) and/or repair procedures given in this service bulletin.
MANPOWER Refer to Paragraph 1.G., Manpower.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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MATERIAL INFORMATION None.
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 05, 2014 777-53A0078 7 of 30 BOEING SERVICE BULLETIN 777-53A0078
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-53A0078 Original Issue: December 05, 2014 ATA System: 5383 SUBJECT: FUSELAGE - Section 48 - Station 2150 - Aft Pressure Bulkhead Web Lap Splice Inspection
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 Refer to Service Bulletin Index D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
This service bulletin is applicable to all 777-200, 777-200LR, 777-300, 777- 300ER and 777F airplanes in 1 Group. The Variable Numbers and Group Information for the applicable airplanes is given below.
NOTE: The Variable Number table below includes all affected airplanes up to Line Number 1356.
Affected airplanes after Line Number 1356 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 777 airplanes-1 Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER, 777F GroupVariable Number 1WA001 - WA017 1WA076 - WA080 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 05, 2014 777-53A0078 9 of 30
GroupVariable Number 1WA086 - WA093 1WA101 - WA104 1WA116 - WA119 1WA131 - WA137 1WA171 - WA175 1WA196 - WA198 1WA206 - WA212 1WA221 - WA223 1WA231 - WA232 1WA241 - WA250 1WA261 - WA266 1WA281 - WA283 1WA301 - WA304 1WB001 - WB021 1WB031 - WB046 1WB051 - WB088 1WB101 - WB106 1WB121 - WB125 1WB131 - WB148 1WB151 - WB155 1WB161 - WB177 1WB181 - WB194 1WB201 - WB215 1WB231 - WB247 1WB271 - WB273 1WB276 - WB286 1WB291 - WB302 1WB306 - WB307 1WB311 - WB337 1WB341 - WB342 1WB366 - WB368 1WB371 - WB388 1WB406 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1WB411 - WB413 1WB416 - WB439 1WB446 - WB453 1WB476 1WB481 - WB484 1WB501 - WB512 1WB531 - WB537 1WB551 - WB554 1WB591 - WB597 1WB601 - WB606 1WB611 - WB622 1WB631 - WB638 1WB646 - WB649 1WC051 - WC073 1WC101 - WC104 1WC111 - WC120 1WC221 - WC224 1WC241 - WC243 1WC281 - WC290 1WC301 - WC308 1WC361 - WC364 1WC371 - WC374 1WC381 - WC395 1WC441 1WC446 - WC449 1WC456 - WC459 1WC486 - WC493 1WC506 - WC508 1WC521 - WC522 1WC531 - WC536 1WC546 - WC548 1WC556 1WC566 - WC567 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1WC571 - WC574 1WC581 1WC586 - WC587 1WC591 - WC595 1WD001 - WD002 1WD011 - WD018 1WD031 - WD036 1WD046 - WD055 1WD066 - WD075 1WD081 - WD089 1WD091 1WD096 1WD101 - WD106 1WD111 - WD112 1WD116 - WD117 1WD121 - WD122 1WD501 - WD513 1WD521 - WD541 1WD546 - WD554 1WD561 - WD573 1WD581 - WD599 1WD606 - WD609 1WD621 - WD632 1WD651 - WD665 1WD671 - WD677 1WD691 - WD709 1WD741 - WD752 1WD761 - WD771 1WD786 - WD788 1WD796 - WD837 1WD846 - WD867 1WD871 - WD899 1WD911 - WD918 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
Original Issue: December 05, 2014 777-53A0078 12 of 30 BOEING SERVICE BULLETIN 777-53A0078