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Commercial Airplanes 777 Requirements Bulletin ALERT Number: 777-53A0091 RB Original Issue: April 08, 2019 ATA System: 5333 5343 5363 SUBJECT: FUSELAGE - Structure Sections 43, 44, and 46 - Circumferential 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:
Copyright © 2019 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Unpublished Work.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: April 08, 2019 777-53A0091 RB 1 of 90
2.0
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 2 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
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Table of Contents
1 . E F F E C T I V I T Y5
A. Airplanes5
B . S p a r e s A f f e c t e d6
2. CONCURRENT REQUIREMENTS6
3 . C O M P L I A N C E6
4. APPROVAL ................................................ 1 9
5. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 1 A. General Information ......................................... 2 1 B. Work Instructions ........................................... 2 2 FIGURE 1: STATION (STA) 655 - STRINGERS S-20L TO S-20R INSPECTIO N [Group 1-2, 5, 7] . . 43 FIGURE 2: STATION (STA) 655 - STRINGERS S-20L TO S-4R AND S-15R TO S-20R INSPECTION [Group 3 ] ................................................ 4 7 FIGURE 3: STATION (STA) 655 - STRINGERS S-20L TO S-6L AND S-6R T O S-20R INSPECTION [Group 4 ] ................................................ 5 1 FIGURE 4: STATION (STA) 655 - STRINGERS S-2L TO S-5L INSPECTION [ G r o u p 1 0 ] ....... 5 5 FIGURE 5: STATION (STA) 655 - STRINGERS S-13L TO S-13R INSPECTIO N [Group 11] ...... 5 9 FIGURE 6: STATION (STA) 655 - STRINGERS S-13L TO S-6L AND S-6R T O S-13R INSPECTION [Group 1 2 ] ................................................ 6 3 FIGURE 7: STATION (STA) 825+210 - STRINGERS S-13L TO S-13R INSPE CTION [Group 2-3, 5-8] . 67 FIGURE 8: STATION (STA) 825+210 - STRINGERS S-13L TO S-6L AND S- 6R TO S-13R INSPECTION [Group 4] ............................................ 7 1 FIGURE 9: STATION (STA) 1434+189 - STRINGERS S-13L TO S-13R INSP ECTION [Group 5-6, 9] . 75 FIGURE 10: STATION (STA) 1434+189 - STRINGERS S-13L TO S-6L AND S-6R TO S-13R INSPECTION [Group 7] ............................................ 7 9 FIGURE 11: STATION (STA) 1832 - STRINGERS S-13L TO S-13R INSPECT I O N [ G r o u p 5 - 7 ] ..... 8 3 FIGURE 12: STATION (STA) 655 - STRINGERS S-20L TO S-4R AND S-14R TO S-20R INSPECTION [Group 6 ] ................................................ 8 7 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 3 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 4 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
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Commercial Airplanes 777 Requirements Bulletin ALERT Number: 777-53A0091 RB Original Issue: April 08, 2019 ATA System: 5333 5343 5363 SUBJECT: FUSELAGE - Structure Sections 43, 44, and 46 - Circumferential Splice Inspection
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. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT. THE BOEING
PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS…) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT.
1. EFFECTIVITY A. Airplanes This bulletin is applicable to 777-300ER, 777F Airplane(s), line number(s) 1386, 1398, 1406, 1428, 1434, 1440, 1442, 1444, 1446, 1448, 1450, 1452, 1470, 1472, 1474, 1476, 1478, 1480, 1482, 1484, 1486-1521, 1523-1541 in 12 Group(s).
DESCRIPTIONCONFIGURATIONGROUP 777-300ER airplanes, line number: 1386.-1 777-300ER airplanes, line numbers:1428, 1434, 1442, 1492, 1493, 1494, 1495, 1496, 1497, 1498, 1499, 1501, 1502, 1503, 1504, 1505, 1507, 1509, 1510, 1511, 1512, 1513, 1515, 1517, 1519, 1527, and 1529.
-2 777-300ER airplanes, line numbers: 1521 and 1523.-3 777-300ER airplanes, line numbers: 1482, 1484, 1486, 1487, 1488, 1489, 1490, and 1491.
-4 777-300ER airplanes, line numbers: 1500, 1506, 1508, 1514, 1516, 1518, 1533, 1535, 1537, 1538, 1539, 1540, and 1541.
-5 777-300ER airplanes, line number: 1530.-6 777-300ER airplanes, line number: 1534.-7 Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 5 of 90
DESCRIPTIONCONFIGURATIONGROUP 777-300ER airplanes, line numbers: 1444, 1446, 1448, 1450, 1452, 1470, 1472, 1474, 1476, 1478, 1480, and 1525.
-8 777-300ER airplanes, line number: 1406.-9 777-300ER airplanes, line number: 1398.-10 777F airplanes, line numbers: 1440, 1524, 1526, 1528, 1531, 1532, and 1536.
-11 777F airplanes, line number: 1520.-12 B. Spares Affected None.
2. CONCURRENT REQUIREMENTS None.
3. COMPLIANCE The Federal Aviation Administration (FAA) will possibly release an Airworthiness Directive related to Requirements Bulletin 777-53A0091 RB. The Airworthiness Directive will make the compliance tasks and times given in Requirements bulletin 777-53A0091 RB mandatory.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When more than one ACTION is given for a CONDITION or an OPTION, do all of the ACTION numbers for that CONDITION or OPTION.
Accomplish the required actions, based on the applicable conditions in Tables 1 through 12, in accordance with the Accomplishment Instructions.
Group 1-2, 5, 7:
Table 1: Station (STA) 655 - Stringers S-20L to S-20R Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 42 months after the Original Issue date of Requirements Bulletin 777-53A0091 RB.
Before 16,000 Total Flight Cycles.
Do a detailed inspection of the stringer splices and skin splice straps, and do a High Frequency Eddy Current (HFEC) inspection of the stringers and stringer splices at STA 655 from S-20L to S-20R for any crack.
All Airplanes Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 6 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
Group 1-2, 5, 7:
Table 1: Station (STA) 655 - Stringers S-20L to S-20R Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Before further flight.ACTION 1: Contact The Boeing Company for repair instructions and do the repair.
CONDITION 1:
ANY CRACK FOUND.
16,000 flight cycles.
-ACTION 2: Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-20L to S-20R for any crack. (a) 16,000 flight cycles.
-Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-20L to S-20R for any crack. (a) CONDITION 2:
NO CRACK FOUND.
(a) It is not required to do repeat inspections in areas where a repair covers the affected inspection zone provided:
1. The repair is the corrective action to the crack condition identified in this service bulletin and installed after the original issue date of this service bulletin, AND
2. The installed repair was approved by the Boeing Organizational Designation Authorization via a FAA Form 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 7 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
Group 3:
Table 2: Station (STA) 655 - Stringers S-20L to S-4R and S-15R to S-20R Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 42 months after the Original Issue date of Requirements Bulletin 777-53A0091 RB.
Before 16,000 Total Flight Cycles.
Do a detailed inspection of the stringer splices and skin splice straps, and do a High Frequency Eddy Current (HFEC) inspection of the stringers and stringer splices at STA 655 from S-20L to S-20R, excluding S-5R to S-14R, for any crack.
All Airplanes -Before further flight.ACTION 1: Contact The Boeing Company for repair instructions and do the repair.
CONDITION 3:
ANY CRACK FOUND.
16,000 flight cycles.
-ACTION 2: Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-20L to S-20R, excluding S-5R to S-14R, for any crack. (a) 16,000 flight cycles.
-Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-20L to S-20R, excluding S-5R to S-14R, for any crack. (a) CONDITION 4:
NO CRACK FOUND.
(a) It is not required to do repeat inspections in areas where a repair covers the affected inspection zone provided:
1. The repair is the corrective action to the crack condition identified in this service bulletin and installed after the original issue date of this service bulletin, AND
2. The installed repair was approved by the Boeing Organizational Designation Authorization via a FAA Form 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 8 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
Group 4:
Table 3: Station (STA) 655 - Stringers S-20L to S-6L and S-6R to S-20R Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 42 months after the Original Issue date of Requirements Bulletin 777-53A0091 RB.
Before 16,000 Total Flight Cycles.
Do a detailed inspection of the stringer splices and skin splice straps, and do a High Frequency Eddy Current (HFEC) inspection of the stringers and stringer splices at STA 655 from S-20L to S-20R, excluding S-5L to S-5R, for any crack.
All Airplanes -Before further flight.ACTION 1: Contact The Boeing Company for repair instructions and do the repair.
CONDITION 5:
ANY CRACK FOUND.
16,000 flight cycles.
-ACTION 2: Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 S-20L to S-20R, excluding S-5L to S-5R, for any crack. (a) 16,000 flight cycles.
-Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-20L to S-20R, excluding S-5L to S-5R, for any crack. (a) CONDITION 6:
NO CRACK FOUND.
(a) It is not required to do repeat inspections in areas where a repair covers the affected inspection zone provided:
1. The repair is the corrective action to the crack condition identified in this service bulletin and installed after the original issue date of this service bulletin, AND
2. The installed repair was approved by the Boeing Organizational Designation Authorization via a FAA Form 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 9 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
Group 10:
Table 4: Station (STA) 655 - Stringers S-2L to S-5L Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 42 months after the Original Issue date of Requirements Bulletin 777-53A0091 RB.
Before 16,000 Total Flight Cycles.
Do a detailed inspection of the stringer splices and skin splice straps, and do a High Frequency Eddy Current (HFEC) inspection of the stringers and stringer splices at STA 655 from S-2L to S-5L for any crack.
All Airplanes -Before further flight.ACTION 1: Contact The Boeing Company for repair instructions and do the repair.
CONDITION 7:
ANY CRACK FOUND.
16,000 flight cycles.
-ACTION 2: Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-2L to S- 5L for any crack. (a) 16,000 flight cycles.
-Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-2L to S-5L for any crack. (a) CONDITION 8:
NO CRACK FOUND.
(a) It is not required to do repeat inspections in areas where a repair covers the affected inspection zone provided:
1. The repair is the corrective action to the crack condition identified in this service bulletin and installed after the original issue date of this service bulletin, AND
2. The installed repair was approved by the Boeing Organizational Designation Authorization via a FAA Form 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 10 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
Group 11:
Table 5: Station (STA) 655 - Stringers S-13L to S-13R Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 42 months after the Original Issue date of Requirements Bulletin 777-53A0091 RB.
Before 16,000 Total Flight Cycles.
Do a detailed inspection of the stringer splices and skin splice straps, and do a High Frequency Eddy Current (HFEC) inspection of the stringers and stringer splices at STA 655 from S-13L to S-13R for any crack.
All Airplanes -Before further flight.ACTION 1: Contact The Boeing Company for repair instructions and do the repair.
CONDITION 9:
ANY CRACK FOUND.
16,000 flight cycles.
-ACTION 2: Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-13L to S-13R for any crack. (a) 16,000 flight cycles.
-Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-13L to S-13R for any crack. (a) CONDITION 10:
NO CRACK FOUND.
(a) It is not required to do repeat inspections in areas where a repair covers the affected inspection zone provided:
1. The repair is the corrective action to the crack condition identified in this service bulletin and installed after the original issue date of this service bulletin, AND
2. The installed repair was approved by the Boeing Organizational Designation Authorization via a FAA Form 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 11 of 90 REQUIREMENTS BULLETIN 777-53A0091
ALERTALERT
Group 12:
Table 6: Station (STA) 655 - Stringers S-13L to S-6L and S-6R to S-13R Inspection Repeat Interval (Not to Exceed) Compliance Time (Whichever Occurs Later) ActionCondition -Within 42 months after the Original Issue date of Requirements Bulletin 777-53A0091 RB.
Before 16,000 Total Flight Cycles.
Do a detailed inspection of the stringer splices and skin splice straps, and do a High Frequency Eddy Current (HFEC) inspection of the stringers and stringer splices at STA 655 from S-13L to S-13R, excluding S-5L to S-5R, for any crack.
All Airplanes -Before further flight.ACTION 1: Contact The Boeing Company for repair instructions and do the repair.
CONDITION 11:
ANY CRACK FOUND.
16,000 flight cycles.
-ACTION 2: Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-13L to S-13R, excluding S-5L to S-5R, for any crack. (a) 16,000 flight cycles.
-Repeat detailed inspection of the stringer splices and skin splice straps, and HFEC inspection of the stringers and stringer splices at STA 655 from S-13L to S-13R, excluding S-5L to S-5R, for any crack. (a) CONDITION 12:
NO CRACK FOUND.
(a) It is not required to do repeat inspections in areas where a repair covers the affected inspection zone provided:
1. The repair is the corrective action to the crack condition identified in this service bulletin and installed after the original issue date of this service bulletin, AND
2. The installed repair was approved by the Boeing Organizational Designation Authorization via a FAA Form 8100-9.
Export Controlled ECCN: 9E991 Copyright © Unpublished Work - See page 1 for details.
Original Issue: April 08, 2019 777-53A0091 RB 12 of 90 REQUIREMENTS BULLETIN 777-53A0091