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Commercial Airplanes 777 Service Bulletin Number: 777-57A0087 Original Issue: November 11, 2010 Revision 1: August 24, 2011 ATA System: 5710 SUBJECT: WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - Inspection Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15 CFR 730-774). 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.
This document includes proprietary information owned by The Boeing Company and/or one or more third parties.
Treatment of the document and the information it contains is governed by contract with Boeing. For more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.
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 the Boeing livery 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.
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Original Issue: November 11, 2010 777-57A0087Revision 1: August 24, 2011 1 of 72
3.0
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Original Issue: November 11, 2010 777-57A0087Revision 1: August 24, 2011 2 of 72 BOEING SERVICE BULLETIN 777-57A0087
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Table of Contents
Revision Transmittal Sheet5
Summary9
1. PLANNING INFORMATION ........................................ 1 3 A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 7 B. Concurrent Requirements ...................................... 1 7 C. Reason ................................................ 1 7 D. Description .............................................. 1 8 E. Compliance .............................................. 1 9 F. Approval ............................................... 2 0 G. Manpower .............................................. 2 0 H. Weight and Balance Changes .................................... 2 1 I. Electrical Load Data ......................................... 2 1 J. References .............................................. 2 2
1. Existing Data .......................................... 2 2
2. Data supplied with this Service Bulletin ............................ 2 2
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 2 2 K. Publications Affected ........................................ 2 2 L. Interchangeability and Intermixability of Parts ........................... 2 2
2. MATERIAL INFORMATION ........................................ 2 3 A. Material - Price and Availability ................................... 2 3 B. Industry Support Information .................................... 2 3 C. Parts Necessary For Each Airplane ................................. 2 3
1. Kits/Parts ............................................ 2 3
2. Parts and Materials Supplied by the Operator ........................ 2 3
3. Parts Modified and Reidentified ................................ 2 3
4. Parts Removed and Not Replaced .............................. 2 3 D. Parts Necessary to Change Spares ................................. 2 3 E. Special Tooling - Price and Availability ............................... 2 3 F. Special Tooling Necessary to do this Service Bulletin ....................... 2 3
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 5 A. GENERAL INFORMATION ..................................... 2 5 B. WORK INSTRUCTIONS ....................................... 2 6 FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION [Group 1] ............... 2 9 FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION [Group 1] ............... 3 4 FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION [Group 1] ............... 3 9 FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION [Group 2] ............... 4 4 FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION [Group 2] ............... 4 9 FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION [Group 2] ............... 5 4 APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB .............. 5 9 APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT TO UPPER AND LOWER CHORD .............................. 6 3 APPENDIX C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL STIFFENER .......................................... 6 8
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APPENDIX D: SCOPE OF WORK ....................................... 7 2
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Commercial Airplanes 777 Service Bulletin Revision Transmittal SheetNumber: 777-57A0087Original Issue: November 11, 2010 Revision 1: August 24, 2011 ATA System: 5710 SUBJECT: WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - Inspection This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION No more work is necessary on the airplane(s) changed in accordance with the original issue of this service bulletin.
REASON FOR REVISION The data given in Information Notice 777-57A0087 IN 01 is included in this revision.
This revision is sent to:
1. Add the data given in Information Notice 777-57A0087 IN 01:
a. Remove web pocket thickness from inspection figures. Subsequent to the Original Issue of this service bulletin, it was determined that not all configurations of web pocket thickness were shown. The web pocket thickness is not required to accomplish the inspections. However, the repairs in the APPENDIX A, APPENDIX B, and APPENDIX C require parts based on the original thickness of web. The reference web pocket thickness in the inspection figures may lead operators to use the incorrect reference web pocket thickness as the original web pocket thickness when designing the repair. Add additional web pocket thickness information to tables.
b. Add an additional reference for application of Chemical Conversion Coating and Fuel Tank Primer.
Subsequent to the Original Issue of this service bulletin an operator requested the additional option be added to APPENDIX A, APPENDIX B, and APPENDIX C.
c. Add the figure numbers in the SRM where the fastener data is located to make it easier to find the data.
d. Add the location in the SRM where the minimum bend radii for the fabricated stiffeners can be found.
e. Add information to clarify the dimension of the free flange height of the fabricated stiffener.
2. Update service history.
3. Delete extra "typical cracks" indicator from Figure 2 illustration.
These sections were changed:
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1. Summary - Update service history in Background.
2. Planning
a. Paragraph 1.C., Reason - Update service history. Add reason for revision.
b. Paragraph 1.D., Description - Add Compliance Information Related to This Revision.
c. Paragraph 1.J.1., Existing Data - Add Structural Repair Manual reference for minimum bend radius for aluminum alloys.
3. Paragraph 3.B., Work Instructions:
a. FIGURE 1 - Deleted column Web Pocket Thickness (Inches) from inspection table.
b. FIGURE 2 - Delete extra "typical cracks" indicator from view A. Deleted column Web Pocket Thickness (Inches) from inspection table.
c. FIGURE 3 - Deleted column Web Pocket Thickness (Inches) from inspection table.
d. FIGURE 4 - Deleted column Web Pocket Thickness (Inches) from inspection table.
e. FIGURE 5 - Deleted column Web Pocket Thickness (Inches) from inspection table.
f. FIGURE 6 - Deleted column Web Pocket Thickness (Inches) from inspection table.
4. APPENDIX A - Add optional reference for chemical conversion coating and fuel tank primer application.
Add figure number in SRM Chapter 51 that fastener data can be found. Add SRM location where data on sheet metal bend radii can be found. Add information to clarify the dimension of the free flange height of the fabricated stiffener. Add additional web pocket thickness information to tables. Add step to measure web thickness.
5. APPENDIX B - Add optional reference for chemical conversion coating and fuel tank primer application.
Add figure number in SRM Chapter 51 that fastener data can be found. Add SRM location where data on sheet metal bend radii can be found. Add information to clarify the dimension of the free flange height of the fabricated stiffener. Add additional web pocket thickness information to tables. Add step to measure web thickness.
6. APPENDIX C - Add optional reference for chemical conversion coating and fuel tank primer application.
Add figure number in SRM Chapter 51 that fastener data can be found. Add SRM location where data on sheet metal bend radii can be found. Add information to clarify the dimension of the free flange height of the fabricated stiffener. Add additional web pocket thickness information to tables. Add step to measure web thickness.
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.
REVISION HISTORY November 11, 2010Original Issue:
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Commercial Airplanes 777 Service Bulletin SummaryNumber: 777-57A0087Original Issue: November 11, 2010 Revision 1: August 24, 2011 ATA System: 5710 SUBJECT: WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - Inspection
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of the inspections in this service bulletin will detect cracks in the Wing Center Section (WCS) spanwise beams before the beam can not carry design load. Inability of the wing center section spanwise beam to carry design loads could result in the loss of the wing center section load path. Loss of the wing center section load path could result in the catastrophic loss of the outer wings.
There are three spanwise beams in the WCS. The beams are numbered from 1 to 3 starting from the aft beam.
These beams are used to stabilize the WCS and are considered primary structure. Three operators have reported finding a crack in the WCS spanwise beam on three airplanes. In the first report, a 1.5 inch crack was found on the web pocket of spanwise beam no. 3 at Right Buttock Line (RBL) 85.20. The airplane had approximately 5,600 flight cycles and approximately 34,500 flight hours. In the second report, a crack was found on the web pocket of spanwise beam no. 3 at Right Buttock Line (RBL) 96.00. The airplane had approximately 8,500 flight cycles and approximately 27,200 flight hours. Both were 777-200 airplanes with wet center sections. In the third report, a 2.5 inch crack was found on the web pocket of spanwise beam no. 3 at at RBL 96.00. The airplane had approximately 2,800 flight cycles and approximately 23,000 flight hours. This was on a 777-300ER airplane with a wet center section. Other airplane models and airplanes with dry center sections are included due to similar design. Metallurgical testing of one of the cracked webs shows that the cracks were the result of fatigue from reverse bending (diagonal tension buckling). If cracking at multiple locations occurs in multiple spanwise beams, the WCS spanwise beams may not be able to carry design loads. This could result in the loss of the WCS load path. Loss of the WCS load path could result in the catastrophic loss of the outer wings.
Inspection of the WCS spanwise beams web pockets will detect cracks before the WCS spanwise beams can not carry design loads.
Boeing Service Related Problem (SRP) 777-SRP-57-0238 is related to this service bulletin.
ACTION (PRR 62777-72S) Drain center tank (airplanes with wet center sections). Purge and prepare center tank for entry (airplanes with wet center sections). Remove the keel beam access door, the center section access door and the WCS spanwise beam baffle doors. Do a detailed inspection (DET) and High Frequency Eddy Current (HFEC) Inspection of selected web bays of Spanwise Beams numbers 1, 2, and 3 for cracks. Install the WCS spanwise beam baffle doors, center section access door, and the keel beam access door.
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EFFECTIVITY 777-200, -200LR, -300, -300ER, and 777F Airplanes. Refer to Paragraph 1.A., Effectivity, 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 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 Elapsed HoursTotal Task HoursAirplanes
19.5037.00Group 1 Airplanes
25.0050.00Group 2 airplanes
MATERIAL INFORMATION None.
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Original Issue: November 11, 2010 777-57A0087Revision 1: August 24, 2011 10 of 72 BOEING SERVICE BULLETIN 777-57A0087
BOEING SERVICE BULLETIN 777-57A0087
DETAILED INSPECTION (DET)
DO A DET OF THE
FORWARD AND AFT
SIDE OF SELECTED
SPANWISE BEAM WEB
POCKETS FOR CRACKS
HIGH FREQUENCY EDDY
CURRENT INSPECTION (HFEC)
DO AN HFEC INSPECTION
OF SELECTED WEB POCKET
FWD RADII FOR CRACKS
SPANWISE BEAM (3 LOCATIONS) WING CENTER
SECTION
ACCESS DOOR 139AZ ACCESS PANEL 139AL 1998826 Original Issue: November 11, 2010 Revision 1: August 24, 2011 BOEING PROPRIETARY - 777-57A0087 Copyright © Unpublished Work - See page 1 for details. 11 of 72
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Original Issue: November 11, 2010 777-57A0087Revision 1: August 24, 2011 12 of 72 BOEING SERVICE BULLETIN 777-57A0087