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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-57A0087 Original Issue: November 11, 2010 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BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET Copyright © 2010 The Boeing Company Unpublished Work - All Rights Reserved Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable subject matter.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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3.0
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 3 B. Concurrent Requirements ...................................... 1 3 C. Reason ................................................ 1 4 D. Description .............................................. 1 4 E. Compliance .............................................. 1 5 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 7 I. Electrical Load Data ......................................... 1 7 J. References .............................................. 1 7
1. Existing Data .......................................... 1 7
2. Data supplied with this Service Bulletin ............................ 1 8
3. Installation Drawings Used in the Preparation of this Service Bulletin ............ 1 8 K. Publications Affected ........................................ 1 8 L. Interchangeability and Intermixability of Parts ........................... 1 8
2. MATERIAL INFORMATION ........................................ 1 9 A. Material - Price and Availability ................................... 1 9 B. Industry Support Information .................................... 1 9 C. Parts Necessary For Each Airplane ................................. 1 9
1. Kits/Parts ............................................ 1 9
2. Parts and Materials Supplied by the Operator ........................ 1 9
3. Parts Modified and Reidentified ................................ 1 9
4. Parts Removed and Not Replaced .............................. 1 9 D. Parts Necessary to Change Spares ................................. 1 9 E. Special Tooling - Price and Availability ............................... 1 9 F. Special Tooling Necessary to do this Service Bulletin ....................... 1 9
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 1 A. GENERAL INFORMATION ..................................... 2 1 B. WORK INSTRUCTIONS ....................................... 2 2 FIGURE 1: WCS SPANWISE BEAM NUMBER 1 - INSPECTION [Group 1] ............... 2 5 FIGURE 2: WCS SPANWISE BEAM NUMBER 2 - INSPECTION [Group 1] ............... 3 0 FIGURE 3: WCS SPANWISE BEAM NUMBER 3 - INSPECTION [Group 1] ............... 3 5 FIGURE 4: WCS SPANWISE BEAM NUMBER 1 - INSPECTION [Group 2] ............... 4 0 FIGURE 5: WCS SPANWISE BEAM NUMBER 2 - INSPECTION [Group 2] ............... 4 5 FIGURE 6: WCS SPANWISE BEAM NUMBER 3 - INSPECTION [Group 2] ............... 5 0 APPENDIX A: REPAIR - CRACK (1.5 INCH MAXIMUM) IN CENTER OF WEB .............. 5 5 APPENDIX B: REPAIR - CRACK (1.5 INCH MAXIMUM) AT TOP OR BOTTOM FILLET RADIUS ADJACENT TO UPPER AND LOWER CHORD .............................. 5 9 APPENDIX C: REPAIR - CRACK (1.5 INCH MAXIMUM) AT SIDE FILLET RADIUS ADJACENT TO VERTICAL STIFFENER .......................................... 6 4 APPENDIX D: SCOPE OF WORK ....................................... 6 8
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Commercial Airplanes 777 Service Bulletin ALERT SummaryNumber: 777-57A0087Original Issue: November 11, 2010 ATA System: 5710 SUBJECT: WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - 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 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. Two operators have reported finding a crack in the WCS spanwise beam on two 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. 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.
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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.
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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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 777-57A0087
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Commercial Airplanes 777 Service Bulletin ALERT Number: 777-57A0087 Original Issue: November 11, 2010 ATA System: 5710 SUBJECT: WINGS - Center Wing - Beams - Spanwise Beam Web Pockets - 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 This service bulletin is for the airplanes shown below. An equivalent change is on subsequent production airplanes. Refer to PRR 62777-72S for data about this change.
Refer to Service Bulletin Index Document D624W001 Part 3 for Airplane Variable Number, Line Number, and Serial Number data.
NOTE: This service bulletin is for the airplanes identified below. The effectivity list shown below is complete for airplanes through line number 919. At least one airplane after line number 919 is also affected by this service bulletin, and these airplanes are in Group(s) 1,2. These airplanes 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 777-200 Airplanes with dry center section, line numbers 1 through
933.
-1 777-200 Airplanes with wet center sections (777-200ER), -200LR, -300, -300ER, and 777F Airplanes line numbers 41 through 933.
-2 Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER, 777F
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GroupVariable Number 1WA001 - WA017 1WA076 - WA080 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 2WB001 - WB021 2WB031 - WB046 2WB051 - WB088 2WB101 - WB106 2WB121 - WB125 2WB131 - WB148 2WB151 - WB155 2WB161 - WB177 2WB181 - WB194 2WB201 - WB215 2WB231 - WB247 2WB271 - WB273 2WB276 - WB286 2WB291 - WB302 2WB306 - WB307 2WB311 - WB337 2WB341 - WB342
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GroupVariable Number 2WB366 - WB368 2WB371 - WB388 2WB406 2WB411 - WB413 2WB416 - WB439 2WB446 - WB453 2WB476 2WB481 - WB484 2WB501 - WB512 2WB531 - WB537 2WB551 - WB554 2WB591 - WB597 2WB601 - WB606 2WB611 - WB622 2WB631 - WB638 2WB646 - WB649 2WC051 - WC073 2WC101 - WC104 2WC111 - WC120 2WC221 - WC224 2WC241 - WC243 2WC281 - WC290 2WC301 - WC308 2WC361 - WC364 2WC371 - WC374 2WC381 - WC395 2WC441 2WC446 - WC449 2WC456 - WC459 2WC486 - WC493 2WC506 - WC508 2WC521 - WC522 2WC531 - WC536
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GroupVariable Number 2WC546 - WC548 2WC556 2WC566 - WC567 2WC571 - WC574 2WC581 2WD001 - WD002 2WD011 - WD018 2WD031 - WD036 2WD046 - WD055 2WD066 - WD075 2WD081 - WD088 2WD091 2WD096 2WD101 - WD103 2WD501 - WD513 2WD521 - WD541 2WD546 - WD554 2WD561 - WD573 2WD581 - WD599 2WD606 - WD609 2WD621 - WD632 2WD651 - WD665 2WD671 - WD676 2WD691 - WD709 2WD741 - WD752 2WD761 - WD771 2WD786 - WD788 2WD796 - WD813 2WD826 - WD837 2WD846 - WD861 2WD871 - WD883 2WD911 - WD915 2WD921 - WD922
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