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Commercial Airplanes 777 Service Bulletin
SPECIAL ATTENTION Number: 777-54-0035 Original Issue: October 30, 2014 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Nacelle Strut - Flammable Fluid Drain Path Change 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Unpublished Work.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: October 30, 2014 777-54-0035 1 of 31
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Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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Table of Contents
Summary5
1. PLANNING INFORMATION9
A. Effectivity9
1. Airplanes9
2. Spares Affected ........................................ 1 4 B. Concurrent Requirements ...................................... 1 4 C. Reason ................................................ 1 4 D. Description .............................................. 1 5 E. Compliance .............................................. 1 5 F. Approval ............................................... 1 6 G. Manpower .............................................. 1 6 H. Weight and Balance Changes .................................... 1 6 I. Electrical Load Data ......................................... 1 6 J. References .............................................. 1 6
1. Existing Data: ......................................... 1 6
2. Data Supplied with this Service Bulletin: ........................... 1 7
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 1 7 K. Publications Affected ........................................ 1 7 L. Interchangeability and Intermixability of Parts ........................... 1 7 M. Software Accomplishment Summary ................................ 1 7
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 ....................... 2 0
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 2 1 A. GENERAL INFORMATION ..................................... 2 1 B. WORK INSTRUCTIONS ....................................... 2 2 FIGURE 1: STRUT TO WING FRONT SPAR - LOWER WING PANELS - SEALANT APPLICATION - LEFT SIDE .............................................. 2 4 FIGURE 2: STRUT TO WING FRONT SPAR - LOWER WING PANELS - SEALANT APPLICATION - RIGHT SIDE .............................................. 2 7 APPENDIX A: GAP BETWEEN LOWER WING PANELS ADJACENT TO STRUT AFT VAPOR BARRIER . 30 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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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
SPECIAL ATTENTION SummaryNumber: 777-54-0035Original Issue: October 30, 2014 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Nacelle Strut - Flammable Fluid Drain Path Change BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
CONCURRENT REQUIREMENTS None.
BACKGROUND Accomplishment of this service bulletin will prevent fire and smoke in the pylon area in the event of a fuel leak.
The existing drainage provisions in the wing leading edge flammable fluid leakage zone above the strut may allow leaked flammable fluid (fuel) to come in contact with an ignition source (aft strut heat shield). When the flammable fluid comes in contact with an ignition source, there is a risk of fire in the pylon area, including uncontrolled fire in the upper strut inside the pylon and personal injury during ground operations.
Boeing has received two in-service events that reported fire and smoke from the aft pylon area after landing and engine shutdown. Subsequent investigation found that there was a fuel leak caused by a damaged o-ring in the fuel coupling attached to the wing front spar. The fuel was captured by the fuel coupling rubber boot and was discharged into the strut-to-wing cavity flammable fluid leakage zone as intended. The fuel did not follow its intended drain paths into the aft strut and lower wing panel drains, but instead followed an unintended drain path through an unsealed gap between the lower wing panels above the strut aft vapor barrier. The leaking fuel then followed gaps and seams in the aft fairing structure and eventually ignited after contact with the hot engine exhaust heat shield causing the fires.
Boeing has done factory testing to analyze and verify the flammable fluid drainage path in the strut-to-wing cavity. The test results showed that the interface between the strut aft vapor barrier and the lower wing panel had an unsealed gap that allowed the fuel to drain down and eventually contact the engine exhaust heat shield, which is an ignition source. Subsequent to the factory testing and analysis, Boeing has developed a sealing method to better control the flammable fluid drain path and prevent fire and smoke in the aft pylon area in the event of a fuel leak.
This service bulletin is sent to provide a wing panel gap sealing method to prevent flammable fluids from taking the unintended path and reaching a possible ignition source.
Boeing Fleet Team Digest (FTD) 777 FTD 54-13004 is related to this service bulletin.
Boeing Service Related Problem (SRP) 777-54-0146 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.
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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 (PRR 62777-94S) Get access to the inboard side of the strut-to-wing front spar area by removing fairing and access panels. Apply sealant to fill the gap between the lower wing panels adjacent to the strut aft vapor barrier. Close access.
EFFECTIVITY 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 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.
Boeing recommends that the change given in this service bulletin be done within 1,875 days after the original issue date of this service bulletin.
INDUSTRY SUPPORT INFORMATION Boeing warranty remedies are available for airplanes in warranty as of February 28, 2013. 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 Elapsed HoursTotal Task HoursAirplanes
2.702.70Group 1 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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MATERIAL INFORMATION Operator Supplied Parts/Materials.
Refer to Paragraph 2.A., Material - Price and Availability.
GET ACCESS TO THE
INBOARD SIDE OF THE
STRUT TO WING FRONT SPAR AREA. APPLY
SEALANT TO FILL THE GAP
BETWEEN THE LOWER WING PANELS. PUT THE
AIRPLANE BACK TO A SERVICEABLE CONDITION.
LEADING EDGE PANELS VAPOR
LEFT STRUT SHOWN BARRIER (RIGHT STRUT OPPOSITE)
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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
SPECIAL ATTENTION Number: 777-54-0035 Original Issue: October 30, 2014 ATA System: 5451 SUBJECT: NACELLES/PYLONS - Nacelle Strut - Flammable Fluid Drain Path Change BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.
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 777-200, 777-200LR, 777-300, 777-300ER, and 777F Airplanes, line numbers 1-1243 in 1 Group(s). The Variable Numbers and Group Information for the applicable airplanes is given below. An equivalent change is on subsequent production airplanes. Refer to PRR 62777-94S for data about this change.
DESCRIPTIONCONFIGURATIONGROUP Airplane line numbers 1 through 1243.-1 Airplane Models:
777-200, 777-200LR, 777-300, 777-300ER, 777F GroupVariable Number 1WA001 - WA017 1WA076 - WA080 1WA086 - WA093 1WA101 - WA104 1WA116 - WA119 1WA131 - WA137 1WA171 - WA175 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 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 1WB411 - WB413 1WB416 - WB439 1WB446 - WB453 1WB476 1WB481 - WB484 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 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 1WC571 - WC574 1WC581 1WC586 - WC587 1WC591 - WC595 1WD001 - WD002 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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GroupVariable Number 1WD011 - WD018 1WD031 - WD036 1WD046 - WD055 1WD066 - WD075 1WD081 - WD089 1WD091 1WD096 1WD101 - WD106 1WD111 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 - WD897 1WD911 - WD918 1WD921 - WD930 1WD936 - WD957 1WD966 - WD970 1WD981 - WD982 1WD986 - WD987 Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details.
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