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NONDESTRUCTIVE TESTING MANUAL Part 4 - Ultrasonic Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Page 1 53- 61- 114 EFFECTIVITY: SEE PARAGRAPH 2 TR 53- 135 TEMPORARY REVISION 53- 135 FILING INSTRUCTIONS: Insert this Temporary Revision facing TASK Part 4, 53- 61- 114.
Record the incorporation of this Temporary Revision on the yellow RECORD OF TEMPORARY REVISIONS sheet at the front of this volume.
Keep this Temporary Revision until Revision 45 incorporates this information into the Nondestructive Testing Manual.
DESCRIPTION: This Temporary Revision revises TASK Part 4, 53- 61- 114 SPECIAL
DETAILED INSPECTION OF THE ENGINE SUPPORT BEAM AT FS640.0 BETWEEN LBL18.0 AND RBL18.0 to introduce a new calibration reference standard (CRS) and make other miscellaneous changes.
Part 4 of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 2 SPECIAL DETAILED INSPECTION OF THE ENGINE SUPPORT BEAM AT FS640.0 BETWEEN LBL18.0 AND RBL18.0,
1. General A. Function
(1) This inspection procedure is used to detect subsurface cracks propagating from the two aft rows of fastener holes in the top and bottom webs, 601−35006−3 and 601−35006−5 respectively, of the engine support beam covered by the transversal angles, along WL119.12 and WL111.09, and between LBL18.00 and RBL18.00, at FS640.00.
NOTE: This subsurface inspection is to be done at the same time as the eddy current inspection (Refer to the NDTM Part 6, 53−61−114).
This inspection procedure applies to both sides of the aircraft.
B. Reference Information
(1) For added data that is necessary to do this inspection, refer to the manuals that follow:
− Nondestructive Testing Manual (NDTM) Part 1 General Information − Structural Repair Manual (SRM) − Aircraft Maintenance Manual (AMM).
certified to an NDT Standard approved by the National Airworthiness Authority.
C. Location
(1) The area is in Zone 311/312 (Refer to the NDTM Part 1 General Information, 51−01−03).
D. Access
(1) The access to the engine support beam is from the aft−equipment compartment door 311BB.
E. Parts Examined in this Procedure Refer to Table 1.
Table 1 − Part Identification Data ITE M NO. [1] DESCRIPTION DRAWING OR PARTNUMBER [2] MATERIAL SPECIFICATION 1 Top web 601−35006−3 7075−T62 QQ−A−250/132 Bottom web 601−35006−5 7075−T62 QQ−A−250/13 NOTE [1]: Parts that do not include an item number are not identified in Figure 3.
NOTE [2]: Numbers that do not include a dashed suffix are drawing numbers.
2. Effectivity A. All aircraft Pre−SB 601R−53−059 Rev. A or later, or Pre−SB 601R−53−065.
NOTE: NDTM Part 6, 53−61−114 must be accomplished in order to complete the full inspection.
TR 53- 135 AWL 53-61-114
(2) This inspection must be done by a Level II or Level III ultrasonic qualified indivual Page 2of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 23.
Tools and Equipment A. Use the items identified as follows, or their equivalent (refer to NDTM Part 1, General Information, 51−20−04):
NOTE: Equivalent ultrasonic equipment may be used provided that it satisfies the requirements of this procedure and is capable of resolving the reference notch in the calibration reference standard at the required level of resolution.
− Ultrasonic Flaw Detector, Sonatest Model: UFDS − Miniature angle−beam transducer, 45 degrees in Al, 0.25 X 0.375 in. (6.35 X 9.52 mm), 5 MHz frequency, Model: VM 7−121−TC−A − Coaxial cable (BNC to microdot) − Gorptech industrial ultrasonic couplant gel supplied by Inspectech Ltd − MHI RJ Aviation calibration reference standard No. EXCM601R30039, similar in cross section as the inspection area containing electrical discharge machined (EDM) notches − High intensity light source.
4. Preparation and Cleaning A. Procedure
(1) Identify the location of the area to be inspected.
WARNING: MAKE SURE THAT THERE IS A GOOD FLOW OF CLEAN AIR AND SUFFICIENT FIRE PROTECTION. USE APPROVED BODY PROTECTION WHEN YOU USE SOLVENTS. ALL SOLVENTS ARE POISONOUS AND SOME ARE FLAMMABLE.
(2) Open the aft−equipment compartment door to get access to the engine support beam (Refer to NDTM Part 1, 51−01−04).
(3) Clean the inspection surfaces (Refer to the SRM, 51−26−00).
NOTE: It is not necessary to remove the finish from the parts unless it shows deterioration or local damage.
(4) If the finish in the area to be inspected is damaged or deteriorated, remove the finish (Refer to the SRM, chapter 51).
5. Inspection for Subsurface Cracks Initiating from the Most Aft Row of Fasteners in the
0.032−Inch (0.81 mm) Thick Section of the Top and Bottom Webs at FS640.00, at BL0.00 and BL4.00, along WL119.12 and WL111.09 A. Equipment Calibration Refer to Figure 1 and Figure 2.
TR 53- 135 Page 3of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 2 rnd5361114_003.dg, jp/gg, 11/09/00
0.62 in.
(15.75 mm) NOTE Letters A through D are EDM notches.
TRANSDUCER PLACEMENT 1
TRANSDUCER PLACEMENT 2 −5 ANGLE A B D C
TRANSDUCER PLACEMENT 3
TRANSDUCER PLACEMENT 4 −4 ANGLE −4 ANGLE CALIBRATION REFERENCE STANDARD EXCM601R 30039
AND TRANSDUCER PLACEMENTS
CHEM MILL LINE (REF)
1.00 in.
(25.4 cm)
0.032 in.
(0.81 mm)
0.050 in.
(1.27 mm)
0.25 in.
(6.35 mm) −3 WEB
0.62 in.
(15.75 mm) −3 WEB (FOUR PLACES) Calibration Reference Standard − Calibration and Inspection Figure 1
TR 53- 135 Page 4of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 2 rnd5361114_004.dg, gg/jp, 01/11/00 NEB NEA IP
CRT DISPLAY IP EFH IP NEC TRANSDUCER PLACEMENT 3 50 1000 TRANSDUCER PLACEMENT 4 TRANSDUCER PLACEMENT 1 TRANSDUCER PLACEMENT 2 50 100 50 10050 1000 0 0 IP NED NOTES 50 100 50 100 50 100SIGNAL AMPLITUDE 50 100
SIGNAL AMPLITUDE SIGNAL AMPLITUDE
SIGNAL AMPLITUDE IP = Initial pulse.
EFH = echo from hole.
NEA = Echo from notch A.
NEB = Echo from notch B.
NEC = Echo from notch C.
NED = Echo from notch D.
CRT DISPLAY
CRT DISPLAY CRT DISPLAY EFH CRT Displays − Calibration and Indications Figure 2
TR 53- 135 Page 5of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 2
(1) Connect the microminiature angle−beam transducer VM 7−121−TC−A to the ultrasonic instrument using the coaxial cable.
(2) Turn the power ON and set the instrument to pulse−echo test mode and 5 MHz test frequency.
(3) Apply an even layer of couplant gel on the 0.032−inch (0.81 mm) thick section of −3 web adjacent to the −4 and −5 angles (0.62−inch (15.75 mm) edge distance side) of the calibration reference standard EXCM601R30039, as shown in Figure
1.
(4) Do the instrument calibration on the calibration reference standard as follows:
(a) Position the front of the transducer against the −4 angle so that the sound beam is directed at EDM notch A, see Transducer Placement 1, Figure 1.
Swivel the transducer to obtain a maximized reflection signal form EDM notch A.
(b) Adjust the instrument (GAIN) control to obtain a 100% full screen height (FSH) signal from EDM notch A.
(c) Use the instrument (DELAY) and (RANGE) controls to set the leading edge of the reflection signal from EDM notch A at 20% of the horizontal limit on the baseline.
B. Inspection Procedure Refer to Figure 2 and Figure 3.
(1) After equipment calibration as outlined in Paragraph 5.A., apply an even layer of couplant gel on the 0.32−inch (0.81 mm) thick sections of the top and bottom webs, 601−35006−3 and 601−35006−5 respectively, aft corner at BL0.00 and BL4.00 adjacent to the edge of the transversal angles (with the vertical flange) at FS640.00.
The couplant gel must cover approximately 0.50 in. (12.70 mm) each side of the most aft row of fasteners.
(2) Position the transducer on the top web 601−35006−3 aft corner with its front against the transversal angle (the side with the vertical flange) at BL0.00. Scan both sides of the fastener with a slight swivel movement and use the edge of the transversal angle as a guide.
(3) Repeat Paragraph 5.B.(2) at BL4.00.
(4) Repeat Para. 5.B.(2) and 5.B.(3) for the bottom web 601−35006−5.
C. Acceptance or Rejection Criteria
(1) Any distinct vertical deflection signal, which is 50% or greater than the response from the 0.040−inch (1.00 mm) deep EDM notch, is classified as a crack indication.
(2) Record and report results in accordance with company guidelines and policies.
(3) For indications that exceed the allowable limits, it is recommended that you contact MHIRJ Customer Support (refer to SRM 51−13−01).
TR 53 - 135 Page 6of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 2 FS 625.30 BL 0.00 WL 119.12 WL 111.09 FS 640.00 rnd5361114_005.dg, gg, 14/09/00 NOTE 1 Examine the shaded area.
A B A 1
TRANSVERSAL (9 PLACES)
TRANSVERSAL (9 PLACES) (9 PLACES) LBL 4.00 RBL 4.00 RBL 9.50
TOP WEB 1 FS 640.00 LBL 9.50
BOTTOM WEB 2 − BB
TOP WEB 1 1
BOTTOM WEB 2 WL 119.12 WL 111.09 FS 640.00 LBL 18.00 RBL 18.00 B
MOST AFT
FASTENER 2ND AFT
FASTENER 2ND AFT
FASTENER Inspection of the Engine Support Beam at FS640.00 Between RBL18.00 and LBL18.00 − Location and Inspection Figure 3
TR 53- 135 Page 7of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 2
6. Inspection for Subsurface Cracks Initiating from the Second Aft Row of Fasteners in the
0.032−Inch (0.81 mm) Thick Section of the Top and Bottom Webs at FS640.00, at BL0.00 and BL4.00, along WL119.12 and WL111.09 A. Equipment Calibration Refer to Figure 1 and Figure 2.
(1) Do the instrument calibration on the calibration reference standard as follows:
(a) Position the front of the transducer against the −4 angle so that the sound beam is directed at EDM notch B, see Transducer Placement 2, Figure 1.
Swivel the transducer to obtain a maximized reflection signal form EDM notch B.
(b) Adjust the instrument (GAIN) control to obtain a 100% full screen height (FSH) signal from EDM notch B.
(c) Use the instrument (DELAY) and (RANGE) controls to set the leading edge of the reflection signal from EDM notch B at 20% of the horizontal limit on the baseline.
B. Inspection Procedure Refer to Figure 3.
(1) After equipment calibration as outlined in Paragraph 6.A., apply an even layer of couplant gel on the 0.32−inch (0.81 mm) thick sections of the top and bottom webs, 601−35006−3 and 601−35006−5 respectively, aft corner at BL0.00 and BL4.00 adjacent to the edge of the transversal angles (with the vertical flange) at FS640.00.
The couplant gel must cover approximately 0.50 in. (12.70 mm) each side of the second aft row of fasteners.
(2) Position the transducer on the top web 601−35006−3 aft corner with its front against the transversal angle (the side with the vertical flange) at BL0.00. Scan both sides of the fastener with a slight swivel movement and use the edge of the transversal angle as a guide.
(3) Repeat Paragraph 6.B.(2) at BL4.00.
(4) Repeat Paragraph 6.B.(2) and 6.B.(3) for the bottom web 601−35006−5.C . Acceptance or Rejection Criteria
(1) Any distinct indications with an amplitude signal of 50% FSH or greater is classified as a crack and cause for rejection.
(2) Record and report results in accordance with company guidelines and policies.
(3) For indications that exceed the allowable limits, it is recommended that you contact MHIRJ Customer Support (refer to SRM 51−13−01).
7. Inspection for Subsurface Cracks Initiating from the Most Aft Row of Fasteners in the
0.05−Inch (1.27 mm) Thick Section of the Top and Bottom Webs at FS640.00, Between BL9.50 and BL18.00, along WL119.12 and WL111.09 A. Equipment Calibration Refer to Figure 1 and Figure 2.
TR 53- 135 Page 8of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 2
(1) Apply a thick even layer of couplant gel on the 0.05−inch (1.27 mm) thick section of the −3 web adjacent to the −4 and −5 angles (0.62−inch (15.75 mm) edge distance side) of the calibration reference standard EXCM601R30039, as shown in Figure 1.
(2) Do the instrument calibration on the calibration reference standard as follows:
(a) Position the front of the transducer against the −4 angle so that the sound beam is directed at EDM notch C, see Transducer Placement 3, Figure 1.
Swivel the transducer to obtain a maximized reflection signal from EDM notch C.
(b) Adjust the instrument (GAIN) control to obtain a 100% full screen height (FSH) signal from EDM notch C.
(c) Use the instrument (DELAY) and (RANGE) controls to set the leading edge of the reflection signal from EDM notch C at 20% of the horizontal limit on the baseline.
B. Inspection Procedure Refer to Figure 3.
(1) After equipment calibration as outlined in Paragraph 7.A., apply an even layer of couplant gel on the 0.05−inch (1.27 mm) thick section of the top and bottom webs, 601−35006−3 and 601−35006−5 respectively, aft corner between BL9.50 and BL18.00 adjacent to the edge of the transversal angles (with the vertical flange) at FS640.00. The couplant gel must cover approximately 0.50 in. (12.70 mm) each side of the most aft row of fasteners.
(2) Position the transducer on the top web 601−35006−3 aft corner with its front against the transversal angle (the side with the vertical flange) at BL9.50. Scan both sides of the fastener with a slight swivel movement and use the edge of the transversal angle as a guide.
(3) Repeat Paragaph 7.B.(2) between BL9.50 and BL18.00.
(4) Repeat Paragraph 7.B.(2) and 7.B.(3) for the bottom web 601−35006−5.
C. Acceptance or Rejection Criteria
(1) Any distinct indications with an amplitude signal of 50% FSH or greater is classified as a crack and cause for rejection.
(2) Record and report results in accordance with company guidelines and policies.
(3) For indications that exceed the allowable limits, it is recommended that you contact MHIRJ Customer Support (refer to SRM 51−13−01).8.
Inspection for Subsurface Cracks Initiating from the Second Aft Row of Fasteners in the
0.05−Inch (1.27 mm) Thick Sections of the Top and Bottom Webs at FS640.00, Between BL9.50 and BL18.00, along WL119.12 and WL111.09 A. Equipment Calibration Refer to Figure 1 and Figure 2.
(1) Apply an even layer of couplant gel on the 0.05−inch (1.27 mm) thick section of the −3 web adjacent to the −4 and −5 angles (0.62−inch (15.75 mm) edge distance side) of the calibration reference standard EXCM601R30039, as shown in Figure 1.
TR 53- 135 Page 9of 10 Sep 15/23
NONDESTRUCTIVE TESTING MANUAL Part 4 − Ultrasonic Part 4 53−61−114 EFFECTIVITY: SEE PARAGRAPH 2
(2) Do the instrument calibration on the calibration reference standard as follows:
(a) Position the front of the transducer against the −4 angle so that the sound beam is directed at EDM notch D, see Transducer Placement 4, Figure 1.
Swivel the transducer to obtain a maximized reflection signal from EDM notch D.
(b) Adjust the instrument (GAIN) control to obtain a 100% full screen height (FSH) signal from EDM notch D.
(c) Use the instrument (DELAY) and (RANGE) controls to set the leading edge of the reflection signal from EDM notch D at 20% of the horizontal limit on the baseline.
B. Inspection Procedure Refer to Figure 3.
(1) After equipment calibration as outlined in Paragraph 8.A., apply an even layer of couplant gel on the 0.05−inch (1.27 mm) thick section of the top and bottom webs, 601−35006−3 and 601−35006−5 respectively, aft corner between BL9.50 and BL18.00 adjacent to the edge of the transversal angles (with the vertical flange) at FS640.00. The couplant gel must cover approximately 0.50 in. (12.70 mm) each side of the second aft row of fasteners.
(2) Position the transducer on the top web 601−35006−3 aft corner with its front against the transversal angle (the side with the vertical flange) at BL9.50. Scan both sides of the fastener with a slight swivel movement and use the edge of the transversal angle as a guide.
(3) Repeat Paragraph 8.B.(2) between BL9.50 and BL18.00.
(4) Repeat Paragraph 8.B.(2) and 8.B.(3) for the bottom web 601−35006−5.
C. Acceptance or Rejection Criteria
(1) Any distinct indications with an amplitude signal of 50% FSH or greater is classified as a crack and cause for rejection.
(2) Record and report results in accordance with company guidelines and policies.
(3) For indications that exceed the allowable limits, it is recommended that you contact MHIRJ Customer Support (refer to SRM 51−13−01).
9. Close Out A. Remove the couplant gel from the inspection surfaces.
B. Make sure that NDTM Part 6, 53−61−114 has been completed.
C. If the finish in the inspection area was removed, replace the finish (Refer to the SRM, Chapter 51).
D. Remove all tools, equipment and unwanted materials from the work area.
E. Close the aft−equipment compartment door (Refer to Part 1, 51−01−04).
TR 53- 135 Page 10 of 10 Sep 15/23