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Sikorsky Aircraft Corporation Sikorsky 6900 Main Street P.O. Box 9729 A United Technologies Company (203) 386-4000 Stratford, Connecticut 06497-9129
SPECIAL
SERVICE INSTRUCTIONS SSI No. 92-021A Subject: TAIL ROTORS - Tail Rotor Blade Wire Mesh, One-Time Inspection of Purpose: Provide instructions to perform an inspection of the tail rotor blade wire mesh.
Background: Tail rotor blade skins manufactured with mislocated aluminum wire mesh have been discovered, and there is a suspect population of these blades in the field that require inspection. This wire mesh is integral to the skin and is located towards the leading edge of the tail rotor blade assembly, and this mislocated wire mesh on the pocket skin resulted in an area of missing wire mesh from the trailing edge of the torque tube bond approximately 0.25 - 1.00-inch chord-wise along the length of blade.
Model: S-92A model helicopters.
Effectivity: S-92A model helicopters delivered with 92170-11000 Series tail rotor blades from serial number A111-00001 to serial number A111-00585.
Description: Helicopter is prepared for maintenance. A one-time inspection is performed on tail rotor blades to identify a possible unacceptable tail rotor blade condition. If a non-conforming condition is found, contact Sikorsky Aircraft Corporation. Tail rotor blades are reinstalled, if required. Helicopter is returned to service.
Drawings Required for Modification: No drawings required References:
(a) Maintenance Manual, SA S92A-AMM-000, Section/Chapter 64-10-01-900-001.
(b) Maintenance Manual, SA S92A-AMM-000, Section/Chapter 64-10-01-900-002.
(c) Structural Repair Manual, SA S92A-SRM-000, Section/Chapter 64-10-01-340-006.
Approval: The change affected by this document is classified as Minor, and is in accordance with the applicable requirements of Federal Aviation Regulations, FAR 29. Such data submitted by the TC holder for use on an EU-registered helicopter and related articles are automatically approved by ED Decision 2004/04/CF, as amended by ED Decision 2007/001/C. Reference to the ED Decisions mentioned above shall be made in the release documents issued by the EASA 145 approved organization, releasing the relevant EU-registered helicopter or component to service.
September 08/09 Revision A - October 21, 2009 Page 1 of 15
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A Instructions:
NOTE
• A complete review of this directive is recommended before starting the inspection.
• Before beginning this inspection procedure, use the material information list to make sure tooling and support equipment are present and in serviceable condition.
• The instructions in this SSI shall be done by personnel experienced in Non-Destructive Inspection (NDI), standard working/repair, and safety practices.
• Slight variations to the instructions contained herein are allowed, as long as the intent of the inspections are accomplished.
A. Preparation for inspection:
NOTE
• Extent of removals may vary according to specific helicopter configuration.
• Tail rotor blade inspection may be performed without removing tail rotor blades from helicopter.
(1) Turn off electrical and hydraulic power and make helicopter safe for ground maintenance.
(2) Remove tail rotor blades, if required, per reference (a).
B. Perform one-time inspection of tail rotor blades as follows:
NOTE
• The intent of this one time inspection is to discover mislocated aluminum wire mesh on tail rotor blade skins. The primary concern is the missing wire mesh over the graphite torque tube region and can exist on both the upper and lower skin airfoils. This aluminum mesh is used for lightning strike protection on the S-92 tail rotor blades.
• Sikorsky Engineering has identified two options for inspection of tail rotor blades: Option A is a NDI (Non-Destructive Inspection) method; Option B is an alternate method to be used at the discretion of the operator, in the event NDI capability does not exist. It's a hand sanding method of sanding through the existing paint to determine if mislocated wire mesh is found.
(1) Perform Option A, Eddy Current Testing as follows:
NOTE
• The Option A Eddy Current inspection must be performed by a Level Il technician.
• The Option A inspection procedures shall be performed for both upper and lower air foils on each tail rotor blade.
• The calibration settings may be altered as necessary to suit equipment characteristics and features.
September 08/09 Revision A - October 21, 2009 2
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A
• Due to coating variations paint, primer, feathering, etc.) on the tail rotor blades which may alter the Calibration Point, calibration must be verified at each position.
(a) Set up Flaw Detector (Phasec 2200 or equivalent) as follows:
SETTING POSITION Frequency 50KHz Mode Diff. - One Channel Disp Phase 58 deg/As required X:Y/H:V/differential gain Equal View Ch 1 Persist 1 Sec Ch 1 Freq 50 KHZ Ch 1 Gain 55dB Ch 1 X:Y 0.0dB Gain -(55dB) Hi Pass DC Lo Pass 200HZ Inp Gain OdB X pos 1 98 Y pos 1 -49 NOTE Use the +/- 1.5-inch tolerance range in the listed template positions (steps b and d) to obtain a consistent calibration gain setting from blade to blade.
(b) Locate the center line of one template (E92-725-15-097) 4.0 inches (+/- 1.5-inches) inboard from the tip of the tail rotor blade (Figures 1 and 2).
(c) Tape the template (E92-725-15-097) in place on both sides of the tail rotor blade with the crease firmly seated on the trailing edge of the blade.
(d) Locate the centerline of the other template (E92-725-15-097) 17.0 inches (+/- 1.5-inches) inboard of the tip of the tail rotor blade.
(e) Tape the template (E92-725-15-097) in place on both sides of the tail rotor blade with the crease firmly seated on the trailing edge of the blade.
(f) Null the instrument in air (Figure 3).
(g) Using the Vertical position and Horizontal position controls move the "Air Null" position to the lower R/H grid of the screen.
(h) Place the probe in the calibration port of the template (E92-725-15-097) (Figure 4).
September 08/09 Revision A - October 21, 2009
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A
(i) Adjust the instrument gain and phase controls to position the "flying dot" in the upper L/H grid of the display.
NOTE
• The composite torque tube in the rotor blade is slightly conductive and will cause a small deflection of the "Flying Dot" even in the absence of aluminum mesh.
• Full screen deflection of the "Flying Dot" does not occur until the probe is more than an inch past the edge of the mesh.
() Repeat null/cal. as necessary until the "flying dot" is visible, centered, in the lower R/H grid of the screen with the probe in air, and visible centered in the upper L/H grid of the screen when the probe is placed in the calibration port.
(k) Null/Balance scope with probe in air (Figure 3).
(I) Place the probe in both of the cutouts labeled "Test Ports" (Figure 5).
1 If the "flying dot" travels more than 10% of the distance along the "lift off line" to the upper L/H corner of the display in any of the test ports the blade is acceptable.
NOTE Tail rotor blades with mesh mislocations identified by Eddy Current Testing as nonconforming may be verified using the sanding method detailed in Option B.
2 If the "flying dot" travels 10% or less of the distance along the "lift off line" to the upper L/H corner of the display in both of the test ports the blade may be nonconforming, proceed to step (p) below.
NOTE Coating variations (paint, primer, feathering, etc.) on tail rotor blades may alter the Calibration Point at each new position.
(m) Verify calibration, at each new position, by repeating the procedure in steps (h) through
(1) for both templates (4.0 inch, +/- 1.5-inch location and 17.0 inch +/- 1.5-inch location) at both positions (upper and lower airfoils) for each tail rotor blade.
(n) Repeat steps (b) through (m) for each tail rotor blade.
(o) Remove templates (E92-725-15-097), tape, and equipment from tail rotor blades.
NOTE Consultation with Sikorsky Aircraft Customer Service Engineering is required prior to disposition of tail rotor blades deemed non-conforming per the above inspection criteria.
(p) Report non-conforming tail rotor blades to Customer Service Engineering at 1-800- Winged-S or 1-203-416-4299, or proceed to Option B inspection in paragraph (2) to verify
(q) Remove non-conforming tail rotor blades from helicopter, if required, per reference (a) September 08/09 Revision A - October 21, 2009 4
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A
(r) Install acceptable tail rotor blades, if required, per reference (b).
(s) Return helicopter to service.
(2) Perform Option B (alternate method) inspection as follows:
NOTE Repeat the Option B inspection procedures for both upper and lower air foils on each tail rotor blade.
(a) Remove paint and primer from tail rotor blade as follows (Figures 6, 7, and 8):
CAUTION
USE EXTREME CAUTION WHEN SANDING TAIL ROTOR BLADE SO AS NOT TO DAMAGE UNDERLYING SKIN AND WIRE MESH.
1 Hand sand tail rotor blade using 180 grit sandpaper at approximately RSTA 49.00 and 62.00, creating a 1.5-inch (maximum) diameter inspection window centered at these span- & chord-wise locations on upper and lower blade surfaces.
2 Carefully sand progressively through the white or yellow paint topcoat and green primer to expose the light tan fiberglass skin and silver colored aluminum wire mesh, if the edge of the mesh is not exposed, carefully remove paint closer to the leading edge until it is visible.
(b) Check for aluminum wire mesh coverage in the inspection area (Figures 6 and 7).
(c) Visually locate the aft edge of the aluminum wire mesh, which is silver in color, contrasted to the light tan color of the fiberglass skin (Figures 6, 7, and 8).
(d) Using a tape measure or scale, measure from the trailing edge of the blade to the trailing edge of the wire mesh, holding the measuring device against the contour of the blade (Figures 6 and 7).
1 If the trailing edge of the wire mesh is located more than 6.38 inches from the trailing edge of the blade, the blade is non-conforming.
2 If the trailing edge of the wire mesh is located 6.38 inches or less from the trailing edge of the blade, the blade is acceptable.
NOTE Consultation with Sikorsky Aircraft Customer Service Engineering is required prior to disposition of tail rotor blades deemed non-conforming per the above inspection criteria.
(e) Report non-conforming tail rotor blades to Customer Service Engineering at 1-800- Winged-S or 1-203-416-4299 for further direction.
(f) For acceptable tail rotor blades, touch up sanded area and paint per reference (c).
(g) Remove non-conforming tail rotor blades from helicopter, if required, per reference (a).
(h) Install tail rotor blades, if required, per reference (b).
September 08/09 Revision A - October 21, 2009 5
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A
(i) Return helicopter to service.
( Proceed to section D.
C. Test Procedure:
None.
D. Record of Compliance:
Make an appropriate logbook/log card entry to show compliance with this Special Service Instructions.
Electrical Load Data:
Not affected.
Software Load Data:
None.
Weight and Balance: Change resulting from these instructions is as follows:
None.
Manpower (Estimated):
No. of Men No. of Hours Man-hours Helicopter Mechanic 2 4.0 8.0 QA Inspector 1 1.0 1.0 Total Man-Hours: 9.0* * Does not include time required to prepare helicopter for maintenance or return it to flight status.
Material Information:
A. Modification Kits required None.
September 08/09 Revision A - October 21, 2009 6
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A B. Consumable Materials
WARNING OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN USING CONSUMABLES.
WHEN APPLICABLE, WEAR NECESSARY PROTECTIVE GEAR DURING HANDLING AND USE.
IF A CONSUMABLE IS FLAMMABLE OR EXPLOSIVE, MAKE CERTAIN CONSUMABLE AND ITS VAPORS ARE KEPT AWAY FROM HEAT, SPARK, AND FLAME. MAKE CERTAIN EQUIPMENT IS
PROPERLY GROUNDED AND FIREFIGHTING EQUIPMENT IS READILY AVAILABLE PRIOR TO USE. FOR ADDITIONAL INFORMATION ON TOXICITY, FLASHPOINT, AND FLAMMABILITY OF
CHEMICALS, CONSULT YOUR MEDICAL PEOPLE, OR MANUFACTURER OF THE CONSUMABLE.
Qty Nomenclature Part Number Source A/R Abrasive Cloth, 180-grit ANSI B74.18, or equivalent (1) A/R Cheesecloth CCC-C-440, or equivalent (1) C. Support Equipment:
Qty Nomenclature Part Number Source 1 Flaw Detector Model: Phasec 2200 (or equivalent) (2) 1 Probe VMD120-05-6-.375, 1-20KHz (1)(2) 1 Tape Measure Standard (1) D. Tooling Required:
Qty Nomenclature Part Number Source 2 Template E92-725-15-097 (9) E. Source
(1) Available through normal supply channels.
(2) Manufacturer: GEIT, Hocking.
September 08/09 Revision A - October 21, 2009 7
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A
CALIBRATION PORT
THE TEST AND CALIBRATION PORTS WILL BE 0.325 - INCHES IN DIAMETER.
TEST
PORTS THE TEST PORTS WILL BE SPACED 1.125 - INCHES APART CENTER TO CENTER.
THE BOTTOM OF THE TEST PORTS WILL BE 6.250 - INCHES FROM THE INSIDE OFTHE FOLD.
THE BOTTOM OF THE
CALIBRATION PORT WILL BE
7.50 - INCHES FROM THE INSIDE OF THE FOLD.
THE TOTAL LENGTH OF THE TEMPLATE BEFORE FOLDING ID 17.0 - INCHES
BOTH SIDES OF THE TEMPLATE WILL
HAVE THREE IDENTICALLY POSITIONED PORTS.
8.437 - INCHES
6.275 - INCHES
FROM THE INSIDE
OF THE FOLD E92-725-15-097
TEMPLATE (REF) -20-INCHES → TWO-PARTFOLD WITHALEGLENGTHOF 0.62-INCH TD64010 E92-725-15-097 TEMPLATE FOR NDI INSPECTION OF TAIL ROTOR BLADE FIGURE 1 September 08/09 Revision A - October 21, 2009
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A
4.0 - INCHES (+ 1.5 - INCHES) FIRST
TEMPLATE SECOND
TEMPLATE
17.0 - INCHES (+ 1.5 - INCHES) 92170-11000-SERIES TAIL ROTOR BLADE TD64001
POSITIONING THE FIRST AND SECOND TEMPLATES ON TAIL ROTOR BLADE FIGURE 2 September 08/09 Revision A - October 21, 2009 9
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A HOCKING PHASEC 2200 FLAW DETECTOR TD64002
NULLING FLAW DETECTOR INSPECTION INSTRUMENT FIGURE 3 September 08/09 Revision A - October 21, 2009 10
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A
CALIBRATION
TEMPLATE PORT PROBE HOCKING PHASEC 2200 FLAW DETECTOR AND PROBE IN CALIBRATION PORT TD64003 PLACING PROBE IN CALIBRATION PORT OF TEMPLATE, POSITIONING "FLYING DOT" FIGURE 4 September 08/09 Revision A - October 21, 2009 11
SPECIAL SERVICE INSTRUCTIONS NO. 92-021A PROBE
TEST TEMPLATE PORTS HOCKING PHASEC 2200 FLAW DETECTOR AND PROBE IN TEST PORT TD64054
PLACING PROBE IN TEST PORT OF TEMPLATE AND INSTRUMENT RESPONSE FIGURE 5 September 08/09 Revision A - October 21, 2009 12