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Scribe Lines

737 Classic

Contents
Background
Inspection Service Bulletin
Overview
Zonal Maps
Zonal Compliance Charts
Limited Return To Service (LRTS)
Pre-Threshold Scribe Finding
Example

Skin Trim
Training
Repairs

March 2005

Background

Since Feb 2003, Boeing has received reports of multiple scribe


lines in multiple locations on fifty-four 737 Classics, eight
747s, one 767, and one 757

One 737-200 airplane had 5 inch crack in a lap joint, a second


airplane had two cracks (5 and 8 inches) in adjacent bays of a
lap joint, and all due to scribe lines

One 747-400 had a 30-inch crack at the BS 2180 butt joint and
one 747-200 had a 30-inch crack at the BS 400 butt joint, both
due to improper sealant removal

March 2005

Background
Scribe lines appear to be caused by the use
of putty knives, razor blades, or other tools
used to remove sealant or to trim decals
(even plastic scrapers can damage the clad
layer of fuselage skins)

Scribe lines are generally 0.001 (0.025 mm)


to 0.005 (0.127 mm) deep, and many times do
not penetrate the ~0.003 clad layer (.076 mm)

Scribe lines typically run parallel (within 0.25


or 6.25 mm) to the upper skin at lap joints and
vertically in the splice strap between skins at
butt joints

Scribe can be hidden by sealant and may


reside just under the lap joint step depending
on tool angle

March 2005

Background

March 2005

Typical Scribe Detail - 737 Classic


Lap Joint (LN 292 -2565)
CL
Frame

Up
Upper Skin
(.036)

10

Inbd

Upper
Doubler
(.036)

Scribe in
Lower Skin

View From Outside

Scribe
Lower Skin
(.036)

Sealant

A-A

March 2005

March 2005

Mapping of Visible Scribe Lines on One


737-200
Cracks (5 and 10 inches)
Visible Scribe Lines

March 2005

737 Crack Assessment

Cracks initiated from scribe lines


Approximately 22,000 to 24,000 cycles from scribe marking to
cracks growing through the thickness of the skin
Cracks initiate at multiple points along the length of each
scribe line (MSD Multi Site Damage)
Scribing across tear straps and adjacent to lap joint lower
row MSD could potentially lead to very long cracks (zipper
effect)
Many variables affect crack initiation and growth (scatter
factor)

March 2005

Scribed Airplanes
Fifty-four 737 Classic airplanes are known to have scribes
(out of 81 inspected ~ 67%)
30 737-200s
20 737-300s

4 737-400s

8 operators in USA, 7 in Europe, 2 in Canada, 1 in Australia,


1 in Africa, 1 in South America, and 1 in Central America

March 2005

10

Lap/Butt Joint Mechanics


Upper Skin

Bonded
Doubler

0 KSI

Outer Fiber

KSI

Inner Fiber
Chem-mill Cracks

Scribe Cracks
Lower Skin

KSI

KSI

Inner Fiber

Outer Fiber

Unloaded Lap Joint


March 2005

Loaded Lap Joint


11

737 Cracking Behavior


Scribe cracks initiate at multiple sites (many per inch) along the
scribe

Multiple Crack Initiation Sites

Skin

Scribe

Multiple small cracks link up before they grow through thickness


creating a continuous long crack partially through the thickness

Skin Thickness

Crack Fronts Link Up Partially Through Skin Thickness

March 2005

12

737 Cracking Scenarios


CL
Frame

Up
Upper Skin
(.036)

10

Inbd

Upper
Doubler
(.036)

Scribe in
Lower Skin

Typical Lower
Skin, Lower
Row Crack

March 2005

View From Outside

.36 TYP

Lower Row
Crack

Lower Skin
(.036)

Scribe

A-A

13

737 Cracking Scenarios


Local Scribe Damage
Scenario
1
Scribe in
Lower Skin

Lower
Row
Cracks
Scribe in
Lower Skin

March 2005

Scribe Induced
Cracks

Scribe/Lower
Row Interaction

Scribe Induced
Cracks

14

737 Cracking Scenarios


Continuous Scribe Damage
Scenario
3
Scribe Induced
Crack

Lower
Row
Cracks

4
Scribe/Lower
Row
Interaction

March 2005

Scribe Induced
Crack

15

Where We Were

The initial position of the FAA was that scribe lines are known
damage and must be repaired before returning the airplane to
service

Boeing worked with the FAA to establish a Limited Return To


Service (LRTS) plan to allow short term operation of airplanes
that would otherwise be grounded

The initial LRTS plan consisted of burdensome inspections of


scribed areas until scribe damage was repaired (based on
limited initial data and analysis)

An inspection service bulletin has now been developed, with


FAA and operator involvement, that maintains safety but is less
burdensome than the original LRTS

March 2005

16

Working Group

Air Transport Association (ATA) sponsored

Integral part of the Lead Airline Process

Members: Boeing, the FAA (ACO and FSDO), ATA, and airlines:
US Airways

- United

Continental

- Lufthansa (LTK)

Delta

- Qantas

Southwest

March 2005

17

737 Classic Fleet Action Plan

An inspection service bulletin using a risk based zonal approach


was released on 09 Dec 04

A Repair/Modification service bulletin is scheduled for release late


in 2005

Improved sealant removal process and tools have been developed


and are continuing to be refined

Training materials for use by airline/MRO/paint facilities are being


developed (posters/videos)

A trim tool is being developed to address hidden lines that


may mitigate inspection/repair costs and reduce down time

March 2005

18

Inspection
Service Bulletin

737-53A1262

Where We Are Going

The FAAs initial position, based on limited data, was that


scribes are known damage and must be repaired

Since that time, more fleet data has become available,


extensive analysis has been performed, and specific
inspection techniques have been developed

These actions support a new position:


Scribes can be viewed as allowable damage and an
inspection program can be implemented to preclude
potential cracks from becoming critical

March 2005

20

Where We Are Going

The FAA views the current service bulletin approach as a


relieving program, allowing operators to fly with allowable
damage

An inspection service bulletin using a phased zonal


approach has been released

Key features of the bulletin are:


Specific inspection locations (zones)
Phased compliance thresholds
Return to service options if scribe lines are found

Boeing understands the FAA is considering regulatory action,


such as an NPRM, to mandate the service bulletin

March 2005

21

Service Bulletin Applicability

Applicable to all 737 Classic airplanes (L/Ns 1 3132)


Some exemptions/exceptions are possible:

Airplanes that have never been stripped or repainted since delivery from Boeing
are exempt from lap joint, butt joint, repair and door scuff plate inspections

Airplanes for which records substantiate that the wing-to-body fairing was never
removed since delivery from the OEM are exempt from the wing-to-body fairing
inspections

Airplanes that have never had decals installed are exempt from inspecting the
decal areas

For each repair, if the operators records show that the airplane has never been
stripped or painted since the repair was installed, then the inspections for that
specific repair are not required

Airplanes for which records substantiate that they have never been stripped or
repainted under the wing-to-body fairing are exempt from the wing-to-body fairing
inspections

Airplanes for which records substantiate sealant removal was performed using the
sealant removal processes identified in this service bulletin during all prior
operations since delivery from Boeing are exempt from lap joint, butt joint, repair
and door scuff plate inspections

March 2005

22

Schedule

Initial release: Covers all 737 Classic airplanes


Released on 09 Dec 2004

Rev 1: Revised for 737-400/500 bonded skins


Release planned for 31 Mar 2005

Rev 2: Revised for 737-300/400/500 solid skins and 737-200C


Release planned for 22 Jul 2005

March 2005

23

Service Bulletin Overview


There are three concepts that are key to understanding the
service bulletin:

Where:

Zonal Maps

When:

Zonal Compliance Charts

Zone

Compliance
LRTS

How to Return to Flight : Zonal LRTS Plan

March 2005

24

Zonal Maps

Zone

Zonal Maps

Zone

Scribe lines have been found over large areas of the airplane: lap joints,
butt joints, wing-to-body fairings, decal areas, window frames, door
thresholds, repair doublers, etc.

To manage the large amount of area requiring inspection while


maintaining safety, SB 737-53A1262 will allow a phased zonal
approach

This approach provides a method to prioritize aircraft inspections by


addressing the more critical locations first

This approach also results in sequenced maintenance activity, thus


reducing operator burden

Zonal maps were developed by extensive analysis of the scribe


locations, examination of specific structural details and local stress
states, and application of a non-linear structural analysis to the details

March 2005

26

Zonal Maps

Zone

Each zone is based on a fatigue threshold


Zone 1: Scribe crack threshold < 30K cycles
- Zone 1A: Areas susceptible to lap joint lower row
Multi Site Damage (MSD)
- Zone 1B: All other zone 1 areas
Zone 2: Scribe crack threshold between 30K and 50K cycles
(No MSD)
Zone 3: Scribe crack threshold between 50K and 100K
(No MSD)
Areas with scribe crack thresholds above 100K are not shown in
the Zonal Maps. For typical scribes found in these areas no
special action is required

March 2005

27

Zonal Maps

Zone

Zonal maps address the following categories:


Lap joint and butt joint
Decal areas
Repair areas
Wing-to-body fairings
Door cutout areas

Zonal maps address the


1 following 737 configurations:
Minor models -100, -200, -200C, -300, -400, -500
Bonded and solid skin configurations
1 L/N 1-291 all lap and butt joints are identified as Zone 1B. The LRTS

plan is not applicable

March 2005

28

737-200 Section 43 & 46 - Lap Splices and


Butt Joints Scribe Threshold Map
Zone 1B

Zone 1A
STA STA STA STA STA STA STA STA STA STA STA STA
360 380 400 420 440 460 480 500 500A500B 520 540
BL0
S-26R
S-25R

S-19R
S-18R
S-16R

Zone 2
STA
663.75

S-26R
STASTA STA STA STA
559 578 597 616 639

Zone

Zone 3

STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA
727 727A 727B 747 767 787 807 827 847 867 887 907 927 947.5 967 986.51006

S-25R
STA STA
685 706
S-20R

S-19R

STA
1016

S-25R
S-20R

S-14R

S-14R

S-10R

S-10R

S-4R

S-4R

BL 0
Top
S-4L

S-4L

S-10L

S-10L

S-14L

S-14L

S-16L
S-19L

E
L
P
M
A
EX
S-19L

S-22L
S-25L
S-26L
BL0

March 2005

S-26L

S-20L

S-20L
S-25L

S-25L

29

737-200 Decal Areas


Scribe Threshold Map

Zone

Zone 3

Zone 2
STA STA STA STA STA STA STA STA STA STA STA STA
360 380 400 420 440 460 480 500 500A500B 520 540
BL0
S-26R

BS
259

S-19R

STA
663.75

S-26R
STASTA STA STA STA
559 578 597 616 639

STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA
727 727A 727B 747 767 787 807 827 847 867 887 907 927 947.5 967 986.51006

S-25R

STA
1016

STA STA
685 706
S-20R

S-25R

S-19R

S-20R

S-14R

S-14R

S-10R

S-10R

S-4R

S-4R

S-4L

S-4L

S-10L

S-10L

S-14L

S-14L

S-19L

S-26L
BL0

March 2005

E
L
P
M
A
EX
S-19L

S-26L

S-20L

S-20L
S-25L

S-25L

30

737-200 External Repair Doubler


Scribe Threshold Map
Zone 1A

Zone 1B

STA STA STA STA STA STASTASTA STA STA STA STA STA STA STA STA STA STA
259. 277 294. 312 328 344 360 380 400 420 440 460 480 500 500A500B 520 540
5
5

STA STA STA STA STA


559 578 597 616 639

BL0

Zone 3
STA
663.75

S-26R

Zone

STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA
727 727A 727B 747 767 787 807 827 847 867 887 907 927 947.5 967 986.51006
STA
1016

S-25R
STA STA
685 706
S-20R

S-25R

S-19R
S-24R
S-19R

S-20R

10

S-14R

S-14R

S-10R

S-10R
S-4R

S-4R
BL 0 Top
S-4L

S-4L

S-10L
S-14L

S-10L

S-19L

S-14L

S-24L

E
L
P
M
A
EX
S-19L

BL0

S-26L

March 2005

S-20L
S-25L

S-20L

S-25L

31

March 2005
S-14R

S-19R

STASTASTA STA ST ST ST
480 500 500 500 A A A
A B 500 500 520
C D

E
L
P
M
A
EX
S-19L

S-14L

S-26L

S-19L

ST
A
57
8

ST
A
59
7

ST ST
A A
61 63
9
6

S-25L

S-20L

20R

ST
A
68
S5

STA 706

S-25R

ST ST ST STA STASTA
A A A 727 727 727
727 727 727 C D E
A B
ST
A
74
7
ST
A
76
7

Zone 2

S-10L

S-4L

19R

ST
A
55
S-9

S-26R

STA
663.
75

Zone 1B

BL 0
Top

S-4R

S-10R

ST
A
54
0

737-200 Wing to Body Fairing


Scribe Threshold Map
Zone

Zone 3

32

Door Cutout Areas

Zone

Inspection for scribes is only required along edge of


repairs that end in the following restricted zones
note that these areas should be considered zone 1B:
1. Fwd Galley Door Cutout Str-10R to Str-14R, from
BS 344 to aft edge of door cutout

5.0
5.0

2. Fwd Entry Door Cutout Str-9L to Str-14L, from


BS 294 to aft edge of door cutout
3. Inspect along edge of repairs ending in restricted
zones of the following cutout corners:
Fwd Entry Door Cutout Fwd Upper Corner
Fwd Entry Airstair Door Cutout Fwd Upper
Corner
Fwd Entry Airstair Door Cutout Aft Lower Corner
Fwd Galley Door Cutout Fwd Upper Corner
Fwd Cargo Door Cutout Fwd and Aft Lower
Corners
Fwd Cargo Door Cutout Aft Upper Corner
Aft Cargo Door Cutout Fwd and Aft Lower
Corners
Aft Entry Door Cutout Fwd Lower Corner
Aft Galley Door Cutout Fwd Lower Corner

March 2005

5.0

Tangent
Points

5.0
Restricted
Zone

Figure 1

33

Zonal Compliance Charts

Compliance

Zonal Compliance Charts

Compliance

Zonal compliance charts provide the initial inspection


thresholds to look for scribe damage

Inspection thresholds are based on total aircraft cycles and


Cycles Since First Scribe Opportunity (Threshold)

The threshold is a function of either a formula or a grace period

If scribe damage is found, the associated LRTS flow chart


provides additional compliance instructions

March 2005

35

Zonal Compliance Charts

Compliance

How to use the charts for each airplane:

1.

Plot the aircraft total cycles and Cycles Since First Scribe
Opportunity to identify the applicable chart area

2.

For airplanes without conclusive records substantiating first


scribe opportunity, Cycles Since First Scribe Opportunity
(Threshold) (CSFSO) shall equal cycles at service bulletin
release less 5,000 cycles

3.

From the associated tables, use the formulas for the


applicable chart area to calculate a threshold

4.

The calculations can be verified by plotting the aircraft data


on the chart

March 2005

36

Cycles Since First Scribe Opportunity

Zone 1 Scribe Inspection


Compliance

Compliance

Area C

Area B

Area A
Area E

Area D

March 2005

37

Zone 1 Compliance Chart


Associated Formula Table
AREA

Compliance

INITIAL COMPLIANCE THRESHOLD:


x = [(Total Flight Cycles as of the date of the initial release of this service bulletin) - (Flight Cycles Since
First Scribe Opportunity (Threshold))]
Threshold (Total Flight Cycles) = [(x/2.3) + (30,000)], or [(4500) + (Total Flight Cycles as of the date of
the initial release of this service bulletin)], whichever is later.

In areas where the cutout modification shown in Boeing Service Bulletin 737-53A1177 was
accomplished:
Threshold (Total Flight Cycles) = [(4500) + (Total Flight Cycles as of the date of the initial release of this
service bulletin)]

In areas where the cutout modification shown in Boeing Service Bulletin 737-53A1177 was not
accomplished:
Threshold (Total Flight Cycles) = [50,000 total flight cycles], or [(4500) + (Total Flight Cycles as of the
date of the initial release of this service bulletin)], whichever comes first.

In areas where the cutout modification shown in Boeing Service Bulletin 737-53A1177 was
accomplished:
Threshold (Total Flight Cycles) = [(4500) + (Total Flight Cycles as of the date of the initial release of this
service bulletin)]

In areas where the cutout modification shown in Boeing Service Bulletin 737-53A1177 was not
accomplished:
Threshold (Total Flight Cycles) = [(1200) + (Total Flight Cycles as of the date of the initial release of this
service bulletin)]

1 See following slide on additional requirements during 4,500 cycle grace period

March 2005

38

Zone 1 Compliance Chart


Associated Formula Table
AREA

Compliance

INITIAL COMPLIANCE THRESHOLD:


x = [Total Flight Cycles as of the date of the initial release of this service bulletin] + [(17,000) -

(Flight Cycles Since First Scribe Opportunity (Threshold))]


Threshold (Total Flight Cycles) = x (calculated above), or [(4500) + (Total flight cycles as of the
date of the initial release of this service bulletin)], whichever comes later.

In areas where the cutout modification shown in Boeing Service Bulletin 737-53A1177 was accomplished:
x = [Total Flight Cycles as of the date of the initial release of this service bulletin] + [(17,000) - (Flight Cycles Since First
Scribe Opportunity (Threshold))]
Threshold (Total Flight Cycles) = x (calculated above), or [(4500) + (Total flight cycles as of the
date of the initial release of this service bulletin)], whichever comes later.

In areas where the cutout modification shown in Boeing Service Bulletin 737-53A1177 was not
accomplished:
x = [Total Flight Cycles as of the date of the initial release of this service bulletin] + [(17,000) - (Flight Cycles Since First
Scribe Opportunity (Threshold))]
Threshold (Total Flight Cycles) = x (calculated above), or [(1200) + (Total flight cycles as of the date of the initial release of
this service bulletin)], whichever comes later.

1 See following slide on additional requirements during 4,500 cycle grace period

March 2005

39

Zone 1A
Grace Periods

Compliance

Each compliance area (A,B,C,D,E) contains grace periods to


provide a reasonable period for inspections
Grace Periods
Area

S/B 53A1177 Accomplished?


Yes

No

A, B or D

4,500 Cycles

4,500 Cycles

C or E

4,500 Cycles

1,200 Cycles

March 2005

40

Zone 1A Lap Joint Lower Row


Inspection Requirements

Compliance

In areas A, B or D, if the airplane is within the grace period (4,500


cycles) and the SB 53A1177 lap joint modification has not been
accomplished, then additional lap joint lower row inspections may
be required

Inspection requirements start at 40,000 total flight cycles

Lap joint lower row external LFEC inspections and/or a onetime internal MFEC

March 2005

41

Zone 1 Compliance Chart: Example

Compliance

Sample Airplane 1:
Total A/C Cycles at release of service bulletin: 27,491
First scribe opportunity:
No decals, no records of first strip and paint

"Cycles Since First Scribe Opportunity": 27,491 - 5,000 = 22,491 cycles


This airplane would be in Area A of the Compliance Chart

Zone 1 Inspection Threshold


[(27,491 - 22,491) / 2.3] + 30,000 = 32,174 cycles or
- 4,500 cycles from release of service bulletin whichever is later
- Since 27,491 + 4,500 = 31,991 cycles is earlier than 32,174 cycles, then

Zone 1 threshold = 32,174 total airplane cycles


Verify with Zone 1 chart

March 2005

42

Cycles Since First Scribe Opportunity

Zone 1: Scribe Inspection Compliance


Chart

Compliance

Threshold = 27,491
+ 30,000
= 32,174
27,49122,491
Cycles Since
1st Scribe
Op + 30,000
2.3
2.3

E
L
PA/C Cyc Cycles Since 1
M
ThresholdA
= Total
EX
2.3
Area A:
Detailed Inspection:
Threshold = The later of:

Threshold = Total A/C Cycles Cyc Since 1st Scribe Op + 30,000


2.3
or 4,500 cycles
**

st

30,000
Scribe Op +Area
C

Area B

22,491
Area A
Area E

Area D

27,491
32,174 Aircraft Cycles
** If scribes are found, then accomplish
Inspections per LRTS Zone 1

March 2005

43

Cycles Since First Scribe Opportunity

Zone 2: Scribe Inspection Compliance

March 2005

Compliance

Area B

Area A

Area C

44

Zone 2: Compliance Chart


Associated Formula Table
AREA

A
B

Compliance

INITIAL COMPLIANCE THRESHOLD:


x = [(Total Flight Cycles as of the date of the initial release of this service bulletin)] - [(Flight Cycles Since
First Scribe Opportunity (Threshold))]
Threshold (Total Flight Cycles) = [(x/1.87) + (45,000 cycles)], or [(4500) + (Total Flight Cycles as of the
date of the initial release of this service bulletin)], whichever is later.
Threshold (Total Flight-Cycles) = [(4500) + (Total Flight Cycles as of the date of the initial release of this
service bulletin)].
x = [Total Flight Cycles as of the date of the initial release of this service bulletin] + [(32,000) - (Flight
Cycles Since First Scribe Opportunity (Threshold))]

March 2005

Threshold (Total Flight Cycles) = x (calculated above), or [(4500) + (Total flight cycles as of the date of
the initial release of this service bulletin)], whichever comes later.

45

Zone 2: Compliance Chart: Example

Compliance

Zone 2 inspection threshold


Area A
[(27,491 - 22,491) / 1.87] + 45,000 = 47,674 cycles or
4,500 cycles from release of service bulletin whichever is later
Since 27,491 + 4,500 = 31,991 cycles is earlier than 47,674
cycles, then
Zone 2 threshold = 47,674 total airplane cycles
Verify with Zone 2 chart

March 2005

46

Cycles Since First Scribe Opportunity

Zone 2: Scribe Inspection


Compliance Chart

Compliance

Threshold = Total A/C Cyc Cycles Since 1st scribe Op + 45,000


1.87

Area B

22,491
Area A

Area C

47,674 Aircraft Cycles


27,491

March 2005

47

Cycles Since First Scribe Opportunity

Zone 3: Scribe Inspection


Compliance

March 2005

Compliance

Area B

Area A

Area C

48

Zone 3: Compliance Chart


Associated Formula Table
AREA

Compliance

INITIAL COMPLIANCE THRESHOLD:


x = [(Total Flight Cycles as of the date of the initial release of this service bulletin)] - [(Flight Cycles Since
First Scribe Opportunity (Threshold))]

Threshold (Total Flight Cycles) = [(x/3.6) + (65,000 cycles)], or [(4500) + (Total Flight Cycles as of the
date of the initial release of this service bulletin)], whichever is later

Threshold (Total Flight Cycles) = [(4500) + (Total Flight Cycles as of the date of the initial release of this
service bulletin)].

x = [Total Flight Cycles as of the date on this service bulletin] + [(52,000) - (Flight Cycles Since First
Scribe Opportunity (Threshold))]

March 2005

Threshold (Total Flight Cycles) = x (calculated above), or [(4500) + (Total flight cycles as of the date of
the initial release of this service bulletin)], whichever comes later.

49

Zone 3: Compliance Chart: Example

Compliance

Zone 3 inspection threshold


Area A
[(27,491 - 22,491) / 3.6] + 65,000 = 66,389 cycles or
4,500 cycles from release of service bulletin whichever is later

Since 27,491 + 4,500 = 31,991 cycles is earlier than 66,389


cycles, then

Zone 3 threshold = 66,389 total airplane cycles


Verify with Zone 3 chart

March 2005

50

Cycles Since First Scribe Opportunity

Zone 3: Scribe Inspection


Compliance Chart

Compliance

Threshold = Total A/C Cyc Cycles Since 1st Scribe Op + 65,000


3.6
Area B

22,491

Area C

Area A

66,389 Aircraft Cycles


27,491

March 2005

51

Threshold Calculator

A Tool To Assist Operators in Calculating Scribe


Inspection Thresholds

Disclaimer

The Service Bulletin is the source for determining


thresholds

This tool can be used to verify the results of using the


threshold charts contained in the Service Bulletin

March 2005

53

Tool Overview

Developed in MS Excel using Visual Basic for Applications


(macros)

Allows multiple aircraft entry such that an operators fleet can


be assessed at one time

Fill each cell with the applicable data

Fill in consecutive rows

Provides input format error checking

Warns the user if the aircraft current cycles exceeds the


threshold value

March 2005

54

Data Entry Form

Y or N
Numeric
Alpha-numeric
March 2005

55

Data Entry Example

Click to calculate
Threshold

March 2005

56

Standard Output Thresholds


for Each Zone

Click to
show
more
threshold
details

March 2005

57

Additional Details Each Compliance Area,


Equation Value & Grace Period Evaluated

March 2005

58

Additional Output is Provided on Tabs

Input
Detailed Output
March 2005

Zone 3 Chart
Zone 2 Chart
Zone 1 Chart
59

Each Zonal Compliance Chart is


Provided With Fleet Data Plotted
Zone 1

E
L
P
M
A
X
E

March 2005

PRELIMINARY

NOT FAA APPROVED

60

Zone 2

E
L
P
M
A
EX

March 2005

PRELIMINARY

NOT FAA APPROVED

61

Zone 3

E
L
P
M
A
EX

March 2005

PRELIMINARY

NOT FAA APPROVED

62

Threshold Calculator Example


Guangzhou Example

March 2005

63

Limited Return
To Service (LRTS)
LRTS

LRTS Overview
A Relieving Program

LRTS

LRTS provides relief to enable continued operation for a


limited time with known damage that is not repaired

Thresholds, repeat inspections, and time limits associated


with repair requirements are based on fleet data, analysis,
the inspection procedures, and coordination with the FAA

March 2005

65

LRTS

LRTS Steps
For each affected area (lap, butt, decal location, etc.):

Assess if the damage is within the parameters of a typical scribe


as defined in the service bulletin

Perform Detail and NDI inspections as defined in the service


bulletin

Repeat inspections based on total aircraft cycles and Cycles


Since First Scribe Opportunity (LRTS) (CSFSO)
CSFSOLRTS is calculated at the start of LRTS, not at service
bulletin release, and could be different for each zone
CSFSOLRTS is the difference between the current airplane
cycles and the cycles when first scribed

March 2005

66

LRTS

LRTS Steps (continued)


For each affected area (lap, butt, decal location etc.):

Perform internal substructure inspections per existing service


bulletins (1085, 1125, 1179, 1255, 1027, 1160, 1177)

Required to support residual strength and crack growth


assumptions utilized to develop the program

These are one-time inspections that are accomplished in all zones


at thresholds as described in the LRTS

March 2005

67

LRTS

LRTS Service Bulletin


Substructure Inspections

The following inspections are required at all locations except those where
it has been confirmed that scribes do not exist in adjacent skin locations.
S/B 737-53

Subject

Threshold

Repeats

-1085

Stringer-to-Frame Tie Clip

40K 50K

None

-1125

Frames and Bulkheads Frame


Splice Mod

40K 50K

None

-1179

Bonded Skin Doubler (T/S)


Delamination

40K 50K

None

A1255

Crown Skin Lap Joint Cracking

41.5K 45K

None

A1027

Fwd & Aft Cargo Frame

40K 50K

None

-1069

Fwd Cargo Damage Prevention

40K 50K

1
1

A1160

Cargo A/C Lower Lobe Left


Frames BS360-500B

40K 50K

A1177

Cracks in Lower Skin at Lap Joints

41.5K 50K

1
1

None
None
1,200 LFEC

For cycles greater than upper threshold value, when entering LRTS, inspect before further flight

March 2005

68

LRTS

LRTS Compliance Data

The LRTS compliance data provided in S/B 737-53A1262 is in paragraph


form
Work Instructions Example:

S/B 737-53A1262 also provides flow or


logic diagrams of the LRTS plans in the
S/B Appendixes
Logic Diagram Example:

To highlight the decisions and demonstrate the steps involved, the


LRTS compliance data is provided in tables in this presentation

March 2005

69

LRTS

Zone 1A: LRTS Compliance


Zone 1A Potential Lower Row MSD Areas
Total
A/C
Cycles

Repeat Inspections for Lap Joints and All Edges of External Doublers
>18 (sealant required only on the leading edge of repair doublers)
(Cycles)

<30K

<15K since first scribe opportunity: Detailed inspections for cracks @ 1,000
cycles until 15K cycles since first scribe opportunity
>15K since first scribe opportunity : Detailed inspections for cracks @ 1,000
+
NDT at 4.5K until 30K total A/C Cycles

30-40K

<15K since first scribe opportunity : Detailed inspections for cracks @ 1,000
cycles until 15K cycles since first scribe opportunity

Time Limit
Until Repair
(Cycles)

Prior to
50,000 total
airplane
cycles

>15K since first t scribe opportunity : Detailed and NDT @ 500 cycles until
40K total A/C cycles
40-50K

Lap Joint Lower Row Internal MFEC inspection


<15K since first scribe opportunity : Detailed inspections for cracks @ 500
cycles until 15K cycles since first scribe opportunity
>15K since first scribe opportunity : Detailed and NDT @ 250 cycles until
50K total A/C cycles

March 2005

70

LRTS

Zone 1B: LRTS Compliance


Zone 1B
Total A/C
Cycles
>15 and <70K

Repeat Inspections
(Cycles)
<15K since first scribe opportunity :
Butt Joints and Wing-to-body Fairings: No inspection required
All other scribed locations: Detailed inspections @ 1,000 cycles
until 15K cycles since first scribe opportunity

Time Limit
Until Repair
(Cycles)
Prior to
70,000 total
airplane
cycles

>15K since first scribe opportunity :


Butt Joints: LFEC at 1,000 cycles intervals
Wing-to-Body Fairings: NDT at 4,500 cycles intervals
All other scribed locations: Detailed at 1,000 + NDT at 4.5K

March 2005

71

LRTS

Zone 2: LRTS Compliance


Zone 2
Total A/C
Cycles

>30 and <70K

Repeat Inspections
(Cycles)

<30K since first scribe opportunity :


Butt Joints: No inspections required
Wing-to-Body Fairings: No inspections required

Time Limit
Until Repair
(Cycles)
Prior to
70,000 total
Airplane
cycles

All other scribe locations: Detailed inspections for scribe


cracks @ 1,000 cycles until 30K cycles since scribing
>30K since first scribe opportunity :
Butt Joints: LFEC inspections at 1,000 cycles intervals
Wing-to-body Fairings: NDT at 4,500 cycles
All other scribed locations: Detailed inspections for scribe
cracks @ 1,000 + NDT at 4.5K

March 2005

72

LRTS

Zone 3: LRTS Compliance


Zone 3
Total A/C
Cycles

> 50 and <70K

Repeat Inspections
(Cycles)

<50K since first scribe opportunity :


Butt Joints: No inspections required
Wing-to-Body Fairings: No inspections required

Time Limit
Until Repair
(Cycles)
Prior to
70,000 total
Airplane
cycles

All other scribe locations: Detailed inspections for cracks


@ 1,000 cycles until 50K cycles since scribing
>50K since first scribe opportunity :
Butt Joints: LFEC inspections at 1,000 cycles intervals
Wing-to-body Fairings: NDT at 4,500 cycles
All other scribed locations: Detailed inspections for cracks
@ 1,000 + NDT at 4.5K until 70K total A/C Cycles

March 2005

73

Inspection Requirement Summary


Inspection

Applicability

When

Zone

Initial

Detailed Visual

All A/C with sealant removed


since production

At compliance
threshold

All

Search

Ext./Int. Lap
Joint Lwr Row

A/C with 4,500 cycle grace


period

Starting at 40K

1A

S/B Internal
Substructure

All A/C with scribes or


unknown scribes

Between 40-50K

All

Internal Lap
Joint Lwr Row

All A/C on LRTS >40K cycles

At 40K

1A

Internal Butt
Joint

All A/C on LRTS with scribes in


butt joint

When scribes are


found

All

All A/C on LRTS

Initially when scribes


are found and repeat
during LRTS

All

LRTS

External NDT
UT and Eddy
Current

March 2005

74

LRTS

LRTS Zone 1: Example

Zone 1 Inspection: @ 32,174 cycles:


Strip paint and sealant per approved process in service bulletin in
Zone 1 areas, including applicable repairs, door cutout areas, and
visually inspect

Result: Scribes found common to laps joints, butt joints and two
repairs

Decision: Continue on Zone 1 LRTS rather than repair:


Step 1: Measure and document scribe damage
Step 2: Accomplish initial UT and Eddy current inspection of lap
joints (from butt joint to butt joint) and the two repairs
Step 3: Accomplish internal and external inspections of butt joints

March 2005

75

LRTS

LRTS Zone 1: Example


Step 4: Determine if internal service bulletin substructure and
lap joint lower row inspections are required at this
time
Since the airplane has 32,174 cycles, internal service
bulletin substructure inspections are not required at this
time. However, if not addressed prior to the service
bulletin thresholds, they will be required at the following
times:

March 2005

76

LRTS Service Bulletin


Substructure Inspections

LRTS

The following inspections are required at all locations except those where it
has been confirmed that scribes do not exist in adjacent skin locations
S/B 737-53

Subject

Threshold

Repeats

-1085

Stringer-to-Frame Tie Clip

40K 50K

None

-1125

Frames and Bulkheads Frame


Splice Mod

40K 50K

None

-1179

Bonded Skin Doubler (T/S)


Delamination

40K 50K

None

A1255

Crown Skin Lap Joint Cracking

41.5K 45K

None

A1027

Fwd & Aft Cargo Frame

40K 50K

None

-1069

Fwd Cargo Damage Prevention

40K 50K

None

A1160

Cargo A/C Lower Lobe Left


Frames BS360-500B

40K 50K

None

A1177

Cracks in Lower Skin at Lap Joints

41.5K 50K

1,200 LFEC

1 For cycles greater than upper threshold value, when entering LRTS, inspect before further flight

March 2005

77

LRTS

LRTS Zone 1: Example

Step 5: Recommended reapplication of sealant and paint:

Do not apply fillet seals to the following areas:


a.

Lap joints from butt joint to butt joint where scribes were found.
It is also recommended that sealant not be applied in areas
where scribes were not found to preclude future scribe concerns

b.

Longitudinal edges of repairs with scribes

c.

Longitudinal edges of scuff plates in restricted zones around


cutouts where scribes were found

Apply sealant to the following areas:


a.

Butt joints

b.

Fillet seals at leading edges of repairs and scuff plates

c.

Wing-to-body fairing

To allow future inspections, do not reapply paint or primer to the


scribed areas

March 2005

78

LRTS

LRTS Zone 1: Example


Step 6: Determine repeat inspection schedule and time
limit for Zone 1 areas by referring to Zone 1
LRTS tables based on:

Aircraft cycles: 32,174

Cycles Since First Scribe Opportunity


(CSFSOLRTS) = 27,174

March 2005

79

LRTS

LRTS Zone 1: Example


Zone 1A Potential Lower Row MSD Areas
Total
A/C
Cycles

Repeat Inspections for Lap Joints and All Edges of External Doublers
>18 (sealant required only on the leading edge of repair doublers)
(Cycles)

<30K

<15K since first scribe opportunity: Detailed inspections for cracks @ 1,000
cycles until 15K cycles since first scribe opportunity
>15K since first scribe opportunity: Detailed inspections for cracks @ 1,000
+
NDT at 4.5K until 30K total A/C Cycles

30-40K

<15K since first scribe opportunity: Detailed inspections for cracks @


1,000 cycles until 15K cycles since first scribe
opportunity

Time Limit
Until Repair
(Cycles)

Prior to
50,000 total
airplane
cycles

>15K since first scribe opportunity: Detailed and NDT @ 500 cycles until
40K total A/C cycles
40-50K

Lap Joint Lower Row Internal MFEC inspection


<15K since first scribe opportunity: Detailed inspections for cracks @ 500
cycles until 15K cycles since first scribe opportunity
>15K since first scribe opportunity: Detailed and NDT @ 250 cycles until
50K total A/C cycles

March 2005

80

LRTS

LRTS Zone 1: Example


Zone 1A areas:

Since the A/C has more than 30K total cycles and more than
15K cycles since first scribe opportunity, accomplish repeat
NDT inspections in Zone 1A areas at 500 cycle repeats until
40K total A/C cycles

At 40K A/C cycles, accomplish internal NDT lower row


inspections per Figures 1 & 2 of SB 737- 53-1255 at Zone 1A
scribe affected lap joints from butt joint to butt joint. Repair
all lower row damage and continue repeat external Detailed
and NDT inspections for scribe cracks at 250 cycle repeats
until 50K total A/C cycles

Prior to 50K A/C cycles, repair all Zone 1A areas

March 2005

81

LRTS

LRTS Zone 1: Example


Zone 1B
Total A/C
Cycles

>15 and <70K

Repeat Inspections
(Cycles)
<15K since first scribe opportunity:
Butt Joints and Wing-to-body Fairings: No inspection required
All other scribed locations: Detailed inspections @ 1,000 cycles
until 15K cycles since first scribe opportunity

Time Limit
Until Repair
(Cycles)
Prior to
70,000 total
airplane
cycles

>15K since first Scribe Opportunity:


Butt Joints: LFEC at 1,000 cycles intervals
Wing-to-Body Fairings: NDT at 4,500 cycles intervals
All other scribed locations: Detailed at 1,000 + NDT at 4.5K

March 2005

82

LRTS

LRTS Zone 1: Example


Zone 1B areas:

Since A/C has less than 70K total cycles and more than 15K
cycles since first scribe opportunity, for the butt joints
accomplish internal stringer inspections (first inspection to
ensure fail-safe capability) and external NDT inspections at
1,000 cycle intervals

At the lap joints, accomplish repeat Detailed inspections at


1,000 cycle intervals and NDT inspections at 4,500 cycle
intervals until 70K total A/C cycles

Prior to 70K A/C cycles, repair all Zone 1B areas

March 2005

83

LRTS

LRTS Zone 2: Example


Zone 2 Inspection: @ 47,674 cycles:

Strip paint and sealant per approved process in service bulletin


in Zone 2 areas, including applicable repairs, and visually
inspect

Result: Scribes found in laps joints and butt joints


Decision: Continue on Zone 2 LRTS rather than repair:
Step 1: Measure and document scribe damage
Step 2: Accomplish initial UT and Eddy current inspection
of lap joints
Step 3: Accomplish internal and external inspections of
butt joints

March 2005

84

LRTS

LRTS Zone 2: Example


Step 4: Determine if internal service bulletin substructure
and lap joint lower row inspections are required at
this time
Since airplane has 47,674 cycles, if not previously
accomplished, internal service bulletin substructure
inspections of the lap joint lower row are required
before further flight
The other service bulletin inspections are required
before 50,000 cycles in areas adjacent to scribe
locations

March 2005

85

LRTS

LRTS Zone 2: Example


Step 5: Recommended reapplication of sealant and paint:
1. Do not apply fillet seals to the following areas:
a. Lap joints from butt joint to butt joint where scribes were found. It is
also recommended that sealant not be applied in areas where scribes
were not found to preclude future scribe concerns
b. Longitudinal edges of repairs with scribes
c. Longitudinal edges of scuff plates in restricted zones around cutouts
where scribes were found
2. Apply sealant to the following areas:
a. Butt joints
b. Fillet seals at leading edges of repairs and scuff plates
c. Wing-to-body fairing
3. To allow future inspections, do not reapply paint or primer to the scribed
areas

March 2005

86

LRTS

LRTS Zone 2: Example


Step 6: Determine repeat inspection schedule and time
limit for Zone 2 areas by referring to Zone 2
LRTS
tables based on:

Aircraft cycles: 47,674

Cycles Since First Scribe Opportunity: 42,674

March 2005

87

LRTS

LRTS Zone 2: Example


Zone 2
Repeat Inspections
Total A/C
Cycles
>30 and <70K

Time Limit
Until Repair
(Cycles)

(Cycles)
<30K since first scribe opportunity:

Prior to
70,000 total
airplane
cycles

Butt Joints: No inspections required


Wing-to-Body Fairings: No inspections required
All other scribe locations: Detailed inspections for
cracks @ 1,000 cycles until 30K cycles since
scribing

scribe

>30K since first scribe opportunity:


Butt Joints: LFEC inspections at 1,000 cycles intervals
Wing-to-body Fairings: NDT at 4,500 cycles
All other scribed locations: Detailed inspections for scribe
cracks @ 1,000 + NDT at 4.5K

March 2005

88

LRTS

LRTS Zone 2: Example


Zone 2 areas:

Since A/C has more than 30K total cycles and more than 30K
cycles since first scribe opportunity, accomplish the
following repeat inspections:

At Butt joints external NDT inspections at 1,000 cycle


intervals

At lap joints Detailed inspections at 1,000 cycle


intervals and NDT inspections at 4,500 cycles repeats,
until 70K total A/C cycles

Prior to 70K A/C cycles repair all Zone 2 areas

March 2005

89

LRTS

LRTS Zone 3: Example


Zone 3 Inspection: @ 66,389 cycles: Strip paint and sealant
per approved process in service bulletin in Zone 3 areas,
including applicable repairs, and visually inspect
Result: Scribes found in laps joints and butt joints
Decision: Continue on Zone 3 LRTS rather than repair:
- Step 1: Measure and document scribe damage
- Step 2: Accomplish initial UT and Eddy current inspection of lap
joints
- Step 3: Accomplish internal and external inspections of butt joints

March 2005

90

LRTS

LRTS Zone 3: Example


Step 4: Determine if internal service bulletin substructure and
lap joint lower row inspections are required at this time
Since the airplane has 66,389 cycles, the service bulletin
internal inspections in Zone 1, 2 and 3 were previously
accomplished per the LRTS between 40,000 and 50,000
A/C cycles, therefore, the internal inspections are not
required
Note: Even though Zone 3 was not previously inspected
for scribes, the service bulletin internal inspections in
Zone 3 areas were required between 40,000 and 50,000
cycles

March 2005

91

LRTS

LRTS Zone 3: Example

Step 5: Recommended reapplication of sealant and paint:


1.

2.

3.

March 2005

Do not apply fillet seals to the following areas:


a.

Lap joints from butt joint to butt joint where scribes were found. It is
also recommended that sealant not be applied in areas where scribes
were not found to preclude future scribe concerns

b.

Longitudinal edges of repairs with scribes

c.

Longitudinal edges of scuff plates in restricted zones around cutouts


where scribes were found

Apply sealant to the following areas:


a.

Butt joints

b.

Fillet seals at leading edges of repairs and scuff plates

c.

Wing-to-body fairing

To allow future inspections, do not reapply paint or primer to the


scribed areas

92

LRTS

LRTS Zone 3: Example


Step 6: Determine repeat inspection schedule and
time limit for Zone 3 areas by referring to Zone 3 LRTS
tables based on:
Aircraft cycles: 66,389
Cycles Since First Scribe Opportunity: 61,389

March 2005

93

LRTS

LRTS Zone 3: Example


Zone 3
Total A/C
Cycles

> 50 and <70K

Repeat Inspections
(Cycles)
<50K since first scribe opportunity:
Butt Joints: No inspections required
Wing-to-Body Fairings: No inspections required

Time Limit
Until Repair
(Cycles)
Prior to
70,000 total
airplane
cycles

All other scribe locations: Detailed inspections for scribe cracks


@ 1,000 cycles until 50K cycles since scribing
>50K since first scribe opportunity:
Butt Joints: LFEC inspections at 1,000 cycles intervals
Wing-to-body Fairings: NDT at 4,500 cycles
All other scribed locations: Detailed inspections for cracks @
1,000 + NDT at 4.5K until 70K total A/C Cycles

March 2005

94

LRTS

LRTS Zone 3: Example


Zone 3 areas:
Since A/C has more than 50K total A/C cycles and more than
50K cycles since first paint, accomplish the following repeat
inspections in Zone 3 areas:
At butt joints external NDT inspections at 1,000 cycles
intervals
At lap joints detailed inspections at 1,000 cycles
intervals and NDT inspections 4,500 cycles repeats until
70K total A/C cycles
Prior to 70K A/C cycles repair all Zone 3 areas

March 2005

95

Inspection
Service Bulletin
Pre-Threshold Finding

LRTS

Pre-Threshold Finding

The service bulletin provides the steps required to address


scribe findings found at a time prior to the threshold, such as a
walk around or a planned paint operation

Pre-threshold scribe findings do not require stripping, cleaning


and/or inspecting other areas until the applicable threshold is
reached

The service bulletin provides instructions on documenting and


inspecting damage or determining if a repair is required

Actions necessary to return the airplane to service will be


covered by a Reduced LRTS plan

March 2005

97

LRTS

Pre-Threshold Finding
Reduced LRTS plan

A candidate airplane may have the Reduced LRTS applied if:


1. Scribing is found prior to the threshold, or
2. If the airplane has local damage only

The inspection program uses the Zonal LRTS tables

Has a 250 cycle grace period prior to Zonal LRTS inspection


requirements

Does not require internal service bulletin substructure


inspections or full panel lap joint inspections

March 2005

98

LRTS

Pre-Threshold Finding: Example

While performing some overnight maintenance, a mechanic


identifies two separate 8 scribes at S-4L where the fillet seal
is missing, just aft of the entry door

Perform a detailed inspection for cracks at the scribe


locations
No cracks found, damage within parameters of a typical
scribe
Scribe locations identified as Zone 1A

March 2005

99

LRTS

Pre-Threshold Finding: Example

Within the next 250 cycles, airplane plan details would be


worked out. For this example, assume the following:
Aircraft cycles at finding: 27,491
First scribe opportunity is unknown, use default value of
5,000 cycles
Cycles Since Scribe Opportunity CSFSOLRTS = 22,491
Zone 1 threshold = 32,174 total A/C cycles

The aircraft is 32,174 - 27,491 = 4,683 cycles from its Zone 1


threshold compliance inspections

Decision: Continue with Zone 1 Reduced LRTS rather than


repair

March 2005

100

LRTS

Pre-Threshold Finding: Example


Zone 1A Potential Lower Row MSD Areas
Total
A/C
Cycles
<30K

Repeat Inspections for Lap Joints and All Edges of External Doublers
>18 (sealant required only on the leading edge of repair doublers)
(Cycles)
<15K since first scribe opportunity: Detailed inspections for cracks @
1,000 cycles until 15K cycles since first scribe
opportunity
>15K since first scribe opportunity: Detailed inspections for cracks @
1,000 + NDT at 4.5K until 30K total A/C Cycles

30-40K

Time Limit
Until Repair
(Cycles)

<15K since first scribe opportunity: Detailed inspections for cracks @


1,000 cycles until 15K cycles since first scribe
opportunity

Prior to
50,000 total
airplane
cycles

>15K since first scribe opportunity: Detailed and NDT @ 500 cycles until
40K total A/C Cycles
40-50K

Lap Joint Lower Row Internal MFEC inspection


<15K since first scribe opportunity: Detailed inspections for cracks @ 500
cycles until 15K cycles since first scribe opportunity
>15K since first scribe opportunity: Detailed and NDT @ 250 cycles until
50K total A/C cycles

March 2005

101

LRTS

Pre-Threshold Finding: Example

Before further flight, perform a detailed inspection of visible


scribe for cracks
Within 250 cycles, strip paint local to scribe and conduct NDT
inspections
Since the A/C has less than 30K total cycles and more than 15K
cycles since first scribe opportunity, accomplish repeat NDT
inspections of the identified scribe locations at 1,000 cycle
repeats until 30K total A/C cycles
At 30K cycles and more than 15K cycles since first scribe
opportunity, accomplish detailed and NDT inspections every
500 cycles until reaching Zone 1A threshold of 32,174 cycles
Upon reaching the 32,174 total A/C cycles threshold per Zone 1
Compliance Charts, inspect all Zone 1 areas and perform the
requirements of the Full LRTS on all findings including the prethreshold finding location

March 2005

102

LRTS

Pre-Threshold Finding: Example


Alternate Decision: Repair local areas

Contact Boeing for repair information


1

Within 250 cycles accomplish local scribe repairs

Upon reaching the 32,174 total A/C cycles threshold per


Zone 1 Compliance Charts, inspect all Zone 1 areas and
perform the requirements of the Full LRTS on all findings
1 250 cycles is prior to the Zonal Compliance Chart threshold

March 2005

103

Service Bulletin Summary

Boeing has released an Alert SB (737-53A1262) to inspect for


possible scribe line damage

Cover initial inspections and LRTS plans


A zonal approach has been developed which is less burdensome
to operators than the previous LRTS, by using:
Specific inspection locations
Phased compliance thresholds

New concepts introduced are:


Zonal maps
Zonal compliance charts
Zonal LRTS tables

March 2005

104

Skin Trim Tool

March 2005

106

Skin Trim Tool


Boeing is investigating trimming up to 0.1 inch from the lower edge of
the upper skin

Trimming offers the following benefits:


Better visibility of scribe lines previously hidden
More reliable NDT inspection possible
Greater intervals between repeat inspections possible

Tooling is being developed using proven technology


Testing is in process

Full scale testing is scheduled for March 05


Business case assessment will be based on results of the full
scale test

March 2005

107

Numerically Controlled Driller/Router

March 2005

108

Industry Awareness Training

Industry Awareness Training


Objective

Increase awareness of issues surrounding scribe line damage

Minimize opportunities for scribe line damage to occur during


future repaint and decal application

Help operators determine what constitutes a scribe

Inform operators of effective means of accomplishing initial


inspections

March 2005

110

Industry Awareness Training


Methods
Posters (currently available)
Video(s) DVD with capability for edit/voice-over (in work)
Web-based training (in work)
New Maintenance Procedures
Sealant Removal Process (currently available)
Ref BCS message 1-J8LN7
SOPM 20-50-19 (1-Nov-2004 revision)
Sealant reapplication (BCS message 1-RPR66)
Decal Installation Process (in work)

March 2005

111

Industry Awareness Training


Message

Training needs to be on-going (frequent refreshers)

New processes need to become part of daily work practices

Training aids (posters, videos) are available from Boeing, but


change needs to occur on the work floor

March 2005

112

Repairs

Repairs

A new service bulletin will be created to address scribe damage


beyond SRM limits or other approved repairs
Repairs to address scribing at lap joints, butt joints and wingto-body fairing
Coverage for additional blend-out allowances

Should enable operators to develop and accomplish most scribe


line damage repairs without Boeings assistance

This repair service bulletin will be released in 2005

March 2005

114

Repairs

Repairs may be required at:


Lap Joints
Wing-to-Body Fairings
Butt Joints
External Repair Doublers
Other areas with external reinforcement (i.e., antenna
cutouts, scuff plates, others)
STC Areas
SB 737-53A1177 modification is terminating action where
applicable in Zone 1A
STC affected areas will require coordination with the STC holder
and the Regulatory Authority

March 2005

115

Repairs - Local

Structural Repair Manual (SRM)


New figures have been added:
Section 51-10-02 Inspection and Removal of Damage
Section 53-00-01 Figures 101/102 Fuselage Skin
Allowable Damage

Local scribe repair


For damage beyond SRM limits
Must be coordinated with Boeing

March 2005

116

Lap Joint - Internal Repair

An internal repair concept has been developed that can address scribes
at some lap joints by providing an alternative load path and reduced
stress at locations of concern

The internal repair may reduce inspection requirements by providing


improved fatigue life at known locations of concern:
Scribe location
Chem-mill location
Lap joint lower row location

Successfully completed residual strength test

Strain data indicates that future inspections of the repair will be


necessary

March 2005

117

Lap Joints Internal Repairs


Up

0.036 Fillers
10
0.032 Shim

Inbd

Scribe
Fail-safe Doublers
0.032, 2024-T3 Clad Sht
A

March 2005

View From Outside

A-A

B-B

118

Internal View

March 2005

119

Solid Skin Panel Replacement

Original bonded skins are very expensive

Too many variable configurations

Equivalent solid skins offer a potential cost reduction, will


significantly reduce the number of configurations, and may
simplify the overall method of addressing damage

March 2005

120

Window Belt Replacement


Due to the number of cracks being found in the
window corners, Boeing is developing a Window Belt
Replacement Program

March 2005

121

Wing-to-Body Fairing Repair

For damage beyond SRM limits


Operators can fabricate detail parts
Minimum gage
Single layer
Boeing to provide necessary configuration detail
information

Considering concepts to protect the underlying skin structure


from future damage that may be associated with frequent
fairing removal and reinstallation

March 2005

122

Repair Summary

There is significant work to be done to address repairs for


all of the scribed areas

All of these issues will be worked based on the criticality of


the structure

The plan is to release a service bulletin providing repair


instructions and options for as many areas as possible

March 2005

123

Scribe Line Summary

For the 737 Classic (-100 thru -500) fleet, this is potentially a
serious safety issue affecting a large portion of the fleet

The economic impact could be significant

Boeing is working with the industry to develop fleet action plans

Boeing has:
Investigated maintenance actions which may produce
scribe lines and clarified maintenance documentation
Developed scribe line training materials

March 2005

124

Scribe Line Summary

Boeing has (continued):


Developed specific NDI inspections to address scribe lines
Updated 737 SRMs to address scribe damage
Published an alert inspection, SB 737-53A1262, which
covers initial inspections and the LRTS plan

Boeing understands the FAA is considering regulatory action,


such as an NPRM, related to this inspection service bulletin

March 2005

125

Questions?

March 2005

126