EASA PART 21 - ASL Airlines Belgium · 2017. 6. 16. · The SRM deviations for these plugged holes...
Transcript of EASA PART 21 - ASL Airlines Belgium · 2017. 6. 16. · The SRM deviations for these plugged holes...
Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan
TASS-EU
Certification Plan
Document number: 152075-CP-014-1.R Page 1 of 41
Part 1: General Description
TITLE: REMOVAL OF SKY RADIO SYSTEM FROM VX CAPITAL 757 AIRCRAFT
VALID ON AIRCRAFT / PART NO:
A/C Type Block No. Basic No. Line No. Serial No.
757-222ER NE147 N3196 421 25397
REVISION STATUS:
Orig: 02 Nov 2015
Rev: 01 27 JAN 2016
DESCRIPTION:
Certification Plan This document and all information and expression contained herein are the property of TASS-EU LTD Limited and are provided to the recipient in confidence. This document contains proprietary information and shall at all times remain the property of TASS-EU LTD, no intellectual property right or licence is granted by TASS-EU LTD Limited in connection with any information contained herein and the information contained herein shall be treated as confidential and not disclosed to any third party without the prior written consent of TASS-EU LTD.
Part 2: Approval
The technical content of this document is approved under the authority of DOA No. EASA.21J.467
Prepared By:
Checked By: Compliance Verification Engineer:
Name: Matt Maberry Name: Pete Cowles Name: Andrew Voice
Date: 27 JAN 2016 Date: 27 JAN 2016 Date:
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Revision status
Draft A: 02 Nov 2015
Rev 00: 2015
Rev 01: 27 JAN 2016; Update to inspection requirements of external skin repair.
Added Appendix C and Appendix D
General Introduction
STC SA5831NM modifies the aircraft by installing USA Today Sky Radio. This document
shows what residual elements remain after removal of that system and how they show
regulatory compliance.
Reference Documents
A/ STC SA5831NM. Issued to Elsinore Aerospace Systems
B/ Passenger to freighter conversion drawing 007D4000 Rev C. Precision Conversions, LLC.
C/ COA 50234 – Sky Radio Installation, STC SA 5831NM
D/ COA 50597 – 757 Sky Radio Removal
E/ Report: COA ACCOMPLISHMENTS FOR N549UA. United Airlines, Jan 12, 2015.
F/ Maintenance records COA 5-0597. Job sequence cards 30009 – 30018. QA sign off for
system removal
G/ TASS EU Document 152075-CB-014-1.R and associated photos.
H/ TASS WDM Supplement 23-34-21, Sky Radio Inertial Reference & DC Power Interface
I/ TASS WDM Supplement 23-34-31, Sky Radio Airborne Receiving Unit & Antenna Wiring
J/ TASS WDM Supplement 23-34-41, Sky Radio System Audio Inputs
K/ D634N201, Boeing 757 SRM. Revision 113.
L/ D634N201, Boeing 757 SRM. Revision 084. Sept 20, 2004.
M/ AMM 23-34-21, 23-34-31, 34-34-41
N/ Boeing Document, SR 1-165592221, with 8100-9 Approval Dated 25 July 2006
O/ United Airlines Document, EC/RA 5331-01933, dated 08/21/2014
Description:
STC SA5831NM, dated August 31, 1992 installs Elsinore Air Radio on 757-200 aircraft. Ref
E/ shows that work was carried out per COA 50234 in June, 1993.
According to Ref’s E/ and F/, COA 5-0597 was carried out in September 2002. See
Appendix A for a copy of these instructions. This was confirmed by inspection per TASS EU
document 152075-CB-014-1.R, carried out on October 02, 2015.
As a result of this activity there are some remaining wires that are capped & stowed as shown
in Refs I/, J/, and K/, an external fuselage skin doubler and four (4) plugged rivet holes in the
frames at STA1340 and STA1360. These residual changes are approved as a minor
modification. See Appendix A for a copy of the wiring diagram changes for this system
deactivation.
It is noted in Ref F/ that the modification work has been carried out, the signed & certified job
cards have been checked and a verification inspection was carried out so no additional
physical action is required on the aircraft. The document is attached in Appendix A at the end
of this document.
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Avionics Modification:
The initial Ref C/ Sky Radio installation COA 50234 installed wiring per the following ER
documents:
ER 8 = Antenna cable and harness installation
ER 9 = Power wiring installation
ER 10 = Audio (MUX) wiring installation
ER 11 = IRS wiring installation
None of these documents make structural alterations to the airframe, instead they pick up on
existing attachment points and/or route with existing wiring.
The removal instructions per COA 5-0597 are summarized in the below leave a number of
residual capped & stowed wires. These wires represent the net avionics change to the aircraft
as a result of the Skyradio removal. This is summarised in the Ref H/ drawing.
ER Title: Details:
1 Procurement
2 Rev:A Remove electronic equip. Cap
& Stow wiring.
CB C9001 removed from P11-2 panel, wires capped
and stowed. (See Appendix B)
Antenna & motor drive removed.
EMI driver removed
PLL-LNB removed.
Receiver removed, blanking tray installed.
3 Rev:A Structural removal. Fuselage frames plugged with 5/32 rivets.
Antenna cutout repaired per SRM 53-00-01 Fig 206
(See hand written notes on Ref F/).
4 IPC change, WDM change 23-34-21, 23-34-31, 34-34-41
Table 1 - System Removal Changes
In addition to the wiring changes, a blanking tray is installed in the E6-2 rack that previously
housed the sky radio receiver. The tray was fabricated from 0.040” thick 2024-T3 clad per
COA 5-0597, ER 2 Revision A as described in figure 1 of this document. The subject
blanking tray is similar to a standard blanking plate and serves to restrict cooling flow losses.
The subject tray is satisfactory by similarity to existing blanking tray designs.
Structures Modification:
Fuselage Frames:
The structural removal is covered by Ref F/ COA 5-0597 ER 3 and involves plugging of the
existing 5/32 rivet holes. From Ref F/, job sequence card 30010 it can be seen that the holes
are plugged with MS20470AD rivets up to 3/16” dia.
Upper lobe frame webs in this area are covered by 757-FCBS-53-008 but Ref G/ 757-200
SRM section 53-00-07, Allowable damage 1, Figure 101, allows holes in the middle 1/3 of
the frame web, up to 0.18” dia with a maximum of 4 holes in 6 inches and requires that such
holes be filled with a 2117-T3 rivet.
In this case each frame has 2 cross sections with 2 holes that are up to 3/16” in diameter. It
can be seen in the attached photos from the Ref G/ inspection that they are spaced well apart
and are not within 3D of any existing fastener hole but they appear to be just outside of the
“middle 1/3” of the web.
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The SRM deviations for these plugged holes and their mitigating factors are:
Deviation: Mitigating Factors:
Holes may be up to 3/16” dia. Cross sectional loss < 10%.
Only 2 holes per cross section.
No evidence of sealant used in fastener
installation. Interior crown location is benign environment.
Standard corrosion protection measures (primer + CIC)
Holes may be outside of middle 1/3 of
frame web. Holes are in flat section of web, well clear of bend
radius. Refer attached photos.
Holes are greater than 4D apart and greater than 3D
from other holes.
Table 2 - Structural Modification Factors
The residual plugged holes constitute minor modification action that deviates from the 757-
200 SRM. This is structurally acceptable as there are mitigating factors as outlined above and
no additional maintenance burden is warranted.
Fuselage Skin:
The subject repair was installed in 2002 per the SRM revision in force at that time and
remains structurally acceptable subject to the associated ongoing inspections.
This repair is covered by Ref F/, job sequence card 30010. As this is a signed and stamped
task card no further approval is required. Refer to figure 4 of this document.
The SRM repair that was installed is an external repair as given in 757-200 SRM Rev 79
dated May 2002, 53-00-01, Figure 204. However, Ref. F/ listed this repair as using the
instructions from Figure 206. This is in reference to the metal bonding procedures required
for Zone C repairs. This makes the Figure 204 repair allowable for Zone C.
As outlined in the Ref. O/ document, UAL corresponded with Boeing for repairing action
associated with the Sky Radio Removal per Ref. D/, as well as several other repairs. The
Boeing Company provided instructions and supplemental inspection requirement per the
approved Ref. N/ SR. These inspection requirements are reiterated in the Ref. O/ UAL ECRA
which was issued to record the transfer of the repair inspections from UAL’s existing Trax
system into their new CF / Dip process. At the time of repair installation, the initial threshold
was noted at 23,000 total aircraft cycles. Based on TAC at the time of the ECRA, the initial
inspections were already accomplished per United’s EQ # 7344. Therefore the ECRA
duplicates the SR inspections with a threshold of 26,760 total aircraft cycles.
The operator is required to conform with the inspection requirements of Ref. O/ UAL ECRA
5331-01933 dated 08/21/2014, Part 2, A. The ECRA and original repair approval are given in
Appendix C and Appendix D.
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Conclusion
The avionics modification consists of:
A number of wires that remain installed on the aircraft but are capped and stowed per
Boeing SWPM 20-10-01. These are documented in the Ref H/, I/, and J/ drawings
and shown in Appendix B.
A blanking tray, installed in the E6-2 rack.
These are minor modifications that have no effect on the operation of any systems of the
aircraft. No additional ICA is required.
The structures modification consists of:
An external skin repair installed per SRM. Continued inspection of the repair in
accordance with Ref. O/ UAL ECRA 5331-01933 is required.
4 plugged holes in the frames at both STA1340 and STA1360. Two at approximately
LBL 1.0 and two at approximately RBL 1.0
Of the structural modifications the net SRM departure is the placement and sizing of the
plugged rivet holes which is structurally acceptable as a minor modification for the reasons
outlined above.
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Figure 1: Blanking Tray for E6-2 rack
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Figure 2A: Skin Repair – External View
Figure 2B: Skin Repair – Internal View
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Figure 2C: Skin Repair - Left Side of S-1
Figure 2D: Skin Repair - Right Side of S-2
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Figure 3A: Plugged fastener holes at STA1340
Figure 3A: Plugged fastener holes at STA1360
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Figure 4: SRM Requirements for holes in upper lobe frames.
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Appendix A – COA 5-0597
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Appendix B – 152075-WDMS-014 Wiring Diagram
23-34-21: INERTIAL REFERENCE SYSTEM AND DC POWER INTERFACE
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23-34-31: AIRBORNE RECEIVING UNIT & ANTENNA SYSTEM WIRING
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23-34-41: SYSTEM AUDIO INPUTS
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Appendix C: Approval for Boeing SR 1-165592221
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Appendix D: United Airlines ECRA 5331-01933
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