Appendix V - P-3 IDP 25 October 2009.pdf

Sustainment IDP, Rev -, 20 Oct 2009

NAVAL AIR SYSTEMS COMMAND

P-3 SUSTAINMENT INSPECTION

DATA PACKAGE

Reviewed by: Prepared by:

Rick Strickland Stephen P. McClure Aerospace Engineer Sustainment Engineer ISSC JAX, Code P3-FST-1 ISSC JAX, Code P3-FST-1

Reviewed by: Approved by:

Paul Kenny Jerry Deans NDI Program Manager P-3 Team Lead ISSC JAX, Code 4.3.4.3 ISSC JAX, Code P3-FST

SUSTAINMENT IDP CHANGE SHEET

CHANGE NO. DATE INCORPORATED

BY

INCORPORATED DATE

Basic 20 Oct 2009 Stephen McClure

1 Sustainment Fatigue Inspections of P-3 Orion

To maintain the structural integrity of the P-3C fleet, a number of sustainment programs were developed to replace components that are experiencing fatigue cracking and inspect fatigue critical components that will not be replaced. The parts replacement eliminates relevant fatigue inspection requirements and allows the airframe to continue in service for an additional period of flight hours. The balance of fatigue sensitive locations that have not been replaced must be inspected to assure the structural integrity of the aircraft.

1.2 Fatigue Inspection Requirements

Table 1 lists the inspection requirements for Aircraft depending on total flight hours at the time of the inspections. Section 2 contains the inspection techniques; section 3 the detailed requirements, and section 4 the hole numbering figures.

Use Table 1 to determine what Fatigue Inspection Requirements are due on an aircraft based on its total FHs and the applicable sustainment event. The inspection threshold is in total Aircraft FHs and refers to at what point in an aircraft’s life it must start having a specific inspection.

Example

An aircraft with 10,000 total flight hours is inducted for SSI-K. The total projected flight hours at the next depot induction would be (11,000+4,500) 15,500 hrs. Since the aircraft will reach more than 15,100 total FHs before the next depot induction, the inspection in section 3 for the “3.7, Outer Wing Lower Panels # 5&6 at WS 275 Tee Clip Attachment” must be performed.

Table 1 Fatigue Inspection Threshold Requirements

1.3 Inspection Requirements of Repairs on Sustainment Aircraft

As aircraft are having a sustainment event performed, a high percentage of the aircraft have had repairs installed in the vicinity of the inspection locations or fatigue critical locations. Inspection of repairs in fatigue critical locations, defined below, is required. Repairs that are located in fatigue critical areas should have an aluminum doubler and steel or aluminum tripler installed per the Structural Repair Manual or other NAVAIR approved technical data. The following inspection and repair requirements apply to all aircraft undergoing a sustainment event.

Evaluate whether the repair is standard, i.e. in accordance with the Structural Repair Manual or other NAVAIR approved technical data. If the repair is non-standard, i.e. does not have the correct number of rows of fasteners, fastener type, fatigue doubler and a tripler, poor edge distance, per Structural Repair Manual or other NAVAIR approved technical data, then the repair shall be evaluated by engineering to determine if the repair is adequate. If the repair is determined to be inadequate then the repair shall be removed and replaced with the correct fatigue repair per Structural Repair Manual, or engineering instructions. The outer two rows of fasteners on the primary structure on the inboard and outboard ends of the original repair shall be inspected using Bolt Hole Eddy Current. If accessible, the original damage location shall be inspected using either Bolt Hole Eddy Current or Eddy Current Surface Scan.

If the repair is a standard repair and is installed correctly or has been determined to be adequate by engineering then the outer two rows of fasteners on the primary structure on the inboard and outboard ends of the repair shall be inspected. If the wing plank is accessible from inside the wing then Eddy Current Surface Scan inspect around the fastener collars in the outer two rows of fasteners. If the wing plank is not accessible from inside the wing then remove the outer two rows of fasteners and perform Bolt Hole Eddy Current inspection and reinstall fasteners.

Document previously installed repairs by completing an inspection form from the closest Sustainment IDP location and identify the hole as a repair hole. Mark the location of the finding on the aircraft, identifying the orientation and part number and take a digital picture of the entire repair and of the hole in which the crack was discovered. Submit digital picture with finding spreadsheets.

The following SSI locations are considered fatigue critical locations on the wing and require inspection and corrective actions on existing repairs.

Outer wing lower surface planks 1-9, B.L. 65 – W.S. 414 Outer wing lower spar caps and web, fwd and aft, B.L. 65 – W.S. 414 Center wing lower surface planks 1-9, B.L. 32 – 65 Center wing lower spar caps and web, fwd and aft, all

1.4 Fatigue Inspection Findings Report (CDRL A00X)

Depot activity shall prepare and submit Fatigue Inspection Findings Report in accordance with the following procedure. Using the hole numbering scheme provided in Section 4, record all positive findings on Excel forms and forward to P-3-FST. Electronic copy of form can be obtained from P3-FST-1 or generated based on sample provided below. Use the following instructions for completing inspection forms.

BUNO – Bureau number of the aircraft being inspected.

Flt. Hrs. – Total flight hours for the aircraft at the time of the inspection.

Landings – Total number of landings/ Number of full stop landings.

Paragraph – Paragraph number of Sustainment IDP for the inspection being performed

Inspection – Title of inspection being reported

Hole Number – Using the hole-numbering scheme from Section 4, identify the hole number in which the defect was detected.

Location – Identify the wing station/buttock line, fuselage station, waterline, and side of the aircraft, (LH/RH), of the hole in which the defect was detected.

Part Name – Name of part in which defect was detected

Part Number – Part number of part in which defect was detected

Orientation – Using aircraft coordinates, identify the orientation of the defect, i.e. , Looking down, forward is 12 o’clock, left wing is 9 o’clock, right wing is 3 o’clock. Looking forward, up is 12 o’clock, left wing is 9 o’clock, right wing is 3 o’clock. Looking outboard left, up is 12 o’clock, forward is 3 o’clock, aft is 9 o’clock.

Length – Approximate length of defect.

Comments – Describe defect and any unusual details of the defect.

Inspector – Name and stamp of the NDI inspector.

Date – Date of the inspection.

NDI Method – NDI method used to inspect part

Verified – Was defect verified by alternate inspection? Yes/No

2 NDI Techniques

There are four NDI techniques used to perform the inspections in the Section. Bolt Hole Eddy Current (BHEC), Eddy Current Surface Scan (ECSS), Ultrasonic Thickness Measurement, and Shear Wave Ultrasonic.

2.1 Bolt Hole Eddy Current

Perform bolt hole eddy current inspection (BHEC) in accordance with the following procedure.

NDI EQUIPMENT REQUIREMENTS

• Flex-hones-aluminum oxide only 240 or 320 grit only, various diameters (BRM 4642 E Floral Dr., LA, CA 90022 (213) 261-2193) or equivalent.

• NORTEC 2000D eddy current instrument or equivalent.

• Probes: split core, differential shielded, EC/NDT – S00R2-YYY-ZZZ or equivalent where YYY-

ZZZ is the diameter range of the probe, or equivalent.

• NRK-3AL aluminum reference standard from NRK-3AST or equivalent (0.030” corner notches required)

• NORTEC RA scanner cable 9122090.00 or equivalent.

• RA scanner gun RA-2000 or equivalent

• S00 R2-19-6FX or S00 R2-20-6FX Flex Probe

PREPARATION

• Remove fastener from hole taking care to not damage the inside diameter of the hole.

• Verify that the holes are round, clean of sealant, and free of corrosion, burrs, and sharp edges prior to inspection. Holes may be cleaned up using flex hones, or nylon brushes. If the holes are more than .005 inches out of round, then step up hole to first oversize to eliminate elongation. If hole does not clean up by oversizing to first oversize, contact cognizant engineering for repair limits and instructions.

• Clean hole ID using nylon or brass brushes.

• If necessary Flex hone hole to clean the hole and remove light corrosion prior to BHEC inspection. Do not make more than 3 passes through hole with flex hone.

SETUP

• Connect appropriate probe and cable to instrument and scanner gun.

• Turn instrument on and warm up per manufacturer specifications.

• Initial equipment settings for rotating phase-analysis eddy current system. Equivalent equipment may be used with appropriate settings that can calibrate the same as here.

• N0RTEC 2000D:

Freq 500 kHz

LPF 500

HPF 200

Scan RPM 1000 Angle As required for horizontal lift-off Gain – H 50.0 dB Gain – V 60.0 Db Probe Drive Mid

Sweep Off Vpos 50% Hpos 50%

CALIBRATION

• Cover rotating eddy current probe with 4-mil tape to protect coil and shim as required to achieve snug fit in hole of calibration standard.

• Adjust the initial equipment settings to obtain a vertical peak-to-peak 4-unit deflection from the

.030” corner notch calibration while maintaining horizontal lift-off.

INSPECTION

• Ensure the probe fits snugly in each hole to be inspected. Adjust shim as required.

• Fail holes that display a 2-unit peak-to-peak or greater vertical deflection not associated with lift-off or other non-relevant geometric effects.

• Visually re-inspect failed holes for scratches, gouges, corrosion, cracks, etc. Additional flex-honing and re-inspecting is authorized to remove surface discrepancies in bore of hole.

• Failed holes shall be re-inspected after hole clean up (flex honing) to ensure removal or verify defect location (layer, clock position).

2.2 Eddy Current Surface Scan

Perform eddy current surface scan inspection in accordance with the following procedure:

• NORTEC 2000D Eddy current instrument or equivalent

• VM202RA-1/4x6 Probe or equivalent

• NORTEC to microdot cable or equivalent

• NRK-3AL reference standard from NRK-3ASTor equivalent (must have .020” surface notch at least 3 coil diameters long)

NOTE:

Any eddy current instrument, probes and connectors that can calibrate as discussed below may be considered equivalent.

PREPARATION:

• Evaluate surface to be inspected to determine if inspection can be performed with coatings in place.

• Clean and strip surface as required to allow ECSS inspection

SETUP:

• Connect probe to adapter. Turn instrument on and warm up per manufacturer’s specifications.

• Adjust instrument to the following initial settings.

• NORTEC 2000:

Frequency 200 kHz Angle as needed for horizontal liftoff H gain 60 dB V gain 69 dB

Probe Drive Mid

LPF WB

HPF off Cont. Null off +/-/off off Horn off Size/pos as desired Sweep off V pos 20% H pos 80% Screen persist off Disp erase off Sweep erase on Dot/box as desired Graticle on

CALIBRATION:

• Adjust angle so lift-off is horizontal and to the left.

• Adjust gain(s) so the vertical component from the 0.020 notch is a 3-unit vertical deflection.

• Adjust as necessary for horizontal lift-off on the inspected part.

INSPECTION:

• Inspect designated inspection area. Maintain proper orientation by monitoring liftoff.

• Reject for any reproducible 1-unit or greater vertical deflection not associated with lift-off or other non-relevant geometric effects.

• Visually re-inspect rejected areas for scratches, gouges, corrosion, cracks, etc. Ensure all primer is removed by non-abrasive methods.

• Failed surfaces shall be re-inspected and rejectable indications verified.

2.3 Ultrasonic Thickness Measurement Inspection.

Perform ultrasonic inspection in accordance with the following procedure to detect exfoliation corrosion.

NDI EQUIPMENT REQUIREMENTS:

• Ultrasonic Thickness Gage, Panametrics 25DL or equivalent

• Cable Assembly, LCM-74-6 or equivalent

• Transducer, Panametrics M208, 20 MHz/0.125” dia. Delay line or equivalent

• Couplant, Glycerin or equivalent

• Standard, Any aluminum commercially available step wedge with thickness (1) above maximum component thickness and (2) at or below 0.050”.

• Clean and strip surface as required to allow Ultrasonic inspection

• Connect transducer to instrument using cable assembly.

• Turn instrument on and allow warming up to manufacturer specifications.

• Equivalent equipment may be used with appropriate settings that can calibrate within 2% of the thicknesses on the appropriate steps of the reference standard.

• Apply couplant to the two thicknesses covering the range discussed in the equipment section.

• Calibrate both velocity and zero:

• Couple transducer to the thicker side and press [cal] followed by [vel].

• Remove transducer and enter that thickness from the standard on the display.

• Couple transducer to the thinner side of the standard and press [cal] then [zero]

• Remove transducer and enter that thinner thickness on the display.

• Place couplant on areas to be inspected.

• Couple probe to inspection region removed from the holes and note thickness.

• Move transducer towards hole and continue noting thickness. Mark as delaminated any areas that exhibit a distinct change to thinner reading or where loss of reading occurs.

2.4 Shear Wave Ultrasonic Inspection

• Ultrasonic flaw detector; Krautkramer, model: USN 52 or equivalent.

• BNC-to-Microdot Cable, FSCM 64552 CA 130 or equivalent

• Ultrasonic transducer, Dapco XTS-70 degree Al 5 Mhz from PD238 kit, NSN 6635-01-381-4368 or equivalent.

• Reference standard-ultrasonic: VMP3C-DM-STD only

• Couplant, Ultragel or equivalent.

• Clean and strip surface as required to allow Shear Wave Ultrasonic inspection

• Connect transducer to instrument using cable assembly.

• Turn instrument on and allow warming up to manufacturer specifications.

• Equivalent equipment may be used with appropriate settings that can calibrate the same as here.

• Adjust the USN 52 to the following settings:

gain 46 range 1.5 mtl vel 0.117 delay -11.5 freq 0.4-10 damping 1000 rectif Full pulser single reflect 0 rep-rate high dac/tcg off transducer frequency 5MHz transducer diameter .25 in test block/standard - P3C-DM-STD shoe/wedge 70 degree Al couplant Ultragel 2

• Apply couplant to reference standard on panel, next to simulated rub strip.

• Wag transducer to maximize the echo from the 1/4 inch notch emanating from the rivet hole and going away from the screw hole.

• Adjust the gain and delay to get a 100% Full screen height echo on screen from the notch. Add

6db to the gain to account for back-surface sealant effects.

• Inspect other dome nut locations on the reference standard to get a “feel” for typical responses from notches between the rivet and screw holes and for unnotched holes.

• Apply couplant to inspection surface.

• Place transducer on surface aimed towards the fastener hole under the flange and optimize the response.

• Scan similarly as with the standard, wagging the transducer to make sure that optimum transducer orientation is achieved.

• If a signal cannot be identified for any hole, gain increases up to 12 dB are permitted. If the hole still cannot be resolved from baseline noise, the hole should be rejected for suspected corrosion.

• Reject for indications that occur as in calibration that exceed 50% full screen height.

3 Detailed Inspection Requirements

3.1 Outer Wing Lower Surface Panels At Main Landing Gear Truss

Requirement – The depot activity shall perform eddy current surface scan inspection of all MLG truss rib fastener holes along lower surface of panels 1-8 as outlined below.

Performance Specification – This requirement is met when:

• NDI is completed;

• Inspection results have been recorded, classified, and reported and.

• Discrepancies approved by Government have been corrected.

Outer Wing Lower Surface Panels # 5 – 8 at Main Landing Gear Truss Rib NDI Map

ECSS Lower Panels #5 & 6 around MLG Truss Rib Fasteners

Preparation:

• Chemically or mechanically strip inspection area as required to perform eddy current surface scan inspection.

Inspection:

• Using procedures described in section 2.2 perform eddy current surface scan inspection of all MLG truss rib fastener holes along lower surface of panels 1-8.

3.2 Horizontal Stabilizer F.S. 1221 Aft Upper Spar Cap Radius

Requirement – The depot activity shall perform eddy current surface scan inspection of radius of aft upper spar cap as outlined below.

• Aircraft structure has been trimmed;

• Inspection results have been recorded, classified, reported; and

Detail A

Horizontal Stabilizer FS 1221 Aft Upper Spar Cap Radius NDI Map

HSS

Detail A

Horizontal Stabilizer FS 1221 Aft Upper Spar Cap Radius NDI Map (View Looking Down)

Trim 0.25 Fixed

Trim 0.30 Fusel

Removable Fuselage Fillet Fairing

Upper Surface Panel

FS 1221

HSS 32

Upper Rear Spar

Outboard Aft

View Looking Down on LHS

Insp R di

Note:

Applicable to aircraft receiving initial inspection only. Aircraft receiving recurring inspection have already been modified.

• Remove fillet fairing, P/N 900703-5/6.

• Insert steel shim between aft fuselage fairing, P/N 917183-5/6, fixed trailing edge panel, P/N

907992-5/6, and aft upper spar cap, P/N 901187-103/104 to protect spar cap during trimming operation.

• Trim corner of aft fuselage fairing .30 x .30 inch and corner of the fixed trailing edge .25 x .25 inch to reveal the radius of the aft upper spar cap.

• Strip radius area of the spar cap of paint and sealant.

• Using procedures described in section 2.2 perform eddy current surface scan inspect radius of aft upper spar cap for cracks.

3.3 Outer Wing Lower Panels 5, 6, & 9 at Panel Runout Splice

Requirement – The depot activity shall perform bolt-hole eddy current inspection of the outer wing lower panels and aft spar cap as outlined below.

(Panel 6 run-out splice shown, typical for other panels) bolt-hole eddy current all holes common to the splice plate and rear spar cap. Remove and inspect 5 fasteners beyond each end of the splice plate. (fastener removal is required due to stack up of parts).

• Remove Hi-Loks attaching aft spar cap to the lower panels as indicated in the NDI map and clean holes in preparation for bolt-hole eddy current inspection.

• Using procedures described in section 2.1 perform bolt-hole eddy current inspection of lower panels and aft lower spar cap holes.

3.4 Horizontal Stabilizer Upper Stringer, Panel Runout, and Deep Frame, FS 1185, 1203

Requirement – The depot activity shall perform a detailed inspection of the horizontal stabilizer upper stringer, panel runout, and deep frame bulkhead web at FS 1185 & 1203, HSS 28 & 26 respectively, left and right. Eddy Current Surface Scan stringer around fastener heads common to the stringer, skin panel runout, and external drag angle and web for cracks at intersection of fuselage and horizontal stabilizer as shown in NA 01-75PAA-3-2, Section 11

Forward Inboard

WS 329

Rear Spar Cap

Outer Wing Lower Panels 5, 6, & 9 at Panel Runout Splice NDI Map

(View Looking Up)

Horizontal Stabilizer Upper Stringer, Panel Runout, and Deep Frame, FS 1185, 1203 NDI Map

• Chemically strip paint and sealant as required in the inspection area that require ECSS inspection.

• Using procedures described in section 2.2 perform eddy current surface scan inspection of area identified in NDI map.

3.5 Horizontal Stabilizer Forward Upper Spar Cap and Deep Frame Webs FS 1167 & 1221

Requirement – The depot activity shall perform a detailed inspection of the horizontal stabilizer forward upper spar cap at FS 1167, HSS 28, and deep frame bulkhead, FS 1167 & 1221, HSS 28 & 26 respectively, left and right. Using Bolt Hole Eddy Current, inspect the fastener holes in horizontal and vertical flanges of the spar cap from HSS 27 to HSS 30 as shown in NA 01-75PAA-3-2, Section 11. Eddy Current Surface Scan around fastener heads common to the spar cap, skin panel and external drag angle and web for cracks at intersection of fuselage and horizontal stabilizer as shown in NA 01-75PAA-3-2, Section 11 .

• Inspection results have been recorded, classified, reported;

Horizontal Stabilizer Forward Upper Spar Cap and Deep Frame Webs

FS 1167 & 1221

HSS 28

• Remove Hi-Loks attaching fwd upper spar cap to the panels and deep frame as indicated in the NDI map and clean holes in preparation for bolt-hole eddy current inspection.

• Chemically strip paint and sealant as required in the inspection area that require ECSS inspection.

• Using procedures described in section 2.1 perform bolt-hole eddy current inspection of fwd upper spar cap holes.

• Using procedures described in section 2.2 perform eddy current surface scan inspection of area identified in NDI map.

3.6 Outer Wing, Aft Lower Spar Web, WS 155-275

Requirement – The depot activity shall perform eddy current surface scan, ultrasonic, and bolt-hole eddy current inspection of aft spar web as outlined below.

RWS

155.0

RWS

167.0

RWS

179.0 RWS

188.0

RWS

197.0

RWS

197.0

RWS

209.0

RWS

221.0

RWS

239.0

Outer Wing, Aft Lower Spar Web, WS 155-275 NDI Map (View Looking Aft)

Eddy Current Surface Scan around Fastener Heads

Remove fastener and Bolt Hole Eddy Current inspect Web

Inspect fastener common to stiffener using Shear-wave Ultrasonic Inspection

• Chemically or mechanically strip web as required to perform ECSS or Shear-Wave UT NDI as indicated in NDI map.

• Remove Hi-Loks attaching aft spar web to the aft lower spar cap as indicated in the NDI map and clean holes in preparation for bolt-hole eddy current inspection.

• Using procedures described in section 2.1 perform bolt-hole eddy current inspection of aft spar web and spar cap holes.

• Using procedures described in section 2.2 perform eddy current surface scan inspection around fasteners common to the aft spar web and aft lower spar cap as indicated in the NDI map above.

• Using procedures described in section 2.4 perform shear-wave ultrasonic inspection of holes in the aft spar web covered by attached structure as indicated in the NDI map above.

RWS

239.0

RWS

257.0

RWS

275.0

Outer Wing, Aft Lower Spar Web, WS 155-275 NDI Map (View Looking Aft)

3.7 Outer Wing Lower Panels # 5&6 at WS 275 Tee Clip Attachment

Requirement – The depot activity shall perform eddy current surface scan inspection of panels # 5&6, WS 275, at fastener holes common to P/N 801077-1 Tee Clip attachments to the risers as outlined below.

• NDI is completed.

• Inspection results have been recorded, classified, and reported.

• Required conversion coat, prime, paint, and sealant of stripped structure has been restored.

Outer Wing Lower Panels # 5&6 at WS 275 Tee Clip Attachment NDI Map

• Chemically or mechanically strip inspection area as required to perform ECSS inspection.

• Using procedures described in section 2.2 perform ECSS inspection of lower panels # 5&6 fastener holes in the panel risers common to the P/N 801077-1 Tee Clips.

3.8 Outer Wing, Aft Spar Cap, WS 167 – 209

Requirement – The depot activity shall perform eddy current surface scan inspection of aft flange of the aft lower spar cap as outlined below

ECSS all holes on the aft flange of the outer wing aft lower spar cap, WS 167 – 209, as shown in NDI map

Outer Wing, Aft Spar Cap, WS 167 – 209 View Looking Up

• Remove 920016-17/-18 Vapor Barrier for access.

• Chemically strip paint and sealant from the inspection area that require ECSS inspection

• Using procedures described in section 2.2 perform eddy current surface scan inspection of aft flange of the aft lower spar cap.

3.9 Outer Wing, Lower Panels #6&7 at MLG Actuating Cylinder

Requirement – The depot activity shall perform bolt-hole eddy current inspection of panels # 6&7 at fastener holes common to the MLG actuator fitting as outlined below

• NDI is completed.

• Inspection results have been recorded, classified, and reported.

• Required conversion coat, prime, paint, and sealant of stripped structure has been restored.

Outer Wing, Aft Spar

WS 221 WS 197 WS 179 WS 167 WS 239 WS 188WS 209

MMLLGG AAccttuuaattoorr FFiittttiinngg

Outer Wing Lower Surface Panels # 6&7 at Main Landing Gear Actuator Fitting NDI Map

(View Looking Up) bolt-hole eddy current Fasteners Common to Actuator Fitting and Panels # 6&7

WWSS 220099

• Remove Hi-Loks attaching MLG actuator fitting to the lower panels # 6&7 as indicated in the NDI map and clean holes in preparation for bolt-hole eddy current inspection.

• Using procedures described in section 2.1 perform bolt-hole eddy current inspection of lower panels # 6&7 fastener holes common to the MLG actuator fitting.

3.10 LG Retract Actuator Support Lug

Requirement – The depot activity shall perform eddy current surface scan inspection of NLG Retract Actuator Support Lug as outlined below.

• Inspection results have been recorded, classified, reported; and.

• Using procedures described in section 2.2 perform eddy current surface scan inspection of LH and RH lugs.

3.11 Outer Wing Upper Panels # 1-3 at Nacelles 2 & 3 Fillet Fairing Dome Nuts

Requirement –The depot activity shall perform ultrasonic inspection and bolt hole eddy current inspection of dome nut holes of inboard nacelle fillet fairing holes in upper wing panels # 1-3 and replace dome nuts

NLG Retract Actuator Support Lug NDI Map with ForceTec fasteners. In locations where ForceTec fasteners will not fit due to interference with existing structure, Hi-Lok fasteners shall be installed.

• Dome nuts have been replaced with ForceTec Fasteners and

Outer Wing Upper Panels #1-2 at Inboard Nacelle Fillet Fairing NDI Map

Remove and replace dome nuts with Force Tec Retainers

• Remove dome nuts and rub strip.

• Mechanically remove sealant in areas of inner surfaces of upper wing panels (used to facilitate installation of previously installed dome nuts).

• Chemically strip the outer surfaces of the wing panel areas approximately two inches wide that covers the entire length of the rub strips with dome nut holes in the middle.

• Visually inspect inner and outer panel surfaces for corrosion. If corrosion is present, clean up corrosion. Fluorescent penetrant inspect following removal of corrosion IAW ASTME 1417 to verify complete removal of corrosion.

In panel areas with existing repairs, contact engineering for direction prior to performing ultrasonic thickness inspection:

• Perform ultrasonic inspection of dome nut holes common to the nacelle fillet fairing in accordance with paragraph 2.3 to detect exfoliation corrosion and correct any discrepancies prior to performing the dome nut hole bolt-hole eddy current inspections.

• Ream satellite holes to .113” pre-cold working diameter prior to inspection.

• Inspect satellite holes in accordance with paragraph 2.1.

• Inspect main dome nut hole in accordance with paragraph 2.1

• Replace all dome nuts at the outer wing upper Panels 1-3 at the inboard nacelle fillet fairing with

ForceTec fastener system in accordance with NA 01-75PAA-3-2, SECTION XII. Nominal size ForceTec fastener shall be installed in the forward lower spar cap, holes 1 and 8. Contact cognizant engineering office if oversized ForceTec is required in holes 1 or 8.

• Modify fillet fairing in accordance with NA 01-75PAA-3-2, SECTION XII to add spacer under the dimpled washers. Reinstall inboard nacelle lower fillet fairing in accordance with NA 01- 75PAA-3-2, SECTION XII using original hardware.

3.12 Outer Wing Upper Panels # 1-2 at Nacelles 1 & 4 Fillet Fairing Dome Nuts

Requirement –The depot activity shall perform ultrasonic inspection and bolt hole eddy current inspection of dome nut holes of outboard nacelle fillet fairing holes in upper wing panels # 1-2 and will be replace dome nuts with ForceTec fasteners. In locations where ForceTec fasteners will not fit due to interference with existing structure, Hi-Lok fasteners shall be installed.

• Dome nuts have been replaced with ForceTec Fasteners and

• Remove dome nuts and rub strip.

• Mechanically remove sealant in areas of inner surfaces of upper wing panels (used to facilitate installation of previously installed dome nuts).

• Chemically strip the outer surfaces of the wing panel areas approximately two inches wide that covers the entire length of the rub strips with dome nut holes in the middle.

• Visually inspect inner and outer panel surfaces for corrosion. If corrosion is present, clean up corrosion. Fluorescent penetrant inspect following removal of corrosion IAW ASTME 1417 to verify complete removal of corrosion.

In panel areas with existing repairs, contact engineering for direction prior to performing ultrasonic thickness inspection:

• Perform ultrasonic inspection of dome nut holes common to the nacelle fillet fairing in accordance with paragraph 2.3 to detect exfoliation corrosion and correct any discrepancies prior to performing the dome nut hole bolt-hole eddy current inspections.

• Ream satellite holes to .113” pre-cold working diameter prior to inspection.

• Inspect satellite holes in accordance with paragraph 2.1.

• Inspect main dome nut hole in accordance with paragraph 2.1

Outer Wing Upper Panels #1-2 at Outboard Nacelle Fillet Fairing NDI Map

Remove and replace dome nuts with Force Tec Retainers

• Replace all dome nuts at the outer wing upper Panels 1-2 at the outboard nacelle fillet fairing with ForceTec fastener system in accordance with NA 01-75PAA-3-2, SECTION XII.

• Modify fillet fairing in accordance with NA 01-75PAA-3-2, SECTION XII to add spacer under the dimpled washers. Reinstall inboard nacelle lower fillet fairing in accordance with NA 01- 75PAA-3-2, SECTION XII using original hardware.

3.13 Outer Wing Upper Panels 1-3 at Nacelle 2 & 3 Attach Angles

Requirement – The depot activity shall perform shear wave ultrasonic inspection of all inboard nacelle upper attach angle holes of Panels 1& 3 as outlined below.

• Inspection results have been recorded and classified; and

Outer Wing Upper Panels #1-3 at Inboard Nacelle Attach Angle NDI Map

Inspect panels 1-3 at holes common to nacelle attach angle

• Chemically or mechanically strip inspection area as required to perform shear wave ultrasonic

• Perform ultrasonic inspection of panels 1-3 at attach angle holes in accordance procedure in section 2.3 to detect exfoliation corrosion and correct any discrepancies prior to performing the dome nut hole inspections.

• Perform shear wave ultrasonic inspection of panels 1-3 at attach angle holes in accordance with section 2.4.

3.14 Outer Wing Upper Panels 1-3 at Nacelle 1 & 4 Attach Angles

Requirement – The depot activity shall perform shear wave ultrasonic inspection of all outboard nacelle upper attach angle holes of Panels 1& 3 as outlined below.

Outer Wing Upper Panels #1-3 at Outboard Nacelle Attach Angle NDI Map

Inspect panels 1-3 at holes common to nacelle attach angle

• Chemically or mechanically strip inspection area as required to perform shear wave ultrasonic

• Perform ultrasonic inspection of panels 1-3 at attach angle holes in accordance procedure in section 2.3 to detect exfoliation corrosion and correct any discrepancies prior to performing the dome nut hole inspections.

• Perform shear wave ultrasonic inspection of panels 1-3 at attach angle holes in accordance with section 2.4.

3.15 Outer Wing Upper Panels 1-8 at MLG Truss Rib

Requirement – The depot activity shall perform eddy current surface scan inspection of outer wing upper panels # 1-8 at the MLG truss rib attachment as outlined below.

Outer Wing Upper Panels #1-8 at MLG Truss Rib NDI Map

Inspect panels 1-8 at holes common to MLG truss rib

• Perform ECSS inspection of panels 1-8 at MLG truss rib holes in accordance procedure in section 2.2.

3.16 Outer Wing Upper Panels 3-5 at Cutouts, WS 209-237

Requirement – The depot activity shall perform eddy current surface scan inspection of outer wing upper panels # 3-5 at cutouts, WS 209-237, as outlined below.

Outer Wing Upper Panels #3-5 at Cutouts NDI Map

Inspect panels 3-5 at holes common to cover plates and radius of cutouts

• Using procedures described in section 2.2 perform eddy current surface scan inspection of dome nuts.

• Using procedures described in section 2.2 perform eddy current surface scan of free edge of the access cutout.

3.17 Empennage HS and VS Drag Angles

Requirement – The depot activity shall perform eddy current surface scan inspection of Horizontal Stabilizer and Vertical Stabilizer Drag Angles as outlined below.

• Using procedures described in section 2.2 perform eddy current surface scan inspection around fasteners and along bend radius of drag angles.

3.18 Underfloor Beams, BL 40, FS 252 - 283

Requirement – The depot activity shall perform eddy current surface scan inspection of Under floor Beams, BL 40, FS 252 - 283 as outlined below.

Empennage HS and VS Drag Angle NDI Map

Using procedures described in section 2.2 perform eddy current surface scan inspection of underfloor beam radius adjacent to pressure deck stiffeners.

3.19 Underfloor Beams, Tank 5A, FS 496-534

Requirement – The depot activity shall perform eddy current surface scan inspection of Under floor Beams, Tank 5A, FS 496-534 as outlined below.

Under floor Beams, BL 40, FS 252 - 283

Underfloor Beams, Tank 5A, FS 496-534

Using procedures described in section 2.2 perform eddy current surface scan inspection of the inside surface of the cut-outs and holes illustrated above.

Underfloor Beams, Tank 5A, FS 496-534