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 2
 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 3
 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 4
 Background

March 2005 5
 Typical Scribe Detail - 737 Classic
Lap Joint (LN 292 -2565)
CL
Frame
Up

Upper Skin
(.036) Inbd
10”

Upper
A
Doubler
(.036)

A
Scribe in
Lower Skin
View From Outside
Scribe
Lower Skin
(.036) Sealant
A-A
March 2005 6
March 2005 7
 Mapping of Visible Scribe Lines on One
737-200
Cracks (5 and 10 inches)
Visible Scribe Lines

March 2005 8
 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 9
 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 0 KSI

Doubler Outer Fiber >20 KSI
Inner Fiber
Chem-mill Cracks

Scribe Cracks <5 KSI

Lower Skin
>20 KSI Inner Fiber
Outer Fiber

Unloaded Lap Joint Loaded Lap Joint

March 2005 11
 737 Cracking Behavior

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

Multiple Crack Initiation Sites 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) Inbd
10”

Upper
A
Doubler
(.036)

A
Scribe in
Lower Skin
View From Outside .36 TYP Lower Row
Crack
Lower Skin
Typical Lower (.036) Scribe
Skin, Lower
Row Crack A-A
March 2005 13
 737 Cracking Scenarios
Local Scribe Damage

Scenario
1
Scribe Induced
Cracks
Scribe in
Lower Skin

Lower
Row
Cracks
2
Scribe in Scribe Induced
Lower Skin Cracks

Scribe/Lower
Row Interaction
March 2005 14
 737 Cracking Scenarios
Continuous Scribe Damage

Scenario
3
Scribe Induced
Crack

Lower
Row
Cracks

4
Scribe Induced
Scribe/Lower Crack
Row
Interaction

March 2005 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 FAA’s 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 operator’s 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

Zone

– When: Zonal Compliance Charts

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 following 737 configurations:
1
– 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

Zone 1A Zone 1B Zone 2 Zone 3

STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA
360 380 400 420 440 460 480 500 500A500B 520 540 663.75 727 727A 727B 747 767 787 807 827 847 867 887 907 927 947.5 967 986.51006

STA
BL0 1016
S-26R S-25R
S-26R
S-25R STASTA STA STA STA STA STA
559 578 597 616 639 685 706
S-20R
S-25R
S-19R
S-19R
S-18R S-20R
S-16R
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 S-20L
S-19L
S-20L S-25L
S-22L
S-25L
S-26L
S-26L S-25L
BL0

March 2005 29
 737-200 Decal Areas
Scribe Threshold Map Zone

Zone 2 Zone 3
STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA
360 380 400 420 440 460 480 500 500A500B 520 540 663.75 727 727A 727B 747 767 787 807 827 847 867 887 907 927 947.5 967 986.51006

STA
BL0 1016
S-26R S-25R
S-26R
STASTA STA STA STA STA STA
559 578 597 616 639 685 706
S-20R
BS S-19R
S-25R
S-19R
259 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-20L
S-19L
S-19L
S-20L S-25L

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

March 2005 30
 737-200 – External Repair Doubler
Scribe Threshold Map Zone

Zone 1A Zone 1B Zone 3

STA STA STA STASTASTA ST STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA STA
259. 277 294. 312 328 344 A 380 400 420 440 460 480 500 500A500B 520 540 663.75 727 727A 727B 747 767 787 807 827 847 867 887 907 927 947.5 967 986.51006
5 5 360
STA
1016
S-26R S-25R

STASTA STA STA STA STA STA

BL0 559 578 597 616 639 685 706
S-20R
S-25R
S-19R
S-24R
S-20R

S-19R 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 S-20L
S-19L
S-20L S-25L
BL0

S-26L S-25L

March 2005 31
March 2005
ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST ST
STA
A A A A A A A A A A A A A A A A
663.
480 500 500 500 500 500 520 54 727 727 727 727 727 727 74 76
75
A B C D 0 A B C D E 7 7

S-26R
S-25R
STA 706

ST ST ST ST ST ST
A A A A A A
55 57 59 61 63 68
S-
8 7 6 9 5
S-19R S-9 20R
19R

S-14R

S-10R
Zone 1B

S-4R

BL 0
Top
Scribe Threshold Map
Zone 2

S-4L

S-10L

S-14L
Zone 3
737-200 – Wing to Body Fairing

S-19L
S-19L
S-20L

S-26L S-25L
32
Zone
 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 5.0”
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 Tangent 5.0”
• Fwd Cargo Door Cutout – Fwd and Aft Lower Points
Restricted
Corners Zone
• Fwd Cargo Door Cutout – Aft Upper Corner
• Aft Cargo Door Cutout – Fwd and Aft Lower
Corners Figure 1
• Aft Entry Door Cutout – Fwd Lower Corner
• Aft Galley Door Cutout – Fwd Lower Corner
March 2005 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
 Zone 1 Scribe Inspection
Compliance Compliance

100
95
Opportunity

90
85
80
75
First Paint

70
First Scribe

65
60
55
Since Since

50
45
Area C
40
CyclesCycles

35
30 Area B
25
20
15
10 Area A
5 Area E
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
**If scribes are found, then accomplish inspections
Area D Aircraft Cycles per LRTS zone 1A or 1B as applicable.

March 2005 37
 Zone 1 Compliance Chart
Associated Formula Table Compliance

AREA 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))]
A
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.1
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)]
B
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.
1
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)]
C
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 Compliance

AREA 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))]

D
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. 1
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.

E 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

S/B 53A1177 Accomplished?

Area
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 one-
time 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
 Zone 1: Scribe Inspection Compliance
Chart Compliance

50
27,491––22,491
Threshold = 27,491 Cycles + 1st Scribe
30,000
Since = 32,174
Op + 30,000
2.3 2.3
Opportunity

45
Area A:
40 Detailed Inspection:
Threshold = The later of:

Threshold = Total A/C Cyc – Cycles Since 1st Scribe Op +Area

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

2.3
30,000
C
SinceScribe

or 4,500 cycles
30
** 2.3 Area B
25
CyclesFirst

20 22,491
Cycles Since

15

10 Area A
Area E
5

0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75
Area D Aircraft Cycles 48.8

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

March 2005 43
 Zone 2: Scribe Inspection Compliance Compliance

100
95
Opportunity

90
85
80
75
First Paint

70
65
Scribe

60 Area B
55
Since

50
Since First

45
40
Cycles Cycles

35
30
25
20 Area C
15 Area A
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
**If scribes are found , then accomplish
Aircraft Cycles inspections per LRTS Zone 2.

March 2005 44
 Zone 2: Compliance Chart
Associated Formula Table Compliance

AREA 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))]
A
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
B 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))]
C 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.

March 2005 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
 Zone 2: Scribe Inspection
Compliance Chart Compliance

100
95
Threshold = Total A/C Cyc – Cycles Since 1st scribe Op + 45,000
Opportunity

90
85
80
1.87
75
First Paint

70
65
SinceScribe

60 Area B
55
50
Since First

45
40
Cycles Cycles

35
30
25
20 22,491 Area C
15 Area A
10
5
47,674 Aircraft Cycles
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
27,491 Aircraft Cycles **If scribes are found , then accomplish
inspections per LRTS Zone 2.

March 2005 47
 Zone 3: Scribe Inspection
Compliance Compliance

100
95
Opportunity

90
85
80
75
First Paint

70 Area B
65
Scribe

60
55
Since

50
CyclesFirst

45
40
35
Cycles Since

30
25
20 Area C
15 Area A
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
**If scribes are found , then accomplish
Aircraft Cycles inspections per LRTS Zone 3.

March 2005 48
 Zone 3: Compliance Chart
Associated Formula Table Compliance

AREA 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))]

A 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)].
B

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

C 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.

March 2005 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
 Zone 3: Scribe Inspection
Compliance Chart Compliance

100
95
Threshold = Total A/C Cyc – Cycles Since 1st Scribe Op + 65,000
First Opportunity

90
85
80 3.6
75
Paint

70
65
Area B
Scribe

60
55
Since

50
CyclesFirst

45
40
35
Cycles Since

30
25
22,491
20
15 Area C
Area A
10
5 66,389 Aircraft Cycles
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
27,491 Aircraft Cycles
**If scribes are found , then accomplish
inspections per LRTS Zone 3.

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 operator’s 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

Zone 3 Chart
Input Zone 2 Chart
Detailed Output Zone 1 Chart
March 2005 59
 Each Zonal Compliance Chart is
Provided Zone
With Fleet
1 Scribe Data
Inspection Plotted
Compliance Chart
B/Tmb=17, B/Tts+mb=30, ISP=40, SMP=50
100 Area C: Detailed Inspection Threshold:

Zone 1
Area B: Detailed Inspection Threshold:
95 The sooner of: Cond 1) 1,200 cyc from release of S/B, if 1177
Cond 1) 4,500 cycles from release of S/B, or... mod has not been accomplished
90 Cond 2) 50,000 total A/C cycles Cond 2) 4,500 cyc from release of S/B, If 1177
** mod has been accomplished
85 Area E: Detailed Inspection Threshold: The later of: **
80 Cond 1) total A/C cycles + [17,000 - cycles since first paint], or...
Cond 2) 1,200 cycles from release of S/B, if S/B 1177 has not been
75 accomplished, or...
Cycles Since First Paint

Cond 3) 4,500 cycles from release of S/B, if S/B 1177 has been accomplished.
70 **

65 Area A: Detailed Inspection Threshold:

The later of:
60 Cond 1) total A/C cycles - cycles since first paint + 30,000 , or...
55 2.3
Cond 2) 4,500 cycles from release of S/B.
50 **

45 Area D: Detailed Inspection Threshold:

40 The later of:
Cond 1) total A/C cycles + [17,000 -
35 cycles since first paint], or…
Cond 2) 4,500 cycles from release of S/B.
30 **

25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
**If scribes are found, then accomplish inspections
Aircraft Cycles per LRTS zone 1A or 1B as applicable.

March 2005 PRELIMINARY NOT FAA APPROVED 60

 Zone 2 Zone 2 Scribe Inspection Compliance Chart
B/T=32, Mid=45, Max=60
100 Area B: Detailed Inspection Threshold:
95 Cond 1) 4,500 cycles from release of S/B.
**
90
85 Area C: Detailed Inspection Threshold: The later of:
Cond 1) total A/C cycles + [32,000 - cycles since first paint],
80 Or …
Cond 2) 4,500 cycles from release of S/B.
75
Cycles Since First Paint

**
70
65
Area A: Detailed Inspection Threshold:
60 The later of:
Cond 1) total A/C cycles – cycles since first paint + 45,000, Or ...
55 1.87
Cond 2) 4,500 cycles from release of S/B.
50 **

45
40
35
30
25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
**If scribes are found , then accomplish
Aircraft Cycles inspections per LRTS Zone 2.
March 2005 PRELIMINARY NOT FAA APPROVED 61
 Zone 3 Zone 3 Scribe Inspection Compliance Chart
B/T=52, Mid=65, Max=70
100 Area B: Detailed Inspection Threshold
95 Cond 1) 4,500 cycles from release of
S/B.
90 **

85
80 Area C: Detailed Inspection Threshold: The later of:
Cond 1) total A/C cycles + [52,000 - cycles since first paint],
75 Or …
Cycles Since First Paint

Cond 2) 4,500 cycles from release of S/B.

70 **

65
Area A: Detailed Inspection Threshold:
60 The later of:
Cond 1) total A/C cycles – cycles since first paint + 65,000, Or …
55 3.6
Cond 2) 4,500 cycles from release of S/B.
**
50
45
40
35
30
25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
**If scribes are found , then accomplish
Aircraft Cycles inspections per LRTS Zone 3.

March 2005 PRELIMINARY NOT FAA APPROVED 62

 Threshold Calculator Example
Guangzhou Example

March 2005 63
Limited Return
To Service (LRTS)

LRTS
 LRTS Overview LRTS

“A Relieving Program”

• 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 1 None

-1125 Frames and Bulkheads – Frame 40K – 50K 1 None
Splice Mod
-1179 Bonded Skin Doubler (T/S) 40K – 50K 1 None
Delamination
A1255 Crown Skin Lap Joint Cracking 41.5K – 45K 1 None
A1027 Fwd & Aft Cargo Frame 40K – 50K 1 None
-1069 Fwd Cargo Damage Prevention 40K – 50K 1 None
A1160 Cargo A/C – Lower Lobe Left 40K – 50K None
1
Frames BS360-500B
A1177 Cracks in Lower Skin at Lap Joints 41.5K – 50K 1 1,200 LFEC

1 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 Repeat Inspections for Lap Joints and All Edges of External Doublers >18” Time Limit
A/C (sealant required only on the leading edge of repair doublers) Until Repair
Cycles (Cycles) (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 Prior to
50,000 total
30-40K <15K since first scribe opportunity : Detailed inspections for cracks @ 1,000
airplane
cycles until 15K cycles since first scribe opportunity
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 Repeat Inspections Time Limit

Cycles (Cycles) Until Repair
(Cycles)
>15 and <70K <15K since first scribe opportunity : Prior to
70,000 total
Butt Joints and Wing-to-body Fairings: No inspection required airplane
All other scribed locations: Detailed inspections @ 1,000 cycles cycles
until 15K cycles since first scribe opportunity

>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 Repeat Inspections Time Limit

Cycles (Cycles) Until Repair
(Cycles)

>30 and <70K <30K since first scribe opportunity : Prior to

70,000 total
Butt Joints: No inspections required Airplane
Wing-to-Body Fairings: No inspections required 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 Repeat Inspections Time Limit

Cycles (Cycles) Until Repair
(Cycles)

> 50 and <70K <50K since first scribe opportunity : Prior to

70,000 total
Butt Joints: No inspections required Airplane
Wing-to-Body Fairings: No inspections required 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

All A/C with sealant removed At compliance

Initial Detailed Visual All
since production threshold

Search Ext./Int. Lap A/C with 4,500 cycle grace

Starting at 40K 1A
Joint Lwr Row period
S/B Internal All A/C with scribes or unknown
Between 40-50K All
Substructure scribes
Internal Lap
All A/C on LRTS >40K cycles At 40K 1A
Joint Lwr Row

LRTS Internal Butt All A/C on LRTS with scribes in When scribes are
All
Joint butt joint found

External NDT – Initially when scribes

UT and Eddy All A/C on LRTS are found and repeat All
Current during LRTS

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 LRTS

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 1 None

-1125 Frames and Bulkheads – Frame 40K – 50K 1 None
Splice Mod
-1179 Bonded Skin Doubler (T/S) 40K – 50K 1 None
Delamination
1
A1255 Crown Skin Lap Joint Cracking 41.5K – 45K None
1
A1027 Fwd & Aft Cargo Frame 40K – 50K None
-1069 Fwd Cargo Damage Prevention 40K – 50K
1 None
A1160 Cargo A/C – Lower Lobe Left 40K – 50K 1 None
Frames BS360-500B
1
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 Repeat Inspections for Lap Joints and All Edges of External Doublers >18” Time Limit
A/C (sealant required only on the leading edge of repair doublers) (Cycles) Until Repair
Cycles (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 Prior to
50,000 total
30-40K <15K since first scribe opportunity: Detailed inspections for cracks @
airplane
1,000 cycles until 15K cycles since first scribe opportunity
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 Repeat Inspections Time Limit

Cycles Until Repair
(Cycles) (Cycles)

>15 and <70K <15K since first scribe opportunity: Prior to

70,000 total
Butt Joints and Wing-to-body Fairings: No inspection required airplane
All other scribed locations: Detailed inspections @ 1,000 cycles cycles
until 15K cycles since first scribe opportunity

>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 Time Limit
Until Repair
Total A/C (Cycles) (Cycles)
Cycles
>30 and <70K <30K since first scribe opportunity: Prior to
70,000 total
Butt Joints: No inspections required airplane
Wing-to-Body Fairings: No inspections required 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 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. 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 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 Repeat Inspections Time Limit

Cycles Until Repair
(Cycles) (Cycles)

> 50 and <70K <50K since first scribe opportunity: Prior to

70,000 total
Butt Joints: No inspections required airplane
Wing-to-Body Fairings: No inspections required 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 Repeat Inspections for Lap Joints and All Edges of External Doublers >18” Time Limit
A/C (sealant required only on the leading edge of repair doublers) (Cycles) Until Repair
Cycles (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 Prior to
50,000 total
30-40K <15K since first scribe opportunity: Detailed inspections for cracks @
airplane
1,000 cycles until 15K cycles since first scribe opportunity
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 pre-
threshold 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 wing-

to-body fairing

– Coverage for additional blend-out allowances

• Should enable operators to develop and accomplish most scribe

line damage repairs without Boeing’s 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
0.036 Fillers Up
10”

A B Inbd
0.032 Shim

Scribe

Fail-safe Doublers
0.032”, 2024-T3 Clad Sht

A B View From Outside A-A B-B

March 2005 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