Thu, Apr 10, 2003
Latest Recommendations to the FAA:
The National Transportation Safety Board
recommends that the Federal Aviation Administration:
Establish appropriate criteria (taking into account the size of
the repair and other relevant considerations) to identify those
pressure vessel repairs to transport-category airplanes that could
be hiding damage that, if not addressed, may lead to multiple-site
fatigue damage and fatigue cracking and could result in structural
failure of the airplane. (A-03-07)
Issue an airworthiness directive requiring all operators of
transport-category airplanes with pressure vessel repairs
identified as a result of applying the criteria discussed in Safety
Recommendation A-03-07 (other than those covered by Service
Bulletin 747-53A2489) to:
- immediately remove the repair doubler to determine whether
hidden damage that could lead to multiple-site fatigue damage (MSD)
or fatigue cracking is present and, if so, repair the damage in
accordance with the applicable structural repair manual (SRM)
or
- perform repetitive visual and nondestructive inspections for
MSD and fatigue cracking at appropriately conservative intervals
until the doubler is removed and, if any cracking is detected,
immediately remove the doubler and repair the damage in accordance
with the applicable SRM.
The results
of these inspections should be provided to the FAA. The only
repairs that should be eligible for exemption from these
requirements are those that are supported by credible and detailed
engineering documentation substantiating that the repair was
performed in accordance with the applicable SRM and only after a
visual inspection to confirm that the repair conforms to that
documentation. (A-03-08)
Inform maintenance personnel about the circumstances of this
accident and emphasize that improper repairs to the pressure vessel
may be hiding damage that allows the development of multiple-site
fatigue damage and fatigue fracturing that could lead to structural
failure. (A-03-09)
Require the manufacturers of pressurized transport-category
airplanes to include in their structural repair manuals, training
programs, and other maintenance guidance, warnings about the
possibility of structural failure resulting from hidden damage.
(A-03-10)
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