ALL OPERATORS TELEX - ALL OPERATORS TELEX

SUBJECT: A318/A319/A320/A321 - ATA 55-40 - INSPECTION OF RUDDER SIDE

SHELLS FOR POTENTIAL SKIN TO HONEYCOMB DISBOND

OUR REF: AOT A320-55A1038 dated 22 April 09

1. AIRCRAFT AFFECTED

All A318/A319/A320/A321 aircraft equipped with rudders having the

Serial Numbers (SN) listed in Technical Disposition ref.

TD/K4/S2/27086/2009 issue C Table 1, and having a honeycomb core

density of 24 kg/m3 (rudders ticked "x" in column "24kg core").

Or

All A318/A319/A320/A321 aircraft equipped with rudders having the

Serial Numbers (SN) listed in Technical Disposition ref.

TD/K4/S2/27086/2009 issue C Table 1, and having accumulated 20000 FC

or more at receipt date of this AOT.

Note: Affected rudders having accumulated less than 20000 FC at

receipt date of this AOT will be inspected through a forthcoming

dedicated Inspection Service Bulletin planned to be issued by end of

May 2009.

The following rudders that have been inspected through the sampling

campaign, do not need to be inspected as per this AOT:

SN TS-2359MSN 998AFR

SN TS-1096MSN 94DLH

SN TS-1149MSN 147DLH

The following rudder that has been inspected through the sampling

campaign, is only to be inspected at trailing edge location, in

accordance with this AOT.

SN TS-1536MSN 533CCM

For this rudder, the ELCh inspection described in paragraph 4.2.2.2

must be performed within 4500 FC from accomplishment of the sampling

inspection, and repeated one time at an interval not exceeding 4500

FC.

In case a rudder originally fitted on one aircraft (refer to Aircraft

Inspection Report delivery document) has been removed and installed

on another aircraft, it is the responsibility of the operator to

apply the required instructions contained in this AOT to the new

aircraft.

If the cross-reference Rudder SN/ Aircraft MSN given in

TD/K4/S2/27086/2009 issue C Table 1 does not reflect the current

status, contact Airbus.

2. REFERENCED DOCUMENTATION

REF.1: OIT 999.0092/08: ATA55 – Rudder side shell skin disbonding

REF.2: A318/A319/A320/A321 SRM 55-41-13 Fig. 1 item 1 and item 5

REF.3: Technical Disposition ref. TD/K4/S2/27086/2009 issue C

REF.4. NTM TASK 51-10-26-220-801 – Temporary Revision TR 51-003 (ELCh

inspection)

REF 5: NTM TASK 51-10-28-220-801 – Temporary Revision TR 51-002

(Vacuum Loss inspection)

REF 6: NTM TASK 51-10-25-290-801 or TASK 51-10-25-290-802

(Thermography inspection)
REF 7: NTM TASK 51-10-19-280-801 (Tap test inspection)

3. REASON

3.1 BACKGROUND

A deformation was visually detected on the rudder side shell of an

A319 and an A321 in-service aircraft. Both rudders were sent to

Airbus facilities for further analysis.

A review of production records revealed that the deformations

reported on both rudders corresponded to areas that had been reworked

in production.

The conclusion of the investigation is that the disbonding most

likely occurred as a consequence of excessive temperature applied,

during a hot curing rework of the inner skin in production. This

rework occurred outside the autoclave.

Operators were informed thru OIT REF.1 dispatched in November 2008

and revised in March 2009.

3.2 AIM

For rudders that have been reworked in production with similar hot

curing process, this AOT calls for:

-a one-time Vacuum Loss inspection at rudder shell reinforced

areas

-a three(3)-times repetitive ELCh inspection at rudder shell

trailing edge area

-a repetitive ELCh inspection in other rudder shell areas; until

a Vacuum Loss inspection is performed (considered as the

terminating action)

4. SHORT TERM ACTION

4.1 PLANNING AND MANPOWER

This AOT is subject to an Airbus Monitored Retrofit Campaign. For

logistic purposes please provide in advance the inspection planning.

Your focal point for the planning and the logistics is:

Wera DIETZ, SEOT2,

Customer Services

Phone: +33 (0)5 67 19 14 22

Fax: +33 (0)5 61 93 27 45

Mailto: wera.dietz@airbus.com

4.1.1 ACCOMPLISHMENT TIMESCALE

Accomplishment timescale depends on the locations of the areas to be

inspected, which are fully described in Technical Disposition ref.

TD/K4/S2/27086/2009 issue C.

4.1.1.1 FOR REINFORCED AREAS

The one-time Vacuum Loss inspection described in paragraph 4.2.2.1

must be performed within 200 days from the receipt date of this AOT.

4.1.1.2 FOR TRAILING EDGE AREA

The ELCh inspection described in paragraph 4.2.2.2 must be performed

within 20 months from the receipt date of this AOT, and repeated two

times at intervals not exceeding 4500 FC.

Further to the third inspection without findings, no further action
is required as per this AOT.

4.1.1.3 FOR OTHER AREAS (SPLICE/LOWER RIB/UPPER EDGE/LEADING

EDGE/OTHER LOCATIONS)

The repetitive ELCh inspection described in paragraph 4.2.2.3.A. must

be performed:

-within 200 days from the receipt date of this AOT

-then, repeated at intervals not exceeding 1500 FC / 200 days

(whichever occurs first)

-up to accomplishment of the terminating one-time Vacuum Loss

inspection mentioned in paragraph 4.2.2.3.B., that must be

performed within 20 months from the receipt date of this AOT.

Accomplishment of this terminating one-time inspection cancels

the repetitive ELCh inspection requirements described in

paragraph 4.2.2.3.A.

4.1.2 MANPOWER

The manpower estimates given below are based on the direct labour to

do the work. These estimates assume that the work will be done by

experienced personnel. They might need to be revised upwards to suit

operators' circumstances.

These estimates do not include the manpower required for repairs in

case of findings.

A) Vacuum Loss inspection:

-Inspection: 1 man-hour per linear meter

-Hole restoration and resin curing time: 12 hours maximum

elapsed time

B) ELCh inspection:

Note: Refer to Technical Disposition ref. TD/K4/S2/27086/2009 issue C

for identification of inspection area:

-Location B: 4 man-hours

-Location C: 2 man-hours

-Location D: 1 man-hour

-Location E : 0.5 man-hours

-Location F : 2 man-hours

Figures are given for one side shell to be inspected.

4.2 DESCRIPTION

4.2.1 JOB PREPARATION AND ACCESS

Refer to Technical Disposition ref. TD/K4/S2/27086/2009 issue C

paragraph "Job preparation".

4.2.2 INSPECTION INSTRUCTIONS

Rudder shells must be inspected only in areas mentioned in Technical

Disposition ref. TD/K4/S2/27086/2009 issue C Table 1.

Example: Rudder SN TS-2205 (end of table 1)

This rudder must be inspected on L/H side shell, at trailing edge

location as per Technical Disposition location B. Other areas are not

to be inspected.

It must be also inspected on R/H side shell, at lower rib location as

per Technical Disposition location D. Other areas are not to be

inspected.

4.2.2.1 FOR REINFORCED AREA

Perform a one-time Vacuum Loss inspection according to Technical

Disposition ref. TD/K4/S2/27086/2009 issue C location A.
Specific inspection instructions are to be requested by mail to:

Nicolas SEYNAEVE, SEES1

Customer Services

Phone: +33 (0)5 61 93 34 38

Fax: +33 (0)5 61 93 36 14

Mailto: nicolas.seynaeve@airbus.com

4.2.2.2 FOR TRAILING EDGE AREA

Perform three(3)-times repetitive ELCh inspection according to

Technical Disposition ref. TD/K4/S2/27086/2009 issue C location B.

4.2.2.3 FOR OTHER AREAS (SPLICE/LOWER RIB/UPPER EDGE/LEADING

EDGE/OTHER LOCATIONS)

A.) Perform a repetitive ELCh inspection according to Technical

Disposition ref. TD/K4/S2/27086/2009 issue C locations C, D, E, F, G

and H.

B.) Perform a one-time Vacuum Loss inspection according to specific

Technical Dispositions. In order to obtain these instructions, please

send a request to:

Nicolas SEYNAEVE, SEES1

Customer Services

Phone: +33 (0)5 61 93 34 38

Fax: +33 (0)5 61 93 36 14

Mailto: nicolas.seynaeve@airbus.com

They will be provided in a time-frame compatible with the inspection

planning (refer to paragraph 4.1).

4.2.3 JOB CLOSE UP

Refer to Technical Disposition TD ref. TD/K4/S2/27086/2009 issue C

paragraph "Job close up)".

4.2.4 ACTIONS IN CASE OF FINDINGS

In case of findings, document accurately the relevant inspection

report sheet, and contact Airbus at the following address before next

flight to get further instructions:

SEER1/SEER2/SEER3

Customer Services

Fax: +33 (0)5 61 93 28 73

Mailto:

region1.StructureRepairSupport@airbus.com

region2.StructureRepairSupport@airbus.com

region3.StructureRepairSupport@airbus.com

Or for AOG request:

AIRTAC (Airbus Technical AOG Center)

Customer Services

Phone: +33 (0)5 61 93 34 00

Fax: +33 (0)5 61 93 35 00

Mailto: airtac@airbus.com

4.2.5 REPORTING

If there are no findings, report to Airbus within 10 days from the

inspection date of each affected rudder, at the following address:

Nicolas SEYNAEVE, SEES1
Customer Services

Phone: +33 (0)5 61 93 34 38

Fax: +33 (0)5 61 93 36 14

Mailto: nicolas.seynaeve@airbus.com

4.2.6 MATERIAL, TOOLING

-Adjustable access platform or Cherry Picker

-Inspection equipment for ELCh as per REF.4

-Inspection equipment for Vacuum Loss inspection as per REF. 5

-Inspection equipment for Thermography as per REF. 6

-Inspection equipment for Tap test as per REF. 7

Note 1: In order for Airbus to provide adequate support to all

affected operators, it is recommended to place a Purchase Order for

ELCh tool two weeks ahead of the first scheduled inspection.

Note 2: A CD-Rom including ELCh familiarization has been shipped to

all affected operators via Airbus Field Service stations.

Note 3: Instructions for restoration of Vacuum Loss inspection holes

are detailed in the specific Technical Dispositions, and can be

performed in 2 steps:

-Temporary restoration: Hole closing with self-adhesive patches,

allowed for 4500 FC

-Permanent restoration: Hole filling with resin and restoration

of surface protection. Local thermography inspection is

required before resin injection, to ensure sandwich structure

is free of liquid.

Note 4: For thermography inspection, as a limited number of equipment

is available for loan from Airbus, necessary Infrared camera could

also be purchased at the following address:

FLIR SYSTEMS

Internet address: <http://www.flir.com/>

5. AOT APPROVAL

The technical content of this AOT has been approved under the

authority of EASA Design Organization Approval number EASA 21J.031.

It is anticipated that this AOT will be rendered mandatory.

6. REPORTING/ACKNOWLEDGMENT

Operators are requested to acknowledge receipt of this AOT within 48

hours after receipt to:

MR. R. LASCOURS, SEE,

SITA CODE TLSBT7X,

FAX: +33 / (0) 5 61 30 00 79

This acknowledgement can be made through the Airbus RCSM when

available.

Best regards,

A. VIEILLARD

VICE PRESIDENT A318/A319/A320/A321 PROGRAMME

CUSTOMER SERVICES DIRECTORATE

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