ALL OPERATORS TELEX - ALL OPERATORS TELEX

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

SHELLS FOR POTENTIAL SKIN TO HONEYCOMB DISBOND (INSPECTION PROGRAM

DIFFERENT FROM AOT A320-55A1038)

OUR REF: A320-55A1039 dated 4 November 09

1. AIRCRAFT AFFECTED

All A319/A320/A321 aircraft equipped with rudders referenced below:

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

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 does not reflect

the current status or if the identification plate is missing, contact

Airbus.

Configuration 1:

Rudder SNMSNA/L

TS-20810711ACA

TS-30041623ACA

TS-25111137AUA

TS-32881901GFA

TS-27681379IBE

TS-21600792LVG

TS-12780275MXA

TS-29991618MXA

TS-21290763TAP

TS-21250759UAL

TS-22010836UAL

TS-30511664UAL

TS-23280953USA

TS-24251050USA

Rudders listed in configuration 1 correspond to rudders that have to

be inspected in bounded shell area only.

Configuration 2:

Rudder SNMSNA/L

TS-21240760ABQ

TS-21230757ACA

TS-10920090IAC

TS-36942322JST

TS-30611673MXA

TS-10320032NWA

TS-24241058NWA

TS-21090745PAL

TS-13140311ART

TS-15200520SWR

TS-20370673SWR

TS-37092340TGW

TS-14280424TCX

TS-25591181TAP

TS-14450442UAL

TS-41482785VLG

Rudders listed in configuration 2 correspond to rudders that have to

be removed from the aircraft within the compliance time given in

paragraph 4.1.1.2.
2. REFERENCED DOCUMENTATION

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

REF 2: AOT A320-55A1038 Rev.02 dated 28 September 2009

REF.3: A319/A320/A321 SRM 55-41-13 Fig. 1 item 1 and item 5

REF.4. NTM TASK 51-10-26-220-801 – (ELCh inspection)

REF 5: NTM TASK 51-10-28-220-801 – (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 51-10-10-260-801 – (X-Ray inspection)

REF 8: NTM TASK 51-10-24-270-801 – Temporary Revision from NTM August

09 – TR 51-004 (Ultrasonic 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.

For rudders that have been reworked in production with similar hot

curing process, an inspection program is being build-up, which calls

for vacuum loss inspection and/or Elasticity Laminate Checker (ELCh)

inspection depending on the affected rudder shell areas:

-Inspection of rudders having accumulated more than 20000 FC

is covered by AOT REF.2, except for those listed in this

AOT.

-Inspection of other rudders will be covered by forthcoming

Service Bulletins, except for those listed in this AOT.

3.2 AIM

Rudders listed in the effectivity of this AOT have also been reworked

with similar hot curing process. However they require a different

inspection program ( due to rework location not fully recorded) than

those inspected through AOT REF.2.

Therefore this AOT calls for a specific process depending on the

rudder configuration.

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

For the purpose of this AOT a Reference Date is defined as the

receipt date of this AOT, or the date when the rudder will accumulate

20000 FC from it first installation on aircraft, whichever occurs

later.

4.1.1.1 RUDDERS CONFIGURATION 1

For each rudder referenced paragraph 1 configuration 1, the

inspection process will have to be carried out in two phases:

-Phase 1 – Inspections including X-Ray: The inspections

described in paragraph 4.2.2.1.1 must be performed within 20

months from the receipt date of this AOT, or within 200 days

from the Reference Date of this AOT, whichever occurs first.

These inspections include:

?For areas with complete documentation

?A one-time ELCh inspection at rudder trailing edge

area (not terminative)

?A terminating one-time vacuum loss inspection at

rudder reinforced areas and other areas

?For areas with not complete documentation

?An ELCh, X-Ray and thermography (when necessary)

inspection

Then, Airbus will provide a second Technical Disposition to:

?For areas with complete documentation

?Provide repetitive ELCh inspection instructions for

trailing edge area.

?For areas with not complete documentation (based on X-Ray

films)

?Provide repetitive ELCh inspection instructions for

trailing edge area.

?Provide terminating one-time vacuum loss inspection

instructions in other areas

-Phase 2 – Remaining inspection actions: The inspections

described in paragraph 4.2.2.1.2 must be performed within 200

days/1500 FC (whichever occurs first) from the inspection phase

1 date. For this phase 2 inspection:

oFor the trailing edge area: The ELCh inspection will have

to be repeated two times, at intervals not exceeding 4500

FC, but not less than 4000 FC from the last inspection.

Following the third inspection without finding, no

further action is required.

oFor the other areas, the one-time vaccum loss inspection

will be a terminating action.

4.1.1.2 RUDDERS CONFIGURATION 2

For rudders SN TS-1032 and SN TS-1092 (which have an honeycomb core

density of 24 kg/m3), the action described in paragraph 4.2.2.2 must

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

For the other rudders in configuration 2, the action described in

paragraph 4.2.2.2 must be performed within 20 months from the receipt

date of this AOT, or 200 days from the Referenced Date of this AOT,

whichever occurs first.

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:

1.5 man-hours per square meter.

C) X-Ray inspection

12 hours maximum elapsed time

4.2 DESCRIPTION

4.2.1 JOB PREPARATION AND ACCESS

Refer to the Technical Dispositions paragraph "Job preparation".

4.2.2 INSPECTION INSTRUCTIONS

4.2.2.1 RUDDERS CONFIGURATION 1

4.2.2.1.1 INSPECTION PHASE 1

Perform vacuum loss inspection (terminating action) or ELCh

inspection according to specific Technical Dispositions referenced

below. For special indicated areas perform ELCh, X-Ray and

thermography inspections.

Airbus will propose an X-ray supervisor to support this activity onsite, and to ensure X-Ray films are accurate enough to map the

production rework. Please contact SEOT2 (c.f parag. 4.1) for

inspection planning.

Rudder SNTechnical Disposition

TS-1278TD/K4/S2/28732/2009 issue A

TS-2081TD/K4/S2/28735/2009 issue A

TS-2125TD/K4/S2/28736/2009 issue A

TS-2129TD/K4/S2/29269/2009 issue A

TS-2160TD/K4/S2/28737/2009 issue A

TS-2201TD/K4/S2/28729/2009 issue A

TS-2328TD/K4/S2/28730/2009 issue A

TS-2425TD/K4/S2/28731/2009 issue A

TS-2511TD/K4/S2/28733/2009 issue A

TS-2768TD/K4/S2/28734/2009 issue A

TS-2999TD/K4/S2/28738/2009 issue A

TS-3004TD/K4/S2/28739/2009 issue A

TS-3051TD/K4/S2/28740/2009 issue A

TS-3288TD/K4/S2/28741/2009 issue A

These Technical Dispositions 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

4.2.2.1.2 INSPECTION PHASE 2

Perform the vacuum loss and/or ELCh inspections according to the
specific Technical Dispositions which will be issued by Airbus, based

on the X-Ray inspection pictures.

Remaining repetitive ELCh inspections for Trailing Edge area will be

also addressed by these phase 2 Technical Dispositions.

A 10 days lead-time is estimated to produce the Technical Disposition

after receipt of the X-Ray films (refer to paragraph 4.2.5).

References are given below:

Rudder SNTechnical Disposition

TS-1278TD/K4/S2/28790/2009 issue A

TS-2081TD/K4/S2/28793/2009 issue A

TS-2125TD/K4/S2/28794/2009 issue A

TS-2129TD/K4/S2/29270/2009 issue A

TS-2160TD/K4/S2/28795/2009 issue A

TS-2201TD/K4/S2/28787/2009 issue A

TS-2328TD/K4/S2/28788/2009 issue A

TS-2425TD/K4/S2/28789/2009 issue A

TS-2511TD/K4/S2/28791/2009 issue A

TS-2768TD/K4/S2/28792/2009 issue A

TS-2999TD/K4/S2/28796/2009 issue A

TS-3004TD/K4/S2/28797/2009 issue A

TS-3051TD/K4/S2/28798/2009 issue A

TS-3288TD/K4/S2/28799/2009 issue A

4.2.2.2 RUDDERS CONFIGURATION 2

The rudder must be removed from the aircraft and replaced. Airbus

must be contacted in order to get instructions for further use of

this rudder.

4.2.3 JOB CLOSE UP

Refer to the Technical Dispositions 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

For rudders in configuration 1: Hardware (developed X-Ray films and

the film layout arrangement) has to be sent within 10 days from the

inspection date to:

Wolfgang Bisle

Department EDSWNG

AIRBUS Deutschland GmbH

Airbus-Allee 1

28199 Bremen

Germany

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 X-Ray as per REF.7

-Inspection equipment for Ultrasonic as per REF.8

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 (option I): Hole closing with selfadhesive patches, allowed for 4500 FC. Correct cover

application has to be ensured by frequent detailed visual

inspections until permanent restoration is performed, at

intervals not exceeding 750 FC/100 days (whichever occurs

first), or

-Temporary restoration (option II): Hole filling with resin.

Ultrasonic inspection in reinforced areas only and local

thermography inspection in other areas are required before

resin injection. Final restoration has to be performed not

later than 4500 FC.

-Permanent restoration: Hole filling with resin and restoration

of surface protection. Ultrasonic inspection in reinforced

areas only and local thermography inspection in other areas are

required before resin injection.

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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attention to the fact that it may be monitored and/or intercepted.

Further, whilst Airbus has taken reasonable measures to ensure the

integrity of this message and its contents, no warranty, whether

express or implied, is given that the contents hereof conform to the

original. In case of any doubt, please retrieve this document from

your SITA address or the Airbus AOLS system or request that it be

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