erjhc54-004/11 r0

ERJHC54-004/11 R0EO. No:

02/15/2011Rev. Date: Pag 2 of 20

ENGINEERING ORDER

FORM QA-073/96 TS-F R0

Date: 02/15/2011

EFFECTIVITY:

EMBRAER ERJ 190-100 19000215

During current heavy check the LH pylon forward fairing 419BT and the relative attachment flange

on the pylon side were damaged while removing a damaged screw with a drill and drill motor. No

SRM repairs address this kind of damage.

Ref. /A/ is the damage report sent to Embraer.

Ref. /B/ is Embraer's disposition for permanent repair.

This EO is issued to perform the permanent repair on subject panel and its relative attachment

flange as per Ref. /B/.

This EO is considered Major.

ENG. ASSESSMENT:

AIRCRAFT MODEL /

COMPONENT

DESCRIPTION MSN FSN REMARKS

TI-BCG


02/15/2011Rev. Date: Pag 3 of 20

ENGINEERING ORDER


Date: 02/15/2011

DISTRIBUTION LIST

(Planning will distribute all copies)

Technical Records

Stockroom

Reliability

Line Maintenance

Hangar Maintenance

Flight Operations

Quality Control

Quality Assurance

Technical Publicactions

Warranty

Other

..............

..............

..............

..............

..............

..............

..............

..............

..............

..............

..............

Comments:

PUBLICATIONS AFFECTED

None

LABOR ESTIMATE:

DOCUMENT NUMBER DOCUMENT TYPE TITLE

SUPPORT DOCUMENTATION

SKILLS: CREW: MAN-HRS: ELAPSED:

20-00-00-910-801-A/200

51-21-01

51-23-04

51-23-05

51-23-06

51-41-02

54-50-02

54-50-21

54-50-21

AMM Part II

SRM Part II

SRM Part II

SRM Part II

SRM Part II

SRM Part II

SRM Part I

SRM Part II

SRM Part I

Aircraft maintenance safety practices

Faying surface sealing

Pretreatment to metal parts

Surface protection primer

Topcoat

Solid rivets flush head

STRUCTURE ASSY IDENTIFICATION,PYLON,LH/RH

Removal / Installation of pylon forward fairings

SKIN 2 IDENTIFICATION ,FAIRING FWD, LH/RH PYLON

STR

MECH

INS

1

1

1

4

1

0.5

4

1

0

TOTAL: 3 5.5

None

---

Chapter Publications

X

X

X

5


02/15/2011Rev. Date: Pag 4 of 20

ENGINEERING ORDER


Date: 02/15/2011

PARTS AND MATERIALS (Per Unit)

PART NUMBER DESCRIPTION QTY UNIT P.O./M.R. REMARKS

Refer to Instructions NA

TOOLS

PART NUMBER DESCRIPTION QTY P.O. REMARKS

Refer to Instruction

ENGINEERING ORDER E.O. No: ERJHC54-004/11 DATE: 02/15/2011 Rev. No: 0 PAGE: 5 of 20 SUBJECT: NACELLES & PYLONS - LH PYLON - DAMAGED SCREW HOLE AT FWD PYLON FAIRING 419BT AND ATTACHMENT

FLANGE - PERMANENT REPAIR

FREQUENCY: N/A TAIL: STATION: DATE:

MECHANIC Q.C. INSTRUCTIONS

FORM QA-073/96-TS-F R0

XXX XXX ACCOMPLISHMENT INSTRUCTIONS

RII WARNING: MAKE SURE THAT THE AIRCRAFT IS IN A SAFE CONDITION BEFORE YOU DO THE MAINTENANCE PROCEDURES. THIS IS TO PREVENT INJURY TO PERSONS AND/OR DAMAGE TO THE EQUIPMENT. CAUTION: BE CAREFUL WITH THE EQUIPMENT AND COMPONENTS INSTALLED IN THE AREA WHERE YOU WILL DO THE REPAIR. IF YOU DO NOT OBEY THIS PRECAUTION, DAMAGE TO EQUIPMENT CAN OCCUR.

XXX XXX A. JOB SET-UP

RII 1. Do the procedure to make the aircraft safe for maintenance. Refer to AMM TASK 20-00-00-910-801-A/200.

XXX 2. Gain access to the damaged area by removing the necessary equipment

XXX 3. Locate the damaged fairing 419BT and its associated attachment flange (on the pylon side) of the LH Pylon. Refer to Ref. /A/.

NDT

XXX

4. Perform NDI as per NDT 51-00-00 to confirm that the damaged attachment flange is crack free.

Is the area crack free? □YES □NO

If YES, proceed with next step. If NO, contact Engineering immediately.

XXX

RII a) The NDT personnel that executed the above NDT Inspections is qualified, the appropriate tools and technical approved data/publications were used during the accomplishment of the inspection and all work .documentation has been correctly filled out.

RII 5. Confirm that the damages are in accordance with Ref. /A/.

Are the damages iaw Ref. /A/? □YES □NO

If YES, proceed with next step. If NO, contact Engineering immediately.

XXX 6. Remove the fairing 419BT from the pylon as per AMM Part II 54-50-21.

XXX XXX B. PERMANENT REPAIR OF PANEL 419BT

XXX 1. Remove and discard the damaged reinforcement P/N 190-08516-001 from the panel 419BT. Refer to SRM Part I 54-50-21 Figure 03.






XXX 2. On the panel, ream the holes to the minimum diameter within H7 tolerance. Make sure to remove all the damage.

RII 3. Manufacture a special bushing as outlined below:

• Bushing material: AL 7475, CRES 15-5PH H1100 or 17-4PH H1100. • External diameter within s6 tolerance. • Interference class: H7 s6 • General roughness: 1.6 Ra • Bushing dimensions: measured in loco • Assure minimum wall thickness of 0.040” (1.0mm)

NOTE: If the bushing is made from AL 7475, apply chemical conversion compound (MIL-DTL-81706 or MIL-C-5541, class 1A or 3) per SRM Part II 51-23-04.

RII 4. Install bushing using cryogenic process. Use Type IV-12 Rubber Interface Sealant (MIL-PRF-81733) as per SRM Part II 51-21-01.

RII 5. Install a new reinforcement P/N 190-08516-001 on the panel 419BT using original type rivets. Refer to SRM Part I 54-50-21 Figure 03 Item 40. Refer to SRM Part II 51-41-02.

RII 6. Reprotect and restore surface finish of the parts as per SRM Part II 51-23-05 (use MEP 10-068) and 51-23-06 (MEP 10-069) as applicable.

XXX XXX C. PERMANENT REPAIR OF PYLON ATTACHMENT FLANGE COMMON TO FAIRING 419BT.

XXX 1. Remove as necessary the retainer plate at the damaged pylon attachment flange to avoid damages to this part during the repair. Refer to SRM Part I 54-50-02 Figure 01 and Ref. /A/ for location.

RII 2. On the pylon structure, ream the holes to the minimum diameter within H7 tolerance. Make sure to remove all the damage.

RII 3. Manufacture a special bushing as outlined below:

• Bushing material: AL 7475, CRES 15-5PH H1100 or 17-4PH H1100. • External diameter within s6 tolerance. • Interference class: H7 s6 • General roughness: 1.6 Ra • Bushing dimensions: measured in loco • Assure minimum wall thickness of 0.040” (1.0mm)

NOTE: If the bushing is made from AL 7475, apply chemical conversion compound (MIL-DTL-81706 or MIL-C-5541, class 1A or 3) per SRM Part II 51-23-04.






RII 4. Install bushing using cryogenic process. Use Type IV-12 Rubber Interface Sealant (MIL-PRF-81733) as per SRM Part II 51-21-01.

RII 5. Re-Install the retainer plate at the damaged pylon attachment flange. Refer to SRM Part I 54-50-02 Figure 01. Refer to SRM Part II 51-41-02.

RII 6. Reprotect and restore surface finish of the parts as per SRM Part II 51-23-05 (use MEP 10-068) and 51-23-06 (MEP 10-069) as applicable.

XXX XXX D. CLOSE UP

RII

1. Make sure that the work areas are clean and clear of tools and other items of equipment.

RII 2. Install the fairing 419BT from the pylon as per AMM Part II 54-50-21.

RII 3. Put the aircraft back to its initial condition.

XXX XXX End of this E.O.

XXX

XXX The following step is for documentation purposes only and is not related to the actual

tasks performed on the subject aircraft.

XXX

XXX

TECHNICAL RECORDS: Insert a copy of this Engineering Order in the records of the subject aircraft.

Name: ______________________________

Title: _______________________________

Date: _______________________________

Signature: ___________________________

XXX

XXX

WARRANTY DEPARTMENT: Make sure that the labor and materials cost required to perform this EO are covered by the Heavy Maintenance Provider.

Name: ______________________________

Title: _______________________________

Date: _______________________________

Signature: ___________________________






XXX

XXX

MAINTENANCE PROGRAM ENGINEERING: Make sure Task 54-50-008-0001 from MPG/MRBR Rev. 05 is included into A/C’s Maintenance Program.

Name: ______________________________

Title: _______________________________

Date: _______________________________

Signature: ___________________________

1

Salvador Azahar

From: [email protected]: Saturday, February 12, 2011 8:05 AMTo: [email protected]; [email protected]: [email protected]; [email protected]; [email protected]; [email protected];

[email protected]; [email protected]; [email protected]; Roberto Cisneros; Salvador Azahar; Carlos Esquivel

Subject: TACA E190 TI-BCG S/N19000215 Damage to Pylon Panel and Pylon attach StructureAttachments: Structural Report.xls; TACA TI-BCG Pylon Panel.pptx; TACA TI-BCG drill start in attach

flange.pptx

Importance: High

Salvador Azahar Ingeniero de Estructuras – TACA Airlines

Aeropuerto Internacional de El Salvador (Acceso No. 6), San Luis Talpa, El Salvador

T.+503 2366-7895 F. +503 2366-7403 M. +503 7129-2646 [email protected]

PS. Favor notar cambio en e-mail a: [email protected] / Please note my e-mail has changed to: [email protected]

-----Original Message-----

From: [email protected] [mailto:[email protected]] Sent: Saturday, February 12, 2011 8:05 AM

To: [email protected]; [email protected] Cc: [email protected]; [email protected]; [email protected]; [email protected];

[email protected]; [email protected]; [email protected]; Roberto Cisneros; Salvador Azahar; Carlos Esquivel Subject: TACA E190 TI-BCG S/N19000215 Damage to Pylon Panel and Pylon attach Structure

Importance: High

Dear Embraer Engineering Team,

Please review attached photos and damage report.

During removal of a damaged screw with a drill and drill motor the mechanic accidentally damaged the pylon access panel P/N 190-03174-403 and the attach flange on the L/H outboard

pylon. the reinforcement ( Filler ) on the panel P/N190-08516-001 is on order but the arrival date is not established at this time and we like to repair the damage as requested below

Repair procedure, remove the damaged filler and replace with a new one remove all damage in

the access panel with the minimum amount of material loss ( circular cut out )and fabricate a repair plug ( press fit ) from 2024T-3 stock.the minor damage on the pylon strap is accepted

as is after all high metal is removed and NDT verified area is crack free.

Alternate repair procedure, if the filler on the access panel is not available remove damage ( circular cut out ) and fabricate a straight bushing ( press fit ) after NDT verified area

is crack free from 2024T-3 stock.

sazahar

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ERJHC54-004/11 R0 REF. /A/ SHEET 1 OF 5 PAGE 9 OF 20

2

original repair procedure has one single plug in the access panel skin and alternate repair

procedure would have two plugs one in the access panel skin and one in the filler

please contact me for any additional information you need for a repair statement

(See attached file: Structural Report.xls)(See attached file: TACA TI-BCG Pylon

Panel.pptx)(See attached file: TACA TI-BCG drill start in attach flange.pptx)

thank you with best regards

RAINER KUBISCH

Structure Lead Technician Embraer Aviation Services

BNA International Airport 10 Airways Boulevard

Nashville TN,37217 cell 615-881-6383 office 615-577-5344

Structure Dept.Hgr.II [email protected]

---------------------------------------------------------------------- The information contained in this transmission may contain confidential and proprietary

information. It is intended only for the use of the person(s) named above. If you are not the intended recipient, you are hereby notified that any review, dissemination, distribution or duplication of this communication is strictly prohibited. If you are not the intended

recipient, please contact the sender by reply email and destroy all copies of the original message. To reply to our email administrator directly, please send an email to

[email protected].

sazahar

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STRUCTURAL REPORT

REQUESTER CONTACT INFORMATION

Name Phone Mobile

Company E-mail

Fax CC

PRIORITY

Answer required within

Return to service date

IDENTIFICATION

Airline Component PN

Model Aircraft serial number 2E+07 Component SN

Airport (IATA) Aircraft FH Component FH

Aircraft FC Component FC

EVENT LOCATION

ATA

Int / Ext

Part number

SSI

EVENT DESCRIPTION

#1

#2

#3

25-fev-10

Click for A/C zone

PylonElongated hole

External

190-03174-403

Type

Panel

Call +55-12-9713-4559to confirm e-mail receipt

NatureWidthLength

L/H Pylon access Panel outboard side and attachflange on pylon structure damage with a drill

depth

Accidental

Accidental

615-577-5344

3,794

615-881-6383

4,826.04

[email protected]

Rainer Kubisch

Embraer Nashville

TACA

ERJ 190

Feb.18,2011am

24 Hours

BNA

Elongated hole

Rem. Thick.

0.320"

Other location details

0.300"

Routine

AOG

#3

#4

#5

#6

Performed inspections

Damage to underlying

structure?

Allowable damage available? Reason damage is not

Damage classification covered by SRM

Additional

description

REQUIRED ACTIONS REPAIR PROPOSAL

Request type

Validity

DER Form required?

REFERENCES give us a generic repair

Ref. /A/:

Ref. /B/:

Ref. /C/:

Ref. /D/:

Ref. /E/:

Ref. /F/:

Permanent

No

Majorsee attached photos

Structural repair

Yes

request permanent repair at this time it is unknown if the reinforcement P/N190-08516-001 on the access panel is available

GVI Ultrasonic Eddy Current Tap Test

DET Dye Penetrant Magnetic Particle Other

Frame

Stringer

Spar

Rib

Bulkhead

Splice Other

Inner skin/doubler

None

None

YOUR REFERENCE E-MAIL SUBJECT (in case the Submit button below is not used)

Reference number Routine - Structures - ATA - 1900021500000 - Structural repair -

sazahar

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TACA TI-BCGL/H Pylon Access Panel P/N190-03174-403

Is damaged at Fastener Hole outboard third hole

From the front edge

FWD

0.462”

0.320”

0.270”

0.435”

Reinforcement P/N190-08516-001

Replace if available if not install a

Plug

Remove damage and

Install a Plug

sazahar

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TACA TI-BCG

Panel P/N190-03174-403 attach point

On upper Pylon has damage from

A Drill no damage to inner Strap or

Nut Plate found

No Damage to inner Structure or Nut Plate

found

Drill start remove any high metal

And fill with sealant accept

Condition after NDI reveals no cracks

0.300”

0.435”

sazahar

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EMBRAER S.A. Av. Brigadeiro Faria Lima, 2170 − 12227-901 São José dos Campos - São Paulo – Brazil

ETD2011-190/01718 REV.:A Embraer Technical Disposition Page 1 of 5

This document was electronically signed by João Fernando F. Bacciotti on Feb 16th, 2011

SUBJECT

ERJ 190 – S/N 19000215 – ATA 5450 – LH Pylon Upper Access Panel and Attachment Flange with Elongated Holes – Permanent structural repair

CONTACT

To:

RAINER KUBISCH Structure Lead Technician Embraer Aviation Services cell 615-881-6383 office 615-577-5344 Structure Dept.Hgr.II [email protected]

From: (RTS) Return To Service - Structures Embraer Technical Support AOG phone: +55 12 9713 4559 Office phone: +55 12 3927 3333 Office fax: +55 12 3927 6600 ext. 0484

IDENTIFICATION

Operator: Taca ATA: 5450

A/C: ERJ 190 A/C S/N: 19000215 FH: 4.826,00

FC: 3.794

P/N:

N/I Part S/N: N/I FH: N/I

FC: N/I

RULES

� The technical disposition contained in this document is based solely on the data explicitly reported by the Operator. As no other information was provided by the Operator, Embraer assumes that the area/structural component(s) related to this technical disposition did not have any other previous damage and/or repair incurred to it. Therefore, Embraer disclaims any and all responsibility for incorrect, inaccurate or incomplete information provided by the Operator related to this matter.

� If the technical disposition contained in this document requires approval from the Local Regulatory Authority, please take the appropriate measures to obtain such approval.

� In case of any conflict between this document and any mandatory requirements issued by the Local Regulatory Authority, including but not limited to Airworthiness Directives, the Local Regulatory Authority document/orientation shall prevail.

� In case a structural repair affects a structure subject to an Airworthiness Directive or any other mandatory requirement issued by Local Regulatory Authority, Embraer strongly recommends the operator to seek for an AMOC (Alternate Means of Compliance) within Local Regulatory Authority, even when the repair is followed by an ANAC form F200-06.

� This revision cancels and supersedes all the previous dispositions.

REFERENCES

Ref. A: E-mail from RAINER KUBISCH, dated February 12th, 2011. Ref. B: E-mail from Salvador Azahar, dated February 15th, 2011

REVISION HISTORY

Rev. : - Rev. A: Changed reference for application of Alodine.

sazahar

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ERJHC54-004/11 R0 REF. /B/ SHEET 1 OF 5 PAGE 14 OF 20




DESCRIPTION

EAMS reports that A/C TI-BCG, S/N 19000215 has elongated holes on the LH pylon upper panel (P/N 190-03174-403) outboard side and on its attachment flange. Damage dimensions:

- Panel: 0.320” - Pylon: 0.300”

The internal reinforcement on the panel (P/N 190-08516-001) is on order but the arrival date is not established at this time, therefore EAMS requests to repair the damage as follows: Repair procedure: - Remove the damaged reinforcement and replace with a new one (P/N 190-08516-001); - Remove all damage in the access panel with the minimum amount of material loss (circular cut out) and fabricate a repair plug (press fit) from 2024T-3 stock. - Accept the minor damage on the pylon strap as is after all sharp edges are removed and NDT confirms the affected area is crack free. Alternate repair procedure: - If the internal reinforcement on the access panel is not available remove damage (circular cut out), perform NDT for cracks, and fabricate a straight bushing (press fit) from 2024T-3 stock. Original repair procedure has one single plug in the access panel skin and alternate repair procedure would have two plugs one in the access panel skin and one in the filler Affected PN is 190-03174-403. No FCS is affected.

sazahar

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sazahar

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DISPOSITION

1) Permanent Repair for Pylon Access Panel and Attachment Flange

a) Setup

i) WARNING: MAKE SURE THAT THE AIRCRAFT IS IN A SAFE CONDITION BEFORE YOU DO THE MAINTENANCE PROCEDURES. THIS IS TO PREVENT INJURY TO PERSONS AND/OR DAMAGE TO THE EQUIPMENT.

ii) CAUTION: BE CAREFUL WITH THE EQUIPMENT AND COMPONENTS INSTALLED IN THE AREA WHERE YOU WILL DO THE REPAIR. IF YOU DO NOT OBEY THIS PRECAUTION, DAMAGE TO EQUIPMENT CAN OCCUR.

iii) Do the procedure to make the aircraft safe for maintenance (AMM TASK 20-00-00-910-801-A/200).

iv) Gain access to the damaged area by removing the necessary equipment.

b) Repair Material List

i) AL 7475, CRES 15-5PH H1100 or 17-4PH H1100.

c) Consumable Material

i) Type IV-12 Rubber Interface Sealant (MIL-PRF-81733); ii) Methyl Ethyl Ketone (ASTM-D-740) iii) High Solids Epoxy-Primer for Exterior (MEP 10-068) iv) Chemical Conversion Compound (MIL-DTL-81706 or MIL-C-5541, class 1A or 3)

d) Repair Procedure

i) Ream the holes to the minimum diameter within H7 tolerance; ii) Manufacture a special bushing as follows:

(1) Bushing material: see Repair Material List above; (2) External diameter within s6 tolerance; (3) Interference class: H7 s6; (4) General roughness: 1.6 Ra; (5) Bushing dimensions: measured in loco; (6) Assure minimum wall thickness of 0.040” (1.0mm).

iii) If the bushing is made from AL 7475, apply chemical conversion coating (alodine) per SRM Part II 51-23-04;

iv) Install bushing using cryogenic process; v) Use interface sealant.

e) Job Close Up

i) Put the aircraft back to its initial condition.

f) Inspection

i) Task 54-50-008-0001 (Internal DET Threshold of 40000FC, Interval of 40000FC) is sufficient and is met using the inspection requirements: MPG/MRBR revision #5. Threshold is counted since new.

See SRM & AMM chapter 51 for general standard procedures / instructions.

sazahar

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Relatório de Verificação de Concordância de Aeronaves e Outros Produtos Aeronáuticos

com os RBHA (Report of Compliance of Aircraft or other Aeronautical Products with the RBHA)

AGÊNCIA NACIONAL DE AVIAÇÃO CIVIL

Gerência Geral de Certificação de Produtos Aeronáuticos

1. Identificação da Aeronave ou Componente: (Aircraft or Component Identification)

ERJ 190 – S/N 19000215

2. Data: (Date)

February 16th, 2011

3. Marca e No Modelo (Make & Model Nr)

Embraer – ERJ 190-100IGW

4. Tipo (aeronave, rádio, helicóptero, etc.) Type (aircraft, radio, helicopter, etc)

AIRCRAFT

5. Nome do Requerente (Name of Applicant)

Embraer

Descrição dos Trabalhos e Lista de Dados Aprovados (Work Description and List of Approved Data)

6. Número (Number) 7. Título (Title)

ETD2011-190/01718A ERJ 190 – S/N 19000215 – ATA 5450 – LH Pylon Upper Access Panel and Attachment Flange with Elongated Holes – Permanent structural repair Operator: Taca SN: 19000215 Tail Number: TI-BCG 4.826,00FH / 3.794FC on February 16th, 2011 See attached page.

“This ANAC approval implies that the airplane or part herein mentioned cannot remain in service after the inspections threshold defined above unless all the inspections established on the approved data are appropriated performed, not dismissing any other scheduled maintenance task. It is only for the design data described and substantiated on the herein listed documents received from the type-certificate holder, and demonstrates compliance only with the regulations specified by paragraph and subparagraph listed below as “Applicable Requirements”. Acceptance is at discretion of the civil aviation authority of the State of Registry. The installer must determine compatibility of this data with the configuration of the airplane or part herein mentioned”.

8. Objetivo dos Dados: (Purpose of Data)

Brazilian DER approval of technical data to support a structural repair on the product identified on field 1

9. Requisitos Aplicáveis – Seções: (Applicable Requirements – Sections)

14CFR/JAR/EASA CS/RBHA: §25.301, §25.303, §25.305, §25.307, §25.601, §25.603, §25.605, §25.607, §25.609, §25.613, §25.571 14CFR §26.43

10. CERTIFICAÇÃO: (CERTIFICATION)

De acordo com a autoridade que me foi delegada pela ANAC/GGCP, certifico que os (Under the authority delegated to me by the ANAC/GGCP, I hereby certify that the

dados acima relacionados e nas folhas anexas de 1 página(s) data listed above and on attached sheets numbered 1 pages

foram examinados conforme os procedimentos estabelecidos e cumprem com os have been examined and found to comply with the

requisitos aplicáveis dos RBHA. applicable airworthiness requirements of the RBHA)

Conseqüentemente: recomendo aprovação destes dados (recommend approval of these data) (I therefore) aprovo estes dados (approve these data)

11. Designação No (Designation Nr)

12. Nome e assinatura do Representante Credenciado (Name and signature of Designated Engineer)

RCE 2002C11-08 Antonio Claret Rodrigues – Engineer

F 200-06G (05.06)

sazahar

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ERJHC54-004/11 R0 REF. /C/ SHEET 1 OF 2 PAGE 19 OF 20

Relatório de Verificação de Concordância de Aeronaves e Outros Produtos Aeronáuticos

com os RBHA (Report of Compliance of Aircraft or other Aeronautical Products with the RBHA)

AGÊNCIA NACIONAL DE AVIAÇÃO CIVIL

Gerência Geral de Certificação de Produtos Aeronáuticos

7. Título – Continuação (Title – Cont’d)

Inspection Instructions: Task 54-50-008-0001 (Internal DET Threshold of 40000FC, Interval of 40000FC) is sufficient and is met using the inspection requirements: MPG/MRBR revision #5. Threshold is counted since new.

sazahar

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ERJHC54-004/11 R0 REF. /C/ SHEET 2 OF 2 PAGE 20 OF 20

erjhc54-004/11 r0

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