Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 1 of 41

Part 1: General Description

TITLE: REMOVAL OF SKY RADIO SYSTEM FROM VX CAPITAL 757 AIRCRAFT

VALID ON AIRCRAFT / PART NO:

A/C Type Block No. Basic No. Line No. Serial No.

757-222ER NE147 N3196 421 25397

REVISION STATUS:

Orig: 02 Nov 2015

Rev: 01 27 JAN 2016

DESCRIPTION:

Certification Plan This document and all information and expression contained herein are the property of TASS-EU LTD Limited and are provided to the recipient in confidence. This document contains proprietary information and shall at all times remain the property of TASS-EU LTD, no intellectual property right or licence is granted by TASS-EU LTD Limited in connection with any information contained herein and the information contained herein shall be treated as confidential and not disclosed to any third party without the prior written consent of TASS-EU LTD.

Part 2: Approval

The technical content of this document is approved under the authority of DOA No. EASA.21J.467

Prepared By:

Checked By: Compliance Verification Engineer:

Name: Matt Maberry Name: Pete Cowles Name: Andrew Voice

Date: 27 JAN 2016 Date: 27 JAN 2016 Date:

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 2 of 41

Revision status

Draft A: 02 Nov 2015

Rev 00: 2015

Rev 01: 27 JAN 2016; Update to inspection requirements of external skin repair.

Added Appendix C and Appendix D

General Introduction

STC SA5831NM modifies the aircraft by installing USA Today Sky Radio. This document

shows what residual elements remain after removal of that system and how they show

regulatory compliance.

Reference Documents

A/ STC SA5831NM. Issued to Elsinore Aerospace Systems

B/ Passenger to freighter conversion drawing 007D4000 Rev C. Precision Conversions, LLC.

C/ COA 50234 – Sky Radio Installation, STC SA 5831NM

D/ COA 50597 – 757 Sky Radio Removal

E/ Report: COA ACCOMPLISHMENTS FOR N549UA. United Airlines, Jan 12, 2015.

F/ Maintenance records COA 5-0597. Job sequence cards 30009 – 30018. QA sign off for

system removal

G/ TASS EU Document 152075-CB-014-1.R and associated photos.

H/ TASS WDM Supplement 23-34-21, Sky Radio Inertial Reference & DC Power Interface

I/ TASS WDM Supplement 23-34-31, Sky Radio Airborne Receiving Unit & Antenna Wiring

J/ TASS WDM Supplement 23-34-41, Sky Radio System Audio Inputs

K/ D634N201, Boeing 757 SRM. Revision 113.

L/ D634N201, Boeing 757 SRM. Revision 084. Sept 20, 2004.

M/ AMM 23-34-21, 23-34-31, 34-34-41

N/ Boeing Document, SR 1-165592221, with 8100-9 Approval Dated 25 July 2006

O/ United Airlines Document, EC/RA 5331-01933, dated 08/21/2014

Description:

STC SA5831NM, dated August 31, 1992 installs Elsinore Air Radio on 757-200 aircraft. Ref

E/ shows that work was carried out per COA 50234 in June, 1993.

According to Ref’s E/ and F/, COA 5-0597 was carried out in September 2002. See

Appendix A for a copy of these instructions. This was confirmed by inspection per TASS EU

document 152075-CB-014-1.R, carried out on October 02, 2015.

As a result of this activity there are some remaining wires that are capped & stowed as shown

in Refs I/, J/, and K/, an external fuselage skin doubler and four (4) plugged rivet holes in the

frames at STA1340 and STA1360. These residual changes are approved as a minor

modification. See Appendix A for a copy of the wiring diagram changes for this system

deactivation.

It is noted in Ref F/ that the modification work has been carried out, the signed & certified job

cards have been checked and a verification inspection was carried out so no additional

physical action is required on the aircraft. The document is attached in Appendix A at the end

of this document.

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 3 of 41

Avionics Modification:

The initial Ref C/ Sky Radio installation COA 50234 installed wiring per the following ER

documents:

ER 8 = Antenna cable and harness installation

ER 9 = Power wiring installation

ER 10 = Audio (MUX) wiring installation

ER 11 = IRS wiring installation

None of these documents make structural alterations to the airframe, instead they pick up on

existing attachment points and/or route with existing wiring.

The removal instructions per COA 5-0597 are summarized in the below leave a number of

residual capped & stowed wires. These wires represent the net avionics change to the aircraft

as a result of the Skyradio removal. This is summarised in the Ref H/ drawing.

ER Title: Details:

1 Procurement

2 Rev:A Remove electronic equip. Cap

& Stow wiring.

CB C9001 removed from P11-2 panel, wires capped

and stowed. (See Appendix B)

Antenna & motor drive removed.

EMI driver removed

PLL-LNB removed.

Receiver removed, blanking tray installed.

3 Rev:A Structural removal. Fuselage frames plugged with 5/32 rivets.

Antenna cutout repaired per SRM 53-00-01 Fig 206

(See hand written notes on Ref F/).

4 IPC change, WDM change 23-34-21, 23-34-31, 34-34-41

Table 1 - System Removal Changes

In addition to the wiring changes, a blanking tray is installed in the E6-2 rack that previously

housed the sky radio receiver. The tray was fabricated from 0.040” thick 2024-T3 clad per

COA 5-0597, ER 2 Revision A as described in figure 1 of this document. The subject

blanking tray is similar to a standard blanking plate and serves to restrict cooling flow losses.

The subject tray is satisfactory by similarity to existing blanking tray designs.

Structures Modification:

Fuselage Frames:

The structural removal is covered by Ref F/ COA 5-0597 ER 3 and involves plugging of the

existing 5/32 rivet holes. From Ref F/, job sequence card 30010 it can be seen that the holes

are plugged with MS20470AD rivets up to 3/16” dia.

Upper lobe frame webs in this area are covered by 757-FCBS-53-008 but Ref G/ 757-200

SRM section 53-00-07, Allowable damage 1, Figure 101, allows holes in the middle 1/3 of

the frame web, up to 0.18” dia with a maximum of 4 holes in 6 inches and requires that such

holes be filled with a 2117-T3 rivet.

In this case each frame has 2 cross sections with 2 holes that are up to 3/16” in diameter. It

can be seen in the attached photos from the Ref G/ inspection that they are spaced well apart

and are not within 3D of any existing fastener hole but they appear to be just outside of the

“middle 1/3” of the web.

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 4 of 41

The SRM deviations for these plugged holes and their mitigating factors are:

Deviation: Mitigating Factors:

Holes may be up to 3/16” dia. Cross sectional loss < 10%.

Only 2 holes per cross section.

No evidence of sealant used in fastener

installation. Interior crown location is benign environment.

Standard corrosion protection measures (primer + CIC)

Holes may be outside of middle 1/3 of

frame web. Holes are in flat section of web, well clear of bend

radius. Refer attached photos.

Holes are greater than 4D apart and greater than 3D

from other holes.

Table 2 - Structural Modification Factors

The residual plugged holes constitute minor modification action that deviates from the 757-

200 SRM. This is structurally acceptable as there are mitigating factors as outlined above and

no additional maintenance burden is warranted.

Fuselage Skin:

The subject repair was installed in 2002 per the SRM revision in force at that time and

remains structurally acceptable subject to the associated ongoing inspections.

This repair is covered by Ref F/, job sequence card 30010. As this is a signed and stamped

task card no further approval is required. Refer to figure 4 of this document.

The SRM repair that was installed is an external repair as given in 757-200 SRM Rev 79

dated May 2002, 53-00-01, Figure 204. However, Ref. F/ listed this repair as using the

instructions from Figure 206. This is in reference to the metal bonding procedures required

for Zone C repairs. This makes the Figure 204 repair allowable for Zone C.

As outlined in the Ref. O/ document, UAL corresponded with Boeing for repairing action

associated with the Sky Radio Removal per Ref. D/, as well as several other repairs. The

Boeing Company provided instructions and supplemental inspection requirement per the

approved Ref. N/ SR. These inspection requirements are reiterated in the Ref. O/ UAL ECRA

which was issued to record the transfer of the repair inspections from UAL’s existing Trax

system into their new CF / Dip process. At the time of repair installation, the initial threshold

was noted at 23,000 total aircraft cycles. Based on TAC at the time of the ECRA, the initial

inspections were already accomplished per United’s EQ # 7344. Therefore the ECRA

duplicates the SR inspections with a threshold of 26,760 total aircraft cycles.

The operator is required to conform with the inspection requirements of Ref. O/ UAL ECRA

5331-01933 dated 08/21/2014, Part 2, A. The ECRA and original repair approval are given in

Appendix C and Appendix D.

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 5 of 41

Conclusion

The avionics modification consists of:

A number of wires that remain installed on the aircraft but are capped and stowed per

Boeing SWPM 20-10-01. These are documented in the Ref H/, I/, and J/ drawings

and shown in Appendix B.

A blanking tray, installed in the E6-2 rack.

These are minor modifications that have no effect on the operation of any systems of the

aircraft. No additional ICA is required.

The structures modification consists of:

An external skin repair installed per SRM. Continued inspection of the repair in

accordance with Ref. O/ UAL ECRA 5331-01933 is required.

4 plugged holes in the frames at both STA1340 and STA1360. Two at approximately

LBL 1.0 and two at approximately RBL 1.0

Of the structural modifications the net SRM departure is the placement and sizing of the

plugged rivet holes which is structurally acceptable as a minor modification for the reasons

outlined above.

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 6 of 41

Figure 1: Blanking Tray for E6-2 rack

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 7 of 41

Figure 2A: Skin Repair – External View

Figure 2B: Skin Repair – Internal View

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 8 of 41

Figure 2C: Skin Repair - Left Side of S-1

Figure 2D: Skin Repair - Right Side of S-2

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 9 of 41

Figure 3A: Plugged fastener holes at STA1340

Figure 3A: Plugged fastener holes at STA1360

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 10 of 41

Figure 4: SRM Requirements for holes in upper lobe frames.

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 11 of 41

Appendix A – COA 5-0597

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 12 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 13 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 14 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 15 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 16 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 17 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 18 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 19 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 20 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 21 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 22 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 23 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 24 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 25 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 26 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 27 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 28 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 29 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 30 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 31 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 32 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 33 of 41

Appendix B – 152075-WDMS-014 Wiring Diagram

23-34-21: INERTIAL REFERENCE SYSTEM AND DC POWER INTERFACE

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 34 of 41

23-34-31: AIRBORNE RECEIVING UNIT & ANTENNA SYSTEM WIRING

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 35 of 41

23-34-41: SYSTEM AUDIO INPUTS

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 36 of 41

Appendix C: Approval for Boeing SR 1-165592221

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 37 of 41

Appendix D: United Airlines ECRA 5331-01933

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 38 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 39 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 40 of 41

Form TASS-P3-004-1 Issue: 6 Rev: 0 Certification Plan

TASS-EU

Certification Plan

Document number: 152075-CP-014-1.R Page 41 of 41