N275

Part: FLOORBEAM — CORRODED (BS 496)

DURING 2C+12A+150M CHECK FOUND UPPER DECK CARGO FLOORBEAM CHANNEL CORROSION AT STA 496.5 X=22.5. REPLACED FLOORBEAM CHANNEL IAW SRM 51-33-01 VOL II REV 38, CONDITION CHECK ALL NORMAL.

Part: STRUCTURE — CORRODED (HORIZONTAL STAB)

ITEM: DURING 2C+12A+150M CHECK WHILE COMPLYING WITH EO 02-5510-098 REV 4, FOUND CORROSION ON HST LT BARREL NUT HOLE NR 7. ACCOMPLISHED BARREL NUT REMOVAL AND INSPECTION IAW EO 02-5510-098 SEC06, REMOVED CORROSION AND OVERSIZED BARREL NUT HOLE, FABRICATED REPAIR BUSHING IAW SECTION 12, REINSTALLED BARREL NUT WITH NEW PLI WASHER IAW SECTION 10.

Part: STRUCTURE — CORRODED (HORIZONTAL STAB)

DURING 2C+12A+150M CHECK WHILE COMPLYING WITH EO 02-5510-098 REV 4, FOUND CORROSION ON HST LH BARREL NUT HOLE NR 4. ACCOMPLISHED BARREL NUT REMOVAL AND INSPECTION IAW EO 02-5510-098 SEC06, REMOVED CORROSION AND OVERSIZED BARREL NUT HOLE, FABRICATED REPAIR BUSHING IAW SECTION 12, REINSTALLED BARREL NUT WITH WITH NEW PLI WASHER IAW SECTION 10.

Part: BARREL NUT — CORRODED (STAB)

ITEM: DURING 2C+12A+150M CHECK WHILE COMPLYING WITH EO 02-5510-098 REV 4 INSPECTION, FOUND CORROSION ON HST LT BARREL NUT HOLE NR 3. ACCOMPLISHED BARREL NUT REMOVAL AND INSPECTION PER EO 02-5510-098 SEC06, REMOVED CORROSION AND OVERSIZED BARREL NUT HOLE, FABRICATED REPAIR BUSHING PER SECTION 12, REINSTALLED BARREL NUT WITH WITH NEW PLI WASHER PER SECTION 10.

Part: BARREL NUT — CORRODED (STAB)

DURING 2C+12A+150M CHECK WHILE COMPLYING WITH EO 02-5510-098 REV 4 INSPECTION, FOUND CORROSION ON HST RT BARREL NUT HOLE NR 12. ACCOMPLISHED BARREL NUT REMOVAL AND INSPECTION PER EO 02-5510-098 SEC06, REMOVED CORROSION AND OVERSIZED BARREL NUT HOLE, FABRICATED REPAIR BUSHING PER SECTION 12, REINSTALLED BARREL NUT WITH WITH NEW PLI WASHER PER SECTION 10.

Part: BARREL NUT — CORRODED (ZONE 300)

ITEM: DURING 2C+12A+150M CHECK WHILE COMPLYING WITH EO 02-5510-098 REV 4, FOUND CORROSION ON HST LT BARREL NUT HOLE NR 1. ACCOMPLISHED BARREL NUT REMOVAL AND INSPECTION PER EO 02-5510-098 SEC06, REMOVED CORROSION AND OVERSIZED BARREL NUT HOLE, FABRICATED REPAIR BUSHING PER SECTION 12, REINSTALLED BARREL NUT WITH WITH NEW PLI WASHER PER SECTION 10.

Part: SPAR — CORRODED (LT WING)

DURING 2C+12A+150M CHECK, FOUND CORROSION ON LT WING REAR SPAR UPPER CHORD UPPER SURFACE XORS 780 TO XORS 790.

Part: SKIN — CORRODED (RT WING)

DURING 2C+12A+150M CHECK FOUND CORROSION ON RIGHT WING UPPER SKIN AT XORS 97 TO XORS 1070 BETWEEN FRONT SPAR AND REAR SPAR.

Part: SKIN — CORRODED (LT WING)

DURING 2C+12A+150M CHECK, FOUND CORROSION ON LEFT WING UPPER SKIN AT XORS 97 TO XORS 1070 BETWEEN FRONT SPAR TO REAR SPAR.

Part: ENGINE — FLAMED OUT (NR 3)

DURING DESCENT NR 3 ENGINE FLAMED OUT. CONFIRMED ENGINE OUT ON MCDU NR 3 FUEL FLOW DROPPED TO 900 LBS AND DROPPING. IGNITION OVERRIDE ON ENGINE RETURNED TO NORMAL. TROUBLESHOT AS PER FIM 71-01-11 AND 71-01-01, FOUND TT2 NO SIGNAL FOR EECB AND GROUND ENGINE RUN UP CHECKED GROUND IDLE AND FLIGHT IDLE. ALL PARAMETERS WITHIN LIMITS. DMI'D ITEM DUE 8/19/06. PLACARD INSTALLED.

Part: CARBON SEAL — LEAKING (ENGINE) · airframe 10,892 hrs · 8,424 cycles

FLIGHT 3192 DEPARTING SDF, DURING TAKEOFF ROLL, THE CREW HAD SMOKE IN THE COCKPIT AND ABORTED THE TAKEOFF. MAINTENANCE INSPECTED THE ENGINE AND FOUND THE LEFT ENGINE "0" CARBON SEAL LEAKING. REMOVED AND REPLACED E1 0 CARBON SEAL. OPS CHECK GOOD.

Part: FLAPPER VALVE — LEAKING (LT WING FUEL) · airframe 10,522 hrs · 8,103 cycles

DURING CLIMB-OUT ON FLIGHT 3098 FROM PHL TO CMH, FUEL WAS SEEN LEAKING OUT OF THE LEFT WING. STREAM WAS APPROXIMATELY 8 INCHES WIDE AND IT WAS COMING OUT AT A STEADY RATE UNTIL THE AIRCRAFT LEVELED OFF. THE STREAM WAS LOCATED APPROXIMATELY 6 TO 8 FEET FROM THE WING TIP AND WAS VISIBLE TO THE PILOT FROM THE COCKPIT. AN EMERGENCY WAS DECLARED AND THE AIRCRAFT RETURNED TO THE FIELD IN PHL WITHOUT INCIDENT. MAINTENANCE FOUND THE FLAPPER VALVE BETWEEN THE MAIN FUEL TANK AND THE FUEL VENT BOX TO BE BAD. REMOVED AND REPLACED FLAPPER VALVE ASSEMBLY P/N 2770138-101 IAW EMB 145 MM 28-11-04. OPS CHECK GOOD.

Part: STRUCTURE — DAMAGED (TAIL)

IMMEDIATELY UPON BRAKE RELEASE DURING TAKEOFF, NOSE RAPIDLY BEGAN TO RISE, RESULTING IN TAIL STRIKE. REPAIRED THE DAMAGE PER DELTA ERA 094364-14 AND 094561-14. PERFORMED AIRCRAFT WEIGHT, ALL CHECKED NORMAL.

Part: COMPRESSOR — STALLED (NR 2 ENGINE)

AIR TURNBACK DUE TO NR 2 ENGINE COMPRESSOR STALLED WITH ANTI-ICE ON THROUGH 11000 FEET. TEMPERATURE APPROX 620 DEG. BROUGHT THROTTLE TO IDLE, NR 2 EGT WAS APPROX 70 DEG HOTTER THAN NR 1 AND NR 3, FF 900LBS HIGHER THAN NR 1 AND NR 3. ADVANCED THROTTLE WITH ANTI-ICE OFF AND ENGINE STALLED AGAIN. PERFORMED BORESCOPE INSPECTION IAW MM 72-00-00, FOUND EXTENSIVE DAMAGE TO HIGH PRESSURE COMPRESSOR. REMOVED AND REPLACED NR 2 ENGINE IAW MM PROCEDURES. ENGINE RUN CHECK NORMAL.

Part: ODOR — DETECTED (COCKPIT) · airframe 9,731 hrs · 7,410 cycles

DURING LATER PORTION OF THE FLIGHT, DETECTED ODOR IN THE COCKPIT AND FORWARD CABIN AREA. IT SMELLED LIKE BURNING PLASTIC AND THERE WAS NO VISIBLE SMOKE. VISUALLY INSPECTED RADAR, FORWARD ELECTRONICS BAY, BATTERY COMPARTMENT, BEHIND OVERHEAD CIRCUIT BREAKER PANEL, RELAYS BEHIND THE CAPTAIN AND FIRST OFFICER, WINDSHIELD HEAT, AND OPS CHECKED PACKS 1 & 2. NO EVIDENCE OF OVERHEATING, PITTING, ARCING, BURNING OR OTHER DEFECTS WERE NOTED.

Part: COUPLING — LOOSE (CABIN PRESSURE) · airframe 5,722 hrs · 4,218 cycles

RAPID DECOMPRESSION, FOUND SPLIT FLEXIBLE COUPLING ON NR 2 PACK AND NR 1 LOOSE FLEX COUPLING. REPLACED SPLIT COUPLING AND TIGHTENED LOOSE ONE AS REQUIRED. NR 2 PACK LEAK CHECKS OK. RAN NR 1 PACK COULD NOT DUPLICATE PACK NR 1 OVHT EICAS MESSAGE.

Part: FLAP — OUT OF ADJ (WING)

ON CLIMB NR 5 L/E FLAP POS IND WITHIN SHOW RETRACTED (GREEN) WITH FLAPS 2 DEG SELECTED. ACFT HANDLED AS IF SLAT WAS FULLY AND CORRECTLY RETRACTED. QRH DIRECT RECYCLING TO 5 DEG POS (EXTENDED) POS AND IND CORRECT THEN FLAPS 2 AND FLAPS UP. LIGHTS WERE OUT TILL PASSED THROUGH 250 KTS ON CLIMB. WENT THROUGH CHECKLIST AGAIN AND NR 5 W/N TO OUT. RETURNED TO AIRPORT. ADJUSTED NR 5 KRUEGER FLAP PER MM 27-82-001-4, OPS CK NORMAL OK FOR SERV.

Part: WARNING SYSTEM — ACTIVATED (COCKPIT) · airframe 2,907 hrs · 2,114 cycles

ICE CONDITIONS AND A/I INOP ON EICAS. ABORTED TAKEOFF AND CANCELLED FLIGHT.