N765SA

Part: HYDRAULIC LINE — CHAFED (HYDRAULIC SYS) · airframe 98,245 hrs · 20,239 cycles

APPROXIMATELY ONE HOUR INTO FLIGHT, NUMBER FOUR HYDRAULIC QUANTITY DROPPED TO 2.4 GALLONS. FOLLOWED QRH PROCEDURES BY TURNING PUMPS OFF. FINISHED QRH PRIOR TO LANDING. FOUND NR 4 HYDRAULIC RETURN LINE LEAKING. REPLACED NR 4 HYDRAULIC RETURN LINE IAW B747-AMM 20-50-01. LEAK CHECK GOOD, NO DEFECTS NOTED.

Part: SENSE LINE — LOOSE (NR 4 ENGINE) · airframe 97,578 hrs · 20,105 cycles

ON 09/16/11, ETH 3718 FROM HAAB TO VHHH - APPROXIMATELY 15 MINUTES AFTER TAKEOFF, CLIMBING THROUGH FL 170, NUMBER FOUR ENGINE FIRE WARNING ANNUNCIATED. THE CREW ACCOMPLISHED ALL MEMORY ITEMS, DECLARED AN EMERGENCY AND COORDINATED WITH ATC TO RETURN TO ADDIS. ADDITIONALLY, THE CREW RAN THE ENGINE FIRE / SEVERE DAMAGE CHECKLIST, THE FUEL JETTISON CHECKLIST, AND 2/3 ENGINE LANDING CHECKLIST. THE CREW ALSO DUMPED 8,000 LBS OF FUEL, RETURNED AND LANDED AT ADDIS WITH OUT INCIDENT. INSPECTED NUMBER FOUR ENGINE AND FOUND SENSE LINE FOR PRESSURE REGULATING VALVE DISCONNECTED. RE-CONNECTED SENSE LINE PER AMM 36-11-19, PG 401 AND PERFORMED NUMBER FOUR ENGINE RUN PER AMM 71-00-00, PG 221. ALL INDICATIONS NORMAL, OK FOR SERVICE.

Part: SKIN PANEL — CORRODED (LT WING) · airframe 97,520 hrs · 20,090 cycles

LT WING / STA WS 1295 / LT OUTER WING LOWER SKIN PANEL LOWER SURFACE AROUND MID SPAR FASTENER HOLES FOUND CORROSION.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 97,520 hrs · 20,090 cycles

BULK CARGO / STA BS 2160 STR 48L / STRINGER FOUND CORROSION.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 97,520 hrs · 20,090 cycles

FORWARD CARGO / STA BS 740RT / FLOORBEAM UPPER CHORD FOUND CORROSION.

Part: SKIN — CORRODED (LT WING) · airframe 97,520 hrs · 20,090 cycles

LT WING / STA WBL 130-140 / UPPER REAR AREA FOUND CORROSION.

Part: SKIN — CORRODED (FUSELAGE) · airframe 97,520 hrs · 20,090 cycles

FUSELAGE / STA BS 2160 BETWEEN STR 46R-47R / SKIN FOUND CORROSION.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 97,520 hrs · 20,090 cycles

FORWARD CARGO / STA BS 760 / FLOORBEAM UPPER CHORD FOUND CORROSION.

Part: STRINGER — CORRODED (FUSELAGE) · airframe 97,520 hrs · 20,090 cycles

BULK CARGO / STA BS 2160 STR 47L / STRINGER FOUND CORROSION.

Part: SKIN — CORRODED (FUSELAGE) · airframe 97,520 hrs · 20,090 cycles

FUSELAGE / STA BS 1900-1920 STR 46R/ LAP SKIN FOUND CORROSION.

Part: STIFFENER — CRACKED (ZONE 400) · airframe 95,098 hrs · 19,619 cycles

PYLON NR1 STIFFENER NR3 BETWEEN NAC STA 234-259 WAS CRACK +/- 25MM. PERFORMED A DETAIL VISUAL REPEAT INSPECTION OF SUBJECT REPAIR AREA AT THE INSPECTION INTERVAL SPECIFICATION IN THE SB 747-54-2223 TO ENSURE ABSENCE OF ANY ADDITIONAL HEAT DAMAGE, LOOSE FASTENER, CORROSION AND CRACKS.

Part: STRINGER — CORRODED (ZONE 100) · airframe 95,098 hrs · 19,619 cycles

STRINGER 43 LT WAS CORROSION STA 960-1000 AT BELOW FWD CARGO AREA. REPAIR CLASSIFICATION FOR SRM REPAIR: CAT 'B', REPETITIVE INSP SRM 53-10-03 FIG 1, SHEET 6, TABLE IV. SRM 51-10-06, 51-21-00, 53-10-03 FIG 1, 51-10-02. REPAIR REPETITIVE INSPECTION REQUIREMENT IAW SRM 53-10-03 FIG 1 SHEET 6 TABLE IV , EXT VISUAL 3000 FC, INT : 6000 FC.

Part: SKIN — CORRODED (ZONE 600) · corrosion level 2 · airframe 95,098 hrs · 19,619 cycles

(WGFY) PYLON NR 4 UPPER DSB LOWER WING SKIN WAS CORROSION LEVEL 2, REFER TO JOB CARDS NR 54-812-01-04. MFG MESSAGE: YDK-SOF-10-0011-04B/18 MAY 2010, YDK-SOF-10-0011-09B/03 JUNE 2010, YDK-SOF-10-0011-11B/05JUNE 2010. PERFORM REPEAT DVI INSPECTION OF THE SUBJECT AREA IAW SB 747 54A2182 R2, REQUIREMENT AT 1200 FC INTERVAL NOT TO EXCEED 24 MONTHS.

Part: SKIN — CORRODED (NR 3 PYLON) · airframe 95,098 hrs · 19,619 cycles

PYLON NR 3 UPPER DSB LOWER WING SKIN WAS CORROSION LEVEL 2.

Part: SKIN — CORRODED (LT WING) · corrosion level 2 · airframe 94,836 hrs · 19,543 cycles

PYLON NR2 LT WING LOWER FRONT SPAR LOWER WING SKIN WBL 470 WAS CORRODED LEVEL 2,

Part: SKIN — CORRODED (ZONE 500) · airframe 94,836 hrs · 19,543 cycles

((WGFY)) THERE IS GAP L=2.73 INCH. W=0.78 INCH .T=0.029 BETWEEN LT LOWER SURFACE AND UNDER WING FUSE PIN FITTING PYLON NR 1 WING STA 116.8. PERFORMED A DETAIL VISUAL INSPECTION OF THE REPAIR ZONE, C-CHECK PERFORMED REPEAT DVI INSPECTION OF THE SUBJECT AREA IAW SB 747-54A2182 R2. REQUIREMENT AT 1200 FLIGHT CYCLES INTERVAL NOT TO EXCEED 24 MONTHS.

Part: SKIN — DELAMINATED (ZONE 400) · airframe 94,836 hrs · 19,543 cycles

((WGFY)) PYLON NR 3 LT INNER SKIN DELAMINATION (BETWEEN NAC STA 201.60 TO 240.00) PERFORMED DVI OF THE REPAIR ZONE AT THE REPEAT "C" CHECK, PERFORM REPEAT DVI INSPECTION PER SB 747 54A2182R2 REQUIREMENT AT 1200 FLIGHT CYCLE INTERVAL NOT TO EXCEED 24 MOUNTHS

Part: SKIN — DELAMINATED (NR 2 PYLON) · airframe 95,098 hrs · 19,619 cycles

PYLON NR2, SKIN PYLON NR2 DELAMINATION ( RT INNER SIDE ) BETWEEN NAC STA 201.4 TO NAC STA 286,00.

Part: SKIN — DELAMINATED (NR 2 PYLON) · airframe 94,836 hrs · 19,543 cycles

((WGFY)) PYLON NR 2, SKIN PYLON NR 2 DELAMINATION (RT INNER SIDE ) BETWEEN NAC 201,4 TO NAC STA 286,00. PERFORM A REPEATED DVI OF THE SUBJECT REPAIRED AREAS AT EVERY "C" CHECK OR 18 MONTHS, WHICH EVER OCCURS FIRST.

Part: SKIN — DELAMINATED (ZONE 400) · airframe 95,098 hrs · 19,619 cycles

PYLON NR 2, SKIN PYLON NR 2 DELAMINATION ( RT INNER SIDE )BETWEEN NAC STA 201.4 TO NAC STA 286,00.

Part: STIFFENER — CRACKED (BS 980) · airframe 94,836 hrs · 19,543 cycles

FUSELAGE RT SIDE VERTICAL STIFFENER STA 980, RBL 11,33 WAS CRACKED AND PERFORM HFEC INSPECTION METHOD TO ENSURE CRACK :+/- 20MM. REPLACED VERTICAL STIFFENER IAW SRM 51-30-02 PART 116.

Part: STIFFENER — CRACKED (ZONE 400) · airframe 94,836 hrs · 19,543 cycles

SUPPLEMENTAL INFORMATION:PYLON NR 1 STIFFENER NR 3 BEWEEN NAC STA.234-259 WAS CRACK +/- 25MM

Part: SKIN — CORRODED (NR 3 PYLON) · airframe 94,836 hrs · 19,543 cycles

PYLON NR 3 UPPER DSB LOWER WING SKIN WAS CORROSION LEVEL 2

Part: STIFFENER — CRACKED (ZONE 100) · airframe 94,836 hrs · 19,543 cycles

FUSELAGE RT SIDE VERTICAL STIFFENER STA.980, RBL 11,33 WAS CRACKED AND PERFORM HFEC INSPECTION METHOD TO ENSURE CRACK :+/- 20MM

Part: STRINGER — CORRODED (BS 960-1000) · airframe 94,836 hrs · 19,543 cycles

STRINGER 43 LT CORRODED STA 960-1000 AT AREA BELOW FORWARD CARGO.

Part: STRINGER — CORRODED (BS 960-1000) · airframe 94,836 hrs · 19,543 cycles

STRINGER 43 LT CORRODED AT STA 960 TO STA 1000 AREA BELOW FORWARD CARGO

Part: SKIN — CORRODED (ZONE 600) · corrosion level 2 · airframe 94,836 hrs · 19,543 cycles

PYLON NR 4 UPPER DSB LOWER WING SKIN WAS CORROTION LEVEL 2, REFER TO JOB CARDS NR 54-812-01-04.

Part: SKIN — CRACKED (ZONE 100) · airframe 94,836 hrs · 19,543 cycles

EAO 4753070 R1 ,FUSELAGE-CENTER SECTION -BODY STATION 1480 BULKHEAD AND SPLICE COMPONENT INSPECTION REPAIR AND MODIFICATION,HFEC INSPECT FOUND HOLE NR 3 OF LONGERON EXTENSION FITTING SKIN PANEL CRACK

Part: SKIN — CORRODED (ZONE 500) · airframe 94,836 hrs · 19,543 cycles

PYLON NR 2 LT WING LOWER FRONT SPAR LOWER WING SKIN WBL 470 WAS CORROTION LEVEL 2, REFER TO JOB CARDS 57-216-02-01.

Part: STIFFENER — CRACKED (ZONE 400) · airframe 94,836 hrs · 19,543 cycles

PYLON NR 1 STIFFENER NR 3 BETWEEN NAC STA .234-259 WAS CRACK +/- 25MM

Part: DUCT — RUPTURED (BLEED AIR) · airframe 94,007 hrs · 19,347 cycles

ON TAKEOFF ROLL OUT OF VHHH ENGINE NR 4 HAD EXHAUST GAS TEMPERATURE OVERTEMP AS WELL AS NACELLE TEMPERATURE RISE. CREW CONTINUED TAKE OFF SUCCESSFULLY BUT ELECTED TO TERMINATE FLIGHT, DUMPED 137,000 LBS OF FUEL, RETURNED AND LANDED SAFELY AT VHHH. AFTER LANDING MAINTENANCE CREW AT VHHH LOCATED A RUPTURED PNEUMATIC DUCT OF THE 14TH STAGE COMPRESSOR BLEED, REMOVED AND REPLACED RUPTURED DUCT AND PERFORMED ENGINE RUN UP TEST IN ACCORDANCE WITH AMM 20-11-18 AND 71-00-00, NO FURTHER LEAKS NOTED AND ENGINE NR 4 PARAMETERS NORMAL DURING RUN UP TEST. AIRCRAFT RESTORED TO NORMAL.