Enhanced Airworthiness Program for Airplane Systems (EAPAS) Presented by: Massoud Sadeghi Aging Systems Program Manager NBAA Convention October 6, 2003
Overview Aircraft Electrical Wiring Functions / Issues Aging Systems Program- Background Initial Aging System Study Aging Transport Systems Rulemaking Advisory Committee (ATSRAC) NTSB Recommendation Small Transport Airplane Aging Study New Technology Development EAPAS Status Summary
Aircraft Wiring Simple System Insulation clad copper conductor Connectors Circuit breakers, switches, relays, Support: clamp, bracket, conduit,...
Aircraft Wiring Complex Problem Lots of it No single causal factor Fit and forget Controls virtually every function of the aircraft Failure poses potentially catastrophic functional and/or physical hazards
Age Related Wire Failures (Example) 737 Fuel Boost Pump Wire Inspections 5 Occurances/million flight hours 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 0-20K 20-30K 30-40K 40-50K 50-60K 60-70K 70K+Fleet Flight hours/aircraft Bare Wire >50% Insulation Gone
Aging Systems Evolution TWA 800 Aging Wiring Issues (1996) White House Commission on Safety and Security Recommendation: Expand Aging Program to include non-structural systems Aging Non-Structural Systems Study Team Formed R & D Projects Wiring - Inspection - Testing - Safety Anal. -Design - Separation - Arc Fault CB Mechanical Sys Aging Transport Non-Structural Systems Plan Developed (1998) New Policy: Wire Installation Requirements Improvement Recommendations Exiting Designs Maintenance Training Regulations R & D Fuel System Reporting Wire Installation Drawings Aging Transport Sys Rulemaking Advisory Committee (ATSRAC) (1999) Fuel Tank Program SFAR 88
ATSRAC Members 1. Federal Aviation Administration 2. Department of Defense 3. Air Line Pilot Association 4. Air Transport Association of America 5. Aerospace Industries Association of America 6. National Aeronautics and Space Administration 7. General Aviation Manufacturers Association 8. International Federation of Airworthiness 9. Transport Canada 10. PEMCO 11. National Air Disaster Alliance/Foundation 12. AECMA (European Association of Aerospace Industries) 13. European Joint Aviation Authorities 14. Northwest Airline 15. AirTran 16. International Air Transport Association 17. Boeing Commercial Airplane Group 18. Airbus Industrie 19. Society of Automotive Engineers 20. National Electric Manufactures Association 21. International Association of Machinists
ATSRAC Phase I Tasks Task 1: Sampling inspection of the Fleet Task 2: Review of fleet service history Task 3: Improvement of maintenance criteria Task 4: Review and update standard practice for wiring Task 5: Review air carrier and repair station inspection and repair training programs Phase I tasks completed and approved in January 2001
Aging Wiring Studies & Results FAA Study Team Inspections Inspection Support Service Data Review Research and Development FAA s EAPAS ATSRAC Fleet Sampling Inspections Service Data Review Working Group Outputs Corrective Actions Inspection & Maintenance Practice Improvements Improved Design Practices Research & Development Improved System Data Reporting Improved Training Information Sharing
Wiring Failure Causal/Contributing Factors Design Installation Maintenance Environment Operation Abuse Training Awareness Repair TIME
Enhance Airworthiness Program for Airplane Systems The EAPAS is designed to enhance current airplane systems airworthiness programs at operator facilities, repair stations, and manufacturing plants based on data-driven initiatives developed under the Aging Transport Non-Structural Systems Plan.
Enhance Airworthiness Program for Airplane Systems The EAPAS implementation plan is organized into six major categories covering design, certification and maintenance of transport airplanes: Training Maintenance Design Research and Development Wire Reporting Information Sharing and Outreach
EAPAS Enhancements Near-Term Raise awareness about aging system issues Enhancements/changes in training and maintenance programs Training for FAA inspectors, engineers, and designees Wring Installation Policy Longer-Term Establishment of aging systems management Changes in inspections and Instructions for Continued Airworthiness Changes to FARs for improvements in certification and maintenance
EAPAS Program Support EAPAS Enhance Airworthiness Program for Airplane Systems AIR FAA, Aircraft Certification Service AAR FAA, Office of Aviation Research ATSRAC Industry + Regulatories (Aging Transport systems Rulemaking Advisory Committee) ASY FAA, Office of System Safety AFS FAA, Flight Standards Service
EAPAS Related Web Sites EAPAS Implementation Plan: http://www.faa.gov/apa/eapas.doc Aircraft Wiring Practices: Training video/self-study materials: course No. 25827 1-580-234-2845 or 1-800-443-3827 Job Aid - http://www.academy.jccbi.gov/airdl/wiringcourse ATSRAC: http://www.mitrecaasd.org/atsrac/index.html
R&D Approach INSPECTION & MAINTENANCE TECHNOLOGIES HAZARD PREVENTION AGING ELECTRICAL SYSTEMS RISK MANAGEMENT AGING & DEGRADATION KNOWLEDGE RESEARCH & ANALYSIS PROTECTIVE DEVICES HAZARD MITIGATION
EAPAS Major R&D Projects Development of new technologies for wire testing/inspection (NDI) Development of wire separation/segregation requirements Development of wire performance requirements Study effects of related and unrelated maintenance on wiring Development of Arc Fault Circuit Breakers
Arc Fault Circuit Breaker Development
Electrical Fault Damage
Arc Fault Power 400 ARC VOLTAGE 300 200 Voltage, V 100 0-100 -200-300 -.002.000.002.004.006.008.010.012.014.016.018.020.022 Res: 320mV, 5µs Time, s 1:52:18 PM, 10 Aug 1999 c:\nic4data\29a\wave0003.wft 400 IA 300 200 100 Current, A 0-100 -200-300 -400 -.002.000.002.004.006.008.010.012.014.016.018.020.022 Res: 320mA, 5µs Time, s 1:52:18 1999 PM, 10 Aug c:\nic4data\29a\wave0004.wft
Arc Fault Circuit Breaker Evolution
Arc Fault Circuit Breaker Development AFCB Phase II Development Joint FAA, NAVAIR, ONR, & USAF Miniaturization MS3320 28VDC 115V/3-phase
ATSRAC Phase II Tasks Improving wire system certification requirements Enhancing wiring maintenance procedures and instructions Enhancing and augment current training programs Standardizing the format of Standard Wiring Practices Manual Study of aging issues in Small Transport Airplanes electrical wiring Phase II tasks completed and approved in January 2003
Aging Small Transport Airplane - Background - NTSB Recommendation A-00-119 Ensure that all transport-category airplanes, regardless of where they are operated under Code of Federal Regulations Parts 91, 121, 125, 135 are included in its review of aging transport aircraft systems and structures. NTSB Letter The Safety Board is also concerned that ATSRAC activities have focused primarily on aging aircraft issues related to wiring. Although these issues are an important safety concern that the Board does not wish to minimize, Safety Recommendation A-00-119 addresses all systems in aging aircraft, not just wiring issues
Aircraft Electrical Wiring Inspections
Non-Intrusive Inspections Non-intrusive inspections of electrical wiring on large transport airplanes 81 Airplanes Inspected 40 findings per airplane average NO IMMEDIATE SAFETY CONCERNS 2 significant items per airplane average 23 ADs issued as results of further investigation
Clamp With Cable Build-Up (Missing Hardware)
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Bundle Riding on on Structure
Wire Bundle close to Control Cable
Bend Radii Problem
Unused Wiring --Improper Termination with Exposed Conductor
Cracked Wire Insulation
Overheated Wire at the Splice
Wires Improperly Tied, Riding on on Hydraulic Lines, Contaminated with Fluid
Non-Intrusive Inspections Non-intrusive inspections of electrical wiring on small transport airplanes 39 Airplanes Inspected 58 findings per airplane average NO IMMEDIATE SAFETY CONCERNS 1.9 significant items per airplane average No ADs issued
Wire bundles supported by a metal tube.
Wire bundles not supported through frames. Baggage compartment.
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Wire rubbing line and loose wire.
Debris in Wire Bundle (Metal Shavings)
Debris on Power Wires (Metal Shavings)
Grommet to short.
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Bundle not properly secured
Safety wire is protruding into harness
Backshell is missing tye wrap
Harness is tied directly to metal tube
Rubber in clamp is deteriorated
Damaged wire insulation
Aging Mechanical Systems Aging Mechanical Systems studies underway Proactive approach with manufactures, operators, and authorities participating. Study includes: design/maintenance evaluations and destructive/non-destructive tests. Study is being conducted in phases: Flight Control System, Hydraulic System, Fuel System, etc. First phase involves: Study of B757 and A320 Control Systems Test critical parts of aged airplanes (737, 747, A300) Small transport mechanical systems will be added.
EAPAS Status All ATSRAC reports completed and received by the FAA January 2003. ATSRAC has accepted new tasks (Phase III) FAA in process of rulemaking based on the industry recommendations. Noticed of Proposed Rulemaking (NPRM) is planned to be published in 1 st quarter 2005.
FAA Commitment FAA fully engaged with implementation of the EAPAS plan. Oversight Committee of senior FAA management with responsibility to: Ensure all goals of EAPAS are accomplished adequately and on time. Provide necessary support, resources, and budget to the EAPAS to meet commitments. Ensure that EAPAS has appropriate priority.
Summary Participation of industry and international airworthiness authorities is vitally important in successful implementation of EAPAS program. Implementation of the EAPAS near-term and longer-term improvements will mitigate the potential safety concerns in aircraft wire systems. The proactive mechanical systems study will successfully identify possible aging issues in the transport mechanical systems. With addition of the aging small transport airplane systems study a wide coverage of aging issues for both large and small transport airplane categories is ensured.
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