Enhanced Airworthiness Programfor 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

0

0.5

1

1.5

2

2.5

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3.5

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4.5

5

0-20K 20-30K 30-40K 40-50K 50-60K 60-70K 70K+FleetFlight hours/aircraft

Occ

uran

ces/

mill

ion

fligh

t hou

rs

Bare Wire >50% Insulation Gone

Aging Systems EvolutionTWA 800 Aging Wiring Issues

(1996)

White House Commission on Safety and SecurityRecommendation: Expand Aging Program to include non-structural systems

Aging Non-Structural Systems Study Team Formed

Aging Transport Non-Structural Systems Plan Developed(1998)

Improvement Recommendations• Exiting Designs• Maintenance• Training• Regulations• R & D• Fuel System • Reporting• Wire Installation Drawings

Aging Transport SysRulemakingAdvisory Committee(ATSRAC)

(1999)

R & D Projects•Wiring- Inspection- Testing- Safety Anal.- Design- Separation- Arc Fault CB

•Mechanical Sys

New Policy:Wire

InstallationRequirements

Fuel TankProgram

SFAR 88

ATSRAC Members

1. Federal Aviation Administration2. Department of Defense3. Air Line Pilot Association4. Air Transport Association of America5. Aerospace Industries Association of

America6. National Aeronautics and Space

Administration7. General Aviation Manufacturers

Association8. International Federation of

Airworthiness9. Transport Canada10. PEMCO

11. National Air Disaster Alliance/Foundation

12. AECMA (European Association of Aerospace Industries)

13. European Joint Aviation Authorities14. Northwest Airline15. AirTran16. International Air Transport Association17. Boeing Commercial Airplane Group18. Airbus Industrie19. Society of Automotive Engineers20. National Electric Manufactures

Association21. 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 & ResultsFAA

•Study Team Inspections

•Service Data Review•Research and Development

Corrective Actions

Inspection &Maintenance Practice

Improvements

Improved Design Practices

Improved SystemData Reporting

Improved Training

ATSRAC

•Inspection Support •Service Data Review•Working Group Outputs

FAA’s EAPAS

•Fleet Sampling Inspections

InformationSharing

Research & Development

Wiring FailureCausal/Contributing Factors

Design InstallationMaintenance EnvironmentOperation AbuseTraining AwarenessRepair

TIME

Enhance Airworthiness Programfor 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 Programfor 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 EnhancementsNear-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

EAPASEnhance Airworthiness

Program for Airplane Systems

ATSRACIndustry +

Regulatories(Aging Transport

systemsRulemaking

AdvisoryCommittee)

AIRFAA,

AircraftCertification

Service

AFSFAA,Flight

StandardsService

ASYFAA,Office

ofSystemSafety

AARFAA,Office

ofAviationResearch

EAPAS Related Web Sites

• EAPAS Implementation Plan:http://www.faa.gov/apa/eapas.doc

• Aircraft Wiring Practices: Training –video/self-study materials: course No. 258271-580-234-2845 or 1-800-443-3827Job Aid -http://www.academy.jccbi.gov/AIRDL/wiringcourse

• ATSRAC:http://www.mitrecaasd.org/atsrac/index.html

R&D Approach

AGING &DEGRADATION KNOWLEDGE

PROTECTIVE DEVICES

INSPECTION &MAINTENANCE

TECHNOLOGIES AGINGELECTRICAL SYSTEMS

RISK MANAGEMENT

HAZARD MITIGATION

HAZARD PREVENTION RESEARCH & ANALYSIS

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

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Res: 320mV, 5µs

Vol

tage

, V

Time, s

ARC VOLTAGE

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-.002 .000 .002 .004 .006 .008 .010 .012 .014 .016 .018 .020 .0221:52:18 PM, 10 Aug 1999c:\nic4data\29a\wave0004.wft

Res: 320mA, 5µs

Cur

rent

, A

Time, s

IA

Arc Fault Power

Arc Fault Circuit BreakerEvolution

Arc Fault Circuit BreakerDevelopment

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 havefocused 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 WiringInspections

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)Clamp With Cable Build-Up (Missing Hardware)

???????

Bundle Riding on StructureBundle Riding on Structure

Wire Bundle close to Control CableWire Bundle close to Control Cable

Bend Radii ProblemBend Radii Problem

Unused Wiring - Improper Termination with Exposed Conductor

Unused Wiring - Improper Termination with Exposed Conductor

Cracked Wire InsulationCracked Wire Insulation

Overheated Wire at the SpliceOverheated Wire at the Splice

Wires Improperly Tied, Riding on Hydraulic Lines, Contaminated with Fluid

Wires Improperly Tied, Riding 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.

???????

???????

Wire rubbing line and loose wire.

Debris in Wire Bundle (Metal Shavings)

Debris on Power Wires (Metal Shavings)

Grommet to short.

????????

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 SystemsAging 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 1st 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.

Any Question?