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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
3
3.5
4
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
-300
-200
-100
0
100
200
300
400
-.002 .000 .002 .004 .006 .008 .010 .012 .014 .016 .018 .020 .0221:52:18 PM, 10 Aug 1999c:\nic4data\29a\wave0003.wft
Res: 320mV, 5µs
Vol
tage
, V
Time, s
ARC VOLTAGE
-400
-300
-200
-100
0
100
200
300
400
-.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?