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National Transportation Safety Board Carol Carmody Chairman Carol Carmody Chairman Speaking at the Aging Aircraft Conference September 12, 2001
National Transportation Safety Board
Carol CarmodyChairman
Carol CarmodyChairman
Speaking at the
Aging Aircraft ConferenceSeptember 12, 2001
National Transportation Safety Board
FAA PassengerGrowth ForecastFAA PassengerGrowth Forecast
1 Billion
664.5Million 2001 2011
Pass
enge
rs
National Transportation Safety Board
FAA FleetGrowth Forecast
FAA FleetGrowth Forecast
2001 2011
U.S
. Jet
Tra
nspo
rts
7,500
5000
National Transportation Safety Board
Fleet Average Age ForecastFleet Average Age Forecast
20.0
18.0
15.8 1998 2008
Ave
rage
Age
National Transportation Safety Board
Aloha Flight 243 (1988)Aloha Flight 243 (1988)
National Transportation Safety Board
Narita 747 Engine SeparationNarita 747 Engine Separation
National Transportation Safety Board
Wire failures in 1970sled to Navy findings
Wire failures in 1970sled to Navy findings
Wire insulation cracked in Navy F-4 Phantoms, such as this.
National Transportation Safety Board
Finding #24 from TWA 800 ReportFinding #24 from TWA 800 Report
Until recently, insufficient attention has beenpaid to the condition of aircraft electricalwiring, resulting in potential safety hazards.
National Transportation Safety Board
Air Canada DC-9, CVG, June 2, 1983
Electrical Events Preceding TWA 800Resulted in Numerous Safety
Recommendations
Electrical Events Preceding TWA 800Resulted in Numerous Safety
Recommendations
National Transportation Safety Board
L-1011 In-flight Fire,March 17, 1991, Near Goose Bay, Canada
FIRELOCATION
National Transportation Safety Board
Although the Board continued to recommendthat the FAA call for better care of electrical
systems, the fleet did not change:
1991 Debris found in L-1011
1998 Debris found in surveyed 747
National Transportation Safety Board
Fluid Testing of Wires DuringTWA800 Investigation
Fluid Testing of Wires DuringTWA800 Investigation
Arcing event photographed during short circuit created by fluid drip on wires.
National Transportation Safety Board
Identify and Protect Critical CircuitsIdentify and Protect Critical CircuitsFirst, identify/triage what is critical:
Passenger Entertainment?Potential fire hazards or problems leading to falsecockpit indications?Wires leading into fuel tanks, fire systems, or foremergency oxygen?
Then identify how to protect the criticalcircuits.
National Transportation Safety Board
Electrical fires continuewhile fleet changes waitElectrical fires continuewhile fleet changes wait
Nov 2000, turn-back at ATL. Lav fluid in wirebundle led to fire that burned through skin.
National Transportation Safety Board
B-767 Wire Fire, LHR, Jan 9, 1998
Example of direct & secondary damage, due toinadequate clearance between bundles
Example of direct & secondary damage, due toinadequate clearance between bundles
REMOTE SECONDARY DAMAGE TO THRUST
REVERSER INDICATIONCIRCUIT CARD
National Transportation Safety Board
FAA Developing Automated ServiceDifficulty Reporting (SDR) System
FAA Developing Automated ServiceDifficulty Reporting (SDR) System
Will facilitate trend analysis & prevention.
Scheduled Implementation:3rd Q 2003
National Transportation Safety Board
Investigation into TWA 800 led to findingaging problems in systems.
National Transportation Safety Board
Wire bundle separation for FQISWire bundle separation for FQIS
National Transportation Safety Board
Non-standard wire repairs
Insulation cracks
Conductive residues
Drill shavings
Com pression dam age to
Residue visible on surface - highconcentrations of silver, copper,and sulfur
Photos from TWA800 wreckagePhotos from TWA800 wreckageTeflon Wrap
Fiberglass LacingBraid
National Transportation Safety Board
Photos of Transport Airplane WiringPhotos of Transport Airplane Wiring
Degraded racewayclamps & chafes
Contaminants
Cracks
National Transportation Safety Board
FAA Aging Systems PlanFAA Aging Systems Plan
• Establish oversight within FAA• Review fleet & fix• Enhance maintenance• Add to aging research• Improve Reporting• Evaluate additional maintenance needs• Improve wire instructions
National Transportation Safety Board
Boeing (5 seats)Airbus (4 seats)Airborne ExpressAir CanadaAirTran AirwaysBombardier
FAA & JAA (2 seats)
ATSRAC Group Membership Example(Example: Standard Wire Practice Manual Revision Group)
British AirwaysCessnaDassaultDelta AirlinesNBAASR TechnicsUnited Airlines
National Transportation Safety Board
Safety Recommendation A-00-108(Initial Text)
Safety Recommendation A-00-108(Initial Text)
Regardless of the scope of theATSRAC’s eventual recommendations,address all of the issues identified in theAging Transport Non-Structural SystemsPlan.
National Transportation Safety Board
Thai International Airways TG114Thai International Airways TG114
Initial explosion and fire in Boeing 737 on March 3, 2001.
National Transportation Safety Board
SwissAir 111 MD-11 ReconstructionSwissAir 111 MD-11 ReconstructionInterior, as viewed forward to the cockpit door.
Accident of Sept 2, 1998, at Peggy’s Cove, Nova Scotia.Airplane built in 1991.
National Transportation Safety Board
NTSB, USAF, and FAA Lab WorkFound Problems in Aged Wiring
NTSB, USAF, and FAA Lab WorkFound Problems in Aged WiringExamples: Hardened and split insulation Work-hardened conductors (fatigued) in
crimps Average distance between breached wires measurable in hundreds of feet.
National Transportation Safety Board
Wire Performance RequirementsWire Performance RequirementsFAA EAPAS calls for R&D to: Investigate and develop performancerequirements, test criteria and procedures foraircraft wire. Estimated completion in 3rd Q 2002 To result in report for inclusion in TSOor FAR Part 25.
National Transportation Safety Board
8+ Years Between Accident and FAAPlanned Implementation (no slippage)
8+ Years Between Accident and FAAPlanned Implementation (no slippage)
Initial TWA800 Rescue & Recovery by New York City and Suffolk County Police
National Transportation Safety Board
Carol CarmodyChairman
Carol CarmodyChairman
Speaking at the
Aging Aircraft ConferenceSeptember 12, 2001
