National Transportation Safety Board Robert L. Swaim Systems Engineering National Resources Specialist Speaking at the Aviation Wire and Inert Gas Generator (AWIGG) Meeting of June 19, 2002

National Transportation Safety Board Title: NTSB Response to FAA Wiring Actions Safety recommendations and evaluation of the resulting actions are determined by the five members of the National Transportation Safety Board. Should Be: Current Awareness of Aging Systems Issues Should Be: Current Awareness of Aging Systems Issues

National Transportation Safety Board Air Canada DC-9, 1983 Electrical Investigations Preceding TWA 800 Resulted in Numerous Safety Recommendations Allegheny Convair, 1967

National Transportation Safety Board Although the Board continued to recommend that the FAA call for better care of electrical systems, the fleet did not change: 1991 Debris found in Delta L Debris found in NTSB-surveyed 747

National Transportation Safety Board Investigations into TWA 800 and SwissAir 111 brought focus to electrical problems

National Transportation Safety Board TWA800 (July 17, 1996) Was Followed By Cracked wire insulation found in wreckage in August 1996, White House (Gore) Commission on Safety and Security (WHCSS) call for emphasis on aging electrical systems on February 12, 1997, NTSB Aircraft Inspections of January 1998, FAA Inspections March-April 1998 followed by release of Aging Transport Non-Structural Systems Plan in October 1998, Industry (ATSRAC) involved in January 1999, FAA Released Enhanced Airworthiness Program for Airplane Systems (EAPAS) on August 16, 2001.

National Transportation Safety Board TWA800 (July 17, 1996) Was Followed By Cracked wire insulation found in wreckage in August 1996, White House (Gore) Commission on Safety and Security (WHCSS) call for emphasis on aging electrical systems on February 12, 1997, NTSB Aircraft Inspections of January 1998, FAA Inspections March-April 1998 followed by release of Aging Transport Non-Structural Systems Plan in October 1998, Industry (ATSRAC) involved in January 1999, FAA Released Enhanced Airworthiness Program for Airplane Systems (EAPAS) on August 16, Months 20 Next Month is 6 years 72

National Transportation Safety Board TWA800 (July 17, 1996) Was Followed By Cracked wire insulation found in wreckage in August 1996, White House (Gore) Commission on Safety and Security (WHCSS) call for emphasis on aging electrical systems on February 12, 1997, NTSB Aircraft Inspections of January 1998, FAA Inspections March-April 1998 followed by release of Aging Transport Non-Structural Systems Plan in October 1998, Industry (ATSRAC) involved in January 1999, FAA Released Enhanced Airworthiness Program for Airplane Systems (EAPAS) on August 16, Months 20 Next Month is 6 years 72

National Transportation Safety Board EAPAS Plan 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

National Transportation Safety Board EAPAS Plan (per FAA) Near-Term Raise awareness about aging system issues Enhancements/changes in training and maintenance programs Training for FAA inspectors, engineers, and designees Tasks to be complete by late 2001 Longer-Term Institutionalize management of aging systems Changes in inspections and Instructions for Continued Airworthiness Changes to FARs for improvements in certification and maintenance Tasks are planned to be complete by mid-2004

National Transportation Safety Board NTSB TWA 800 Findings #23-25 of August 23, 2000 NTSB TWA 800 Findings #23-25 of August 23, 2000 The condition of the wiring system in the accident airplane was not atypical for an airplane of its age, and the airplane was maintained in accordance with prevailing industry practices. Until recently, insufficient attention has been paid to the condition of aircraft electrical wiring, resulting in potential safety hazards. The issues defined in the FAA’s Aging Transport Non- Structural Systems Plan are important safety issues that must be fully addressed through appropriate changes, including rulemaking.

National Transportation Safety Board Safety Recommendation A (Initial Text) Regardless of the scope of the ATSRAC’s eventual recommendations, address all of the issues identified in the Aging Transport Non- Structural Systems Plan.

National Transportation Safety Board What issues (not initiatives) were cited by the FAA in the Aging Transport Non-Structural Systems Plan? (page 6) …deterioration of wiring components… …contamination… …metal shavings… …excessive dust and various fluids… …cracking of…insulation in some wire types… …ground terminal resistance… …corrosion on connector pins…

National Transportation Safety Board What issues (not initiatives) were cited by the FAA in the Aging Transport Non-Structural Systems Plan? (page 6) “Current maintenance practices do not adequately address wiring components” “…criteria is too general…details pertaining to unacceptable conditions are lacking…” “Airlines report shortcomings in manufacturer’s maintenance and repair manual on wire…Wire replacement criteria may be inadequate “…wire in conduits is not inspected…improper installation and repair of wiring” “…current trend reporting system lacks visibility…”

National Transportation Safety Board The initiatives called for by the plan were to be in place by October 2000 (with one exception). What did FAA Aging Transport Non- Structural Systems Plan call for?

National Transportation Safety Board Examinations of airplanes since NTSB TWA 800 Findings #25 of August 23, 2000 Examinations of airplanes since NTSB TWA 800 Findings #25 of August 23, 2000 The issues defined in the FAA’s Aging Transport Non- Structural Systems Plan are important safety issues that must be fully addressed through appropriate changes, including rulemaking.

National Transportation Safety Board In-flight Fires Continue. Nov 2000, turn-back at ATL when fire from area of wire bundle burned through skin. Evidence of lavatory fluid found in bundle and connectors.

National Transportation Safety Board Lint & dirt at 737 rudder pedals seen in two airplanes since NTSB Finding #25 December 2001, and 10 days out of C-check: February 2002 Over 66 months (~5½ years) since TWA months since TWA800

National Transportation Safety Board The Members of the Safety Board criticized FAA effectivity in the correction of similar deficiencies that were the subject of earlier safety recommendations.

National Transportation Safety Board Open Questions: Ability of FAA to correct basic issues this time? Ability of FAA to change industry philosophy, as it has done for structure? Industry willingness to change? Can savings drive industry actions? Incentive from future accident findings? Incorporation schedule near 2010?

National Transportation Safety Board Robert L. Swaim Systems Engineering National Resources Specialist Speaking at the Aviation Wire and Inert Gas Generator (AWIGG) Meeting of June 19, 2002