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Old March 13th, 2013, 05:32 PM   #1681
Pedro EM
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Well at least something positive- Id say we're still a few weeks away before approval. I was just thinking the same regarding the engines.
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Old March 13th, 2013, 06:15 PM   #1682
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Originally Posted by Deadeye Reloaded View Post

Looks like the 787 is powered by diesel engines.
I was about to say something similar, just like propeller engines at start.
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Old March 13th, 2013, 06:33 PM   #1683
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FAA Approves Boeing Plan to Fix 787's Batteries

WASHINGTON March 12, 2013 (AP)

A Boeing plan to redesign the 787 Dreamliner's fire-plagued lithium-ion batteries won approval Tuesday from the Federal Aviation Administration, moving the cutting-edge planes a step closer to flying passengers again.

The plan includes changes to the internal battery components to minimize the possibility of short-circuiting, which can lead to overheating and cause a fire. Among the changes are better insulation of the battery's eight cells and the addition of a new containment and venting system, the FAA said in a statement.

The FAA statement didn't provide an estimate for when the grounded planes might return to service. Rep. Rick Larsen, D-Wash., who was briefed by the agency, said that if all goes well, the FAA could give final approval by mid- to late April for the 787 to resume flight.

Boeing would still have to retrofit the 50 planes already delivered to eight airlines in seven countries, Larsen said in an interview. That could mean the plane wouldn't return to the skies until late April or early May, he said.

First, Boeing's redesigned batteries have to pass a series of 20 separate lab tests, Larsen said, then flight tests would follow.

"If there's any one test that isn't passed, it's back to the drawing board for that particular part of the tests," he said.

So far, test flights of two 787s have been approved — one with a complete prototype of the new battery, the other with only a new, more robust containment box for the battery, Boeing spokesman Marc Birtel said.

The plan is an outline for a recertification of the plane's batteries, the FAA said. The 787 has two identical lithium-ion batteries, one of which is located toward the front of the plane and powers cockpit electrical systems, the other toward the rear and used to start an auxiliary power unit while the plane is on the ground, among other functions.

Every item that is part of an airplane, down to its nuts and bolts, must be certified as safe before FAA approves that type of plane as safe for flight.

The 787 fleet worldwide has been grounded by the FAA and civil aviation authorities in other countries since Jan. 16, following a battery fire on a Dreamliner parked in Boston and a smoking battery that led to the emergency landing of another 787 in Japan.

"This comprehensive series of tests will show us whether the proposed battery improvements will work as designed," Transportation Secretary Ray LaHood said in a statement. "We won't allow the plane to return to service unless we're satisfied that the new design ensures the safety of the aircraft and its passengers."

All Nippon Airways, the largest customer for the plane so far, said in a statement from Japan that it saw the FAA decision as significant progress. "Putting safety as the first priority, we hope to get the planes back in the air as soon as possible," the airline said.

The airliner's troubles have raised concerns that the FAA has ceded too much responsibility for evaluating the safety of new aircraft to manufacturers. To save manpower, the FAA designates employees at aircraft makers and their subcontractors to conduct the safety testing of new planes. Boeing's battery testing concluded that short-circuiting wouldn't lead to a fire and that the chance of a smoke event was one in every 10 million flight hours.

Instead, there were two battery failures when the entire fleet had clocked less than 52,000 flight hours.

The FAA's approval of Boeing's plan "is a critical and welcome milestone toward getting the fleet flying again and continuing to deliver on the promise of the 787," Jim McNerney, the aircraft maker's CEO, said in a statement.

The 787 is Boeing's newest and most technologically advanced plane. Its grounding on Jan. 16, an enormous black eye for Boeing, marked the first time since 1979 that FAA had ordered every plane of a particular type to stay out of the air for safety reasons.

UBS analyst David Strauss estimated that the 787 will cost Boeing $6 billion this year. Besides the battery problems, the plane already costs more to build than it brings in from customers.

United Airlines is the only U.S. carrier with Dreamliners in its fleet. It has six, plus another 44 on order. American and Delta have also ordered 787s. Boeing has orders for more than 800 of the planes from airlines around the globe.

Steven Udvar-Hazy, CEO of Air Lease Corp., which has ordered 12 of the planes, said it could still take months for the plane to fly again and that a very long-term grounding could damage the 787 Dreamliner brand.

"It's important to get the airplane back in the air," Udvar-Hazy said while attending an airplane finance conference in Orlando, Fla. "Every plane has mechanical issues, but this was one that was considered serious by the authorities and I think Boeing has done everything it can to get that under control."

Udvar-Hazy has had weekly updates from Boeing's CEO of commercial airplanes, Ray Conner, and daily conversations with others at the airplane manufacturer. He has then relayed that information to his airline customers around the world.

"Boeing has been very transparent and I think they've made a very concerted effort to address this issue ... to come up with a fix that hopefully is a permanent fix, not just sort of a Band-Aid solution," he said.

Boeing plans to begin test flights within days, Birtel said. The new battery design will be tested on a plane that has been identified elsewhere as being built for LOT Polish Airlines. Boeing also plans to fly a 787 that is used exclusively for testing. That plane has the stronger battery box, and will also be used for unrelated engine tests.

Before the fire on Jan. 7, Boeing shares had closed at $77.69. They closed as low as $73.65 three weeks later, after the planes had been grounded. But the shares have been recovering as anticipation grew for a battery fix. Boeing's gains have outpaced the strong rise in the Dow Jones industrial average, of which Boeing Co. is a member.

On Tuesday, Boeing shares rose $1.22 to close at $84.16, and rose another 28 cents to $84.44 in aftermarket trading.

———

Freed reported from Minneapolis. Associated Press writers Scott Mayerowitz in Orlando, Fla., and Elaine Kurtenbach in Tokyo contributed to this report.
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Old March 14th, 2013, 09:32 AM   #1684
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Together with the ZA005 testframe Boeing will use the LN 86, SP-LRC for LOT for the test flights for the new battery design. The plane has gotten a new registration, N1791B and I think it's just a matter of days before it will make it's first test flight.

http://kpae.blogspot.com/2013/03/pai...-march-13.html
http://nyc787.blogspot.com/2013/03/f...very-plan.html


Analyst now predict that the 787s will back in service in May.
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Old March 14th, 2013, 06:50 PM   #1685
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Good news.
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Old March 15th, 2013, 02:40 PM   #1686
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Boeing says Dreamliner back in service in 'weeks'


http://www.bangkokpost.com/news/world/340634/


The grounded Dreamliner is "absolutely" safe and will be back in the air within weeks, planemaker Boeing said in Japan on Friday as it sought to reassure airlines and passengers about the aircraft.
Mike Sinnett, the chief project engineer on the Boeing 787, poses at a photo session with an improved battery for the 787 Dreamliner series during a press conference in Tokyo on March 15, 2013. The grounded Dreamliner is "absolutely" safe and will be back in the air within weeks, planemaker Boeing said in Japan on Friday, as it sought to reassure airlines and passengers about its aircraft.

The 50 planes grounded around the world since two lithium-ion battery malfunctions sparked a global no-fly order in mid-January will undergo fixes to their systems and be operational again soon, senior executives said.
"I get often asked if I think the airplane is still safe. My answer is simple: absolutely," Mike Sinnett, the chief project engineer on the 787, told reporters.
The Dreamliner "is among the safest airplanes our company has ever produced", he added.
Ray Connor, president of Boeing Commercial Airplanes, said measures the company had put in place and which were now undergoing flight testing would put the aircraft back in the skies.
"We are going to be dependent upon (moving) through the certification process. We will determine when we actually get back in the air in terms of flights," he said.
"Previously as I have been anticipating that in months, we are talking more along the line of weeks," he said.
The company chose to give its first public explanation of the fix in Japan, home to two of its biggest customers -- All Nippon Airways and Japan Airlines -- and to suppliers who make around a third of the aircraft's parts.
The Dreamliner has been lauded for its use of next-generation materials that have cut weight and slashed fuel costs.
Boeing opted to use lithium-ion batteries for the plane, which engineers say are lighter than other batteries, provide a higher power output and retain their charge when not in use.
But the batteries have come under scrutiny after a small fire on a parked 787 at Boston's Logan Airport in January. Days later, what appeared to be smoke from a battery on an ANA flight forced an emergency landing in Japan.
The company said despite the efforts of a 500-strong team of engineers from different disciplines, the fundamental problem had eluded them.
But teams identified 80 potential scenarios that could cause a battery failure and worked to provide solutions and preventative measures.
These included boosting insulation inside the battery pack and adding vent lines so any escaping vapour is discharged outside the aircraft.
"We design so that no single failure can place flight landing at risk," Sinnett said. "Every critical system on an airplane has multiple layers of redundancy."
Sinnett said the probe into the two incidents had proved the aircraft's safety measures had worked.
"After the battery failure the airplane responded in exactly the way we had designed and anticipated," he said.
Sinnett said there had been no fire inside the battery on either aircraft, and what appeared to the untrained eye to be smoke was electrolyte venting from the cells.
"Are we confident that there will never, ever be another battery failure? The answer to that is: parts fail," he said.
"We know that someday a battery may fail. We need to make sure that there is no significant impact at the airplane level when it does."
The worldwide grounding of Dreamliners threw schedules into disarray, especially in Japan where ANA, the biggest operator of the plane, has been forced to cancel more than 3,600 flights to the end of May.
The Federal Aviation Administration, the US watchdog, gave Boeing the go-ahead to begin flight testing after "thoroughly reviewing" Boeing's February 22 plan to address risks.
Aviation expert and Waseda University professor Hajime Tozaki said Boeing's going ahead with flight testing before it knew for sure what exactly had gone wrong was not ideal.
"Boeing should really start flight testing after knowing 100 percent what went wrong," he said.
"The potential of a lithium-ion battery has been recognised in other fields, including automobiles. They should continue investigating what the fundamental problem was."
Aviation shares gained on Friday, with ANA up 1.43 percent at 212 yen and JAL up 1.90 percent at 4,540. Battery maker GS Yuasa also rose 1.35 percent at 448, all broadly in line with the market.
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Old March 15th, 2013, 05:36 PM   #1687
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Old March 15th, 2013, 09:22 PM   #1688
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Boeing's press release on the battery improvements:

Quote:
Boeing Provides Details on 787 Battery Improvements


EVERETT, Wash., March 14, 2013 /PRNewswire/ -- Boeing (NYSE: BA) announced today that a comprehensive set of improvements that will add several layers of additional safety features to the lithium-ion batteries on 787 commercial jetliners are in production and could be ready for initial installation within the next few weeks. New enclosures for 787 batteries also are being built and will be installed in airplanes in the weeks ahead.

These improvements, which continue to undergo extensive certification testing, will allow operators to resume commercial flights with their 787s as soon as testing is complete and the U.S. Federal Aviation Administration (FAA) and other international regulators grant their final approval.

The improvements include enhanced production and operating processes, improved battery design features and a new battery enclosure.

"As soon as our testing is complete and we obtain regulatory approvals, we will be positioned to help our customers implement these changes and begin the process of getting their 787s back in the air," said Boeing Commercial Airplanes President and CEO Ray Conner. "Passengers can be assured that we have completed a thorough review of the battery system and made numerous improvements that we believe will make it a safer, more reliable battery system." Battery system changes include changes to the battery itself, the battery charging unit and the battery installation.

Earlier this week the FAA approved Boeing's certification plan, which lays out the discrete testing to be done to demonstrate that the battery improvements address the conditions laid out in the Airworthiness Directive that has suspended 787 commercial operations.

Development Team Created Solution

The enhancements to the battery system address causal factors identified by the Boeing technical team as possible causes of battery failure. The technical team's findings also were verified by an independent group of lithium-ion battery experts from a number of industries, universities and national laboratories.

"We've come up with a comprehensive set of solutions that result in a safer battery system," said Mike Sinnett, vice president and chief project engineer, 787 program, Boeing Commercial Airplanes. "We have found a number of ways to improve the battery system and we don't let safety improvements go once they are identified. We incorporate them into our processes and products."

Enhanced Production Controls and Operating Processes

The first layer of improvements is taking place during the manufacture of the batteries in Japan. Boeing teamed with Thales, the provider of the integrated power conversion system, and battery maker GS Yuasa to develop and institute enhanced production standards and tests to further reduce any possibility for variation in the production of the individual cells as well as the overall battery.

"We've all developed a better understanding of the sensitivities of this technology to variations during the manufacturing process," said Sinnett. "And we all feel the need to increase monitoring of this process on an ongoing basis."

Four new or revised tests have been added to screen cell production, which now includes 10 distinct tests. Each cell will go through more rigorous testing in the month following its manufacture including a 14-day test during which readings of discharge rates are being taken every hour. This new procedure started in early February and the first cells through the process are already complete. There are more than a dozen production acceptance tests that must be completed for each battery.

Boeing, Thales and GS Yuasa have also decided to narrow the acceptable level of charge for the battery, both by lowering the highest charge allowed and raising the lower level allowed for discharge. Two pieces of equipment in the battery system – the battery monitoring unit and the charger are being redesigned to the narrower definition. The battery charger will also be adapted to soften the charging cycle to put less stress on the battery during charging.

Improved Battery Design Features

Changes inside the battery will help to reduce the chances of a battery fault developing and help to further isolate any fault that does occur so that it won't cause issues with other parts of the battery.

To better insulate each of the cells in the battery from one another and from the battery box, two kinds of insulation will be added. An electrical insulator is being wrapped around each battery cell to electrically isolate cells from each other and from the battery case, even in the event of a failure. Electrical and thermal insulation installed above, below and between the cells will help keep the heat of the cells from impacting each other.

Wire sleeving and the wiring inside the battery will be upgraded to be more resistant to heat and chafing and new fasteners will attach the metallic bars that connect the eight cells of the battery. These fasteners include a locking mechanism.

Finally, a set of changes is being made to the battery case that contains the battery cells and the battery management unit. Small holes at the bottom will allow moisture to drain away from the battery and larger holes on the sides will allow a failed battery to vent with less impact to other parts of the battery.

New Battery Enclosure

The battery case will sit in a new enclosure made of stainless steel. This enclosure will isolate the battery from the rest of the equipment in the electronic equipment bays. It also will ensure there can be no fire inside the enclosure, thus adding another layer of protection to the battery system. The enclosure features a direct vent to carry battery vapors outside the airplane.

New titanium fixtures are being installed in the electronics equipment bays to ensure the housing is properly supported.

"Our first lines of improvements, the manufacturing tests and operations improvements, significantly reduce the likelihood of a battery failure. The second line of improvements, changes to the battery, helps stop an event and minimize the effect of a failure within the battery if it does occur. And the third line of improvements, the addition of the new enclosure, isolates the battery so that even if all the cells vent, there is no fire in the enclosure and there is no significant impact to the airplane," said Sinnett.

Testing Status

Testing to gain FAA approval of the battery enhancements has already started, with the FAA's permission.

During engineering testing, which occurs prior to certification testing, the team demonstrated that the new housing could safely contain a battery failure that included the failure of all eight cells within the battery. The "ultimate" load is the equivalent of 1.5 times the maximum force ever expected to be encountered during a battery failure. The housing easily withstood this pressure and did not fail until the pressure was more than three times the ultimate load.

Through another test, the team demonstrated that fire cannot occur within the new enclosure. Its design eliminates oxygen, making the containment unit self-inerting. Inerting is a step above fire detection and extinguishing as it prevents a fire from ever occurring. The design also vents all vapors by venting directly outside of the airplane rather than into the equipment bay.

"We put this new design through a rigorous set of tests. We tried to find a way to introduce a fire in the containment but it just wouldn't happen. Even when we introduced a flammable gas in the presence of an ignition source, the absence of oxygen meant there was no fire.

"We drew from the new industry standard, DO311, established by RTCA, to establish our testing plan," said Sinnett. "These standards weren't available when we set the testing plan for the baseline battery and they helped us ensure the new design is robust and safe. We intend to show, during certification, that the 787 battery meets all objectives of DO-311 and only deviates from specific requirements where the 787-unique items are not covered by the standards." RTCA is a not-for-profit organization that serves as a federal advisory committee in establishing guidelines for the aviation industry.

Working towards Resuming Flights

"We are following all of the necessary protocols to get our new design fully approved and properly installed so that we can help our customers start flying as soon as possible. We're simultaneously moving out on an effort to resume deliveries but completing our certification work and getting the delivered fleet flying again is our first priority," said Conner. "Our customers and their passengers have been incredibly patient as we have worked through this process and we thank them very sincerely for their continued support and confidence in the 787.

"The more-electric architecture of the 787 brings real value not just to the airlines but to our industry. By reducing fuel use, we are reducing our environmental footprint. This battery technology is an important part of the more-electric architecture, which is helping us to cut fuel use by more than 10 billion gallons of fuel over the life of this program.

"New technologies require extra attention and hard work, but the benefits are real."
http://boeing.mediaroom.com/index.php?s=43&item=2622
The presentation in Tokyo was streamed live as a webcast, you can still watch it here:
http://787updates.newairplane.com/Certification/Webcast
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Old March 16th, 2013, 05:27 PM   #1689
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PAE
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Mixed Boeing 787's by moonm, on Flickr
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Boeing 787's by moonm, on Flickr
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Old March 16th, 2013, 05:33 PM   #1690
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Wow... The backlog of B787's is building up again...
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Old March 16th, 2013, 05:34 PM   #1691
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Yup. Hope to see them delivered and off the ground soon
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Old March 16th, 2013, 05:47 PM   #1692
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Dont think this has been posted here yet:

PAE
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Originally Posted by Danfer21 View Post




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Old March 16th, 2013, 07:08 PM   #1693
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LN43 ZA382 B-2727 engines attached again:
[img]http://i47.************/2w3uhhf.png[/img]
http://kpae.blogspot.com/
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Old March 16th, 2013, 08:06 PM   #1694
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Isn't that a 777?
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Old March 16th, 2013, 08:07 PM   #1695
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All this talk about battery improvements ... but did they figure out why those fires happened in the first place?
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Old March 16th, 2013, 08:38 PM   #1696
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Quote:
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Isn't that a 777?
look below the 777's nose
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Old March 16th, 2013, 08:38 PM   #1697
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Really nice images!
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Old March 16th, 2013, 11:29 PM   #1698
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Quote:
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All this talk about battery improvements ... but did they figure out why those fires happened in the first place?
Boeing actually says that the root cause of both incidents might never be found.

That's the reason why the fix mainly focuses on containing any future thermal runaway incidents of individual battery cells. If it happens again it should spread to other battery cells, and the box is airtight preventing a fire to start from the heat that comes from the thermal runaway.
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Old March 17th, 2013, 03:42 AM   #1699
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Has the 1st Norwegian plane been painted yet? I'm looking forward to check out that livery.

Next is British Airways, right? I want to see all new liveries, including soon to be built Aeromexico, Qantas/Jetstar, Royal Brunei Airlines, Kenya Airways and Air Canada .
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Old March 17th, 2013, 01:00 PM   #1700
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The 1st 787 for Norwegian just came out of assembly last week, it hasn't been painted yet. The 1st 787 for BA will come out of assembly in mid April.
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