Technical Committee Special Project ATSRAC EWIS

Electrical Wiring Interconnect System

Not Just Another Acronym!

What is EWIS?
All wiring related components connecting LRUs such as:
Wiring Cannon Plugs Modular Blocks Clamps Terminal Strips Etc.

Why the concerns about EWIS?

History
NTSB, following the TWA 800 accident, determined that wiring inside a fuel tank developed a short causing an explosion which downed the aircraft. Vice Presidential Committee Gore Commissioned detailed study be performed on the health of aircraft wiring in regards to aging of an aircraft.

Why the concerns about EWIS?

History (cont.) The FAA in conjunction with regulatory agencies worldwide and industry developed a focus group to study the potential problem. ATSRAC (Aging Transport Systems Rulemaking Advisory Committee) Originally formed to perform non-intrusive, intrusive inspections and develop recommendations to the FAA for Large Transport Aircraft. (ADs, SFAR) After the Payne Stewart incident, NTSB recommended that all Transport Aircraft be included in ATSRAC study - STA

ATSRAC HWG10 - STA

WIRING EVALUATIONS - Summary

39 privately owned in-service a/c

No Safety of Flight Concern 2256 discrepancies 73 of them are considered as significant* items *Significant items need to be rectified/repaired for
continued airworthiness throughout aircraft operational life

ATSRAC - STA
WIRING EVALUATIONS (Cont'd)
No aging issue specific to wire insulation and conductor were detected 29 % of discrepancies are inadequate clearance with structure, racks, equipments 43 % of discrepancies are bad clamp conditionning/sizing/spacing 68 % of significant items are due to inadequate clearance or bad clamp conditionning: sizing / spacing.

Aircraft Type Findings Summary Number of Aircraft Inspected % of the Model Fleet Age Range Hour Range Landing (Cycles) Range Inspections Performed By AC Model A AC Model B 5 5 5.90% 2.90% 19 to21 11 to 24 4785 to 7835 4130 to 12001 4846 to 5684 3473 to 8558 WG & OEM WG & OEM AC Model C AC Model D 5 5 0.61% 0.90% 10 to 18 18 to 25 3258 to 8413 7223 to 12408 2682 to 5692 5709 to 9873 WG & OEM WG & OEM AC Model E AC Model F AC Model G AC Model H Summary 4 5 5 5 39 2.10% 2.10% 1.05% 0.80% 0.6% to 6% 11 to 12 20 to 30 12 to 15 11 to 32 10 to 32 4130 to 8083 8770 to 17389 4271 to 5904 3572 to 13014 3258 to 17389 2746 to 7498 4843 to 8500 2638 to 3389 3187 to 13252 2638 to 13252 WG & OEM WG & OEM OEM WG & OEM WG & OEM Immediate Fleet Wide Safety Significant Items Significant Items per AC (Avg.) Total Findings Findings per AC (Avg.) Evaluation Findings % to Specific Model Totals by Appendix A Categories: Connectors 3.20% 1.90% 5.40% 3.30% Terminations 2.30% 0.60% 0.30% 6.70% Installations (General) 80% 79.50% 87% 87% Wiring Condition 14.40% 18% 7.30% 2.90% Significant Items % of Significant Items (73 Items) to All Model (2256 Items) Evaluation Findings 0 73 1.9 2256 58

1.70% 0 90.50% 7.80%

1.80% 0.40% 86.40% 11.40%

0% 0% 97.40% 2.60%

2.30% 5.50% 80.70% 11.50%

2.75% 1.99% 84.53% 10.73%

3.24%

Damaged Clamp

Zone: 310 Aft equipment compartment below APU

Oxygen line

Installation inverted Teflon shim

Disabled system connectors pulled from rack Tied to environmental system duct

Conduit rubbing on connector hardware

Wires pinched in clamp

Zone: 140 Under floor area above wing box

Improperly Installed Clamp (pinching wire)

Chaffed through

Zone: 220 Flight compartment above floor behind circuit breaker panel (copilots feet)

Bend Radius

Improper installation Bend radius

Installation deterioration and inadequate clearances

Inadequate clearance

Zone: 114/115 Flight compartment under floor bottom of fuselage

Inadequate Clearance to Structure

Damaged Conduit

Zone: 143/144 Main landing gear wheel well

Outer Jacket of Power Cable Pulled Back Wires Exposed

Zone: 310 Aft equipment bay (APU compartment)

Zone: 143/144 Main landing gear wheel well

Improper Repair

Debris on Power Wires (Metal Shavings)

Zone: 240/250 Cabin area above floor

Contaminated Wires

Zone: 250 Cabin area above floor near luggage compartment door

ATSRAC HWG10
General Comments - From a/c evaluations
Aircraft in good overall condition Reasons of Discrepancies
Wiring Repair
Training Issues Lack of use of OAM Standard Practice Manuals

Routing of Modification Wiring

Training Issues Lack of use of Industry Standard Guidelines (AC 43.13) and OAM Standard Practice Manuals

ATSRAC HWG10
General Comments (cont'd)
Clamping and Structural Contact
Training Issues Instructions for Continued Airworthiness Issues

Protect, Clean as you go philosophy

Training Issue ICA possible no mention

Industry cultural concerns

ATSRAC HWG10
Aircraft Maintenance Program Philosophy
STA = OEMs Develops and Maintains Maintenance Programs FAA approves Chapter 4/5 and accepts Mx Manuals (ICAs)
Owner/Operator typically follows OEM Recommendations

STA = Owner/Operator to # Aircraft - 1 to 1.4

Each Aircraft is Very Unique as each owner Avionics Packages vary from aircraft to aircraft Corporate Interiors and the associated wiring vary from aircraft to aircraft

ATSRAC HWG10
Organizational Differences
STA = Smaller Organizations within each Department
Dispatch Flight Maintenance (35%)

STA Owner/Operators tend to be more interdependent with TC and STC Holders

NBAA Operator Demographics

Operators
3500 3000 2500 2000 1500 1000 500 0 669 362 314 237 588 2358

W /O MX W ith MX

2
Aircraft Operated

>2

ATSRAC HWG10 Lessons Learned

Before April of 2002 the Majority of the Working Group was not Aware of EWIS Concepts Based on the review of:
Aircraft Evaluations Service History/ADs Intrusive Inspection Report HWG-6 through HWG-9 Final Reports

ATSRAC HWG10 Lessons Learned

HWG-10 determined areas of need:
Awareness and Training Installation Guidance (FAA driven Standardization Issues) Inspection Criteria Maintenance Procedures Enforcement of Current Regulations

HWG-10 Recommended
FAA and industry implement an EWIS Awareness program to effect cultural change
Rationale
The aircraft evaluations support the need for TC and STC holders, approvers, designers, installers, and technicians to become more aware of the concepts of EWIS during design, certification, installation and maintenance. HWG-10 feels that the current regulations with slight modifications are adequate if properly communicated and enforced.

HWG-10 Recommendations
FAA FAR Part 147 Appendix E is revised to include the concepts of AC 120-YY (EWIS, Detailed Inspection (DET), General Visual Inspection (GVI), and Special Detailed Inspection (SDI)). Rationale
To fully effect a culture change, in the aviation industry, this should include a ground up approach (e.g. future technicians are trained from day one on EWIS concepts)

HWG-10 Recommendations
FAA The following Advisory Circulars be revised to include EWIS concepts:
43.13 43.204 65-9A 65-11B 65-12A 65-15A * concepts and language with standardized criteria for EWIS

HWG-10 Recommendations
Rationale
These Advisory Circulars are the basis for certification, maintenance, and training of industry personnel. EWIS concepts revision would generate awareness to a large group of existing and future approvers, designers, installers, and technicians.

Installation Guidelines/Criteria
Standardization - Installation Guidelines must be FAA/Industry driven
Currently, Installation Guidance is based off of:
AC43.13 Outdated Needs to Be Revised to Latest Technologies
Current Non-Turbine Powered Aircraft have more technology than AC can support

ATA Spec 117 ANM-104 Created Confusion throughout ACOs and subsequently industry

Inspection Criteria
Rationale There is a lack of Inspection Criteria for wiring and its subcomponents. Development of this Criteria will ensure that inspectors know what is to be inspected.

Maintenance Procedures
Recommendations Review existing manufacturer inspection/maintenance programs and enhance for EWIS considerations Manufacturer standards - wiring practices
pass fail criteria

Training program

Maintenance Procedures
OEMs and STC Holders to enhance the current Maintenance Procedures
Enhancement doesnt necessarily drive to EZAP.
Maintenance Program Development Philosophies of the Various STA OEMs should be capable of enhancing current programs incorporating concepts of EWIS Future Small Transport Aircraft Designs will most likely follow the version of MSG-3 of that time period or applicable analytical logic process of that time period.

ATSRAC - STA
Whats next?
HWG 13 New Tasks - further define and develop for STA
Criteria for enhanced wiring inspection procedures Means of compliance

So now we know
Installation of wiring (EWIS) has not had the awareness of the Approvers & Maintainers it requires Concerns for installation & functionality of equipment was the priority not wiring Current practices will not be allowed to continue as is

Future - demands an EWIS priority

Communicate through existing industry venues and forums available (i.e. AEA, GAMA, PAMA, NBAA) and through FAA and state DOT sponsored activities (i.e. D.E.R renewals, IA renewal)

Future - demands an EWIS priority

Enhance Maintenance Procedures Instructions for Continuous Airworthiness both TC and STC Holders Enhancement of Advisory Material both Current and Future Development of EWIS Installation Guidance Inspection Criteria Pass/Fail Inspection Criteria for go/no-go decisions

EWIS Reference Information

Websites
Official ATSRAC Website:
www.mitrecaasd.org/atsrac/index.html

FAA Wiring Training Website:

www.academy.jccbi.gov/AIRDL/wiringcourse

Questions?

Thank You!
Eli Cotti Ecotti@nbaa.org