February 23, 2013 in Business

Boeing proposes fix for its 787’s batteries

Cause of overheating still unknown; repair covers several possibilities
Joan Lowy And Joshua Freed Associated Press
 
Associated Press photo

A line of Boeing 787 jets are parked nose-to-tail at Paine Field in Everett. Congressional officials say Boeing is proposing a long-term fix for the 787 Dreamliner’s troubled batteries.
(Full-size photo)

Better insulation

Boeing’s plan calls for revamping the 787’s two lithium ion batteries to ensure that any short-circuiting that could lead to a fire won’t spread from one battery cell to the others. That would be achieved by placing more robust ceramic insulation around each of the battery’s eight cells.

WASHINGTON – Boeing attempted a major step Friday toward getting its 787 Dreamliners flying again, proposing a fix for the plane’s troubled batteries that could allow the flights to resume as early as April, congressional officials said.

The next question is whether the Federal Aviation Administration will agree to let the planes fly even though the root cause of a battery fire in one plane and a smoking battery in another is still unknown.

A Boeing team led by CEO Ray Conner presented the plan to Federal Aviation Administration head Michael Huerta. The airliners, Boeing’s newest and most technologically advanced, have not been allowed to fly since mid-January.

The plan – a long-term solution rather than a temporary fix – calls for revamping the aircraft’s two lithium ion batteries to ensure that any short-circuiting that could lead to a fire won’t spread from one battery cell to the others, officials said. That would be achieved by placing more robust ceramic insulation around each of the battery’s eight cells. The aim is to contain not only the short-circuiting, but any thermal runaway, a chemical reaction that leads to progressively hotter temperatures.

The additional spacers will enlarge the battery, requiring a bigger battery box to hold the eight cells. That new box would also be more robust, with greater insulation along its sides to prevent any fire from escaping and damaging the rest of the plane, officials said.

The plan will require testing and partially recertifying the safety of the plane’s batteries, said the officials, who spoke on condition of anonymity because they weren’t authorized to speak publicly.

The testing and recertification will take time, with engineers currently estimating completion sometime in April at the soonest, they said. Even after the batteries are recertified, it could take some more time to get the planes back into the air. Boeing will have to send teams to eight airlines in seven countries to retrofit their planes.

It’s up to Huerta to decide whether to approve the plan. But Boeing’s plan is not a surprise, since the company has kept regulators closely informed, the officials said.

Boeing, the FAA and the National Transportation Safety Board still have not identified the root cause of a Jan. 7 fire that erupted in an auxiliary power unit battery of a Japan Airlines 787 about a half-hour after the plane landed at Boston’s Logan International Airport. The safety board is investigating that incident, but NTSB officials didn’t attend Friday’s meeting and declined to comment on the proposal.

Engineers and battery experts gathered by Boeing developed a list of possible causes for the fire and a plan to modify the batteries to address the spread of a fire created by any of those causes, officials said.

Nine days after the Boston fire, an All Nippon Airways 787 with a smoking battery made an emergency landing by in Japan. The FAA and aviation authorities overseas ordered the planes grounded soon afterward. There are a total of 50 of the planes in service worldwide, and Boeing had orders for 800 of the airliners at the time they were grounded.

The 787 is the world’s first airliner made mostly from lightweight composite materials. It also relies on electronic systems rather than hydraulic or mechanical systems to a greater degree than any other airliner. And it is the first airliner to make extensive use of lithium ion batteries, which are lighter, recharge faster and can hold more energy than other types of batteries.

Boeing has billed the plane to its customers as 20 percent more fuel efficient than other mid-size airliners. That’s a big selling point, since fuel is the biggest expense for most airlines.

One question is how much weight Boeing’s proposed fix would add. The heavier the plane is, the less fuel-efficient it is.

Having the plane flying as soon as April “would be fantastic news for Boeing,” said Carter Leake, an aerospace analyst at BB&T Capital Markets.

If the battery fix ends up being as described, “I don’t think it’s that difficult to retrofit. I think it would be viewed very favorably” by investors, Leake said. If the FAA were to approve Boeing’s proposed fix as early as next week, that would be a “home run” for the company, he said.

However, the idea of recertifying part of the design is trickier. Getting certification from the FAA for a particular part or design is an involved process – and one that’s likely to make investors nervous.

“Recertification suggests time,” Leake said. “Given what most know about aircraft certification processes, six months would be sort of quick.”

Leake added: “The FAA takes it slow. You’re talking about statistical testing. You’re proving through testing that this meets very stringent criteria. That usually involves time, and time is not on Boeing’s side.”

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