March 13, 2013 in City

787 battery redesign OK’d

FAA says changes in ventilation, insulation aimed at preventing future fire
Joan Lowy Associated Press
 
Associated Press photo

Joseph Kolly of the National Transportation Safety Board holds a damaged battery casing.
(Full-size photo)

WASHINGTON – A Boeing plan to redesign the 787 Dreamliner’s fire-plagued lithium-ion batteries won approval Tuesday from the Federal Aviation Administration, although officials gave no estimate for when the planes would be allowed to fly 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.

A series of tests, including flight tests, must be passed before the 787 can return to service. So far, flight tests of two 787s with prototypes of the new battery design have been approved, the agency 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 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 other 787s 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.”

The cutting-edge 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 oversee 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.

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