EWIS Training
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Transcript of EWIS Training
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EWISEWIS
Electrical Wiring Interconnect SystemNot Just Another Acronym!
Technical Committee
Special Project ATSRAC
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What is EWIS?
All wiring related components connecting
LRUs such as: Wiring
Cannon Plugs
Modular Blocks
Clamps
Terminal Strips
Etc.
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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 ofan aircraft.
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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 developrecommendations to the FAA for LargeTransport Aircraft. (ADs, SFAR)
After the Payne Stewart incident, NTSBrecommended that all Transport Aircraft beincluded in ATSRAC study - STA
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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 forcontinued airworthiness throughout aircraft operational
life
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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.
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Aircraft Type
Findings Summary AC Mode l A AC Mode l B AC Mode l C AC Mode l D AC Mode l E AC Mode l F AC Mode l G AC Mode l H Summary
Number of Aircraft Inspected 5 5 5 5 4 5 5 5 39
% of the Model Fleet 5.90% 2.90% 0.61% 0.90% 2.10% 2.10% 1.05% 0.80% 0.6% to 6%
Age Range 19 to21 11 to 24 10 to 18 18 to 25 11 to 12 20 to 30 12 to 15 11 to 32 10 to 32
Hour Range 4785 to 7835 4130 to 12001 3258 to 8413 7223 to 12408 4130 to 8083 8770 to 17389 4271 to 5904 3572 to 13014 3258 to 17389
Landing (Cycles) Range 4846 to 5684 3473 to 8558 2682 to 5692 5709 to 9873 2746 to 7498 4843 to 8500 2638 to 3389 3187 to 13252 2638 to 13252
Inspections Performed By WG & OEM WG & OEM WG & OEM WG & OEM WG & OEM WG & OEM OEM WG & OEM WG & OEM
0
73
1.9
2256
58
Evaluation Findings % to Specific M odel Totalsby Appendix A Categories:
Connectors 3.20% 1.90% 5.40% 3.30% 1.70% 1.80% 0% 2.30% 2.75%
Terminations 2.30% 0.60% 0.30% 6.70% 0 0.40% 0% 5.50% 1.99%
Installations (General) 80% 79.50% 87% 87% 90.50% 86.40% 97.40% 80.70% 84.53%
Wiring Condition 14.40% 18% 7.30% 2.90% 7.80% 11.40% 2.60% 11.50% 10.73%
Significant Items
% of Significant Items(73Items) to All Model (2256
Items) Evaluation Findings3.24%
Findings per AC (Avg.)
Immediate Fleet Wide Safety
Total Findings
Significant Items
Significant Items per AC (Avg.)
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Damaged Clamp
Zone: 310 Aft equipmentcompartment below APU
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Oxygen line
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Installation invertedTeflon shim
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Disabled system connectors pulled from rack
Tied to environmental system duct
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Conduit rubbing on connector hardware
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Wires pinched in clamp
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ImproperlyInstalled Clamp
(pinching wire)
Zone: 140 Under floor area above wing box
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Chaffed through
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Bend Radius
Zone: 220 Flight compartment above floor
behind circuit breaker panel (copilots feet)
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Bend radius
Improper installation
ll i d i i d i d l
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Installation deterioration and inadequate clearances
Inadequate clearance
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Inadequate clearance
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Inadequate Clearanceto Structure
Zone: 114/115 Flight compartment
under floor bottom of fuselage
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Damaged ConduitZone: 143/144 Main landinggear wheel well
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Improper
Repair
Zone: 143/144 Main landing gear wheel well
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Debris on Power Wires
(Metal Shavings)
Zone: 240/250 Cabin area above floor
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Contaminated
Wires
Zone: 250 Cabin area above floornear luggage compartment door
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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
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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
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ATSRAC HWG10
Organizational Differences
STA = Smaller Organizations within eachDepartment
Dispatch
Flight Maintenance (35%)
STA Owner/Operators tend to be more
interdependent with TC and STC Holders
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NBAA Operator Demographics
669
2358
314
362588
237
0
500
1000
1500
2000
2500
3000
3500
1 2 >2
W/O MX
With MX
Operators
Aircraft Operated
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ATSRAC HWG10
Lessons Learned
Before April of 2002 the Majority of theWorking 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
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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
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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), andSpecial Detailed Inspection (SDI)).
Rationale
To fully effect a culture change, in theaviation industry, this should include aground up approach (e.g. future technicians
are trained from day one on EWIS concepts)
d i
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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 forEWIS
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HWG-10 Recommendations
Rationale
These Advisory Circulars are the basis forcertification, maintenance, and training of industry
personnel.
EWIS concepts revision would generateawareness to a large group of existing and future
approvers, designers, installers, and technicians.
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I i C i i
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Inspection Criteria
Rationale
There is a lack of Inspection Criteria forwiring and its subcomponents.
Development of this Criteria will ensure
that inspectors know what is to be
inspected.
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Maintenance Procedures
Recommendations
Review existing manufacturerinspection/maintenance programs and
enhance for EWIS considerations
Manufacturer standards - wiring
practices
pass fail criteria
Training program
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Maintenance Procedures
OEMs and STC Holders to enhance thecurrent Maintenance Procedures
Enhancement doesnt necessarily drive toEZAP.
Maintenance Program DevelopmentPhilosophies of the Various STA OEMs shouldbe capable of enhancing current programsincorporating concepts of EWIS
Future Small Transport Aircraft Designs willmost likely follow the version of MSG-3 of that
time period or applicable analytical logic processof that time period.
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ATSRAC - STA
Whats next?
HWG 13 New Tasks - further define anddevelop for STA
Criteria for enhanced wiring inspectionprocedures
Means of compliance
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So now we know
Installation of wiring (EWIS) has not had the
awareness of the Approvers & Maintainers itrequires
Concerns for installation & functionality ofequipment was the priority not wiring
Current practices will not be allowed to
continue as is
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Future - demands an EWIS
priority
Communicate through existingindustry 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)
d d
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Future - demands an EWIS
priority Enhance Maintenance Procedures
Instructions for Continuous Airworthiness
both TC and STC Holders
Enhancement of Advisory Material bothCurrent and Future Development of EWIS
Installation Guidance
Inspection Criteria Pass/Fail Inspection
Criteria for go/no-go decisions
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EWIS Reference Information
Websites Official ATSRAC Website:
www.mitrecaasd.org/atsrac/index.html
FAA Wiring Training Website:
www.academy.jccbi.gov/AIRDL/wiringcourse
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Thank You!Thank You!Eli [email protected]
Questions?Questions?