Getting Tougher On Wire

Aviation Today
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Aviation Maintenance
November 2002
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Safety News: Aging Systems

Think tougher rules on wiring inspection and maintenance are only a problem for "heavy iron" operators and their maintenance professionals? Think again.

The condition of wiring in aircraft became a concern after a string of major in-flight electrical fire episodes in the late 1990s. An FAA-industry committee set up to identify means of reducing the risk of wiring-related in-flight fires and critical-system failures wrapped up its three and a half years of work—which was monitored closely by European regulators—in early July (AM, September 2002, page 58).

That panel, the Aging Transport Systems Rulemaking Advisory Committee (ATSRAC), called for new wiring inspection and design requirements, more stringent standard wiring practices, and thorough and regular training of mechanics on those practices.

The committee was dominated by individuals who work for, support, or regulate airline operations. That made sense, since the committee was focused on turbine-powered, transport-category aircraft that carry 30 or more passengers and weigh 7,500 pounds or more.

But ATSRAC’s recommendations make business aircraft makers, operators, and maintainers nervous. They fear the FAA will apply those recommendations wholesale to general aviation. To prevent that, the National Business Aviation Association and the General Aviation Manufacturers Association pulled together a team of about 35 industry representatives to assess wiring in the business aircraft fleet and recommend how the ATSRAC findings should be tailored to general aviation.

The group began last May to inspect wiring on 37 aircraft representative of the fleet that carries more than six passengers and maximum payloads up to 7,500 pounds. Group members have wrapped up that work, and planned to meet October 22-24 in Wichita, Kansas to brief their findings to, as one member put it, "all the ATSRAC people who don’t know the first thing about business aviation."

Like their transport counterparts, the members of this assessment group say they have found no major wiring discrepancies in the inspected aircraft. Unfortunately, like their counterparts, they found lots of minor gripes—wire bundles tied to hydraulic lines, or showered with metal shavings because they were not protected during sheet-metal work, or secured with tie wraps, clamps, and terminals wrong for the job. ATSRAC found such poor maintenance and housekeeping can lead to damaged insulation, exposed conductors, and increased risks of critical system failures and in-flight fires.

The group is expected to issue its report to the FAA in January. Don’t be surprised if the agency requires business aircraft makers, operators and maintenance shops to adhere to new design, training, maintenance, and inspection requirements similar to those facing transport operators.—


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