Introducing the 787 - Effect on Major Investigations - and Interesting Tidbits

Introducing the 787 - Effect on Major Investigations - And Interesting Tidbits

Tom Dodt Chief Engineer – Air Safety Investigation ISASI September, 2011

767-400 787-8 777-300 ~Pax 3-Class 245 250 368 ~Span 170 ft 197 ft 200 ft ~Length 201 ft 186 ft 242 ft ~MTGW 450,000 lbs 500,000 lbs 660,000 lbs ~Range 5,600 NM 7,650 NM 6,000 NM Cruise Mach 0.80 0.85 0.84

Other Carbon laminate Steel 5% Carbon sandwich 10% Fiberglass Titanium 15% Composites Aluminum 50% Aluminum/steel/titanium pylons Aluminum 20%

On-Ground 0 ft

1G Flight ~12 ft

On-Ground 0 ft

1G Flight

Ultimate-Load ~26 ft

1G Flight ~12 ft

On-Ground 0 ft

Max-Load

• Terms: Composites Aluminum disbond fatigue delaminate beach marks inter-laminar shear striation counts water absorbsion corrosion fiber architecture metallurgical prop.

• Material Forensics Techniques will be different

• On-Site with Exposed Composite Fibers Eyes - goggles or full face protection Nose - HEPA filter Hands - gloves Exposed Skin - coveralls

787 787

777

Vertical Gust Suppression

2 • Uses the flaperons and elevators 1 • Counters light to moderate 0 turbulence to improve ride quality

-1 • Passengers have a more

Change in altitude (m) in altitude Change comfortable flight -2 0 20 40 60 80 100 120 140 160 180 Time (sec)

With Enhanced Gust Suppression

Without Enhanced Gust Suppression

Windows - Larger

Pressure - Lower

Humidity - Higher

Air Quality - Improved

Ride Quality - Improved

Food Service - Unchanged (sorry)

787 - Gaseous Oxy @ 3000 psi - Steel cylinder 777 - Chem Oxy Generators (2x)

85 dB Noise Contours at Heathrow London Heathrow

787 noise footprint stays in the airport property

767-300 787- 8

Feet 0 5000 • 85 dBA contours Meters Source MS Mappoint, (c) Microsoft, Inc. • 3,000 nmi mission 0 1500 4001041404

• No-engine-bleed-air systems architecture

• Higher bypass ratio

• Low-noise nacelles with chevrons

• No-engine-bleed-air systems 777 787 Wing LE Anti-Ice bleed air electric Air Conditioning bleed air electric Cabin Pressure bleed air electric Engine start bleed air electric

• Engine Generators 777 787 240 kVA 1000 kVA (2 @ 120 kVA) (4 @ 250 kVA)

Generators Starter/Gen’s

777 115 VAC 400 Hz

787 230 VAC 360-800 Hz

COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 21 FLIGHT DECK NON-NORMAL CB BY STATE CB SEARCH Electronic SYS MENU CB CB CB RECENT CB CB BY ATA CB BY BUS Circuit Breakers BY LOCATION USED CB CUSTOM LIST CE2100713 CIRCUIT BREAKER NAME 1 TRIPPED DETAILS CONTROL  • No physical CBs in Flight Deck CE2100714 CIRCUIT BREAKER NAME 2 DETAILS CONTROL  CE2100715 CIRCUIT BREAKER NAME 3 DETAILS CONTROL

CE2100701 CIRCUIT BREAKER NAME 4 DETAILS CONTROL • CB control and state indication CE2100702 CIRCUIT BREAKER NAME 5 DETAILS CONTROL are display based. 1 CK2100780 CONTACTOR NAME 6 TRIPPED DETAILS CONTROL

CE2100716 CIRCUIT BREAKER NAME 7 ? UNK DETAILS CONTROL

• Accessible on Multi-Function CE2100717 CIRCUIT BREAKER NAME 8 DETAILS CONTROL

Display (MFD) and DO NOT CE2100718 CIRCUIT BREAKER NAME 9 CLOSE DETAILS CONTROL

maintenance access devices CE2100719 CIRCUIT BREAKER NAME 10 DETAILS CONTROL

CE2100703 CIRCUIT BREAKER NAME 11 DETAILS CONTROL 2 • A few Thermal CB are located CE2100721 CIRCUIT BREAKER NAME 12 DETAILS CONTROL

DO NOT in the Fwd EE-Bay CE2100722 CIRCUIT BREAKER NAME 13 CLOSE DETAILS CONTROL CE2100723 CIRCUIT BREAKER NAME 14 ? UNK DETAILS CONTROL

CK2100724 CONTACTOR NAME 15 DETAILS CONTROL 

787 777

777777 787787 IntegratedIntegrated SurveillanceSurveillance WXRWXR EGPWSEGPWS TCASTCAS ATCATC SurveillanceSurveillance SystemSystem (ISS)(ISS)

NavNav RadiosRadios VORVOR MBMB MMRMMR DMEDME RARA RARA DMEDME IntegratedIntegrated NavigationNavigation RadiosRadios (INR)(INR)

CommComm RadiosRadios VHFVHF HFHF SATCOMSATCOM SATCOMSATCOM HFHF VHFVHF

InertialInertial ADIRUADIRU SAARUSAARU EarthEarth ReferenceReference SystemSystem (ERS)(ERS)

OtherOther LRUsLRUs WEUWEU OthersOthers CommonCommon CoreCore ResourceResource (CCR)(CCR) AirAir DataData AIMSAIMS CrewCrew AlertingAlerting DisplaysDisplays CommComm Management Management DFDACDFDAC DataData AcquisitionAcquisition FMFM // TMTM DisplaysDisplays CMFCMF // ACMFACMF // QARQAR FMFM // TMTM // ATAT FDCFFDCF HealthHealth ManagementManagement GatewaysGateways GatewaysGateways OthersOthers OthersOthers

777

PSA

ACE PFC

787 AFDC FSEU

PCMPCM ACEACE FCMFCM

CommonCommon ComputingComputing ResourceResource ••High High integrityintegrity computingcomputing resourcesresources forfor hostedhosted systemssystems applicationsapplications

CommonCommon DataData NetworkNetwork ••High High IntegrityIntegrity NetworkNetwork • Open industry standard interfaces A664 • Open industry standard interfaces A664 RemoteRemote DataData ConcentratorsConcentrators ••21 21 RDCsRDCs ••Remote Remote I/OI/O capabilitycapability ••Reduces Reduces airplaneairplane wiringwiring COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 26 CCS Hosted Functions

• Avionics Communication and Audio • Avionics Flight Management and Navigation • Avionics Thrust Management and Auto-throttle • Avionics Primary Display Function • Avionics Crew Alert/Warning and Surveillance • Avionics Crew Information Services • Avionics Maintenance and Data Loading • Cabin Management and Air Show • Environmental Control System Functions: Power Electronics and Other Equipment Liquid/forced air Cooling, Air Conditioning, Cabin Pressurization, Ice & Rain Protection, Air Distribution, Galley Refrigeration, Low Pressure Systems, Cargo Heat, Wheel Well Fire Detection and Cargo Fire Detection/Protection • Electrical Utility System Control Functions Remote Power Distribution System (RPDS), Power Distribution Panels (PDPs), Generator/Bus Power Control Units (GCU/BPCU), Proximity Sensors, Window Heat, Tail Strike, Emergency Passenger Assist System (EPAS), Exterior Lighting • Data Interface to Flight Controls Electronics (FCE) • Interface to Flight Deck Panels and Switches • Fuel Management and Fuel Quantity Indication • Hydraulics Control • Mechanical System Interface Functions in Brakes, Landing Gear, Nose Wheel Steering • Payloads Interface Functions in Galleys, Water & Waste, Emergency Lighting • Data Interface to Propulsion Controls in EEC, Engine Fire Detection/Protection, Thrust Reverser • Specific functionality supported by the CCS is described in the CCS SDD (Ref. 4) as well as in individual 787 CCS hosted function System Description • Documents (SDDs) identified in their respective certification plans listed in Ref. 4.).

COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 27 Hydraulic System Architecture 5000 psi systems Left Left System Center System Right Right System Engine Engine 25 gpm +/- 270V DC 27 gpm 27 gpm +/- 270V DC 25 gpm +/- 270V DC Engine Electric Driven Pump Electric Electric 13 gpm Driven Pump Electric (EDP) Electric Motor Pump Motor Pump (EDP) Motor Pump Motor Pump (EMP) (EMP) Ram Air (EMP) Turbine (EMP) 27 gpm (RAT) 27 gpm

OB Aileron – L Wing: OB & IB L Wing: OB L Wing: IB IB Flaperon R Wing: IB R Wing: OB & IB R Wing: OB L Wing: 3 L Wing: 1, 7 L Wing: 2, 6 Spoilers IB & OB R Wing: 12 R Wing: 8, 14 R Wing: 9, 13

Elevator Left Left & Right Right

Rudder PCU PCU PCU

Thrust Reverser Left Right

Trailing Edge Flaps Motor

Leading Edge Flaps Motor

Nose Landing Normal Gear & Steering Reserve Main Landing Gear Left & Right

• Landing Gear Actuation - Electronic control and sequencing of landing gear and doors

• Brake System - Control-by-wire brakes, autobrake and anti-skid - Electric Brake Actuators

• Nose Gear Steering - Control-by-wire (pedals & dual tillers) - Hydraulic actuation

HeatHeat ExchangerExchanger inletinlet

HeatHeat CabinCabin AirAir ExchangersExchangers CompressorCompressor InletInlet (Deflector(Deflector doordoor shownshown deployed)deployed)

CabinCabin AirAir CompressorsCompressors ElectricElectric RamRam FanFan

Heat Exchanger Inlet

• Dual-Combi Architecture • Both recorders are same P/N - self contained acquisition function - FRED file in memory (Flight Rec. Elec. Doc. - ARINC 647) - flight data 25 hours minimum -voice -2 hours -datalink

• FWD EAFR - RIPS for voice recording only

• AFT EAFR -no RIPS

• EAFR Flight Data recording format - ARINC 767 - raw data file size ~800 MB (zips to 200 MB) - Approx equivalent to 5000+ WPS recorder

• The 787 “QAR” - called "Continuous Parameter Logging" (CPL) - stored on the mass storage devices (server) - ARINC 767 recording format

Common 777 / 787 Fly-by-wire Functionality

• Stall Protection • Overspeed Protection • Bank Angle Protection • Tail Strike Protection • Thrust Asymmetry Compensation • Yaw Damping, Over-yaw Protection • Gust Load Alleviation • Fin Load Alleviation • Flap Load Relief & Autogap • Lateral Gust Suppression • Modal Suppression

• P-Beta control law • Vertical Gust Suppression (turbulence) • Enhanced Stall Protection - Limits high angles of attack • Enhanced Thrust Asymmetry Compensation - Adds inertial yaw detection on ground - Generates rudder & steering for yaw disturbances

• Wheel commands roll rate (P) • Pedals command sideslip angle (Beta) • Opposes disturbances • Coordinates lateral and directional control • Automatic aileron & rudder trim - No aileron trim switch

Federated AD & IR Voted AD & IR (all previous models) (777, 787)

AD PFD PFD IR   FO FO SAARU AD AD Stby AD/IR Stby IR AD AD AD PFD AD FDI PFD IR  IR  Capt Capt VotedFT-ADIRU AD-IR

Fault arbitration Fault arbitration by CREW by SYSTEM

AD = Air Data IR = Inertial Reference FDI = Fault Detection & Isolation PFD = Primary Flight Display

• Common Mode Hazards to Pitot-Static sensors - Mud Daubers - Icing - Volcanic Ash - Hail -Radomefailure -Birds - Pitot covers - Taped Static Ports - Maintenance errors (pneumatic plumbing)

• 787 new capabilities for protection - Synthetic airspeed - GPS altitude - Common Mode Monitor

• Calculated from angle of attack and inertial data - AOA – voted dual sensors plus inertial data

- Accurate Coefficient of Lift (CL) - Airplane Mass from FMC - Validated after Takeoff

• Algorithm developed for enhanced stall protection

• Avoid displaying data known to be bad

- Loss of valid voted VCAS = Display synthetic airspeed VSYN

- Loss of valid voted PSTATIC = Display GPS altitude

Objective: Reduce schedule interruptions and maintenance costs

IntegratedIntegrated datadata loadload andand AirplaneAirplane levellevel faultfault configurationconfiguration reportingreporting consolidationconsolidation andand correlation,correlation, andand datadata collectioncollection ElectronicElectronic DistributionDistribution ofof SoftwareSoftware

Media-lessMedia-less datadata transfertransfer to/fromto/from groundground stationsstations ElectronicElectronic linklink toto maintenancemaintenance manualsmanuals CoordinatedCoordinated airplaneairplane andand groundground processingprocessing FaultFault PredictionPrediction approachapproach

Observer State of Occurrence (UK) British Airways Investigator-In-Charge AAIB Observer EASA

State of Manufacture (UK) State of Manufacture (USA) State of Manufacture (USA) Technical Advisor US Accredited Representative US Accredited Representative Rolls-Royce NTSB Inv. Agency

Technical Advisor FAA

Technical Advisor Boeing

Technical Advisor Technical Advisor Supplier Sub-Supplier

COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 44 COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 45 COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 46 747 Dream Lifter

U.S. Australia Asia Europe Boeing Boeing Fuji Messier-Dowty Spirit Mitsubishi Rolls-Royce GE Canada Kawasaki Latécoère Wing tips Goodrich Boeing KAL-ASD Alenia Seoul, Korea Messier-Dowty Saab

Fixed trailing edge Wing Nacelles Nagoya, Japan Nagoya, Japan Chula Vista, CA Mid forward fuselage Nagoya, Japan Forward fuselage Moveable trailing edge Center fuselage Wichita, KS Melbourne, Australia Grottaglie, Italy 41

43 Tail fin 44 Cargo access doors Frederickson, WA Passenger entry doors Linköping, Sweden Toulouse, France 46

47 Wing/body fairing Landing gear doors 48 Winnipeg, Canada 11 45 Main landing gear Horizontal stabilizer Aft fuselage wheel well Foggia, Italy Charleston, SC Nagoya, Japan Engines Center wing box GE – Evandale, Ohio Nagoya, Japan Rolls Royce – Derby, UK

Fixed and moveable Landing gear leading edge Gloucester, UK Tulsa, OK

Section 44 Section 11/45 Section 41 Grottaglie, Italy to Nagoya, Japan to Charleston, SC Wichita, KS to Everett, WA Charleston, SC

Horizontal Stabilizer Joined Foggia, Italy Section 43 Section to Charleston, SC Nagoya, Japan to Charleston, SC 47-48 Joined Section 46 Charleston, SC to Grottaglie, Italy Section 43-46 Everett, WA to Charleston, SC Charleston, SC to Everett, WA Wing Nagoya, Japan to Everett, WA

Worldwide operations, less work in process

• Efficient transport of 787 major sub- assemblies from international partners

• Main deck is 65,000 cubic feet - 3x capacity of 747-400 Freighter

• Reduced transportation times versus surface transportation - Dramatically reduced final assembly flow times - Less inventory

COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 50 COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 51 COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 52 COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 53 COPYRIGHT © 2010 THE BOEING COMPANY Smith, 7-April-2011, ESASI-Lisbon | 54 787 Structure from Asia

FujiFuji HeavyHeavy IndustriesIndustries KawasakiKawasaki HeavyHeavy IndustriesIndustries

MitsubishiMitsubishi HeavyHeavy IndustriesIndustries KoreanKorean AirAir International partners providing key 787 structure

AleniaAlenia AeronauticaAeronautica AleniaAlenia AeronauticaAeronautica

LatecoereLatecoere Messier-DowtyMessier-Dowty SaabSaab International partners providing key 787 structure

SpiritSpirit BoeingBoeing -- Charleston Charleston

BoeingBoeing -- Charleston Charleston

International partners providing key 787 structure