787 Test Flight Update from Boeing

Boeing Photo

Boeing Press Release:

Boeing 787 Dreamliner Passes 1,000 Hours of Flying

EVERETT, Wash., June 17 /PRNewswire-FirstCall/ --The Boeing (NYSE: BA) 787 Dreamliner flight test fleet passed 1,000 hours of testing yesterday. The program estimates that it is about 40 percent through the test conditions required to certify the first version of the all-new jetliner.

"More work remains but we are seeing excellent progress in flight test," said Scott Fancher, vice president and general manager of the 787 program for Boeing Commercial Airplanes. "Even more important than the hours we've logged are the test conditions we have completed. The team is being very efficient in getting the data we need."

"It's also important to note that we are making solid progress on the ground testing required on the flight test fleet as well," Fancher said.

Follow the progress of 787 flight test at http://787flighttest.com.

Boeing's Statement on ZA005 First Flight

Boeing Photo

UPDATE: Now that ZA005's first flight is in the bag, sources have told me that the aircraft will go though post first flight inspections as well as some ground tests. The next time this aircraft will fly is June 28th.

From Boeing:

News Release Issued: June 16, 2010 11:04 PM EDT

Boeing Completes First Flight of GE-Powered 787

EVERETT, Wash., June 16 /PRNewswire-FirstCall/ -- The first Boeing (NYSE: BA) 787 Dreamliner with General Electric (GE) engines, the airplane referred to as ZA005, completed its first flight at 6:29 p.m. (Pacific time) today, following a 3-hour-and-48-minute flight over the state of Washington.

GE executives and Boeing employees were on hand to welcome Captains Mike Bryan and Mike Carriker to Boeing Field in Seattle following completion of the flight.

"The airplane handled just like I expected," said Bryan, who captained the flight. "It was just like every other 787 flight that I've flown in the last several months –smooth, per plan and excellent."

"We're pleased to introduce the fifth Dreamliner to the flight-test fleet and to start flight testing with GE engines," said Scott Fancher, vice president and general manager of the 787 program for Boeing Commercial Airplanes. "It's taken the collective resources and dedication of our teams to get to this day. There's just nothing like a first flight to validate that it has been worth the sacrifices we have all seen our teams make in the past several years."

ZA005 will be used to test the General Electric engine package and demonstrate that the changes made with the new engine do not change the airplane's handling characteristics.

The sixth, and final, 787 to join the flight test program is expected to fly before the end of July.

Dreamliner 5 taxi tests on video

Matt Cawby got some great pictures and video of ZA005 performing its taxi tests around Everett Field. Things are looking good for the aircraft to conduct its first flight tomorrow. No time has been given but the last four 787s were given 10 AM PT target times for their first flights. Check out Matt Cawby's post:

Matt Cawby: 787 Update - June 15

Flightblogger: ZA002 going to So. Cal.

Flightblogger is reporting that ZA002 will fly to Victorville, Ca. this week as part of the 787 flight test program. The Southern California Logistics Airport (SCLA) is in the high desert of southern California and has a a long 15,000 ft runway and dry weather which would be ideal for Boeing to conduct flight testing.

It is not known when or how long ZA002 will beat Victorville or if other 787s will be joining it but the certification test program has the 787 test fleet making trips away from Boeing Field at times.

Flightblogger : Roadtrip! 787 heading for Victorville this week.

Through today's test flights, the 787 fleet has racked up slightly over 250 test flight hours across the three plane test fleet. ZA00 s expected to return to the air very soon (possibly by the end of this coming week) and ZA003 is expected to take to the air for the first time around March 14th. ZA005 should follow soon after that.

Continuing the roadtrip theme, Guy Norris at Aviation Week is reporting on his blog that Boeing is seriously considering sending the 787 AND the 747-8 to the Farnborough Air Show this summer. It would the first time since 1982 that two new Being Commercial Air products would be featured at the air show. Of course, all this hinges on how well the test program goes for both these airplanes.

Guy Norris: Show Time!

Guy also reports on the upcoming trip for ZA002 to California as well as updates on the rest of the 787 flight test fleet. Of note is that ZA003 will have it's two day gauntlet test this week. This would corroborate a flight test date of March 14 for this airplane.

Guy Norris : 787 Heads South

Flight Test Review

Boeing Photo
Yesterday was a busy day for Boeing...and this blogger! Boeing has a large staff to keep track of all the flight testing going on but I'm just all by my lonesome trying to keep up with all the events that were going on. So here's a summary plus a little look forward.

ZA001 - Took off yesterday at around 11:42 AM PT and proceeded to fly for about 6 hours easily the longest 787 test flight to date. During that time ZA001 reached speeds of about 0.93M or about 538 knots and as a high as 30,900 ft as this aircraft continues the all important flutter tests ahead of receiving the TIA (Type Inspection Authorization).

ZA002 - Took off yesterday at about 9:11AM PT and only flew for about an hour and twenty minutes. It flew no higher than about 16,000 feet and reached speeds of around 0.54M or about 310 knots. It continues to evaluate the stability and control characteristics of the 787. It landed and Moses Lake and was on the ground for a few hours (presumably conducting ground tests) then took off and flew straight into Boeing Field.

ZA004 - Flew for the first time yesterday morning at about 11:43AM PT yesterday morning and flew directly to 30,000 ft where it would cruise around at speeds of about 0.68M. The airplane flew for about 3 hours which included a touch and go at Moses Lake and then flew directly to Boeing Field in Seattle.

Going forward - I heard that we shouldn't expect ZA003 to be in the air until mid March at the earliest so for the time being we'll be entertained with the flying of Dreamliners 1, 2, and 4. Know I was told that if Boeing readies ZA005 sooner than that would be the next fly because each 787 test airplane is on its own independent assembly and test track. ZA005 does have its GEnx-1B engines installed and the pace to get the airplane ready for its first flight is quickening. It could be that ZA003 and ZA005 could fly at about the same time it all depends on how each of these airplanes progresses through the reassembly process and the pre-flight ground testing that will follow.

For now ZA004 will be conducting some ground tests but will return to the air soon according to Guy Norris and I expect that ZA001 will push out the flutter envelope further in the days to come.

Guy Norris' 787 Update

Randy Tinseth also marked the first flight of ZA004 with a blog post of his own. In it he explained the need to fly Dreamliner 4 because of data that Boeing engineers need to help with the design of the 787-9. I suspect that Boeing will quickly ramp up test flight on ZA004 as quickly as possible.

Randy's Journal - First Flight of ZA004

Boeing Photo

One last note, Boeing and United Airlines jointly announced that they had finalized United's order for 25 787-8. United also has options on a further 50 787s though I'm sure they can switch those options (as well as the firm orders) amongst the different 787 variants (current and future). Here's the joint press release from Boeing and United:

News Release Issued: February 25, 2010 11:04 AM EST

Boeing and United Airlines Finalize 787 Order

United to expand international service with fuel-efficient Dreamliner

SEATTLE and CHICAGO, Feb. 25 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) and United Airlines (Nasdaq: UAUA) have finalized an order for 25 787-8 jetliners. The agreement includes the opportunity to purchase another 50 Dreamliners.

"Boeing and United Airlines share an 80-year partnership," said Jim Albaugh, president and CEO of Boeing Commercial Airplanes. "United, which launched the Boeing 777, now begins a new chapter with the 787 Dreamliner, the most technologically advanced commercial jetliner ever built."

The order is valued at $4.2 billion at average list prices.

"United's Boeing 787 order represents a substantial investment in our future and will enhance the significant progress we are making in improving the global competitiveness of our company while providing the opportunity to open new profitable markets and serve a broader range of international destinations," said John Tague, president of United Airlines.

United expects to take delivery of the 787s at the same time it will begin to retire its Boeing 747s and 767s operating on international routes.
The 787 Dreamliner, currently in flight test, will provide greater fuel efficiency,
allowing airlines to add new, nonstop city pairs and the additional frequencies that passengers prefer.

The 787 also promises a more comfortable flying experience for passengers. Its innovations include a new interior environment with improvements in air filtration, higher cabin pressurization resulting in reduced physical fatigue, larger windows, more stowage space, improved lighting and other passenger-preferred conveniences.

The technologically advanced 787 will also provide airlines with up to 45 percent more cargo revenue capacity.

Including United Airlines, 57 customers around the world have ordered 876 Dreamliners, making the 787 the fastest-selling new commercial jetliner in history.

Guy Norris: Intermediate Gauntlet Testing Continues with further block tests

Guy posted that Boeing is still continuing with gauntlet testing and are now up to test blocks 8 through 11 with block 11 expected to be completed by late Tuesday. Boeing does expect to complete intermediate gauntlet by this Wednesday. No word on when final gauntlet will start.

I do expect that ZA002 will go through gauntlet testing as will ZA005 which is the first GEnx airplane. I'm not sure about the other test airplanes but they will eventually go through some period of pre-flight testing before their first flights. I'm still maintaining my prediction for first flight after the Paris Air Show and specifically around June 19th (note: I erroneously put the 9th, duhhh).

Boeing will make it June 18th just to spite me. Just kidding Boeing!

Guy's 22nd 787 post.

Flightblogger: ZA001 intermediate gauntlet to start today

UPDATE: Flightblogger is reporting that gauntlet testing along with the pre-gauntlet engine tests won't start until tomorrow. Today was "Shop Gauntlet Work" that took place.

Flightblogger is reporting that intermediate gauntlet testing on ZA001 may start as early as mid day today.

Boeing was to have some engine runs today followed by pre-gauntlet test meetings following those engine runs.

If things look good then Boeing should start the intermediate gauntlet tests today starting with a simulated first flight profile test with simulated failures of the aircraft systems. Boeing had already run through the intermediate gauntlet tests on the integrated test vehicle (ITV).

Lastly, Jon reports that ZA002 ran through its gear swing tests and ZA004 and ZA005 have their engines. That's Trent 1000s for ZA004 and GEnx for ZA005.

Also it appears that the LCF is not delivering the main fuselage section for ZA100 today.

Jon's May 28th Update

Dreamliner 5 to start final assembly soon

The 5th flying 787 should start final assembl by tomorrow or Wednesday at the latest now that all the major assemblies have been delivered to Boeing's Everett facility. This is another important milestone in the 787 program as this plane will be the first GEnx powered 787 and will be used to certify the GEnx powered 787.

I expect that the airplane parts arrived with about a 95% to 98% completion. I think with Dreamliner 8 we'll see no traveled work from the major tier 1 partners and improved final assembly time from Boeing.

Forward Fuselage of Dreamliner 5 heading for Everett

Looks like the forward fuselage section (section 41) for Dreamliner 5 is being shipped tonight on the LCF. Here's the flightaware alert

It's entirely possible that the main fuselage can be delivered next week and LN 5 will enter final assembly before the end of the month. The wings for LN 6 have already been delivered to Everett.

Dreamliner 5 to start final assembly soon?

Jon Ostrower is reporting on his blog that the rear fuselage section for Dreamliner 5 will be arriving this week. That only leaves the forward fuselage and the main fuselage sections to be delivered. I'm still trying to find out when those sections will be delivered.

Also Jon reported that the pieces for the main fuselage section for Dreamliner 9 have been delivered to Global Aeronautica this past weekend to start that section's assembly and systems integration process.

UPDATE (1/12/2009): Jon Ostrower reported on his blog here, that the aft fuselage for LN 5 has arrived in Everett and that it is 95% complete. It has it fasteners repalced. Jon things the remaining two sections should be in Everett by the end of the month to start final assembly.

Flightblogger: 787 Update for 2009

Jon Ostrower has posted a great updates for the near term milestones that Boeing hopes to accomplish with the 787 on the road to first flight.

Please read it here.

Here is a summary:

Dreamliner 1 will leave the 787 final assembly bay in 40-26 and will go to a spot in the 767 final assembly building in 40-24. It will occupy a spot that the 787 fatigue test frame occupies. ZY998 will be towed to the Everett flight line where it will be completed and towed to the fatigue test area.

Dreamliner 1 will be in 40-24 for one month to finish up fastener replacement and minor assembly tasks. It will then start the first of three gauntlet tests. The first is the factory gauntlet where the flight test division puts the 787's systems through its paces.

After that Dreamliner 1 will go through the aqueous wash and the repainting as reported on this blog earlier in December.

By the end of March Dreamliner 1 will start the 2nd gauntlet test which is the starting of it's RR Trent 1000 engines for the very first time. The last guantlet is the running of all the 787 systems for 8 days straight to ensure that there aren't any issues.

Presumably, taxi test and RTO (rejected take off) tests will occur soon after the third gauntlet followed by first flight.

Dreamliner 2 is continuing fastener replacement which should be concluded by mid February. Then this aircraft will conduct ground vibrations testing presumably from late February to late March. There is still no word on when Dreamliner 2 will finish assembly and join the flight test program.

With the first 787 leaving the factory floor, this will now open up a spot in the final assembly hall for Dreamliner 5. The aft section of which will probably be delivered to Everett by the end of January. The wings, horizontal stab and vertical stab are all at Everett. The main fuselage section is being paced by the fastener replacement work that is on going. No word on the forward fuselage section but I presume that there is still on going fastener work with that airplane as well.