Boeing: Changes to Power Panel Design; revised schedule still weeks away

Boeing has acknowledged the rumors circulating around that it was indeed FOD (foreign object damage) that had caused a short circuit that led to the fire in the P100 power panel.

As a consequence Boeing will undertake a minor redesign of the power panel to reduce the chance of FOD creating and electrical arc or short circuit. Boeing will also implement software changes to make sure that power distribution is improved. This appears to be an acknowledgement that the electrical power redundancies failed as well.

Boeing did not present a revised schedule as they have yet to work that out but they are saying it should be ready in a few weeks. They are developing a plan to present to the FAA for the resumption of flight tests as well asto ferry ZA002 back from Laredo.

Also Flightblogger reports that the foreign object was small and not something the size of a tool as had been earlier reported. KING 5, a Seattle TV station says that it was a washer that caused the short circuit.

Again there is no word on how long it will take the implement the redesign or the software changes. Additionally, the FAA will have to approve all these changes so the schedule will remain in flux.

Boeing will be closed tomorrow and Friday for the Thanksgiving holidays.

Here is Boeing's press release:

Boeing Initiates Changes to 787 Power Panel, Updates to Software

EVERETT, Wash., Nov. 24, 2010 /PRNewswire/ -- Boeing (NYSE: BA) is developing minor design changes to power distribution panels on the 787 and updates to the systems software that manages and protects power distribution on the airplane. These changes come as the result of what has been learned from the investigation of an onboard electrical fire on a test airplane, ZA002, earlier this month in Laredo, Texas.

"We have successfully simulated key aspects of the onboard event in our laboratory and are moving forward with developing design fixes," said Scott Fancher, vice president and general manager of the 787 program. "Boeing is developing a plan to enable a return to 787 flight test activities and will present it to the U.S. Federal Aviation Administration (FAA) as soon as it is complete."

Engineers have determined that the fault began as either a short circuit or an electrical arc in the P100 power distribution panel, most likely caused by the presence of foreign debris. The design changes will improve the protection within the panel. Software changes also will be implemented to further improve fault protection.
The P100 panel is one of five major power distribution panels on the 787. It receives power from the left engine and distributes it to an array of systems.

The 787 team is now assessing the time required to complete the design changes and software updates that are being developed. A revised 787 program schedule is expected to be finalized in the next few weeks.

"Our team is focused on developing these changes and moving forward with the flight test program," said Fancher. "The team in Laredo is also well along in preparing to return ZA002 to Seattle.

Flightblogger: Breaking: Electrical redesign to push 787 delivery

Guy Norris: 787 fire - arc or short

Scott Hamilton: 78 fire caused by FOD, design changes coming, no word on delay

Randy Tinseth: Likely cause of ZA002 incident determined

Aubrey Cohen: Boeing: 787 will need minor changes; schedule impact unknown

At the end of the day everyone wants to know what is the schedule impact of the fire and the resulting redesign of software and hardware. A source told me that he believes that it would set back the 787 no more than three months. Given the information that has come out thus far and my discussions with sources, I do feel that mid to late May delivery time frame is probably about right given the redesign efforts as well as the rework that has to be done on the production aircraft.

Seattle TV Station says washer caused fire on ZA002

A Seattle TV (KING 5) station is reporting that a washer came into contact with parts inside the P100 panel which started the fire. The contact caused a short circuit which sparked the fire on ZA002. The good news is that there will be relatively simple redesign but we have yet to hear about this as well as and potential redesign to make sure that the 787 has full electrical redundancies in these types of emergency situations.

KING 5 also says that Boeing is expected to make a statement today. The stock market is closed so it should be out soon. Stay tuned....

KING 5: KING 5 learns cause of 787 fire

Flightblogger: 787 fire investigation coming to an end

In posting today, Flightblogger is reporting that Boeing has concluded its investigation of the fire aboard ZA002 and they could be in a position to publicly release the results as well as a new schedule but it seems all but certain that there will be another delay. What is not known is how long the delay will be with estimates ranging from 6 months to as much as a year.

Indications are pointing towards FOD as the culprit but there is still open questions as to what the FOD was and where was it located. Additionally, a more important flag was raised about the 787s power redundancies in case of a loss of a unit like P100.

Fligthblogger also revealed that Boeing was able to recreate the effects in the systems integration lab.

Boeing needs to understand why the 787 had assumed that all power was loss and the RAT was deployed (it only deploys in the event of a total power loss). This might necessitate a software and/or hardware fix though it is not known at this time.

On a related note, Susanna Ray of Bloomberg News put out an article where Wall Street analysts say that a 7th delay is a foregone conclusion. Dominic Gates also has an article detailing the investigation and the possibility that FOD played a role in the fire.

The fire may have revealed a potential problem with how power is distributed in the event one of the power distribution panels failed like the P100 did. It is better to find these issues now instead of an revenue flight with 200 passengers on board.

You can read each of the article by clicking the link below:

Flightblogger: Boeing nears end to 787 fire investigation

Susanna Ray: Boeing Dreamliner Faces Seventh Delay, Analysts Say

Dominic Gates: Boeing investigating if foreign object caused 787 electrical fire

Boeing releases more information on ZA002

Boeing came out what now seems like daily updates on their investigation into the fire about ZA002. Boeing is saying that the P100 panel that apparently started the fire in the electronics bay by setting an insulation blanket on fire. Boeing has removed the faulty unit and is sending a replacement unit to be installed in Laredo.

Boeing also states that while there is significant damage to the P100 unit, there doesn't seem to be much damage to the surrounding area or systems. Their investigation is still preliminary so there may be changes in this assessment as the investigation progresses. Boeing stated that they did find molten metal (aluminum according to Flightblogger) near the P100 panel but this was to be expected in light of the fire that took place. Boeing still stresses that their investigation of the area around the P100 panel including the composite fuselage is not completed yet and will take a few more days. They are also trying to assess repair time and plans as well as plans to return the test flight fleet to the air.

Here is Boeing's press release:

Updated Boeing Statement on 787 Dreamliner ZA002 Incident

EVERETT, Wash., November 11, 2010 - Boeing continues to investigate Monday's incident on ZA002. We have determined that a failure in the P100 panel led to a fire
involving an insulation blanket. The insulation self-extinguished once the fault in the P100 panel cleared. The P100 panel on ZA002 has been removed and a
replacement unit is being shipped to Laredo. The insulation material near the
unit also has been removed.

Damage to the ZA002 P100 panel is significant. Initial inspections, however, do not show extensive damage to the surrounding structure or other systems. We have not completed our inspections of that area of the airplane.

The P100 panel is one of several power panels in the aft electronics bay. It receives power from the left engine and distributes it to an array of systems. In the event of a failure of the P100 panel, back-up power sources - including power from the right engine, the Ram Air Turbine, the auxiliary power unit or the battery - are designed to automatically engage to ensure that those systems needed for continued safe operation of the airplane are powered. The backup systems engaged during the incident and the crew retained positive control of the airplane at all times and had the information it needed to perform a safe landing.

Molten metal has been observed near the P100 panel, which is not unexpected in the presence of high heat. The presence of this material does not reveal anything meaningful to the investigation.

Inspection of the surrounding area will take several days and is ongoing. It is too early to determine if there is significant damage to any structure or adjacent systems.

As part of our investigation, we will conduct a detailed inspection of the panel and insulation material to determine if they enhance our understanding of the incident.
We continue to evaluate data to understand this incident. At the same time, we are working through a repair plan. In addition, we are determining the appropriate steps required to return the rest of the flight test fleet to flying status.

Boeing will continue to provide updates as new understanding is gained.

Dominic Gates of the Seattle Times has a very detailed report up as well. In it he says that he has access to Boeing photos showing the damage to the P100 unit including damage to the contactors within the unit which close and open circuits when power is needed. Dominic also said that the insulation blanket which caught fire was placed between the P100 unit and the composite fuselage skin. Once the pilots cut power to P100 (which is on the left side of the airplane), the P200 unit which is on the right side of the airplane provided power as did the aircraft's APU (auxiliary power unit) and RAT. This is why the aircraft was able to land safely with power.

You can read Dominic's article below:

Dominic Gates: Boeing photos show damage to key 787 electrical components

Additionally, Flightblogger has posted his update as well:

Flightblogger: A Closer Look: 787 fire investigation points to P100 power panel

I've added Guy Norris' report that he put out this morning:

Guy Norris: 787 - new detail of fire and damage on ZA002