Upcoming 787 deliveries

Now that the battery modifications are underway Boeing is gearing up to re-start deliveries to customers.

First up will be deliveries to ANA and LOT Polish Airlines.  ANA (ZA512, LN 83, JA818A) should deliver tomorrow 5/13/2013 (flyaway the next day) while LOT Polish (ZA272, LN 86, SP-LRC) should deliver the following day on 5/14/2013 (flyaway the next day).

Thomson Airways is expecting their first 787 (ZA317, LN 92, G-TUIA) on 5/30/2013 with the second (ZA318, LN 94, G-TUIB) to follow on 6/2/2013.

JAL can also take delivery this week of ZA184 (LN 89, JA830J) though I haven't heard about a delivery date.

Hainan and China Southern could take their first 787s as early as the end of this month but that could easily slip into June since the delivery is waiting on Chinese aviation authorities certifying the 787 for use by Chinese carriers.

British Airways is looking to take delivery within the next few weeks but it does look like that they'll pick up their first 787s next month.

 

Transaero Airlines to get early build 787s

I got word that Boeing has officially allocated 3 very early build 787s to Transaero Airlines.  The three frames are ZA800 (LN 11), ZA801 (LN 12), and ZA803 (LN 14).  All three were previously going to be delivered to ANA but has since asked for later built 787s.  Boeing still has about 7 more that need to be re-allocated to other airlines.  These are among the group of 787s that are known as the "terrible teens."  It has been rumored that Transaero would pick up these aircraft from Boeing on the cheap when they closed on the order of 4 787s early last year.  It's also rumored that Lion Air will be picking up their 5 aircraft from this block as well but that change has yet to be reflected in the system.

Production flight testing has picked up today with ZA318 (LN 94, G-TUIB) for Thomson making its first flight today.  ZA512 (LN 83, JA818A) made it 12th flight and this aircraft should be delivered to ANA late next week though it still has to go through customer acceptance flight(s). Two Charleston built 787s for Hainan  swapped places today as ZA431 (LN 76, B-2722) flew back to Charleston and ZA433 (LN 81, B-2723) flew to Ft. Worth for painting from Charleston.

 

787 production testing accelerating

In the last 8 days Boeing has sent 6 787s into the air for each aircraft's first flight since the grounding ended.  This included two 787s that were flown on their B-1 flights today, April 30th.  Boeing had indicated that they would aggressively conduct production testing in order to get caught up on deliveries.  Though Boeing hasn't delivered a Dreamliner since the grounding ended, they have said that deliveries would re-start in early May.  It may re-start by the end of this week though I do expect that ZA512 (LN 83, JA818A) should be delivered sometime next week after customer test flights are conducted by ANA pilots.

I expect that in the next 8 weeks, Boeing should be able to deliver 787s to Air India, JAL, ANA, Qatar Airways, ILFC (for Norwegian), LOT Polish Airlines, Hainan, Thomson Airways, and China Southern.  Thus far, 787s for Hainan, Air India, ANA, Thomson, LOT Polish, and JAL have entered production test flights with the revised lithium ion battery set up and there is a pattern.

Boeing is conducting test flights roughly in order that each aircraft emerged from final assembly.  There have been exceptions most notably a Hainan airframe which does not have any engines and a couple for LOT which are expected to be delivered later in the year.  If the current pattern holds then I expect that from Everett the following will be making their first flights in this order:

ZA383 - China Southern
ZA318 - TUI
ZA319 - TUI
ZA513 - ANA
ZA185 - JAL
ZA465 - Qatar

From Charleston these aircraft will be making their first flights in this order:

ZA434 - Hainan
ZA243 - Air India
ZA384 - China Southern
ZA385 - China Southern

I estimate that Boeing can deliver between 12 to 14 787s by the end of the second quarter including a few to Chinese carriers who are expecting that the 787 will be finally given its airworthiness certificate by Chinese authorities next month.

Prior to the grounding it took Boeing about 6 weeks after rolling out a 787 to the flightline to conduct all the necessary company and customer tests, finalize paperwork and make final delivery.  I see no reason why that would change now, though some aircraft that have already had quite a few test flights done prior to the grounding won't take that long since much of the flight testing is already completed.

Flight testing will continue to pick up pretty aggressively over the next few weeks as Boeing needs to work down the inventory of 37 787s that have built up over the last few weeks.

 

More progress on the 787 return to flight

As the 8 airlines get closer to resuming their 787 service I've updated the list below since new information has been coming out:

ANA - early June (after completing test flights and pilot training)
Air India - around mid May
Ethiopian - April 27
JAL - early June (after completing test flights and pilot training)
LAN - unknown
LOT Polish Airlines - June 5
Qatar Airways - end of April
United Airlines - May 31st but may be able to restart earlier

Today the amended Airworthiness Directive was posted in the Federal Register thus making the FAA's certification of the battery fix official.  Any US registered 787 can now fly with the battery fix. Already Japan and Europe has followed the FAA's lead on this as has approved of Boeing's fix though I also expect that India, Ethiopia, Chile and Qatar will all follow suit fairly quickly.  The first set of 787s should be completed by now.  LOT Polish Airlines is (or already has) ferrying its 787 stranded in Chicago to Addis Ababa where a Boeing team is there to install the battery fix on the 4 aircraft belonging to Ethiopian.  Word is that LOT's second aircraft, which is currently in Warsaw, will also be flown to Ethiopia for the fix.  Qatar 787 that was stranded at London Heathrow was ferried back to Doha for the fix and one United jet at LA was ferried to San Antonio, Tx. for the repairs.

Given Japan's approval of Boeing's fix, ANA announced that starting this Sunday, May 28th, their 787s will fly about 230 test flights in order to re-train their team of 787 pilots as well as reassure their passengers that the airplane is safe to fly one.  They plan on resuming regular passenger service in June.  ANA is also looking to see a resumption of 787 deliveries with ZA512 (LN 82, JA818A) being the first 787 to be delivered since the grounding in January. It can be delivered as early as late next week but ANA pilots still have to fly the customer flights on this airplane. 

Outside of this one pending delivery, I can see LOT Polish, Air India, JAL and even China Southern and Hainan taking deliveries in May. In June we can see deliveries to Thomson, Qatar, JAL, ANA and ILFC being made.  I do expect that Boeing will now be aggressive in their production flight test program as they need to clear the inventory sitting at Everett and Charleston.

Lastly, a reader sent me this link to a video from the BBC detailing the 787 battery fix work that is going on in Ethiopia.

 

FAA give it's blessing to Boeing's 787 fix

The FAA, as expected, approved Boeing's plan to retrofit the 787s with new batteries and a new containment system to eliminate the risk of fire and electrolyte spills in the two E/E bays. Very importantly the 787 doesn't loss its ETOPs 180 certification meaning they can fly as much as 3 hours from a divert airport.  I do believe that Boeing will still pursue the ETOPS 330 certification but the FAA will make them jump through hoops for that which they will do. While the AOG (aircraft on Ground) teams from Boeing are in position, Boeing still needs to ship the kits to the locations where each aircraft is while GS Yuasa will be shipping out the new batteries to those same locations as well.

Now that the FAA has given approval the next step is for Boeing's AOG teams along with airline maintenance personnel to start preliminary work on the aircraft until they get the first kits and replacement batteries.  They will in stall them at which point it's up to the each country's aviation regulators to sign off on the modification and lift the grounding on the 787 based in that country.  The FAA says they will send out instructions to the operators detailing the fix and then publish the final airworthiness directive in the Federal Register making the approval official.  It is after that that any US-based airlines with the 787 whose aircraft has been modified under the directive will be allowed to resume revenue service of the 787.  This would apply to United Airlines as it is currently the only US operator of the aircraft but typically foreign aviation regulators follow suit.  One exception though maybe Japan's JCAB.  They may require more stringent oversight of the lithium ion batteries including more frequent visual inspections and more detailed monitoring of the voltage in each battery.

The timeline to get these airplanes flying again doesn't end with the regulators tamp of approval for each of the airlines. The carriers must engage in flight training as well as scheduling the resumption of service and, of course, sell tickets for those flights.  Some carriers may re-substitute the 787 in place of the aircraft type currently flying certain routes while other will re-start routes like the Tokyo-Boston route serviced by JAL when the fire broke out at Logan.  Routes that were temporarily suspended will likely take longer to get back on line but I see that happening by June. Still I do believe that Boeing will be able to complete work on all 50 aircraft in about 6 weeks. Each AG team has about 30 members (this jives with what I reported in an earlier post with a team in Ethiopia).  There are 10 teams that are deployed though for certain there must be several teams in Japan as well as one in Qatar and Ethiopia.  The 787s that have to be modified are in 9 different countries including the United states so it would be reasonable to assume that there are 2 teams in Japan as there are 23 787s on the ground in that country that need the modification.  I anticipate that one team each will be sent to Chile, Germany, the UK, Qatar, India, Ethiopia, Poland, and one will be in the US.

So when can flights resume? Well Ethiopian has been vocal about resuming flights next week which is possible just as long as the fix is in place and that the Ethiopian aviation regulators sign off.  Qatar Airways is also eyeing restarting revenue flights by the end of April.  I don't expect JAL and ANA to start flying until mid May at the earliest.  United is currently evaluating when they can restart their service.

Deliveries are also the minds of 787 watchers.  Boeing is concurrently modifying the 787s at Everett and Charleston.  So far as I know there are three airplanes that have the battery fix:

ZA272 (LN 86, SP-LRC) for Polish LOT
ZA512 (LN 83, JA818A) for ANA
ZA380 (LN 34, B-2725) for China Southern

The later was supposed to make its first flight today but it didn't come to pass and may fly tomorrow.  One thing Boeing made clear is that they do intend to still deliver 60+ 787s this year per their guidance but they also said that production flight testing will have to be aggressively ramped up. I still believe that Boeing will have to deliver on average of 8 787s per month in order to meet heir guidance. They have to clear the current ready to deliver backlog of 34 aircraft (doesn't include any 787s that will be added to this pile in the next few months) thus they would probably clear this backlog over the next 5 to 6 months.  What is uncertain is which aircraft (other than the aforementioned three aircraft) will be delivered first.  We do know that 31 787s between Everett and Charleston will need to be modified first but I don't know which one have already been modified or of the order in which they'll be modified.  We'll only know when these airplanes take to the sly for their first flight.

When everything is all said and done, it does look like that Boeing's gamble to keep up with the current full rate production of 5/month will pay off...just as long as they can deliver the backlog sitting in Washington and South Carolina.

Here's the FAA Press Release announcing the approval:

FAA Approves Boeing 787 Battery System Design Changes

For Immediate Release
April 19, 2013
Contact: Laura Brown
Phone: (202) 267-3883

---

WASHINGTON, D.C. – The Federal Aviation Administration (FAA) today took the next step in returning the Boeing 787 to flight by approving Boeing's design for modifications to the 787 battery system. The changes are designed to address risks at the battery cell level, the battery level and the aircraft level.
Next week, the FAA will issue instructions to operators for making changes to the aircraft and will publish in the Federal Register the final directive that will allow the 787 to return to service with the battery system modifications. The directive will take effect upon publication. The FAA will require airlines that operate the 787 to install containment and venting systems for the main and auxiliary system batteries, and to replace the batteries and their chargers with modified components.
“Safety of the traveling public is our number one priority. These changes to the 787 battery will ensure the safety of the aircraft and its passengers,” said Transportation Secretary Ray LaHood.
“A team of FAA certification specialists observed rigorous tests we required Boeing to perform and devoted weeks to reviewing detailed analysis of the design changes to reach this decision,” said FAA Administrator Michael Huerta.
To assure proper installation of the new design, the FAA will closely monitor modifications of the aircraft in the U.S. fleet. The FAA will stage teams of inspectors at the modification locations. Any return to service of the modified 787 will only take place after the FAA accepts the work.
As the certifying authority, the FAA will continue to support other authorities around the world as they finalize their own acceptance procedures.

Next here is Boeing's Press Release:

Boeing to Begin Modifying 787s as FAA Approves Battery Improvements

- Modifications to existing fleets to begin; deliveries to resume soon

- Boeing to provide customers support for return to service

EVERETT, Wash., April 19, 2013 /PRNewswire/ -- Today's approval of battery system improvements for the 787 Dreamliner by the U.S. Federal Aviation Administration (FAA) clears the way for Boeing (NYSE: BA) and its customers to install the approved modifications and will lead to a return to service and resumption of new production deliveries.
"FAA approval clears the way for us and the airlines to begin the process of returning the 787 to flight with continued confidence in the safety and reliability of this game-changing new airplane," said Boeing Chairman, President and CEO Jim McNerney. "The promise of the 787 and the benefits it provides to airlines and their passengers remain fully intact as we take this important step forward with our customers and program partners."
The FAA's action will permit the return to service of 787s in the United States upon installation of the improvements. For 787s based and modified outside the United States, local regulatory authorities provide the final approval on return to service.
Approval of the improved 787 battery system was granted by the FAA after the agency conducted an extensive review of certification tests.  The tests were designed to validate that individual components of the battery, as well as its integration with the charging system and a new enclosure, all performed as expected during normal operation and under failure conditions. Testing was conducted under the supervision of the FAA over a month-long period beginning in early March.
"The FAA set a high bar for our team and our solution," said McNerney. "We appreciate the diligence, expertise and professionalism of the FAA's technical team and the leadership of FAA Administrator Michael Huerta and Secretary of Transportation Ray LaHood throughout this process.  Our shared commitment with global regulators and our customers to safe, efficient and reliable airplanes has helped make air travel the safest form of transportation in the world today."
Boeing, in collaboration with its supplier partners and in support of the investigations of the National Transportation Safety Board and the Japan Transport Safety Board, conducted extensive engineering analysis and testing to develop a thorough understanding of the factors that could have caused the 787's batteries to fail and overheat in two incidents last January.  The team spent more than 100,000 hours developing test plans, building test rigs, conducting tests and analyzing the results to ensure the proposed solutions met all requirements.
"Our team has worked tirelessly to develop a comprehensive solution that fully satisfies the FAA and its global counterparts, our customers and our own high standards for safety and reliability," said Boeing Commercial Airplanes President and CEO Ray Conner. "Through the skill and dedication of the Boeing team and our partners, we achieved that objective and made a great airplane even better."
Boeing also engaged a team of more than a dozen battery experts from across multiple industries, government, academia and consumer safety to review and validate the company's assumptions, findings, proposed solution and test plan.
The improved battery system includes design changes to both prevent and isolate a fault should it occur. In addition, improved production, operating and testing processes have been implemented. The new steel enclosure system is designed to keep any level of battery overheating from affecting the airplane or even being noticed by passengers.
"This is a comprehensive and permanent solution with multiple layers of protection," said Conner.  "The ultimate layer of protection is the new enclosure, which will ensure that even if a battery fails, there is no impact to the airplane and no possibility of fire. We have the right solution in hand, and we are ready to go.
"We are all very grateful to our customers for their patience during the past several months," said Conner. "We know it hasn't been easy on them to have their 787s out of service and their deliveries delayed. We look forward to helping them get back into service as quickly as possible."
Boeing has deployed teams to locations around the world to begin installing improved battery systems on 787s. Kits with the parts needed for the new battery systems are staged for shipment and new batteries also will be shipped immediately. Teams have been assigned to customer locations to install the new systems.  Airplanes will be modified in approximately the order they were delivered.
"The Boeing team is ready to help get our customers' 787s back in the air where they belong," said Conner.
Boeing will also begin installing the changes on new airplanes at the company's two 787 final-assembly plants, with deliveries expected to resume in the weeks ahead. Despite the disruption in deliveries that began in January, Boeing expects to complete all planned 2013 deliveries by the end of the year. Boeing further expects that the 787 battery issue will have no significant impact to its 2013 financial guidance.

 

BREAKING: Boeing confirms resuming 787 production test flights

Boeing confirmed to me that they are resuming standard Boeing production flight testing under the approval of the FAA.  The production flights will be normal Boeing flights meant to validate the aircraft's systems.  There are no restrictions that the FAA has placed on these aircraft.  All airplanes that are to be production tested will have the new batteries and the containment system installed.  ZA512 (LN 83, JA818A) for ANA was the first aircraft to fly today and fly with the new battery and containment system on a functional check flight.

We should see more and more 787s parked in Everett and Charleston to start conducting their standard B-1, B-2 and C-1, C-2 flights but these airplanes won't be delivered until the FAA has certified the batteries and the containment system for commercial use.

Japan Airlines 787 suffers fire in aft electrical bay

The most recently delivered 787 to Japan Airlines (ZA183, L/N 84, JA829J delivered on Dec. 20, 2012) suffered a small but intense fire in the aircraft's aft electrical bay less than a half an hour after landing at Boston's Logan International Airport. The aircraft had its first flight on Dec. 7, 2012 and conducted 3 test flights after completing final assembly in Everett. The passengers and crew had already deplaned by the time a maintenance worker smelled smoke in the cabin. Mass port and Boston FD responded to the fire to find smoke in the bay and had the fire under control a short time later.

Initial reports indicate that a battery exploded but it unclear if that happened because of the fire or was the cause of the fire. The NTSB has dispatched a team of investigators to Boston to determine the cause. Reports also indicate that there was a minor injury to one firefighter. Jon Ostrower reports in the Wall Street Journal that the fire may have been exacerbated by damage to the LiON battery by a fire ax.

The aft electrical bay has been a source of problems for the 787 since a fire on ZA002 a little over two years ago forced an emergency landing in Laredo, Tx and set back deliveries by 6 months. In the last few months, there has been an increasing number of in service 787s experiencing electrical issues, some in the aft electrical bay. The airlines that have reported electrical issues include United, Air India, Qatar and LAN. Today's fire is by far the most serious of the problems. One cannot ascribe these issues to teething problems as it now seems that the problems may be far more serious than initially thought but hat determination must await the NTSB report.

It is unclear what affect this fire will have on production, testing and delivery of new 787s from Everett and Charleston though ZA512 for ANA did fly not 1 but 2 test flights today well after the fire had occurred. I do suspect Boeing will continue production and testing while the investigation is on going unless the FAA orders a grounding.

Projected 787 Delivery Dates for December; AMR in a position to finalize their 787-9 order?

With many of the 787s that are in pre-delivery having gone through their first (B-1) flights. I am going to take a moment and speculate on delivery dates for these airplanes.  These are my own assumptions assuming that these aircraft will have to fly the minimal number of acceptance flights.  For now I'm assuming that these planes will deliver between 21 and 24 days after each B-1 flight though there are exceptions (as in Air India, Chinese carriers, and LOT).  This also assumes that there aren't any issues that would need to be corrected and re-tested in subsequent test flights prior to delivery.

Here's my projected delivery dates for this month:

ZA289 (LN 55, N45905) United Airlines - 12/12/12 - 12/15/12
ZA462 (LN 62, A7-BCK) Qatar Airways - 12/15/12 - 12/18/12
ZA464 (LN 82, A7-BCC) Qatar Airways - 12/24/12 - 12/27/12
ZA510 (LN 59, JA817A) ANA - 12/26/12 - 12/29/12
ZA512 (LN 83, JA818A) ANA - 12/27/12 - 12/30/12
ZA287 (LN 52, N27903) United Airlines - 12/28/12 - 12/31/12
ZA183 (LN 84, JA829J) JAL - 12/28/12 - 12/31/12

Again this is my own speculation but it's based on previous and recent deliveries of the 787.  These dates are always in flux and can change easily so I trust the reader will not hold me responsible if all the actual delivery dates turn out to be something totally different. 

Lastly, these numbers could change as Boeing can deliver 787s to Air India (2), China Southern (1) and even LOT Polish (1).  Boeing is making a huge effort to try and delivery these aircraft within the next 24 days and the way we can accurately tell is the flight activity of each of these airplanes over the next 2-3 weeks.

Lastly, the pilots union at American Airlines has ratified the new labor agreement with AMR today. This could be significant for 787-9 order that AA intends to finalize with Boeing as the order is dependent on AMR agreeing to a new contract with their pilots.  Now this was all before AMR entered Chapter 11 so the bankruptcy judge and AMR's creditors may have something to say about this order and whether it can proceed.  Additionally, a report emerged this evening that US Airways had submitted a bid for American in November.  What effect an AMR-US Airways merger would have on the MoU for the 42 787-9 American intends to finalize is unclear though US Airways does have an outstanding order for 18 A350-800 and 4 A350-900 by Airbus.  Boeing can deliver the 787-9 to American starting in 2014 (theoretically) which is much earlier than US Airways can get either variant of the A350 that they have ordered.  Also a combined company may be opened to operating a mixed Boeing-Airbus fleet as with Delta/Northwest and United/Continental.  A US Airways/American tie up would retain the American name.

Boeing conducts 6 new 787 first flights in one week.

UPDATE (6:38PM): Looks like Boeing has delivered LAN's 3rd 787 today.  Flightware shows a 787 delivery flight leaving Everett at 5:10PM local time for Santiago, Chile.

Boeing is quickening the pace of flying production 787s on their first flight.  Starting on Dec. 1, Boeing has sent up 6 different 787s for their first flight, otherwise known as the B-1 flight.  It appears that Boeing is aggressively trying to ramp up deliveries of these airplanes before the end of the year.  In addition to these 6 airplanes making their first flight, several others have had follow on test flights either by Boeing or customer pilots on several other 787s.

The planes that flew were as follows:

12/1/12
ZA271 (LN 78, SP-LRB) for LOT Polish Airlines

12/3/12
ZA464 (LN 82, A7-BCC) for Qatar Airways

12/4/12
ZA510 (LN 59, JA817J) for ANA

12/6/12
ZA512 (LN 83, JA818A) for ANA

12/7/12
ZA287 (LN 52, N27903) for United Airlines
ZA183 (LN 84, JA829J) for Japan Airlines

Obviously not all of these will be delivered this month, most notably ZA271 but I do still believe Boeing can deliver 8 787s this month possibly going to 10 if Air India sorts out its financial mess.

Given this pace, I can see Boeing delivering a couple airplanes next week but the bulk of deliveries should come around the week of December 17th.  The plan would be for Boeing to fly more test flights next week in preparation for delivery the following week (week of Dec. 17th). Boeing will be mostly closed during the week of Christmas but not fully shut down so we can certainly still see a couple of deliveries during the week of Dec. 24th depending on customer availability and needs.

I have made changes to the notes of some of the airplanes in the table.  Notably I am tracking the number of tests flights that each airplane takes during pre-delivery. After delivery I note which order it was delivered to that particular customer (i.e. ANA #1 meaning the first airplane delivered to ANA, etc.).

Updated 787 Production - 7/5/2012

The 787 production and disposition list has been updated to reflect the firing order for airplanes 81 to 90.  This lot of aircraft should be in production through mid-October 2012.  There are no new customers on the list but LOT Polish Airlines will receive its 3rd, 4th and 5th 787s from a total order of 8.  All these aircraft should be delivered, assuming no issues with production or the aircraft, by the end of this year.  The airlines that are to get aircraft from this lot of 10 are Hainan (2), ANA, JAL (2), LOT Polish (3), Qatar, and Air India.  Airplane 90 also marks a start of the block point of 787s where Boeing is to get the 787-8 down to the promised contractual weight when the program was launched in 2004.  The airline that will receive the first aircraft in this block point is Air India, surprisingly.  Please note that this firing order can change between know and the time that these airplanes start final assembly perhaps even after they've been rolled out of the final assembly hall.