3- 9 individual airplane. Under the procedures in the ALS, repeated use on the same airplane or on similar airplanes in the operator’s fleet is not allowed.
3.8.3 Airworthiness Limitation Extension Requests. The extension request must be submitted to the PI, who will forward the request along with comments to the responsible Aircraft Certification Service office for approval. Any such request must include substantiating data. After Aircraft Certification Service Office approval, the operator will submit to the PI for review the revisions to their maintenance and inspection program incorporating the Aircraft Certification Service office-approved extension. (For the purposes of the FTS requirements and this AC, short-term escalation procedures authorized by air carrier OpSpecs cannot be used for exceptional short-term extension of a fuel tank system airworthiness limitation.)
3.9 Changes in ICA Resulting from Alterations. The EAPAS/FTS Final Rule requires that after December 16, 2008, before returning an aircraft to service after any alteration for which fuel tank ICA are developed under SFAR 88, or 14 CFR § 25.1529 and part 25 appendix H (effective June 6, 2001), the operator must incorporate the fuel tank ICA into its maintenance or inspection program.
3.9.1 Major Alterations. The only alterations for which fuel tank system ICA will be developed are those for which compliance with either SFAR 88 or 14 CFR § 25.1529 must be shown. These are major alterations approved under STCs or amended TCs.
3.9.2 Scheduled Maintenance Visit/Check. These alterations would normally be scheduled by an operator to occur during a period of allocated downtime such as a scheduled maintenance visit/check. Operators should include in their maintenance planning for such modification actions necessary to incorporate fuel tank ICA into their maintenance or inspection program.
3.10 Fuel Tank System Ignition Prevention Training. The EAPAS/FTS introduced new requirements that affect DAH and operators.
3.10.1 New Philosophical Approach. To fully realize the objectives of fuel tank system ignition prevention, the operators need to rethink their current philosophical approach to maintaining, inspecting, and altering aircraft wiring and systems that could affect the fuel tank system ignition prevention features. This approach has begun at the airplane manufacturers with maintenance program enhancements that address fuel tank system ignition prevention. It is incumbent that the operators include these DAH fuel tank system maintenance program enhancements into their respective programs. Furthermore, they should commit to training their maintenance and inspection work force to understand the new philosophical approach to fuel tank system ignition prevention.
3.10.2 New Procedures. In addition to CDCCLs, there will be new maintenance manual and job card procedures, inspection devices, graphical information showing required tasks, or changes in tasks such as wire splicing. Operators should provide training to maintenance, inspection, and engineering personnel, including persons who write and edit job cards and EOs. Heightened awareness of these critical areas is needed. Additionally, operators
3- 10 must have procedures in place that ensure maintenance record entries for complying with a CDCCL are consistent with 14 CFR §§ 43.9 and 43.11, or in accordance with the applicable provisions of 14 CFR part 121 or part 129 and the operators’ manual.
3.10.3 Operator Training Program. The operator training program should emphasize the importance of accomplishing the fuel tank system airworthiness limitations, CDCCLs, inspections, and other procedures while accomplishing scheduled and unscheduled maintenance. (See paragraphs 3.4.2–3.4.5 for further guidance on this subject.)
3.10.4 Critical Design Features. Maintenance and engineering personnel can ensure that the fuel tank system airworthiness limitations are properly performed throughout the operational life of the airplane by having a thorough understanding of the airplane fuel tank system critical design features.
3.10.5 Manufacturer-Developed Training Programs. Operators should take advantage of any airplane manufacturer-developed training programs that address fuel tank ignition prevention.
3.11 Operator’s Maintenance Program Approval Under 14 CFR §§ 121.1113 and 129.113. OpSpec D097, Aging Aircraft Programs, signifies the FAA has reviewed the certificate holder’s (CH) policies and procedures incorporated into their maintenance and/or inspection programs for compliance with the Aging Aircraft Program rules. The operator will submit to the PI for review the revisions to their maintenance and inspection program incorporating the Aircraft Certification Service office-approved ICA changes.
The PI will ensure the operator has incorporated FTS ICA and any subsequent revisions in their maintenance and inspection programs. When the review is complete, the PI will issue or amend OpSpec D097.
3.12 Operator’s Inspection Program Approval Under 14 CFR § 125.507. Certificated 14 CFR part 125 operators will be issued OpSpec D097 and A125 Letter of Deviation Authority (LODA) holders will be issued Letter of Authorization (LOA) D097, which signifies the FAA has reviewed the CH’s policies and procedures incorporated into their maintenance and/or inspection programs for compliance with the Aging Aircraft Program rules. The operator will submit to the PI for review the revisions to their maintenance and inspection program incorporating the Aircraft Certification Service office-approved ICA.
The PI will ensure the operator has incorporated FTS ICA and any subsequent revisions into their maintenance and/or inspection programs. When the review is complete, the PI will issue or amend OpSpec D097 or A125 LOA D097.
3.13 Operator Inspection Program Approval Under 14 CFR § 91.1507. Title 14 CFR part 91 and part 91K operators will be issued LOA/MSpec D097, which signifies the FAA has reviewed the operator’s policies and procedures incorporated into their maintenance and/or inspection programs for compliance with the Aging Aircraft Program rules. The operator will submit to the PI for review the revisions to their maintenance and inspection program incorporating the Aircraft Certification Service office-approved ICA.
The PI will ensure the operator has incorporated FTS ICA and any subsequent revisions
3-11 into their maintenance and/or inspection programs. When the review is complete, the PI will issue or amend LOA/MSpec D097.
3.14 Operators that are Authorized OPSPEC/MSPEC/LOA D097. The issuance of this OpSpec signifies the FAA has reviewed the operator/CH/program manager’s policy and procedures incorporated into their maintenance and/or inspection programs for compliance with the Aging Aircraft Program rules. Table 1 of D097 will consist of three columns that list:
• The Aging Aircraft Program rules;
• The manual and section where the policy and procedures are located for the applicable Aging Aircraft Program; and
• The date of the manual and section where the current policy and procedures are located for the applicable Aging Aircraft Program.
Note: Table 3-3 below illustrates a sample D097 Table 1 that lists the various 14 CFR part rules. The operator/CH/program manager will have a specific OpSpec D097 template for their operation.
Table 3-3. Sample D097 Table 1–Aging Aircraft Maintenance Programs Aging Aircraft Program Rules Operator/CH/Program Manager’s Maintenance and/or Inspection Program Procedures (Manual and Section) Date Repairs Assessment for Pressurized Fuselages — § 91.1505, § 121.1107, § 125.505, § 129.107 Supplemental Inspections — § 121.1109, § 129.109 Electrical Wiring Interconnection Systems (EWIS) Maintenance Program — § 121.1111, § 129.111 Fuel Tank System Maintenance Program — § 121.1113, § 129.113 Flammability Reduction Means — § 121.1117, § 125.509, § 129.117 Fuel Tank System Inspection Program — § 91.1507, § 125.507
3.14.1 Submission to PI for Review. Initial submission and any subsequent revisions to these policy and procedures sections must be submitted to the PI for review for compliance with the Aging Aircraft Program rules.
3.14.2 Aircraft Certification Service Office-Approved ICAs. Any proposed revisions or deletions of Aircraft Certification Service office-approved ICAs must be coordinated
3-12 with the PI for review and concurrence. The PI will then forward the proposed revisions or deletions to the responsible Aircraft Certification Service office for approval prior to implementation or incorporation into the maintenance and/or inspection program.
3.14.3 Operator Action. An operator must have procedures to ensure that ICAs are incorporated into their maintenance and/or inspection program.
Appendix A A-1 APPENDIX A. ACRONYMS 14 CFR Title 14 of the Code of Federal Regulations A4A Airlines for America AC Advisory Circular AD Airworthiness Directive AED Aircraft Evaluation Division ALI Airworthiness Limitation Item ALS Airworthiness Limitation Section AMC Acceptable Means of Compliance AMM Aircraft Maintenance Manual AMOC Alternative Method of Compliance ASI Aviation Safety Inspector CAMP Continuous Airworthiness Maintenance Program CDCCL Critical Design Configuration Control Limitations CMM Component Maintenance Manual CWT Center Wing Fuel Tank DAH Design Approval Holder DOT Department of Transportation DRS Dynamic Regulatory System EAPAS Enhanced Airworthiness Program for Airplane Systems EO Engineering Order EWIS Electrical Wiring Interconnection System EZAP Enhanced Zonal Analysis Procedure ESPM Electrical Standard Practices Manual FAA Federal Aviation Administration FEC Failure Effect Category FLSS Fuel Level Sensor System FQIS Fuel Quantity Indicating System FR Federal Register FS Flight Standards FSU Fuel System Unit FTS Fuel Tank Safety GFI Ground Fault Interrupter IBR Incorporated by Reference ICA Instructions for Continued Airworthiness LOA Letter of Authorization
Appendix A A-2 LODA Letter of Deviation Authority MPD Maintenance Planning Data MRB Maintenance Review Board MRBR Maintenance Review Board Report MSG Maintenance Steering Group MSI Maintenance Significant Items MSpec Management Specification MWG Maintenance Working Group NAA National Aviation Authority NTSB National Transportation Safety Board OEM Original Equipment Manufacturer OpSpec Operations Specification PI Principal Inspector PMA Parts Manufacturer Approval RII Required Inspection Item SFAR Special Federal Aviation Regulation STC Supplemental Type Certificate SWPM Standard Wiring Practice Manual TC Type Certificate TSO Technical Standard Order TWA Trans World Airlines VTO Volumeric Top-off WDM Wiring Diagram Manual
Appendix B B-1 APPENDIX B. LIST OF APPLICABLE SUPPLEMENTAL TYPE
CERTIFICATES (STC) Supplemental Type Certificate (STC) Number STC Holder Airplane Models Description Operator Actions ST00069BO Goodrich Corporation DC8-62, -62F, -63F, -72, -72F, -73F Fuel quantity indicating system (FQIS) (external to tank) STC amended January 5, 2004.
Operators must incorporate instructions for continued airworthiness (ICA) T3068-0005-01, Initial Issue, dated October 23, 2003 (or later version). (At “D” check interval, inspections of flight deck wiring and connectors.)
ST00020BO Goodrich Corporation B747-100, -100B, -100B SUD, -200B, -200C, -200F, -300, B747SP & B747SR Retrofit of entire Fuel Quantity Gauging System STC amended October 19, 2004.
Operators must incorporate ICA T3070-0005-0101, Initial issue, dated July 2, 2004 (or later version). (At D check interval, inspections of wiring separation, shielding, bonding.)
ST00142BO Goodrich Corporation B737-300 Isolation fuel quantity transmitter system STC amended February 10, 2004.
Operators must incorporate ICA T3072-0005-0101, Revision A, dated January 22, 2004 (or later version).
(Periodic inspections of wiring and bonding) SA298NE Goodrich Corporation B727-100, -200 Computerized FQIS STC amended April 19, 2004.
Operators must incorporate ICA T3066-0005-0101, Revision D, dated March 10, 2004 (or later version).
(Inspections to determine the condition of the wiring and connector interfaces every 16,000 flight hours.)
ST00053BO Goodrich Corporation B727, -100, -100C, -200, -200F, 727C FQIS indicators with Volumetric Top-off (VTO) and optional fuel system unit (FSU), In-tank harnesses.
STC amended April 19, 2004.
Operators must incorporate ICA T3065-0005-0101, Revision D, dated March 10, 2004 (or later version).
(Inspections to determine the condition of the wiring and connector interfaces every 16,000 flight hours) Note: These STCs have mandatory actions associated with them in accordance with Title 14 of the Code of Federal Regulations (14 CFR) §§ 91.1507, 121.1113,
125.507, and 129.113. Other STCs may be addressed via Airworthiness Directives (AD).
Appendix C C-1 APPENDIX C. DEFINITIONS C.1 Aircraft Certification Service (AIR). The office having oversight responsibility for the relevant TC or STC as determined by the Administrator. (See Appendix D, Aircraft Certification Service (AIR) Offices by Airplane Manufacturer, for a list of offices for certain transport airplane TC holders.)
C.2 Aircraft Evaluation Division (AED). FS representatives who know the operational and maintenance aspects of the certification project and are responsible for determining the operational acceptability and continuing airworthiness requirements of newly certified or modified aircraft, engines, and propellers intended to be operated under the provisions of 14 CFR. This function includes providing the cognizant Aircraft Certification Service office support in the review and approval of the initial and subsequent changes to the type design.
C.3 Aircraft Maintenance Manual (AMM). A manual developed by the manufacturer of a particular airplane that contains information necessary for the continued airworthiness of that airplane.
C.4 Airworthiness Limitation. Mandatory maintenance of the fuel system that includes CDCCL, inspections, or other procedures determined necessary to ensure that fuel tank ignition sources do not occur and are not introduced into the fuel system as a result of maintenance actions, repairs, or alterations throughout the operational life of the airplane.
C.5 Airworthiness Limitation Item (ALI). A term used by some DAH to group maintenance/inspection type fuel tank airworthiness limitations separately from CDCCL type fuel tank ALs.
C.6 Airworthiness Limitations Section (ALS). “Airworthiness Limitations” is the title required by 14 CFR part 25 appendix H, § H25.4(a) and (a)(2) for the section of the ICA that contains “each mandatory replacement time, inspection interval, related inspection procedure, and all critical design configuration control limitations approved under Sec. 25.981 for the fuel tank system.”
C.7 Airworthy. An aircraft, aircraft engine, or component that conforms to its type certificate and is in a condition for safe operation.
C.8 Auxiliary Tanks. Fuel tanks installed which make additional fuel available to increase the flight range of that airplane and are secondary to the airplane’s main fuel tanks.
Auxiliary tanks have been installed in various locations including center wing structure, horizontal stabilizers, wings, and cargo compartments.
C.9 AMOC. Alternative method of compliance.
C.10 CMM Deviation.
C.10.1 Term used for approval of changes to CMMs that are the subject of CDCCLs adopted by a type design change.
Appendix C C-2 C.10.2 Term used for the approval of changes to CMMs referenced in CDCCLs that are mandated by ADs, provided the CDCCL includes wording that allows use of “later approved” CMMs. Otherwise, approval is granted as an AMOC to the AD. As with AMOC approvals, a CMM deviation approval is by a letter from the responsible Aircraft Certification Service office.
C.10.3 Component Maintenance Manual (CMM). A manual developed by a manufacturer that contains information necessary for the continued airworthiness of a particular component.
C.11 Continued Airworthiness. Certified aircraft, engines, propellers, and appliances are safe to operate for the intended purpose; they are maintained safely throughout their service life; the product meets its type design; and is in a condition for safe operation.
C.12 Critical Design Configuration Control Limitation (CDCCL). A CDCCL is an airworthiness limitation required by 14 CFR §§ 25.981 and H25.4 that defines those parameters of the design that must be maintained to ensure that ignition sources will not develop within the fuel tank. CDCCLs include any information necessary to maintain those design features that have been determined by analysis of the fuel tank system as needed to preclude development of ignition sources. This information is essential to ensure that maintenance, repairs, or alterations do not unintentionally violate the integrity of the original type design of the fuel tank system.
C.13 Design Approval Holder (DAH). The holder of any design approval, including TC, amended TC, STC, amended STC, Parts Manufacturer Approval (PMA), Technical Standard Order (TSO) authorization, letter of TSO design approval, and field approvals (refer to FAA Form 337).
C.14 Exceptional Short-Term Extension. An increase in a fuel system ALI interval that may be used by the operator to cover an uncontrollable or unexpected situation where the ALI cannot be performed within the ALI timeframe.
C.15 Electrical Arc or Spark. The transfer of electrons across a gap.
C.16 Enhanced Zonal Analysis Procedure (EZAP). An analytical process for developing maintenance and inspection instructions for the EWIS.
C.17 Electrical Wiring Interconnection System (EWIS). Any wire, wiring device, or combination of these, including termination devices, installed in the airplane for transmitting electrical energy between two or more termination points.
C.18 Failure Effect Category (FEC).
1. Category 5. Functional failures that have evident safety effects.
2. Category 6. Functional failures that have evident operational effects.
3. Category 7. Functional failures that have evident economic effects.
Appendix C C-3
4. Category 8. Functional failures that have hidden function safety effects.
5. Category 9. Functional failures that have hidden function non- safety effects.
C.19 Field Approval. A method for obtaining FAA approval of a design change to the airplane. An FAA FS inspector can approve the design change using FAA Form 337.
C.20 Flammable. With respect to a fluid or gas, flammable means susceptible to igniting readily or to exploding (refer to 14 CFR Part 1, Definitions and Abbreviations).
C.21 Flammable Fluid Leakage Zones. Any area where flammable liquids or vapors are not intended to be present, but where they might exist due to leakage from flammable fluid carrying components (e.g., leakage from tanks, lines). Examples of these areas include:
• The wing leading (including any adjacent compartment such as the strut) and trailing edges;
• Fairings located below the fuel tanks;
• Wheel wells;
• Fuel pump enclosures;
• Unpressurized areas of the fuselage surrounding fuel tanks; and
• Areas containing flammable fluid lines or tanks.
C.22 Flight Standards(FS). Offices responsible for developing guidance and policy applicable to transport category airplanes for AEG personnel and FS field personnel (maintenance, avionics, and Operations ASI in the conduct of their responsibilities.
C.23 Fuel System Airworthiness Limitation. An airworthiness limitation that contains “each mandatory replacement time, inspection interval, related inspection procedure, and all CDCCL approved under 14 CFR § 25.981 for the fuel tank system.”
C.24 Functional Failures. The failure of a component or subsystem to perform its intended function within specified limits.
C.25 Hidden Failure. A failure whose presence may not be readily apparent to the flightcrew or maintenance personnel.
C.26 Hidden Functional Failure Safety Effect. A combination of a hidden (or latent) functional failure and one additional failure of a system-related or backup function that will have an adverse effect on operational safety.
C.27 Hot Short. Electrical energy introduced into equipment or systems as a result of unintended contact with a power source, such as bent pins in a connector or damaged insulation on adjacent wires.
C.28 Instructions for Continued Airworthiness (ICA). The information developed in accordance with applicable airworthiness requirements that include the applicable
Appendix C C-4 inspection tasks, intervals, methods, processes, procedures, and airworthiness limitations to keep the product Airworthy throughout its operational life.
C.29 Maintenance and Inspection Instructions. Information that provides, for each part of the airplane and its engine auxiliary power units, propellers, accessories, instruments, and equipment, the recommended periods at which they should be cleaned, inspected, adjusted, tested, lubricated, and the degree of inspection, the applicable wear tolerances, and work recommended at these periods needed to provide for the continued airworthiness of the airplane. The recommended overhaul periods and necessary cross-reference to the airworthiness ALS of the manual are also included.
C.30 Maintenance Planning Data (MPD). Data developed by the manufacturer of a particular airplane that contain the information each operator of that airplane needs to develop a customized, scheduled maintenance program.
C.31 Maintenance Review Board (MRB). An FAA group that supports industry development of the MRBR and approves the final MRBR.
C.32 Maintenance Review Board Report (MRBR). A report which contains the initial minimum scheduled maintenance and inspection requirements for a particular transport category airplane and on-wing engine program. Air carriers may use those provisions, along with other maintenance information contained in the ICA, in the development of their maintenance programs.
C.33 Maintenance Significant Items (MSI).
C.33.1 Under MSG-3, items other than ALI that are identified by the DAH whose failure could cause one of the following effects:
1. It could affect safety on the ground or in flight,
2. It could be undetectable during operations,
3. It could have a significant impact on operations, or
4. It could have a significant economic impact.
C.33.2 In terms of development of maintenance and inspection instructions, MSIs include systems, subsystems, modules, components, accessories, units, or parts.
C.34 Maintenance Steering Group - 3 (MSG-3). A voluntary structured process developed by the industry and maintained by Airlines for America (A4A) to make decisions used to develop maintenance and inspection tasks and intervals for an airplane.
C.35 Maintenance Working Group (MWG). A working group of maintenance specialists from participating operators, the prime manufacturer, and the regulatory authority whose function is to develop airplane maintenance programs. The MWG should have representatives knowledgeable about the fuel tank system under analysis and about the requirements of SFAR 88.
Appendix C C-5 C.36 Mandatory Action Advisory Board. A committee composed of representatives from the responsible Aircraft Certification Service office whose function was to review the findings from the SFAR 88 safety review for determination of an unsafe condition using the criteria in FAA policy memorandum 2003-112-15, SFAR 88—Mandatory Action Decision Criteria.
C.37 National Aviation Authority (NAA). The aviation authority responsible for the certification and continued airworthiness of those airplanes having a U.S. TC within its state of design as established in accordance with agreements with the United States.
C.38 Products. Products are certified aircraft, engines, propellers, and appliances.
C.39 Supplemental Type Certificate (STC) ICA. The STC holder ICA consists of the inspection tasks, intervals, methods, processes, and procedures to keep an alteration affecting the fuel tank system approved under an STC Airworthy throughout its operational life. The STC holder ICA must meet the requirements of SFAR 88 or 14 CFR § 25.981 and part 25 appendix H, and be approved by the responsible Aircraft Certification Service office.
C.40 Type Certificate (TC) Holder ICA. The TC holder ICA consists of the inspection tasks, intervals, methods, processes, and procedures to keep the product’s fuel tank system Airworthy throughout its operational life. It is typically the result of the MRB process.
During this process the TC holder develops MSIs and subjects them to maintenance program development logic, such as in MSG-3 or later revisions. The TC holder ICA must comply with the requirements of SFAR 88 or 14 CFR § 25.981 and part 25 appendix H, and be approved by the responsible Aircraft Certification Service office.