Par 3-9 Page 17 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.
b. 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 must have procedures in place that ensure maintenance record entries for complying with a CDCCL are consistent with §§ 43.9 and 43.11, or in accordance with the applicable provisions of part 121 or part 129 and the operators’ manual.
c. 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.
(Refer to subparagraphs 3-4 b, c, d, and e for further guidance on this subject.)
d. 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.
e. 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 §§ 121.1113 AND 129.113. Parts 121 and 129 operator will be issued OpSpec D097, Aging Aircraft Programs, to implement FTS requirements. The operators must submit its fuel tank system maintenance program changes that include ICA (inspections, procedures and limitations) to the PI, who will review and approve operator incorporation with OpSpec D097. Operator-proposed changes must be submitted to the PI for review and approval. Any changes to the operators’ FAA Oversight Office-approved ICA will be handled as stated in this AC.
3-12. OPERATOR’S INSPECTION PROGRAM APPROVAL UNDER § 125.507. Part 125 operators will be issued Letter of Authorization (LOA) Aging Aircraft Programs to implement FTS requirements. The operator must submit its fuel tank system inspection program changes that include ICA (inspections, procedures and limitations) to the PI, who will review and approve operator incorporation with the LOA. Operator-proposed changes must be submitted to the PI for review and approval. Any changes to the operators’ FAA Oversight Office-approved ICA will be handled as stated in this AC.
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3-13. OPERATOR INSPECTION PROGRAM APPROVAL UNDER § 91.1507. Part 91 and part 91K operators will be issued LOA/Management Specification (MSpec) MD097, Aging Aircraft Programs, to implement FTS requirements. The operator must submit its fuel tank system inspection program changes that include ICA (inspections, procedures and limitations) to the PI, who will review and approve operator incorporation with LOA/ MSpec MD097.
Operator-proposed changes must be submitted to the PI for review and approval. Any changes to the FAA Oversight Office-approved ICA will be handled as stated in this AC.
a. PI Action.The PI will approve incorporation into the maintenance/inspection program by issuing OpSpec/MSpec D097. The free text area of the OpSpec/MSpec D097 is used to:
• Identify and record the document(s)— by document number, revision number, and date—used as the source of the FAA Oversight Office-approved EWIS/FTS ICA, or
• If this information is contained in the operator’s manual system, a reference to that location in their manual system can be recorded in the free text area.
b. Operator Action. The operator must have procedures in its manual that track any changes and approvals made to the FAA Oversight Office-approved EWIS/FTS ICA.
Appendix 1 6B6BAPPENDIX 1. ACRONYMS 14 CFR Title 14 of the Code of Federal Regulations AC Advisory Circular ACO Aircraft Certification Office AD Airworthiness Directive AEG Aircraft Evaluation Group AFS Flight Standards Service 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 ATA Air Transport Association of America 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 EAPAS Enhanced Airworthiness Program for Airplane Systems EWIS Electrical Wiring Interconnection System EZAP Enhanced Zonal Analysis Procedure ESPM Electrical Standard Practices Manual FAA Federal Aviation Administration FEC Failure Effects Category FQIS Fuel Quantity Indicating System FR Federal Register FSU Fuel System Unit FTS Fuel Tank Safety HQ Headquarters IBR Incorporated by Reference ICA Instructions for Continued Airworthiness LOA Letter of Authorization 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 MWG Maintenance Working Group NAA National Aviation Authority NTSB National Transportation Safety Board OEM Original Equipment Manufacturer OpSpec Operations Specification PI Principal Inspector RGL Regulatory and Guidance Library
Appendix 1 RII Required Inspection Items SFAR Special Federal Aviation Regulation STC Supplemental Type Certificate SWPM Standard Wring Practice Manual TC Type Certificate TSO Technical Standard Order TWA Trans World Airlines VTO Volumeric Top-off WDM Wiring Diagram Manual
Appendix 2 Page 1 (and 2) 7B7BAPPENDIX 2. LIST OF APPLICABLE SUPPLEMENTAL TYPE CERTIFICATES 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) part 91, § 91.1507; part 121, § 121.1113; part 125, § 125.507; and part 129, § 129.113. Other STCs may be addressed via Airworthiness Directives (AD).
Appendix 3 3B3BAPPENDIX 3. DEFINITIONS
a. Aircraft Evaluation Group (AEG). AFS 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 the 14 CFR. This function includes providing the cognizant ACO support in the review and approval of the initial and subsequent changes to the type design.
b. 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. Airworthy. An aircraft, aircraft engine, or component that conforms to its type design and is safe to operate.
d. 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 part 25, § 25.981 for the fuel tank system.”
e. 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.
f. 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.
g. Airworthiness Limitations Section (ALS). “Airworthiness Limitations” is the title required by 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.”
h. 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.
i. AMOC. Alternative method of compliance.
j. Component Maintenance Manual (CMM). A manual developed by a manufacturer that contains information necessary for the continued airworthiness of a particular component.
Appendix 3
k. CMM Deviation.
(1) Term used for approval of changes to CMMs that are the subject of CDCCLs adopted by a type design change.
(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 FAA Oversight Office.
l. 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.
m. Critical Design Configuration Control Limitation (CDCCL). A CDCCL is an airworthiness limitation required by §§ 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.
n. Design Approval Holder (DAH). The holder of any design approval, including TC, amended TC, STC, amended STC, parts manufacturer approval, TSO authorization, letter of TSO design approval, and field approvals (refer to FAA Form 337).
o. 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.
p. Electrical Arc or Spark. The transfer of electrons across a gap.
q. Enhanced Zonal Analysis Procedure (EZAP). An analytical process for developing maintenance and inspection instructions for the EWIS.
r. 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.
s. FAA Oversight Office. The ACO or the office of the Transport Airplane Directorate having oversight responsibility for the relevant TC or STC as determined by the Administrator.
(Refer to Appendix 4 FAA Oversight Offices by Airplane Manufacturer, for a list of FAA Oversight Offices for certain transport airplane TC holders.)
t. 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).
Appendix 3
u. 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.
(4) Category 8. Functional failures that have hidden function safety effects.
(5) Category 9. Functional failures that have hidden function non-safety effects.
v. Field Approval. A method for obtaining FAA approval of a design change to the airplane. An FAA Flight Standards inspector can approve the design change using FAA Form 337.
w. 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.
x. Flight Standards Service (AFS). Offices located in FAA headquarters (HQ) responsible for developing guidance and policy applicable to transport category airplanes for AEG personnel and AFS field personnel (maintenance, avionics, and Operations ASI in the conduct of their responsibilities.
y. Functional Failures. The failure of a component or subsystem to perform its intended function within specified limits.
z. Hidden Failure. A failure whose presence may not be readily apparent to the flightcrew or maintenance personnel.
aa. 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.
bb. 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.
Appendix 3 cc. Instructions for Continued Airworthiness (ICA). The information developed in accordance with applicable airworthiness requirements that include the applicable inspection tasks, intervals, methods, processes, procedures, and airworthiness limitations to keep the product airworthy throughout its operational life.
dd. 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.
ee. 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.
ff. Maintenance Review Board (MRB). An FAA group that supports industry development of the Maintenance Review Board Report (MRBR) and approves the final MRBR.
gg. 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.
hh. Maintenance Significant Item (MSI).
(1) Under MSG – 3rd Task Force (MSG-3), items other than ALI that are identified by the DAH whose failure could cause one of the following effects:
• It could affect safety on the ground or in flight,
• It could be undetectable during operations,
• It could have a significant impact on operations, or
• It could have a significant economic impact.
(2) In terms of development of maintenance and inspection instructions, MSIs include systems, subsystems, modules, components, accessories, units, or parts.
ii. Maintenance Steering Group-3 (MSG-3). A voluntary structured process developed by the industry and maintained by the ATA to make decisions used to develop maintenance and inspection tasks and intervals for an airplane.
jj. 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 3 Page 5 (and 6) kk. Mandatory Action Advisory Board. A committee composed of representatives from the cognizant FAA Oversight Office and the Transport Airplane Directorate 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.
ll. 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.
mm. Products. Products are certified aircraft, engines, propellers, and appliances.
nn. Supplemental Type Certificate 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 § 25.981 and part 25 appendix H, and be approved by the FAA Oversight Office.
oo. Type Certificate Holder ICA. The TC holder ICA consists of the inspection tasks, intervals, methods, processes, 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 § 25.981 and part 25 appendix H, and be approved by the FAA Oversight Office.