Maintenance Managers Conference 2015
Rich Bean 28 Years in Aviation 21 Years Active Duty Military E&E Technician QA Field Instructor Director, Operations
Session Time 1:30 pm 2:20 pm
Electrical Wiring Interconnect System EWIS
EWIS Discussion Points What is Electrical Wiring Interconnect System (EWIS)? History Training Best Practices NextTech Summary
EWIS What is EWIS? The Electrical Wiring Interconnect System or Electrical system means those parts of the aircraft that generate, distribute and use electrical energy, including their support and attachments
History In the late 1990 s wiring concerns were raised due to accidents and incidents (TWA 800 mid-air explosion, Swiss Air 111 electrical arcing from an inflight entertainment system) These disasters prompted the review of commercial wiring policies and the formation of Aging Transport Systems Rulemaking Advisory Committee (ATSRAC) as well as small business funded opportunities by the FAA, NASA, NAVAIR and others
Investigation ATSRAC Investigated 5 areas (phase I) Fleet Condition Fleet Service History Maintenance Criteria Standard Practices for Wiring Inspection and Repair Training Investigation, findings and recommendations changed the way we view EWIS
Investigation EWIS systems should be treated as a system General findings identified wiring is effected by: Design Maintenance Repair Environment Age Training Wiring is not immortal and degrades over time
Degradation EWIS Degradation is a process that is a function of many variables: Age Environment Physical properties Installation Maintenance
Degradation Causes of EWIS Degradation Time Vibration Moisture Maintenance Indirect damage Chemical contamination Heat installation
Best Practices How do we apply the lessons learned to ensure one of the most critical systems (EWIS) is being properly maintained and inspected? Training AC 120-94 EWIS Best Practices Job Aid Standard Wiring Practice Manual
Training Developing a Training Program (AC 120-94) Objective is to help organizations standardize an EWIS training program that ensures proper processes and procedures when performing maintenance, preventive maintenance and repair of EWIS Developed for eight different target groups Essential elements for the training program: Train to the appropriate level by providing initial and refresher training
Training Target Groups 1-4 Group 1: Personnel performing EWIS maintenance Group 2: Personnel performing EWIS inspections Group 3: Personnel performing EWIS engineering on in-service aircraft Group 4: Personnel performing general maintenance / inspections not involving EWIS
Training Target Groups 5-8 Group 5: Personnel performing other engineering or planning work on in-service aircraft Group 6: Other service staff with duties in proximity to EWIS Group 7: Flight Deck Crew Group 8: Cabin Crew
Training EWIS Curriculum Module A: General EWIS practices Module B: Wiring practices documentation Module C: Inspection Module D: Housekeeping Module E: Wire Module F: Connective devices Module G: Connective devices repair
Group 1 Training Module C: Inspection General visual inspection (GVI) Detailed inspection (DET) Special detailed inspection (SDI) zonal inspection criteria and standards
Group 1 Training Module C: Inspection Cont. Human factors in inspection Zonal areas of inspection Wiring system damage
Group 1 Training Module D: Housekeeping Airplane external contamination sources Airplane internal contamination sources Other contamination sources Contamination protection planning Protection during airplane maintenance and repair Cleaning process
Group 1 Training Module E: Wire Wire identification, type and construction Insulation qualities and damage limits Inspection criteria and standards for wire and wire bundles Wire bundle installation practices
Group 1 Training Module E: Wire Cont. Typical damage and areas found Maintenance and repair procedures Sleeving Unused wires-termination and storage Electrical bonding and grounding
Best Practices Aircraft Maintenance Manual Aircraft Standard Wiring Practices Manual FAA Aircraft Wiring Practices Job Aid
Federal Aviation Administration Aircraft Wiring Practices (Job Aid)
NextTech What is the future for Aviation Technicians Complex systems Advanced Skill Requirements Highly Integrated EWIS systems
SUMMARY EWIS History Organizational Training Best Practices NextTech
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