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Sinnett testified that the Dreamliner’s lithium-ion battery had passed a “state of the art” short circuit test. Nevertheless, fires erupted on two planes.

Boeing led 787 battery tests

Hearings examine roles in failure of new Dreamliner

Associated Press photos
Seated at the witness table at right, Boeing engineer Mike Sinnett speaks during a hearing Tuesday in Washington. The National Transportation Safety Board is investigating battery fires aboard the jet maker’s new 787.

– Federal regulators let Boeing help write the safety conditions for the problematic battery system in its beleaguered 787 Dreamliner, prescribe how to test it and carry out those tests itself, according to testimony and documents released at a hearing Tuesday.

As airlines prepare to resume flying the 787 after a three-month grounding, the National Transportation Safety Board is looking at how the Federal Aviation Administration, Boeing and the company’s subcontractors tested and approved the 787’s lithium ion batteries, and whether the government gives aircraft makers too much leeway when it comes to safety.

Batteries aboard two 787s failed less than two weeks apart in January, causing a fire aboard one plane and smoke in another. The root cause of those incidents is still unknown.

“We are looking for lessons learned, not just for the design and certification of the failed battery, but also for knowledge that can be applied to emerging technologies going forward,” NTSB’s Chairman Deborah Hersman said at the opening of a two-day board hearing.

The 787, which is Boeing’s newest and most technologically advanced plane, is the first airliner to make extensive use of lithium-ion batteries.

Since the FAA doesn’t have safety regulations for those batteries as installed equipment in planes, the agency and Boeing jointly developed the special safety conditions that the plane’s battery system should have to meet, according to documents and testimony.

The FAA also agreed to Boeing’s proposed tests for the batteries, and the company and its subcontractors were the ones responsible for performing those tests.

In one key test, a nail was driven into one of the battery’s eight cells to create a short circuit. Based on the test results, Boeing concluded that a short circuit in one cell wouldn’t start a fire or cause the battery’s other cells to short.

Yet that’s exactly what NTSB investigators say happened in the battery fire in Boston, although they still don’t know the origin of the short circuiting.

The test was “state of the art at the time,” Mike Sinnett, Boeing’s chief engineer for the 787, testified at the hearing. “In retrospect, we don’t think it was conservative enough.”

Boeing has since developed and tested a revamped version of the battery system, with changes designed to prevent a fire or to contain one should it occur. FAA officials approved the revamped batteries last week and agreed to lift the grounding order.

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