AMC 20-22 Effective: 05/09/2008 Annex III to ED Decision 2008/007/R of 29/08/2008 AMC 20-22 Aeroplane Electrical Wiring Interconnection System Training Programme 1 PURPOSE This AMC provides acceptable means of compliance for developing an enhanced Electrical Wiring Interconnection System (EWIS) training programme. The information in this AMC is derived from the best practices training developed through extensive research. This AMC is an effort by the Agency to officially endorse these best practices and to dispense this information industry-wide so that the benefits of this information can be effectively realised. Following this AMC will result in a training programme that will improve the awareness and skill level of the aviation personnel in EWIS production, modification, maintenance, inspection, alterations and repair. This AMC promotes a philosophy of training for all personnel who come into contact with aeroplane EWIS as part of their job and tailors the training for each workgroup to their particular needs. 2 OBJECTIVE This AMC has been published in order to provide the approved organisations with acceptable means of compliance to comply with their training obligations as required in paragraphs 21.A.145 and 21.A.245 of Part-21, 145.A.30 and 145.A.35 of Part-145 and M.A.706 of Part-M with respect to EWIS. To fully realise the objectives of this AMC, operators, holders of type certificates (TC), holders of supplemental type certificates (STC), maintenance organisations and persons performing modifications or repairs, will need to rethink their current approach to maintaining and modifying aeroplane wiring and systems. This may require more than simply updating maintenance manuals and work cards and enhancing training. Maintenance personnel need to be aware that aeroplane EWIS should be maintained with the same level of intensity as any other system in the aeroplane. They also need to recognise that visual inspection of wiring has inherent limitations. Small defects such as breached or cracked insulation, especially in small gage wire may not always be apparent. Therefore, effective wiring maintenance combines visual inspection techniques with improved wiring maintenance practices and training. The objective of this EWIS training programme is to give operators, holders of TC, holders of STC, maintenance organisations and persons performing field approval modifications or repairs a model for the development of their own EWIS training programme. This will ensure that proper procedures, methods techniques, and practices are used when performing maintenance, preventive maintenance, inspection, alteration, and cleaning of EWIS. The training syllabus and curriculum for those personnel directly involved in the maintenance and inspection of EWIS, identified as Target Group 1 and 2, are in Appendix A and C to this AMC. This AMC also provides guidance on the development of EWIS training programmes for personnel who are not directly involved in the maintenance and inspection of EWIS. Although there is no direct regulatory requirement for EWIS training of these personnel, operators may choose to provide EWIS training. The training syllabus and curriculum for these personnel, identified as Target Groups 3 through 8, are in Appendix B and C to this AMC. It is believed that training personnel in these groups would greatly enhance awareness of the importance of EWIS safety in the overall safe operation of aeroplanes. Although these groups are not directly involved in the maintenance of EWIS, they have the potential to 1 have an adverse impact on EWIS. This can occur through inadvertent contact with EWIS during aeroplane cleaning or when individuals perform unrelated maintenance that could impact the integrity of EWIS. Mechanics leaving drill shavings on wire bundles is one example of how this could occur. Some people prepare paperwork that guides mechanics, training this target group in EWIS should help to ensure that proper attention is paid to EWIS issues. This programme was developed for eight different target groups and may be used for the minimum requirements for initial and recurrent training (see training matrix). Depending on the duties, some may fall into more than one target group and, therefore, must fulfil all objectives of the associated target groups. The target groups are: a. Qualified staff performing EWIS maintenance. These staff members are personnel who perform wiring systems maintenance and their training is based on their job description and the work being done by them (e.g. avionics skilled workers or technicians cat B2). b. Qualified staff performing maintenance inspections on wiring systems. These staff members are personnel who perform EWIS inspections (but not maintenance), and their training is based on their job description and the work being done by them (e.g. inspectors/technicians cat B2). c. Qualified staff performing electrical/avionic engineering on in-service aeroplane. These staff members are personnel who are authorised to design EWIS installations, modifications and repairs (e.g. electric/avionic engineers). d. Qualified staff performing general maintenance/inspections not involving wire maintenance (LRU change is not considered wire maintenance). These staff members are personnel who perform maintenance on aeroplane that may require removal/reconnection of electrical connective devices (e.g. inspectors/technicians cat A or B1). e. Qualified staff performing other engineering or planning work on in-service aeroplane. These staff members are personnel who are authorised to design mechanical/structure systems installations, modifications and repairs, or personnel who are authorised to plan maintenance tasks. f. Other service staff with duties in proximity to EEWIS. These staff members are personnel whose duties would bring them into contact/view of aeroplane wiring systems. This would include, but not be limited to: Aeroplane cleaners, cargo loaders, fuelers, lavatory servicing personnel, de-icing personnel, push back personnel. g. Flight Deck Crew. (E.g. Pilots, Flight Engineers) h. Cabin Crew. 3 APPLICABILITY This AMC describes acceptable means, but not the only means, of compliance with the appropriate certification, maintenance and operating regulations. The information in this AMC is based on lessons learned by Aging Transport Systems Rulemaking Advisory Committee (ATSRAC) Harmonised Working Groups, regulatory authorities, manufacturers, airlines and repair stations. This AMC can be applied to any aeroplane training programme. 2 4 RELATED DOCUMENTS • Regulation (EC) No 216/20081 • Regulation (EC) No 1702/20032 • Regulation (EC) No 2042/20033 • EASA Certification Specification CS-25 Large Aeroplanes4 • EU-OPS Commercial Air Transportation (Aeroplanes)5 5 RELATED READING MATERIAL a. EASA AMC-20 • AMC 20-21 Programme to Enhance Aeroplane Electrical Wiring Interconnection System Maintenance • AMC 20-23 Development of Electrical Standard Wiring Practices Documentation b. FAA 14 CFR Parts • Part 21, Certification Procedures for Products and Parts • Part 25, Airworthiness Standards, Transport Category Aeroplanes • Part 43, Maintenance, Preventive Maintenance, Rebuilding, and Alteration • Part 91, General Operating and Flight Rules • Part 119, Certification: Air Carriers and Commercial Operators • Part 121, Operating Requirements: Domestic, Flag, and Supplemental Operations • Part 125, Certification and Operations: Aeroplanes Having a Seating Capacity of 20 or More Passengers or a Maximum Payload Capacity of 6,000 pounds or More • Part 129, Operations: Foreign Air Carriers and Foreign Operators of U.S.- Registered Aircraft Engaged in Common Carriage • Part 135, Operating Requirements: Commuter and On-demand Operations • Part 145, Repair Stations c. FAA Advisory Circulars (AC) • AC 20-13, Protection of Aircraft Electrical/Electronic Systems against the Indirect Effects of Lightning 1 Regulation (EC) No 216/2008 of the European Parliament and of the Council of 20 February 2008 on common rules in the field of civil aviation and establishing a European Aviation Safety Agency, and repealing Council Directive 91/670/EEC, Regulation (EC) No 1592/2002 and Directive 2004/36/EC (OJ L 79, 19.3.2008, p. 1). 2 Commission Regulation (EC) No 1702/2003 of 24 September 2003 laying down implementing rules for the airworthiness and environmental certification of aircraft and related products, parts and appliances, as well as for the certification of design and production organisations (OJ L 243, 27.9.2003, p. 6). Regulation as last amended by Regulation (EC) No 287/2008 (OJ L 87, 29.3.2008, p. 3). 3 Commission Regulation (EC) No 2042/2003 of 20 November 2003 on the continuing airworthiness of aircraft and aeronautical products, parts and appliances, and on the approval of organisations and personnel involved in these tasks (OJ L 315, 28.11.2003, p. 1). Regulation as last amended by Regulation (EC) No 376/2007 of (OJ L 94, 4.4.2007, p. 18). 4 Executive Director Decision No 2003/2/RM of 14 October 2003 on certification specifications, including airworthiness codes and acceptable means of compliance, for large aeroplanes («CS-25»). Decision as last amended by Executive Director Decision No 2008/006/R of 29 August 2008 (CS-25 Amendment 5). 5 Council Regulation (EEC) No 3922/91 of 16 December 1991 on the harmonisation of technical requirements and administrative procedures in the field of civil aviation (OJ L 373, 31.12.1991, p. 4). Regulation as last amended by Regulation (EC) No 8/2008 of 11 December 2007 (OJ L 10, 12.1.2008, p. 1). 3 • AC 20-53A, Protection of Aeroplane Fuel Systems against Fuel Vapour Ignition due to Lightning AC 25-16, Electrical Fault and Fire Protection and Prevention • AC 25.981-1B, Fuel Tank Ignition Source Prevention Guidelines • AC 25.17YY Development of Standard Wiring Practices Documentation • AC 43-3, Non-destructive Testing in Aircraft • AC 43-4A, Corrosion Control for Aircraft • AC 43-7, Ultrasonic Testing for Aircraft • AC 43-12A, Preventive Maintenance • AC 43.13-1A, Acceptable Methods, Techniques and Practices - Aircraft Inspection and Repair • AC 43.13-1B, Acceptable Methods, Techniques and Practices for Repairs and Alterations to Aircraft • AC 43-204, Visual Inspection for Aircraft • AC 43-206, Avionics Cleaning and Corrosion Prevention/Control • AC 65-15A, Airframe and Powerplant Mechanics Airframe Handbook, Chapter 11. Aircraft Electrical Systems • AC 120-XX, Programme to enhance aircraft Electrical Wiring Interconnection System maintenance • AC 120-YY Aircraft Electrical Wiring Interconnection System training programme d. Reports • Transport Aircraft Intrusive Inspection Project, (An Analysis of the Wire Installations of Six Decommissioned Aircraft), Final Report, The Intrusive Inspection Working Group, December 29, 2000. http://www.mitrecaasd.org/atsrac/intrusive_inspection.html • FAA Aging Transport Non-Structural Systems Plan, July 1998. • National Transportation Safety Board, Safety Recommendation, September 19, 2000, A-00-105 through -108. http://www.ntsb.gov/recs/letters/2000/A00_105_108.pdf • Wire System Safety Interagency Working Group, National Science and Technology Council, Review of Federal Programmes for Wire System Safety 46 (2000). • Aging Transport Systems Rulemaking Advisory Committee, Task 1 and 2, Aging Systems, Final Report. http://www.mitrecaasd.org/atsrac/final_reports/Task_1&2_Final%20_August_2000.pd f • Aging Transport Systems Rulemaking Advisory Committee, Task 3, Final Report. http://www.mitrecaasd.org/atsrac/final_reports/Task_3_Final.pdf • Aging Transport Systems Rulemaking Advisory Committee, Task 4, Final Report, Standard Wiring Practices. http://www.mitrecaasd.org/atsrac/final_reports/Task_4_Final_Report_Sept_2000.pdf • Aging Transport Systems Rulemaking Advisory Committee, Task 5, Final Report, Aircraft Wiring Systems Training Curriculum and Lesson Plans. http://www.mitrecaasd.org/atsrac/final_reports/Task_5_Final_March_2001%20.p df • ATA Specification 117 (Wiring Maintenance Practices/Guidelines). 4 • Aging Transport Systems Rulemaking Advisory Committee, Task 6, Task 7 and Task 9 Working Group Final Reports. http://www.mitrecaasd.org/atsrac/final_reports.html e. Other Documents • ATA Operator/Manufacturer Scheduled Maintenance Development as revised, ATA Maintenance Steering Group (MSG-3), may be obtained from the Air Transport Association of America; Suite 1100: 1301 Pennsylvania Ave, NW, Washington, DC 20004-1707. • FAA Handbook Bulletin 91-15 "Origin and propagation of inaccessible aircraft fire under in-flight airflow conditions". 6 DEFINITIONS Arc tracking: A phenomenon in which a conductive carbon path is formed across an insulating surface. This carbon path provides a short circuit path through which current can flow. Normally, a result of electrical arcing. Also referred to as "Carbon Arc Tracking", "Wet Arc Tracking", or "Dry Arc Tracking". Combustible: For the purposes of this AMC, the term combustible refers to the ability of any solid, liquid or gaseous material to cause a fire to be sustained after removal of the ignition source. The term is used in place of inflammable/flammable. It should not be interpreted as identifying material that will burn when subjected to a continuous source of heat as occurs when a fire develops. Contamination: For the purposes of this AMC, wiring contamination refers to either of the following: • The presence of a foreign material that is likely to cause degradation of wiring. • The presence of a foreign material that is capable of sustaining combustion after removal of ignition source. Detailed Inspection (DET): An intensive examination of a specific item, installation, or assembly to detect damage, failure or irregularity. Available lighting is normally supplemented with a direct source of good lighting at an intensity deemed appropriate. Inspection aids such as mirrors, magnifying lenses or other means may be necessary. Surface cleaning and elaborate access procedures may be required. Electrical Wiring Interconnection System (EWIS): See CS 25.1701. Functional Failure: Failure of an item to perform its intended function within specified limits. General Visual Inspection (GVI): A visual examination of an interior or exterior area, installation, or assembly to detect obvious damage, failure or irregularity. This level of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to enhance visual access to all exposed surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight, hangar lighting, flashlight or droplight and may require removal or opening of access panels or doors. Stands, ladders or platforms may be required to gain proximity to the area being checked. Lightning/High Intensity Radiated Field (L/HIRF) protection: The protection of aeroplane electrical systems and structure from induced voltages or currents by means of shielded wires, raceways, bonding jumpers, connectors, composite fairings with conductive mesh, static dischargers, and the inherent conductivity of the structure; may include aeroplane specific devices, e.g., RF Gaskets. Maintenance: As defined in Regulation (EC) 2042/2003 Article 2(h) “maintenance means inspection, overhaul, repair, preservation, and the replacement of parts, but excludes preventive maintenance.” For the purposes of this advisory material, it also includes preventive maintenance. 5 Maintenance Significant Item (MSI): Items identified by the manufacturer whose failure: • could affect safety (on ground or in flight). • is undetectable during operations. • could have significant operational impact. • could have significant economic impact. Needling: The puncturing of a wire’s insulation to make contact with the core to test the continuity and presence of voltage in the wire segment. Stand-alone General Visual Inspection (GVI): A GVI which is not performed as part of a zonal inspection. Even in cases where the interval coincides with the zonal inspection, the stand-alone GVI shall remain an independent step within the work card. Structural Significant Item (SSI): Any detail, element or assembly that contributes significantly to carrying flight, ground, pressure, or control loads and whose failure could affect the structural integrity necessary for the safety of the aeroplane. Swarf: A term used to describe the metal particles, generated from drilling and machining operations. Such particles may accumulate on and between wires within a wire bundle. Zonal Inspection: A collective term comprising selected GVI and visual checks that are applied to each zone, defined by access and area, to check system and powerplant installations and structure for security and general condition. 7 BACKGROUND Over the years there have been a number of in-flight smoke and fire events where contamination sustained and caused the fire to spread. Regulators and Accident Investigators have conducted aircraft inspections and found wiring contaminated with items such as dust, dirt, metal shavings, lavatory waste water, coffee, soft drinks, and napkins. In some cases, dust has been found completely covering wire bundles and the surrounding area. Research has also demonstrated that wiring can be harmed by collateral damage when maintenance is being performed on other aircraft systems. For example, a person performing an inspection of an electrical power centre or avionics compartment may inadvertently cause damage to wiring in an adjacent area. Aviation Accident Investigators have specifically cited the need for improved training of personnel to ensure adequate recognition and repair of potentially unsafe wiring conditions. This AMC addresses only the training programme. It does not attempt to deal with the condition of the fleet's wiring, or develop performance tests for wiring. This AMC captures, in EASA guidance form, the aeroplane EWIS training programme developed by ATSRAC. This includes a training syllabus, curriculum, training target groups and a matrix outlining training for each training group. 8 ESSENTIAL ELEMENTS FOR A TRAINING PROGRAMME a. Initial Training. Initial training should be conducted for each designated work group. The initial training for each designated work group is outlined in EWIS Minimum Initial Training Programme - Appendix A and B. Curriculum and Lesson Plans for each dedicated module are included in Appendix C. 6 The most important criteria are to meet the objectives of the Lesson Plans – Appendix C (using classroom discussion, computer-based training or hands-on practical training). Assessment or achieving the objectives should be at the discretion of the training organisation (such as written test, oral test or demonstration of skills). Supporting documentation such as AMC is an integral part of training and should be used to support development of the Curriculum and Lesson Plans. b. Refresher Training. Refresher training should be conducted in a period not exceeding two years. It could consist of a review of previously covered material plus any new material or revisions to publications. Refresher training will follow the EWIS Minimum Initial Training Programme - Appendix A or B for that particular target group. 7 Appendix A – EWIS Minimum Initial Training Programme for Group 1 And 2 Target Group 1: Qualified staff performing EWIS maintenance. Target Group 2: Qualified staff performing maintenance inspections on EWIS. 1 2 TARGET GROUP A – GENERAL ELECTRICAL WIRING INTERCONNECTION SYSTEM PRACTICES Know or demonstrate safe handling of aeroplane electrical systems, line replaceable units (LRU), tooling, troubleshooting procedures, and electrical measurement. 1. Safety practices X X 2. Electrostatic discharge sensitive (ESDS) device handling and X X protection 3. Tools, special tools, and equipment X 4. Verifying calibration/certification of instruments, tools, and X equipment 5. Required wiring checks using the troubleshooting procedures and X charts 6. Measurement and troubleshooting using meters X 7. LRU replacement general practices X X B – WIRING PRACTICES DOCUMENTATION Know or demonstrate the construction and navigation of the applicable aeroplane wiring system overhaul or practices manual. 8. Standard wiring practices manual structure/overview X X 9. Chapter cross-reference index X X 10. Important data and tables X X 11. Wiring diagram manuals X X 12. Other documentation as applicable X X C – INSPECTION Know the different types of inspections, human factors in inspections, zonal areas and typical damages. 13. General visual inspection (GVI), detailed inspection (DET), special detailed X X inspection (SDI), and zonal inspection, and their criteria and standards 14. Human factors in inspection X 15. Zonal areas of inspection X 16. Wiring system damage X X D – HOUSEKEEPING Know the contamination sources, materials, cleaning and 8 1 2 TARGET GROUP protection procedures. 17. Aeroplane external contamination sources X X 18. Aeroplane internal contamination sources X X 19. Other contamination sources X X 20. Contamination protection planning X 21. Protection during aeroplane maintenance and repair X 22. Cleaning processes X E – WIRE Know or demonstrate the correct identification of different wire types, their inspection criteria and damage tolerance, repair and preventative maintenance procedures. 23. Wire identification, type and construction X X 24. Insulation qualities and damage limits X X 25. Inspection criteria and standards for wire and wire bundles X 26. Wire bundle installation practices X X 27. Typical damage and areas found (aeroplane specific) X X 28. Maintenance and repair procedures X X 29. Sleeving X X 30. Unused wires - termination and storage X X 31. Electrical bonding and grounds X X F – CONNECTIVE DEVICES Know or demonstrate the procedures to identify, inspect, and find the correct repair for typical types of connective devices found on the applicable aeroplane. 32. General connector types and identification X X 33. Cautions and protections X X 34. Visual inspection procedures X X 35. Typical damage found X X 36. Repair procedures X X G – CONNECTIVE DEVICE REPAIR Demonstrate the procedures for replacement of all parts of typical types of connectors found on the applicable aeroplane. 37. Circular connectors X 38. Rectangular connectors X 39. Terminal blocks - modular X 40. Terminal blocks - non-modular X 41. Grounding modules X 42. Pressure seals X 9 APPENDIX B – EWIS MINIMUM INITIAL TRAINING PROGRAMME FOR GROUP 3 THROUGH 8 Target Group 3: Qualified staff performing electrical/avionic engineering on in-service aeroplane. Target Group 4: Qualified staff performing general maintenance/inspections not involving wire maintenance (LRU change is not considered wire maintenance) Target Group 5: Qualified staff performing other engineering or planning work on in-service aeroplane Target Group 6: Other service staff with duties in proximity to electrical wiring interconnection systems Target Group 7: Flight Deck Crew Target Group 8: Cabin Crew TARGET GROUPS 3 4 5 6 7 8 A – GENERAL ELECTRICAL WIRING INTERCONNECTION SYSTEM PRACTICES Know or demonstrate the safe handling of aeroplane electrical systems, line replaceable units (LRU), tooling, troubleshooting procedures, and electrical measurement. 1. Safety practices X X X X 2. Electrostatic discharge sensitive (ESDS) device handling and protection X 7. LRU replacement general practices X B – WIRING PRACTICES DOCUMENTATION Know or demonstrate the construction and navigation of the applicable aeroplane wiring system overhaul or practices manual. 8. Standard wiring practices manual structure/overview X 9. Chapter cross-reference index X 10. Important data and tables X 11. Wiring diagram manuals X 12. Other documentation as applicable X C – INSPECTION 10 10