Boeing Reveals Flight Test Plans For 787
Guy Norris/Seattle guy_norris@aviationweek.com
Boeing is providing new details about what the 787 and its sister ships will do as part of its upcoming flight test and certification plan, noting that nearly 60% of the documentation required for certification has been submitted to the FAA.
Once it begins the flight test effort, ZA001 will be used to explore the fundamental aerodynamics and handling qualities envelope. This includes flutter, stability and control, flight controls, major systems work, low-speed handling including stalls, and checks of the full data system.
The flight test fleet is made up of six aircraft, four (ZA001-004) of which are Rolls-Royce Trent 1000-powered and two (ZA005-006) of which are General Electric GEnx-1B powered.
The second aircraft (ZA002) will test stability and control, autopilot, avionics, propulsion and electric systems. The third 787 (ZA003) will cover tests of electro-magnetic/high-intensity radiated fields (EME/HIRF), systems, noise, flight deck, ETOPS, avionics and minimum data system. ZA004 will cover high speed aerodynamic performance, community noise, propulsion, ETOPS and flight loads survey.
ZA005 will also repeat some flutter work because it is the first GEnx-1B powered version, as well as performing stability and control, aerodynamic performance, propulsion, avionics, community noise and ETOPS. The second GE-powered aircraft, ZA006, will undertake lightning-specific EME tests, and HIRF, more ETOPS and miscellaneous tests with minimal analog requirements.
The Rolls-powered fleet is expected to amass some 2,430 flight test hours and 3,100 ground test hours, while the smaller GE fleet is expected to build up 670 flight test hours and 600 ground test hours.
Mike Delaney, vice president and chief project engineer on 787, says nearly 60% of the documentation required for certification has been submitted and, of the remaining 40%, less than 10% will be generated as part of flight tests. "There are about 4,000 deliverables we will deliver to the FAA. Of the remaining parts, around 300 are flight test dependent," he adds.
The 787 is currently subject to 152 issue papers with the FAA covering minor details of the certification requirements. "Boeing and the FAA are in negotiation on those," says Delaney. The aircraft is also subject to 16 special conditions - many of which cover the new technology areas such as the composite primary structure that have not previously been certificated.
Boeing adds it is in discussions with the FAA on two exemptions - one of which relates to emergency descent time in the event of an engine failure and rapid cabin decompression. Delaney adds, "There is potential for a third" exemption related to the stretch out of the development cycle. As the 787 development now exceeds a five-year period from when the certification process was begun, talks are underway to evaluate if the aircraft should be subject to rules subsequently adopted regarding emergency egress lighting.
Photo credit: Boeing
