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NTSB Identifies Origin Of JAL Boeing 787 Battery Fire
By Jim Douglas

February 8, 2013 - NTSB identified the origin of the January 7 battery fire that occurred on a Japan Airlines 787 parked at Boston Logan Airport, and said that a focus of the investigation will be on the design and certification requirements of the battery system. 

"U.S. airlines carry about two million people through the skies safely every day, which has been achieved in large part through design redundancy and layers of defense," said Hersman.

"Our task now is to see if enough - and appropriate - layers of defense and adequate checks were built into the design, certification and manufacturing of this battery." 


After an exhaustive examination of the JAL lithium-ion battery, which was comprised of eight individual cells, investigators determined that the majority of evidence from the flight data recorder and both thermal and mechanical damage pointed to an initiating event in a single cell. That cell showed multiple signs of short circuiting, leading to a thermal runaway condition, which then cascaded to other cells. Charred battery components indicated that the temperature inside the battery case exceeded 500 degrees Fahrenheit. 

As investigators work to find the cause of the initiating short circuit, they ruled out both mechanical impact damage to the battery and external short circuiting. It was determined that signs of deformation and electrical arcing on the battery case occurred as a result of the battery malfunction and were not related to its cause. 

Chairman Hersman said that potential causes of the initiating short circuit currently being evaluated include battery charging, the design and construction of the battery, and the possibility of defects introduced during the manufacturing process. 

During the 787 certification process, Boeing studied possible failures that could occur within the battery. Those assessments included the likelihood of particular types of failures occurring, as well as the effects they could have on the battery. In tests to validate these assessments, Boeing found no evidence of cell-to-cell propagation or fire, both of which occurred in the JAL event. 



The NTSB learned that as part of the risk assessment Boeing conducted during the certification process, it determined that the likelihood of a smoke emission event from a 787 battery would occur less than once in every 10 million flight hours. Noting that there have been two critical battery events on the 787 fleet with fewer than 100,000 flight hours, Hersman said that "the failure rate was higher than predicted as part of the certification process and the possibility that a short circuit in a single cell could propagate to adjacent cells and result in smoke and fire must be reconsidered." 

As the investigation continues, which will include testing on some of the batteries that had been replaced after being in service in the 787 fleet, the NTSB will continue to share its findings in real time with the FAA, Boeing, the Japan Transport Safety Board, and the French investigative agency, the Bureau d'Enquêtes et d'Analyses. 

"The decision to return the fleet to flight will be made by the FAA, which underscores the importance of cooperation and coordination between our agencies," Hersman said. She also announced that the NTSB would release an interim report of factual findings within 30 days.

Boeing reports it welcomes the progress reported by the U.S. National Transportation Safety Board (NTSB) in the 787 investigation, including that the NTSB has identified the origin of the event as having been within the battery. “The findings demonstrated a narrowing of the focus of the investigation to short circuiting observed in the battery, while providing the public with a better understanding of the nature of the investigation”. 

“The 787 was certified following a rigorous Boeing test program and an extensive certification program conducted by the FAA. We provided testing and analysis in support of the requirements of the FAA special conditions associated with the use of lithium ion batteries. We are working collaboratively to address questions about our testing and compliance with certification standards, and we will not hesitate to make changes that lead to improved testing processes and products”.

Secretary LaHood and Administrator Huerta - “DOT is focused on the safety of the traveling public.  From day one, we have said that the comprehensive review of the Boeing 787 and the root cause analysis of the two battery incidents would be a data-driven process.  Based on what information our experts find, the FAA will take any action necessary to further ensure safety.  We must finish this work before reaching conclusions about what changes or improvements the FAA should make going forward.  The leading experts in this field are working to understand what happened and how we can safely get these aircraft back into service. 

“Last month, we announced a comprehensive review of the 787’s critical systems including the aircraft’s design, manufacture and assembly.  Since then, the FAA's team of technical experts has been working around the clock to understand what happened and how best to prevent these issues from recurring. As part of this effort, the FAA is looking at both the certification process and specifically at the required tests and design of the aircraft’s lithium ion battery.  The FAA invited the NTSB to observe this FAA-led process. 

“The FAA is also lending our technical experts to support the NTSB's investigation into the probable cause of the battery incidents. The agency will also evaluate information from the investigations of these incidents and will take action as appropriate.  

“As the agency said last month, the FAA is focused on the review and activities to understand the root cause. Once the review is complete, the FAA will make any analysis and conclusions public.”

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