[Federal Register Volume 78, Number 244 (Thursday, December 19, 2013)]
[Rules and Regulations]
[Pages 76731-76734]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 2013-30232]
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DEPARTMENT OF TRANSPORTATION
Federal Aviation Administration
14 CFR Part 25
[Docket No. FAA-2013-0723; Special Conditions No. 25-511-SC]
Special Conditions: Boeing Model 777-200, -300, and -300ER Series
Airplanes; Rechargeable Lithium Ion Batteries and Battery Systems
AGENCY: Federal Aviation Administration (FAA), DOT.
ACTION: Final special conditions.
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SUMMARY: These special conditions are issued for the Boeing Model 777-
200, -300, and -300ER series airplanes. These airplanes as modified by
the ARINC Aerospace Company will have a novel or unusual design
feature, specifically the installation of rechargeable lithium ion
batteries and battery system that will be used on an International
Communications Group (ICG) ePhone cordless cabin handset. The
applicable airworthiness regulations do not contain adequate or
appropriate safety standards for this design feature. These special
conditions contain the additional safety standards that the
Administrator considers necessary to establish a level of safety
[[Page 76732]]
equivalent to that established by the existing airworthiness standards.
DATES: Effective Date: January 21, 2014.
FOR FURTHER INFORMATION CONTACT: Nazih Khaouly, FAA, Airplane and
Flight Crew Interface Branch, ANM-111, Transport Airplane Directorate,
Aircraft Certification Service, 1601 Lind Avenue SW., Renton,
Washington 98057-3356; telephone 425-227-2432; facsimile 425-227-1149.
SUPPLEMENTARY INFORMATION:
Background
On August 10, 2012, the ARINC Aerospace Company applied for a
supplemental type certificate for installing equipment that uses
rechargeable lithium ion batteries and battery systems in the Boeing
Model 777-200, -300, and -300ER series airplanes. The Model 777-200
series airplanes are long-range, wide-body, twin-engine jet airplanes
with a maximum capacity of 440 passengers. The Boeing Model 777-300 and
777-300ER series airplanes have a maximum capacity of 550 passengers.
The Model 777-200, -300, and -300ER series airplanes have fly-by-wire
controls, fully software-configurable avionics, and fiber-optic
avionics networks.
Existing airworthiness regulations did not anticipate the use of
lithium ion batteries and battery systems on aircraft. Lithium ion
batteries and battery systems have new hazards that were not
contemplated when the existing regulations were promulgated. In Title
14, Code of Federal Regulations (14 CFR) 25.1353, the FAA provided an
airworthiness standard for lead acid batteries and nickel cadmium
batteries. These special conditions provide an equivalent level of
safety as that of the existing regulation.
Type Certification Basis
Under the provisions of 14 CFR 21.101, the ARINC Aerospace Company
must show that the Boeing Model 777-200, -300, and -300ER series
airplanes, as changed, continue to meet the applicable provisions of
the regulations incorporated by reference in Type Certificate No.
T00001SE or the applicable regulations in effect on the date of
application for the change. The regulations incorporated by reference
in the type certificate are commonly referred to as the ``original type
certification basis.'' The regulations incorporated by reference in
Type Certificate No. T00001SE are as follows: Part 25, as amended by
Amendments 25-1 through 25-82, except for Sec. 25.571(e)(1), which
remains at Amendment 25-71 level. In addition, the certification basis
includes special conditions and exemptions that are not relevant to
these special conditions.
If the Administrator finds that the applicable airworthiness
regulations (i.e., 14 CFR part 25) do not contain adequate or
appropriate safety standards for the Boeing Model 777-200, -300, and -
300ER series airplanes because of a novel or unusual design feature,
special conditions are prescribed under the provisions of Sec. 21.16.
Special conditions are initially applicable to the model for which
they are issued. Should the applicant apply for a supplemental type
certificate to modify any other model included on the same type
certificate to incorporate the same or similar novel or unusual design
feature, the special conditions would also apply to the other model
under Sec. 21.101.
In addition to the applicable airworthiness regulations and special
conditions, the Boeing Model 777-200, -300, and -300ER series airplanes
must comply with the fuel-vent and exhaust-emission requirements of 14
CFR part 34, and the noise-certification requirements of 14 CFR part
36.
The FAA issues special conditions, as defined in 14 CFR 11.19, in
accordance with Sec. 11.38, and they become part of the type
certification basis under Sec. 21.101.
Novel or Unusual Design Features
The Boeing Model 777-200, -300, and -300ER series airplanes will
incorporate the following novel or unusual design features: An
International Communications Group (ICG) ePhone cordless cabin handset
that will use a rechargeable lithium ion battery and battery system.
Lithium ion batteries and battery systems have certain failure,
operational, and maintenance characteristics that differ significantly
from those of the nickel cadmium and lead acid rechargeable batteries.
Rechargeable lithium ion batteries and battery systems are considered
to be a novel or unusual design feature in transport category
airplanes, with respect to the requirements in Sec. 25.1353.
Discussion
The current regulations governing installation of batteries in
large transport category airplanes were derived from Civil Air
Regulations (CAR) part 4b.625(d) as part of the re-codification of CAR
4b that established 14 CFR part 25 in February 1965. The new battery
requirements, Sec. 25.1353(c)(1) through (c)(4), basically reworded
the CAR requirements.
Increased use of nickel cadmium batteries in small airplanes
resulted in increased incidents of battery fires and failures which led
to additional rulemaking affecting large transport category airplanes
as well as small airplanes. On September 1, 1977 and March 1, 1978,
respectively, the FAA issued Sec. 25.1353(c)(5) and (c)(6), governing
nickel cadmium battery installations on large transport-category
airplanes.
The proposed use of lithium ion batteries and battery systems for
equipment and systems on the Boeing Model 777-200, -300, and -300ER
series airplanes has prompted the FAA to review the adequacy of these
existing regulations. Our review indicates that the existing
regulations do not adequately address several failure, operational, and
maintenance characteristics of lithium ion batteries and battery
systems that could affect the safety and reliability of the airplanes
with the ICG ePhone cordless cabin handset lithium ion battery
installations.
At present, there is limited experience with use of rechargeable
lithium ion batteries and battery systems in applications involving
commercial aviation. However, other users of this technology, ranging
from wireless telephone manufacturers to the electric vehicle industry,
have noted safety problems with lithium ion batteries and battery
systems. These problems include overcharging, over-discharging, and
flammability of cell components.
1. Overcharging
In general, lithium ion batteries and battery systems are
significantly more susceptible to internal failures that can result in
self-sustaining increases in temperature and pressure (i.e., thermal
runaway) than their nickel cadmium or lead acid counterparts. This
condition is especially true for overcharging, which causes heating and
destabilization of the components of the cell, leading to the formation
(by plating) of highly unstable metallic lithium. The metallic lithium
can ignite, resulting in a self-sustaining fire or explosion. Finally,
the severity of thermal runaway due to overcharging increases with
increasing battery capacity due to the higher amount of electrolyte in
large batteries.
2. Over-Discharging
Discharge of some types of lithium ion batteries and battery
systems beyond a certain voltage (typically 2.4 volts) can cause
corrosion of the electrodes of the cell, resulting in loss of battery
capacity that cannot be reversed by recharging. This loss of capacity
may not be detected by the simple voltage measurements commonly
available to
[[Page 76733]]
flightcrews as a means of checking battery status--a problem shared
with nickel cadmium batteries.
3. Flammability of Cell Components
Unlike nickel cadmium and lead acid batteries, some types of
lithium batteries and battery systems use liquid electrolytes that are
flammable. The electrolyte can serve as a source of fuel for an
external fire, if there is a breach of the battery container.
These problems experienced by users of lithium ion batteries and
battery systems raise concern about the use of these batteries in
commercial aviation. The intent of the special conditions is to
establish appropriate airworthiness standards for lithium ion battery
installations in the Boeing 777-200, -300, and -300ER series airplanes
and to ensure, as required by Sec. Sec. 25.1309 and 25.601, that these
lithium ion batteries and battery systems are not hazardous or
unreliable. To address these concerns, these special conditions adopt
the following requirements:
Those sections of 14 CFR 25.1353 that are applicable to
lithium ion batteries.
The flammable fluid fire protection requirements of 14 CFR
25.863. In the past, this rule was not applied to batteries of
transport category airplanes, since the electrolytes used in lead-acid
and nickel-cadmium batteries are not flammable.
New requirements to address the hazards of overcharging
and over-discharging that are unique to lithium ion batteries.
New maintenance requirements to ensure that batteries used
as spares are maintained in an appropriate state of charge.
These special conditions are similar to lithium-ion batteries and
battery systems special conditions adopted for the Boeing Model 787 (72
FR 57842; October 11, 2007).
Discussion of Comments
Notice of proposed special conditions no. 25-13-03-SC, for the
Boeing Model 777-200, -300, and -300ER series airplanes, was published
in the Federal Register on August 22, 2013 (78 FR 52107). No comments
were received, and the special conditions are adopted as proposed.
Applicability
As discussed above, these special conditions are applicable to the
Boeing Model 777-200, -300, and -300ER series airplanes. Should the
ARINC Aerospace Company apply at a later date for a supplemental type
certificate to modify any other model included on Type Certificate No.
T00001SE to incorporate the same novel or unusual design feature, the
special conditions would apply to that model as well.
Conclusion
This action affects only certain novel or unusual design features
on one model series of airplanes. It is not a rule of general
applicability, and it affects only the applicant who applied to the FAA
for approval of these features on the airplane.
List of Subjects in 14 CFR Part 25
Aircraft, Aviation safety, Reporting and recordkeeping
requirements.
The authority citation for these special conditions is as follows:
Authority: 49 U.S.C. 106(g), 40113, 44701, 44702, 44704.
The Special Conditions
Accordingly, pursuant to the authority delegated to me by the
Administrator, the following special conditions are issued as part of
the type certification basis for Boeing Model 777-200, -300, and -300ER
series airplanes modified by the ARINC Aerospace Company.
These special conditions require that (1) all characteristics of
the rechargeable lithium ion batteries and battery systems and their
installation that could affect safe operation of the Boeing Model 777-
200, -300, and -300ER series airplanes are addressed, and (2)
appropriate instructions for continued airworthiness, which include
maintenance requirements, are established to ensure the availability of
electrical power from the batteries when needed.
In lieu of the requirements of 14 CFR 25.1353(b)(1) through (b)(4)
at Amendment 25-113, the following special conditions apply.
Rechargeable lithium ion batteries and battery systems on Boeing Model
777-200, -300, and -300ER series airplanes must be designed and
installed as follows:
(1) Safe cell temperatures and pressures must be maintained during
any foreseeable charging or discharging condition and during any
failure of the charging or battery monitoring system not shown to be
extremely remote. The lithium ion batteries and battery systems must
preclude explosion in the event of those failures.
(2) Design of the lithium ion batteries and battery systems must
preclude the occurrence of self-sustaining, uncontrolled increases in
temperature or pressure.
(3) No explosive or toxic gases emitted by any lithium ion
batteries and battery systems in normal operation, or as the result of
any failure of the battery charging system, monitoring system, or
battery installation that is not shown to be extremely remote, may
accumulate in hazardous quantities within the airplane.
(4) Installations of lithium ion batteries and battery systems must
meet the requirements of Sec. 25.863(a) through (d).
(5) No corrosive fluids or gases that may escape from any lithium
ion batteries and battery systems may damage surrounding structure or
any adjacent systems, equipment, or electrical wiring of the airplane
in such a way as to cause a major or more severe failure condition, in
accordance with Sec. 25.1309(b) and applicable regulatory guidance.
(6) Each lithium ion battery and battery system must have
provisions to prevent any hazardous effect on structure or essential
systems caused by the maximum amount of heat the battery can generate
during a short circuit of the battery or of its individual cells.
(7) Lithium ion batteries and battery systems must have a system to
control the charging rate of the battery automatically, so as to
prevent battery overheating or overcharging, and:
(i) A battery temperature sensing and over-temperature warning
system with a means for automatically disconnecting the battery from
its charging source in the event of an over-temperature condition, or,
(ii) A battery failure sensing and warning system with a means for
automatically disconnecting the battery from its charging source in the
event of battery failure.
(8) Any lithium ion battery and battery system whose function is
required for safe operation of the airplane must incorporate a
monitoring and warning feature that will provide an indication to the
appropriate flight crewmembers whenever the state-of-charge of the
batteries has fallen below levels considered acceptable for dispatch of
the airplane.
(9) The instructions for continued airworthiness required by Sec.
25.1529 must contain maintenance requirements to assure that the
lithium ion batteries are sufficiently charged at appropriate intervals
specified by the battery manufacturer and the equipment manufacturer.
The instructions for continued airworthiness must also contain
procedures for the maintenance of batteries in spares storage to
prevent the replacement of batteries with batteries that have
experienced degraded charge retention ability or other damage due to
prolonged storage
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at a low state of charge. Replacement batteries must be of the same
manufacturer and part number as approved by the FAA. Precautions should
be included in the instructions for continued airworthiness maintenance
instructions to prevent mishandling of the rechargeable lithium ion
batteries and battery systems, which could result in short-circuit or
other unintentional impact damage caused by dropping or other
destructive means.
Note 1: The term ``sufficiently charged'' means that the battery
will retain enough of a charge, expressed in ampere-hours, to ensure
that the battery cells will not be damaged. A battery cell may be
damaged by lowering the charge below a point where there is a
reduction in the ability to charge and retain a full charge. This
reduction would be greater than the reduction that may result from
normal operational degradation.
Note 2: These special conditions are not intended to replace
Sec. 25.1353(b) at Amendment 25-113 in the certification basis of
Boeing Model 777-200, -300, and -300ER series airplanes. These
special conditions apply only to rechargeable lithium ion batteries
and battery systems and their installations. The requirements of
Sec. 25.1353(b) at Amendment 25-113 remain in effect for batteries
and battery installations on Boeing Model 777-200, -300, and -300ER
series airplanes that do not use rechargeable lithium ion batteries.
Issued in Renton, Washington, on December 10, 2013.
John P. Piccola, Jr.,
Acting Manager, Transport Airplane Directorate, Aircraft Certification
Service.
[FR Doc. 2013-30232 Filed 12-18-13; 8:45 am]
BILLING CODE 4910-13-P