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Boeing Dreamliner Catches Fire In Boston

19061969 writes "The BBC reports that a Boeing 787 Dreamliner caught fire in Boston. Carter Leake, an analyst at BB&T Capital Markets in Virginia, said, 'I don't want to be an alarmist, but onboard fires on airplanes are as bad as it gets.' This represents bad news for Boeing especially after the FAA identified errors in the assembly of fuel line couplings in the Dreamliner."

47 of 151 comments (clear)

  1. With one fire by Cryacin · · Score: 5, Funny

    The dreamliner turns into a nightmare. Film at 11.

    --
    Science advances one funeral at a time- Max Planck
    1. Re:With one fire by girlintraining · · Score: 3, Insightful

      The dreamliner turns into a nightmare. Film at 11.

      The Dreamliner is one of the most sophisticated planes ever created. It's going to have problems. I don't think it's a "nightmare", as the FAA fully qualified it for flight. These are the kinds of problems you can only find when it's in production.

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    2. Re:With one fire by Richard_at_work · · Score: 4, Interesting

      Every commercial plane is "one of the most sophisticated" when its first created, as no customer will accept last years technology with last years performance.

      That said, there have been plenty of issues on the 787 which should not have made it to production - the QA issues that have hit over a dozen aircraft, numerous technical faults and electrical system issues etc etc etc. These are the things that the route proving part of the flight test regime are meant to find, but for some reason they haven't. If this most recent fire is due to a design fault rather than a production fault, then the FAA will be looking at their certification requirements more stringently, as they were updated for the 787s certification requirements.

    3. Re:With one fire by Anonymous Coward · · Score: 5, Interesting

      ... there have been plenty of issues on the 787 which should not have made it to production - the QA issues that have hit over a dozen aircraft, numerous technical faults and electrical system issues etc etc etc.

      I fully agree. Yes, all planes have issues when they're first deployed. For example, it was discovered that some parts of the wing structure on the A380 needed to be strengthened in order to meet the fatigue lifetime. However, this is not the kind of thing that would have caused failures in flight - it's a long term fatigue issue that was discovered years before it would have caused a problem. Issues like this are common since strength/fatigue vs. weight is such a difficult compromise on aircraft. 787 issues have been more the kind of thing that should have been fixed during design and testing.

      The problem with the 787, and the reason that it was years behind schedule and has so many problems, is that the executive geniuses at Boeing decided to outsource as much of the engineering as they could ("outsource" here referring to both domestic and offshore outsourcing). Many of the companies that engineering was outsourced to simply didn't have the expertise. Large airliners are not exactly the kind of thing that every job shop and subcontractor has the know-how to design. There are only two companies worth mentioning in the world that do.

      The only way they got the 787 out the door at all (and stemmed the financial bleeding of Boeing) was by taking emergency steps to find a large cadre of engineers who had decades of deep experience in airliner design. They found them at (surprise, surprise) Boeing! Golly, you mean there was some wisdom to the way the world's most successful airliner manufacturer has designed planes for decades? Whodda thunk it? No doubt the top execs at Boeing will get large bonuses for discovering this brilliant last minute solution, and blame Boeing engineering for the problems that do remain.

    4. Re:With one fire by Anonymous Coward · · Score: 5, Interesting

      Yes- this ^

      I live in Boeing's former home town (Seattle) and it may be sour grapes, but the buzz I hear here is that the other/new assembly site in South Carolina is an amateur hour kind of thing. Boeing set up shop there because of the union workers here, and the quality went away. I hear from labor and management folks both that Boeing is no longer in the aircraft business- they are now in the vendor management business, and there are no effective mechanisms for enforcing quality or delivery timeframes.

    5. Re:With one fire by kilodelta · · Score: 2

      Very interesting post. Of course outsourcing cannot be applied to EVERY project. There's a certain amount of cultural knowledge that gets completely lost in the process when you're building something as complex as an airframe. And as you so point out, the Execs at Boeing completely screwed the pooch!

    6. Re:With one fire by Richard_at_work · · Score: 4, Interesting

      The problem is, there are categories of problems which are acceptable to find after certification, and there are categories of problems which are not acceptable to find after certification - fatigue life issues that manifest after the initial certified inspection window (the window between certification and the first deep inspection of the first inservice airframes) are acceptable, because they do not pose an undue risk to the aircraft before they can be discovered. This is because the fatigue testing of a new airframe design continues well beyond that of the certification testing, which only tests for such things as ultimate strength etc while fatigue life, inspection periods etc are done off the basis of longer term testing.

      Components causing fires are in the category of things that should have been discovered during the certification period - there should be no risk from components like that for inservice aircraft, thats the point of certifying the compoments...

      Out of all the problems the Boeing 787 has suffered over its so far short life, the bulk of them have not been engineering issues - only two major issues have been linked to engineering quality, and that is the side of body join problem and the initial arcing problem which caused the first airborne 787 fire during testing.

      The 787s wing, designed and built by the Japanese, has proven to be better than expected spec wise.

      The 787 fuselage sections built by Spirit have proven to be bang on spec.

      There have been a few QA issues with the empennage and other parts, but nothing major.

      The major problems stem from the decision to roll out the 787 as an essentially mocked up CFRP model on the 7/8/07 - rather than wait for the build process to proceed in the planned stages, management pushed for the aircraft to be ready for the public reveal. This lead to non-aviation-grade materials to be used to mock it up, and the aircraft had to be essentially rebuilt in the most difficult way possible afterward. This management decision made a 3 month delay into a 18 month delay.

    7. Re:With one fire by Martin+Blank · · Score: 4, Interesting

      There was an article a couple of years ago where Boeing said that "the process is the product." They truly believed that managing the process of building the plane was a more important product over the plane itself. I've seen so much of this kind of thing that I used it as an example of process management gone wrong where I worked, and it triggered an interesting discussion and some changes in how IT marketed itself to the rest of the enterprise.

      --
      You can never go home again... but I guess you can shop there.
    8. Re:With one fire by Martin+Blank · · Score: 2

      The flights sell out regularly, quickly, and well ahead of the flight times. Despite this, I'm still planning on flying on one on a trip in either April or May.

      --
      You can never go home again... but I guess you can shop there.
    9. Re:With one fire by slashmydots · · Score: 2

      Every commercial plane is "one of the most sophisticated" when its first created

      And which automobiles have the most obscure, complicated, frequent problems? It's the super advanced once with 500 sensors and 1000 stupid, needless features.

    10. Re:With one fire by Richard_at_work · · Score: 3, Insightful

      It would seem you have a selective memory about the reliability, economy and safety of older vehicles :)

  2. Lithium ion battery by Dan+East · · Score: 5, Informative

    It was one of the two large lithium ion battery packs the power the plane when the engines are off. The FCC and pilots were already concerned about the use of lithium ion batteries for this purpose (apparently it's a first), and they issued special regulations just for this plane.

    Also the only person on board when this happened was a mechanic (which is probably a good thing at least someone was able to spot the smoke right away).

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    1. Re:Lithium ion battery by SternisheFan · · Score: 4, Funny

      It could've been worse, at least the battery fire occured after it landed. Statistically speaking, flying in an airplane is still far safer than flying in your own bathtub.

    2. Re:Lithium ion battery by YrWrstNtmr · · Score: 5, Insightful

      ...but I have thrown out a NiCad that was swelling and smelling. Yes, I mean thrown out, from 35,000 ft, somewhere over the North Atlantic. Glad we had a door that opened in.

      Uh huh. Sure you did.

    3. Re:Lithium ion battery by Anonymous Coward · · Score: 2, Interesting

      how exactly do you open a door inwards on a pressurized hull? or, how do you manage to breath for more than 30 sec at 35k ft on an unpressurized one?

    4. Re:Lithium ion battery by ElectricTurtle · · Score: 3, Funny

      I think AC is immune to all pressure effects.... don't you remember the time that AC escaped from the nazis by scuba diving out of a torpedo tube at 180 meters depth?

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    5. Re:Lithium ion battery by DieByWire · · Score: 3, Informative

      But if it was the ground power battery pack that powers the plane when the engines are off, how likely would it have started while flying?

      The battery in question doesn't power the aircraft. It's used to power the control circuitry and starter of the auxilary power unit (APU). The APU is a small turbine engine used to generate electrical power and high pressure bleed air for engine starting, or if additional electrical power is needed in flight ( follwing a generator failure, for example.)

      I can't speak specifically to the 787, but APU batteries are typically always connected and kept charged in case you need to start the APU without any other source of power. I would assume it can be remotely disconnected as it can be on other aircraft, but once the battery is on fire electrically isolating it is not going to solve your woes.

      An inflight fire, especially in an aircraft that could be three hours from shore, is a scary, scary thing.

      --
      Never shake hands with a man you meet in a fertility clinic.
    6. Re:Lithium ion battery by VorpalRodent · · Score: 4, Funny

      I was considering lauding your rigorous statistics, but I can't find anything to support it. The closest thing I can find is the fact that there have been zero deaths of human cannonballs in the last 18 months. This suggests to me that flying in nothing at all is better than flying in an airplane. While ducks and other seasonal game may disagree on the point, I would think that most other birds would agree that plane-less flight is actually safer on a per-mile basis.

      Besides, bathtubs can't fly. That's just silly.

      --
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    7. Re:Lithium ion battery by khallow · · Score: 2

      It was so much fun, he did it eight times.

    8. Re:Lithium ion battery by slinches · · Score: 3, Informative

      What you stated is generally true, but the 787 is somewhat of a special case. It uses a no-bleed APU system which replaces most of the traditionally bleed-driven systems (e.g. engine start, cabin air and wing anti-icing) with electrical equivalents and probably needs a larger set of batteries and higher current (and/or voltage) wiring.

      --
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    9. Re:Lithium ion battery by DieByWire · · Score: 2

      Interesting - I knew the engines were no bleed but didn't realize the APU was also. Nevertheless, the point I was trying to make is that the APU battery is used for the APU, not for powering the whole aircraft when the engines are shutdown, and that it stays powered and charging even when the APU is not in use.

      --
      Never shake hands with a man you meet in a fertility clinic.
    10. Re:Lithium ion battery by jbwolfe · · Score: 2

      While I can't vouch for the account given by the AC (my aircraft had a service ceiling of 29,000ft), I can attest to having flown an aircraft with a "P-chute". This is a lot like an airlock in that one can fill the chute and close the door, then eject the contents without having to depressurize. Mostly used for special buoys and excrement.

      --
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  3. Re:Titanic by webmistressrachel · · Score: 4, Insightful

    | "onboard fires on airplanes are as bad as it gets"

    Hmm... I'm sure a missing wing, or rapid loss of pressure due to a collision, or massive power failure, or lots of other things could be a lot worse than a battery fire.

    Am I correct in assuming TFA doesn't know what on earth (or off it) they're on about?

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  4. Re:MSM Strikes Again by Dupple · · Score: 5, Informative

    From TFA

    "The fire started after a battery in the jet's auxiliary power system overheated."

    http://www.bbc.co.uk/news/business-20942484

    --
    Watch those corners
  5. Re:MSM Strikes Again by alen · · Score: 2

    yeah, but this is a BBC story so you should trust it at face value

  6. Re:Titanic by SomePgmr · · Score: 4, Insightful

    Yeah I'd say, "The airline said that no passengers or crew members were hurt as they had already disembarked." puts the kibosh on "as bad as it gets [on airplanes]".

  7. Re:MSM Strikes Again by X0563511 · · Score: 3, Informative

    Totally unqualified "educated" guess: crew left the APU on even though it's supposed to be off after the engines are up to speed?

    From what simulation and speaking with pilots I've gathered, usually you are "supposed" to turn the APU off after engine starts, though usually this is not done as it consumes a tiny fraction of fuel and gives you some wiggle room in the event of an engine failure.

    --
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  8. Serious. It is. by udippel · · Score: 2

    Make it serious square. From what we have been told until here, at least.
    First factor, fire is the last thing you want on a plane. Over.
    Second factor, fire without clear-cut reason is what you don't want.
    The commentator who seemingly played the matter down "The only person on board ..." is mistaken. If a plane can experience its batteries overheating beyond the temperature that incenses wild fire, without shutting the batteries off beforehand (no temperature control??), and when almost not in service (passengers and crew disembarked), it not airworthy at all.
    In this sense webmistressrachel's comment is uncalled for. Losing a wing or pressure due to a collision is in a sense 'more normal'. Because the reason is clear-cut. But a fire out of the blue is simply a 'must not, ever'.

  9. Re:Titanic by Anonymous Coward · · Score: 2, Insightful

    Actually, they are as bad as it gets. Wing off, you die. Cabin fire, you suffer while knowing you're going to die. There is a distinct difference. Listened to the tapes; they still haunt me.

  10. Re:MSM Strikes Again by Rich0 · · Score: 4, Insightful

    If leaving an APU turned on causes a catastrophic loss of the aircraft, then there is a design flaw.

    However, I don't see how leaving one on should cause a battery to overheat. The batteries should be on circuits that limit currents appropriately, whether charging or discharging. This is an aircraft - not a plastic toy.

  11. Re:Titanic by rickb928 · · Score: 2

    Yeah, wing off, you watch the ground rise to meet you and you die.

    Not sure which waiting period is worse. At least with a missing wing, you hope Sully is in the right seat and can figure out how to land on one wing. Fire is very hard to escape from on a plan, if it manages to find any occupied compartments. I suppose you could try climing, popping the oxygen masks, starve the fire, and hope the emergency oxygen system doesn;t catch fire. And other problems.

    Given my druthers, I guess snakes may actually be the second-least problematic next to crying babies. Or being between an air marshal and a grandmother^H^H^H^H^H^H^H^H^H^H^H terrorist.

    --
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  12. Re:A bit alarmist and FUD by tompaulco · · Score: 4, Funny

    Citing a thing like "FAA identified errors in the assembly of fuel line couplings in the Dreamliner." when the actual fire, according to this morning's Boston Globe, was "[a] Small electrical fire..."
    This article brought to you by Airbus Industries.

    --
    If you are not allowed to question your government then the government has answered your question.
  13. Re:MSM Strikes Again by Richard_at_work · · Score: 5, Insightful

    The aircraft wasn't departing, it had just arrived and the passengers and crew had deplaned.

    Also, no certified crew on a commercial carrier leaves the APU running after its needed - it takes up substantially more than a "tiny fraction of fuel" and leaving it on for even a short haul flight can cost the operator thousands of dollars in extra fuel costs for just that one flight.

    Here's a more educated guess: faulty battery underwent thermal runaway and caught fire, causing a minor explosion and a heck of a lot of smoke.

  14. Makes you wish by Quila · · Score: 4, Funny

    you could open a window

    1. Re:Makes you wish by ThatsNotPudding · · Score: 2

      Makes you wish you could open a window.

      That's quite enough, Mitt.

  15. Re:Titanic by Capt.Albatross · · Score: 2

    | "onboard fires on airplanes are as bad as it gets"

    Hmm... I'm sure a missing wing, or rapid loss of pressure due to a collision, or massive power failure, or lots of other things could be a lot worse than a battery fire.

    Am I correct in assuming TFA doesn't know what on earth (or off it) they're on about?

    No, you are not correct, you are either over-estimating your expertise or over-estimating the importance of being pedantic.

    En-route cabin or hold fires fall into the category of events that will almost certainly be fatal to everyone on board. With a slight application of analytical thinking, it is possible to see that a fire on the ground immediately raises the question of whether this could occur in flight.

  16. Re:Titanic by Anonymous Coward · · Score: 5, Funny

    Dear passengers: I have bad and good news for you. The bad news: we lost a wing. The good news: it was on fire anyway.

  17. Re:MSM Strikes Again by Nidi62 · · Score: 4, Interesting

    Totally unqualified "educated" guess: crew left the APU on even though it's supposed to be off after the engines are up to speed?

    From what simulation and speaking with pilots I've gathered, usually you are "supposed" to turn the APU off after engine starts, though usually this is not done as it consumes a tiny fraction of fuel and gives you some wiggle room in the event of an engine failure.

    Seeing as how the plane was at the gate and the passengers from the ariving flight had deplaned, the engines better not have been up to speed or they would have had bigger problems. Usually if the APU is on while in the gate, it is because ground power is not available. This can happen, but running the APU is much more expensive than electrical ground power. As an educated guess (since I actually work on a ramp) I would assume the APU was not on. If the APU wasn't on, then a fire in the APU battery is definitely not good.

    --
    The only thing necessary for evil to triumph is for it to be pitted against a slightly greater evil
  18. Re:A bit alarmist and FUD by Luckyo · · Score: 2

    The problem with "small electrical fires" is that they tend to become "large electrical fires" and eventually "catastrophic electrical fires" as fire propagates along electric cables quite fast.

  19. Re:Titanic by webmistressrachel · · Score: 2

    1st off, it's Madame, not sir.

    2nd off, every plane with two wings that lost a wing crashed. Not every plane that ever had a fire on it crashed. Go figure.

    What's with the attacks too, who's an idiot now?

    Simple logic puts your links to shame.

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  20. Re:MSM Strikes Again by Luckyo · · Score: 2

    No, but lithium batteries tend to have highly flammable lithium as base.

  21. Re:Titanic by LeadSongDog · · Score: 5, Insightful

    Stop, you're both wrong.
    1. This is not, by definition, an aviation accident: even the crew had deplaned.
    2. Many parked aircraft have lost wings without crashing: all it takes is wind passing over the tarmac on the wrong vector.
    3. A fire, even in flight, doesn't have to be the end of the world if the systems design detects the fire and limits its ability to spread. This was the principal lesson-learned from SR111, which has since changed material approvals for aircraft. SA295 was never adequately explained, so teaches us little, but evidently the firefighting routines were not followed. VJ592 was caused by illegally carried hazmat (oxygen generators) in the cabin. AC797 had many similarities to SR111 (insulation burning spread the fire), but the lessons learned were not applied to designs in time to prevent SR111. I'd blame the FAA's inaction on NTSB recommendations.

    --
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  22. Re:Titanic by bigdanmoody · · Score: 4, Informative

    Indeed, as a former aircraft mechanic, I know that all of the planes that I've worked on have taken fire safety very seriously. The Dash-8's that I've worked on have their batteries placed outside of the pressure vessel. Although I have not personally worked on a plane that uses Li-Ion batteries like the 787 does, my understanding is that aircraft that do use these batteries have numerous warning and safety features to prevent thermal runaway, which sounds like what happened here. Based on the very limited information in TFA, I hypothesize that if the flight crew had been on board, they would have noticed a battery overheat condition and could have taken appropriate action well before a fire broke out.

  23. Re:Titanic by Martin+Blank · · Score: 2

    Orphan Girl Scouts. Gotta have the orphans in there.

    --
    You can never go home again... but I guess you can shop there.
  24. Re:Titanic by HornWumpus · · Score: 2

    An Israeli Air Force F-15 lost almost all of one wing in a midair and was able to land. You can find video, it's insane.

    Not exactly on point, many warplanes have lost big parts of wings and landed. Flying buses aren't in the same league.

    --
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  25. Re:Titanic by bill_mcgonigle · · Score: 2

    Not the whole plane - you make the passenger compartment detachable and capable of parachute descent. It's been designed, shown to be workable, and calculated to be too expensive.

    If there were lower barriers to entry, an airline might be started that had these kinds of planes and people who wanted to pay a premium for that kind of technology could choose to do so. There are many cheap bastards in the world, but many people will pay more to cover their fears, so it might work out.

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  26. Another One Today by MichaelJ · · Score: 4, Informative

    Another Dreamliner just got a fuel leak and dumped a good mess all over a taxiway at Logan until the engine was shut down. Not a good week for 787s in Boston.

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    Michael J.
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