Maintenance of Emergency Evacuations Systems for Aircraft Operating Under Part 121

Advisory

U.S. Department of Transportation Federal Aviation Administration

Circular

Date: 10/8/15 AC No: 43-208 Subject: Maintenance of Emergency Evacuation Systems for Aircraft Initiated by: AFS-300 Change: 1 Operating Under Part 121 1. PURPOSE. This advisory circular (AC) provides information and guidance for the maintenance of emergency evacuation systems (EES) used on aircraft operating under the provisions of Title 14 of the Code of Federal Regulations (14 CFR) part 121. Additionally, this AC discusses the responsibilities and means of compliance for the air carrier and persons performing maintenance. EES include components of all aircraft slide-equipped exits affecting the emergency egress function (e.g., slides, slide/rafts, exit doors, exit door or hatch mechanisms, exit door or hatch opening assist mechanisms, tail cone release mechanisms, arm/disarm mechanisms, slide activation mechanisms, electronic slide monitoring systems, and slide-to-airframe attachments).

2. PRINCIPAL CHANGES. This change updates information on emergency evacuation systems (EES) to make it consistent between this AC and FAA Order 8900.1 Volume 3, Chapter 45, Section 1, Safety Assurance System: General. It also corrects the Life Cycle Document Review findings.

PAGE CONTROL CHART Remove Pages Dated Insert Pages Dated Pages 3, 5, 6, and 7 4 /4/03 Pages 3, 5, 6, and 7 1 0 / 8 / 15 John Barbagallo Deputy Director, Flight Standards Service

Advisory

U.S. Department of Transportation Federal Aviation

Circular

Administration Date: 4/4/03 AC No: 43-208 Subject: Maintenance of Emergency Evacuation Systems for Aircraft Initiated by: AFS-300 Change: Operating Under Part 121 1. PURPOSE. This advisory circular (AC) provides information and guidance for the maintenance of emergency evacuation systems (EES) used on aircraft operating under the provisions of Title 14 of the Code of Federal Regulations (14 CFR) part 121. Additionally, this AC discusses the responsibilities and means of compliance for the air carrier and persons performing maintenance. EES include components of all aircraft slide-equipped exits affecting the emergency egress function (e.g., slides, slide/rafts, exit doors, exit door or hatch mechanisms, exit door or hatch opening assist mechanisms, tail cone release mechanisms, arm/disarm mechanisms, slide activation mechanisms, electronic slide monitoring systems, and slide-to-airframe attachments).

2. AUDIENCE. This AC applies to 14 CFR part 121 air carriers.

3. BACKGROUND. Why was the Emergency Evacuation Task Force created?

a. National Transportation Safety Board (NTSB). The NTSB made safety recommendations A-99-99–103, relating to accidents/incidents where the failure of an EES component was a factor. Past efforts aimed at improving EES reliability did not result in significant improvements. Therefore, a comprehensive strategic plan was designed to improve aircraft EES reliability. The overall strategy is to increase awareness of the EES maintenance processes, for equipment installed on and taken off of the aircraft, and to develop new air carrier operations specifications for EES maintenance programs.

b. Public Technical Conference. In 1985, the Public Technical Conference was held to solicit and review information on topics relating to the emergency evacuation of transport category airplanes. Participants included experts in aircraft design, manufacture, operations and maintenance, passenger safety, and aircraft emergency evacuation. During the conference, it became clear that an extended effort would be necessary to properly consider the issues raised by the participants. As a result, in September 1985, the Federal Aviation Administration (FAA) Administrator established the Emergency Evacuation Task Force, which consisted of FAA personnel, part 121 air carriers, 14 CFR part 145 repair stations, and manufacturers, to accomplish the following: (1) Pursue issues raised during the Public Technical Conference; (2) Reassess existing regulations on emergency evacuation of transport category airplanes; and

4/4/03 AC 43-208 (3) Prepare a public report of the findings and recommendations of the task force.

4. FOCUS. What issues did the Emergency Evacuation Task Force identify?

a. Emergency Evacuation Task Force. The Emergency Evacuation Task Force consisted of three technical working groups that were formed to consider the issues raised at the Public Technical Conference. The technical working groups were organized into the following disciplines: Design and Certification, Training and Operations, and Maintenance and Reliability.

A complete record of the Emergency Evacuation Task Force proceedings is available in the U.S.

Department of Transportation (DOT) FAA Report Number DOT/FAA/VS-86/1, Task Force Report on Emergency Evacuation of Transport Airplanes, Volumes I and II.

b. Reliability of Emergency Evacuation Slides. The Maintenance and Reliability group identified the following issues on the reliability of emergency evacuation slides and recommended the development of an AC to address them: (1) Improper maintenance; (2) Training and qualifications; (3) Mandatory reporting of malfunctions, defects, and failures of evacuation systems; (4) Required Inspection Items (RII); (5) Functional testing of evacuation systems on the aircraft; and (6) Inspection intervals.

c. Deficient Maintenance Practices. A study and evaluation of slide maintenance facilities by the Emergency Evaluation Task Force revealed various deficiencies in current maintenance practices. These deficiencies can compromise the safe and reliable operation of EES and contribute to slide malfunctions and failures during emergency evacuations, emergency evacuation demonstrations, and functional testing. An analysis of Service Difficulty Reports (SDR) and accident/incident data involving aircraft evacuations disclosed the following problem areas: (1) Improper packing defects, which include: (a) Slides not folded in accordance with packing instructions; (b) Slides twisted in containers; (c) Improper cover configuration; (d) Nylon webbing installed around the slide after folding; (e) Improper routing of the inflation hose; (f) Cross threading of the jet pump line; Par 3 Page 2

10/8/15 AC 43-208 CHG 1 (g) Improper routing of the firing lanyard; (h) Improper packboard installation; and (i) Incorrect frangible link installation.

(2) Improper installation defects, which include: (a) Improperly routed firing inflation cable; (b) Unattached girt bar release cable; (c) Uninstalled slide cover retainer cable; and (d) Improperly positioned slides.

(3) Component failures/defects, which include: (a) Separated seams; (b) Low pressure in inflation bottle; (c) Bent slide fork fitting; (d) Inflation tube failure; (e) Worn girt bar latch; (f) Torn fabric at girt bar attachment area; (g) Broken pull handle cable assembly; (h) Broken lanyard; (i) Squib failure; (j) Flapper valve failure; and (k) Jammed girt bar.

5. MAINTENANCE REQUIREMENTS. Certain elements are essential for maintenance programs to reduce EES malfunctions and failures. An air carrier’s inspection program and Continuous Airworthiness Maintenance Program (CAMP) should contain the maintenance requirements for EES. The following program areas are identified as essential to an adequate maintenance program to reduce EES malfunctions and failures.

a. Maintenance Organization. The air carrier’s maintenance organization is responsible for ensuring maintenance on the EES is performed in accordance with its manual. The organization will also ensure that competent personnel, adequate facilities, and equipment training is provided for EES maintenance. Air carriers using the maintenance services of a Par 4 Page 3 4/4/03 AC 43-208 contractor will also provide the contractor with a copy of current, complete, and accurate instructions from its maintenance manual.

b. Maintenance Manuals and Documents.

(1) Each service and maintenance facility will maintain current applicable maintenance manuals for the specific equipment being maintained. A maintenance manual control system will be used to see that all manuals are current and include applicable manufacturers’ Service Letters (SL) and Service Bulletins (SB).

(2) Minimum performance standards for emergency evacuation slides are provided in the current edition of Technical Standard Order TSO-C69, Emergency Evacuation Slides, Ramps, Ramp/Slides, and Slide/Rafts.

c. Training and Qualification. Because of the complexity and safety-critical nature of EES maintenance, the air carrier should see that each person performing maintenance or inspections on EES is properly trained and qualified and understands the current maintenance instructions.

Inspection personnel training and documentation of EES maintenance should be part of the training program. In addition, the air carrier should consider including recurrent training as part of its training program and should determine the competency and currency of any contracted maintenance provider. The air carrier should also promote safety-critical awareness to any person who works with or in the vicinity of EES.

d. Records and Reports.

(1) The mechanic or repairman should accomplish maintenance recordkeeping and reporting requirements in accordance with applicable regulations and the air carrier’s requirements.

(2) The air carrier is required to have airworthiness release procedures for any EES maintenance, in accordance with § 121.709.

(3) The air carrier is required to have procedures for reporting the occurrence or detection of each failure, malfunction, or defect of any component of the EES, in accordance with § 121.703. This includes any failure, defect, or malfunction identified during an actual emergency or during training, testing, maintenance, demonstrations, or inadvertent deployments.

e. RII. The manufacturer should identify in its overhaul manual the critical tasks involved in packing, installing, and maintaining EES components. These tasks should be incorporated into the air carrier’s manual as RII items.

f. Functional Testing.

(1) Functional testing of the evacuation slide while it is installed on the aircraft tests the complete EES. This includes the operation of door systems with the evacuation system engaged, as well as slide inflation and deployment. Air carriers may perform functional testing of the slides in conjunction with hands-on flight attendant training.

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10/8/15 AC 43-208 CHG 1 (2) Documentation of functional testing is necessary to determine that any malfunction or failure is adequately defined. This can identify potential maintenance and design changes to increase the reliability for the aircraft EES. Video recording is an effective method to use in documenting functional tests.

(3) All functional testing of the EES should be performed in accordance with the manufacturer’s instructions and in accordance with the air carrier’s manual.

g. Maintenance Facility. Maintenance and testing facilities should be kept clean, environmentally regulated (e.g., temperature/humidity control), and equipped with appropriate air handling and vacuum systems. To prevent foreign object damage to the slide assembly, slide-servicing areas should be segregated from all other types of work areas.

6. DISCUSSION. What EES maintenance tasks should be conducted during scheduled maintenance?

a. Instructions for Continued Airworthiness. Maintenance tasks should be performed in accordance with the air carrier’s maintenance program, which is usually based on the manufacturer’s instructions for continued airworthiness. For EES’ continued airworthiness, manufacturers and air carriers should determine appropriate life limits of safety critical components.

b. EES Maintenance Tasks. The following are examples of EES maintenance tasks incorporated into a typical maintenance program.

(1) Check the evacuation slide assembly for proper inflation bottle pressure.

(2) Clean, inspect, and lubricate the girt bar and attachment latches.

(3) Check the slide assembly operation by deploying the slide from the aircraft.

Accomplish this check on a sampling inspection basis so that continued maintenance requirements remain valid and include, as part of the sampling inspection, accidental slide deployment data. Accidental deployment data may not be used as the sole source to support revised inspection or overhaul times.

(4) Remove the slide from the aircraft and inspect the surrounding areas to determine that nothing could interfere with or prevent deployment.

(5) Visually check the slide packboard release and deployment mechanism.

(6) Perform an off-aircraft operational test of the slide to determine proper inflation and air retention using facilities equipped for this type of testing.

(7) If a slide inadvertently falls from an aircraft, inspect it in accordance with the manufacturer’s instructions and procedures before reinstallation. Internal damage, which may not be detectable by external inspections, may be present.

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10/8/15 AC 43-208 CHG 1 c. Why Are Maintenance Time Limitations Needed?

(1) Inspection periods for EES will determine the continued serviceability and immediate readiness of EES equipment for its intended emergency purpose. Major inspection periods are established to determine that all components of the equipment are complete and serviceable and may be expected to remain in this condition until either the next major inspection or actual use under emergency conditions.

(2) Two types of inspection tasks are used in aircraft maintenance: failure-finding tasks, which identify functional failures, and failure prevention tasks, which identify potential failures.

Therefore, an air carrier’s maintenance time limitations should contain a list of EES tasks, consisting of on-aircraft inspections, measurements, or tests, from which a determination is made of the item’s capability to immediately perform its intended emergency purpose. Deployment or functional testing should be included and used on a sampling basis to validate the serviceability of each item of the EES. In the Continuing Analysis and Surveillance System (CASS) process (see subparagraph 6d below) for EES, an increase of failures during deployments or functional testing will initiate a corresponding increase in the sampling rate.

(3) Scheduled deployments on the aircraft or during a combination of on-aircraft functional tests, inspections, and test-fixture usage may be used, provided the test-fixture replicates the aircraft installation. The number of scheduled deployment checks should be included for statistical validity. Inadvertent deployments, while a source of useful information, should not be considered or used as the sole source of reliability information.

(4) The inspection and overhaul time limits for EES may be revised after an air carrier has gained service experience and has substantiating data to justify a revision. The inspection periods for EES will determine the continued service readiness for emergency use. Revisions to inspection and overhaul times should be accomplished in accordance with the manufacturer’s recommendations and the air carrier’s maintenance program, where appropriate.

d. What is CASS? CASS is an air carrier quality assurance (QA) system. The FAA introduced regulatory requirements that require air carriers to establish and use a system for the continued analysis and surveillance of the performance and effectiveness of inspection and maintenance programs.

7. RELATED READING MATERIAL (current editions).

a. Title 14 CFR. Title 14 CFR §§ 121.309, 121.310, and 121.373. Copies of regulations can be obtained at http://www.faa.gov/regulations_policies/faa_regulations.

b. FAA Documents.

(1) DOT FAA Report Number DOT/FAA/VS-86/1, Task Force Report on Emergency Evacuation of Transport Airplanes, Volumes I and II. Volume I can be obtained at https://ntrl.ntis.gov/NTRL/dashboard/searchResults.xhtml?searchQuery=ADA171641 , and Volume II can be obtained at https://ntrl.ntis.gov/NTRL/dashboard/searchResults.xhtml?searchQuery=ada172256 .

Par 6 Page 6 10/8/15 AC 43-208 CHG 1 (2) Technical Standard Order TSO-C69, Emergency Evacuation Slides, Ramps, Ramp/Slides, and Slide/Rafts, can be obtained at https://www.faa.gov/about/initiatives/cabin_safety/regs/tso .

c. ACs. Copies of ACs can be obtained at http://www.faa.gov/regulations_policies/advisory_circulars .

(1) AC 00-46, Aviation Safety Reporting Program.

(2) AC 20-41, Substitute Technical Standard Order (TSO) Aircraft Equipment.

(3) AC 20-62, Eligibility, Quality, and Identification of Aeronautical Replacement Parts.

(4) AC 20-77, Use of Manufacturers’ Maintenance Manuals.

(5) AC 20-176, Service Bulletins Related to Airworthiness Directives and Indicating FAA Approval on Service Documents.

(6) AC 120-16, Air Carrier Maintenance Programs.

(7) AC 120-17, Maintenance Control by Reliability Methods.

(8) AC 121-22, Maintenance Review Boards, Maintenance Type Boards, and OEM/TCH Recommended Maintenance Procedures.

Par 7 Page 7 Advisory Circular Feedback Form If you find an error in this AC, have recommendations for improving it, or have suggestions for new items/subjects to be added, you may let us know by contacting the Aircraft Maintenance Division (AFS-300) or the Flight Standards Directives Management Officer.

Subject: AC 43-208 CHG 1, Maintenance of Emergency Evacuation Systems for Aircraft Operating Under Part 121 Date: _____________________ Please check all appropriate line items: ☐ An error (procedural or typographical) has been noted in paragraph ____________ on page _______.

☐ Recommend paragraph _____________ on page __________ be changed as follows: ______________________________________________________________________ ______________________________________________________________________ ☐ In a future change to this AC, please cover the following subject: (Briefly describe what you want added.)

______________________________________________________________________ ______________________________________________________________________ ☐ Other comments: ______________________________________________________________________ ______________________________________________________________________ ☐ I would like to discuss the above. Please contact me.

Submitted by: Date: ______________________