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Boeing 787 Dreamliner completes test flight with new battery system

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Boeing hopes to show aircraft meets safety standards following worldwide grounding of all 50 Dreamliners in January

A Boeing 787 Dreamliner has completed a test flight aimed at showing that the plane's new lithium-ion battery system meets regulatory safety standards, a key step in ending a two-month worldwide grounding of the high-tech jet.

Monday's two-hour flight "went according to plan", said Beoing. If regulators agree they will let Boeing go ahead with a second flight test in coming days that would gather data to be submitted to the Federal Aviation Administration (FAA) to certify the new battery system, Boeing spokesman Marc Birtel said.

The FAA and other regulators grounded all 50 Dreamliners in mid-January after batteries overheated on two separate aircraft: one parked at an airport and the other forced to make an emergency landing in Japan. The FAA in early March agreed on tests Boeing would conduct to return the plane to service.

Resuming flights would be a relief for Boeing, which is losing an estimated $50m (£33m) week while the 787 is grounded. Airlines in Japan, the United States, the Middle East, Europe and Africa that bought the fuel-efficient jet but are barred from using those planes are also suffering. Boeing is still building 787s but cannot deliver them to customers during the grounding.

Some Boeing officials have said the jet could be back in service by 1 May or earlier. But Oliver McGee, an aerospace and mechanical engineer who was a deputy assistant secretary of transportation under US president Bill Clinton, said he was sceptical that regulators would allow service to resume so soon.

"Take whatever date is agreed upon and add three to six months to it," McGee told Reuters. "I don't think that you're going to see any type of quick fix or compromising on the FAA side."

McGee said the trauma of the Columbia and Challenger shuttle disasters would make federal officials reluctant to sign off on the new battery system until they were absolutely sure it would work as Boeing promised.

The US National Transportation Safety Board on Monday set a two-day forum for 11-12 April to examine the design and performance of lithium-ion batteries in transportation – a comprehensive review sparked by the twin battery failures in January. The NTSB also plans to hold a separate hearing on the 787 battery later in April.

Monday's flight, the first with Boeing's new battery system, took off at approximately 12.11pm Pacific time (7.11pm GMT) from Paine Field in Everett, Washington, on a planned two-hour mission designed to validate that all systems on the plane are working as designed.

Live video showed the jet, with LOT Polish Airlines livery, soaring into a clear sky with snow-capped mountains in the distance. It flew south down the west coast of Washington and about halfway down the coast of Oregon before turning back to Paine Field, according to flight-tracking website Flightware.com.

It made a loop out the Strait of Juan de Fuca at low altitude and speed, then turned back towards the airport. The flight landed at 2.20pm Pacific time and the flight crew reported the test "went according to plan", Boeing said in a statement.

Once data from Monday's flight has been analysed Boeing has said it will prepare for a ground and flight demonstration aimed at certifying the company's proposed changes to the battery system. The system is made by Thales SA of France and the battery is made by Japan's GS Yuasa Corp.

Boeing plans to conduct one certification demonstration flight using the same LOT plane to show that the new battery system performs as intended during flight conditions. The system includes a steel box designed to contain a battery explosion and prevent fire, as well as a tube to vent fumes and heat out of the aircraft.

Birtel said it was not clear if the demonstration test for the FAA would conclude Boeing's testing of the new battery system, which was unveiled in Tokyo on 15 March. The tests are being conducted in labs, in planes on the ground and in flight. "Obviously, progress is being made on all three fronts," Birtel said.

Boeing's shares closed up three cents at $84.85 on the New York Stock Exchange.

Despite uncertainty about when the FAA will approve Boeing's new battery system, some experts said the revamped unit is likely to prove successful. The former NTSB chairman, Mark Rosenker, said Boeing has invested hundreds of thousands of engineering hours to develop the improved battery system. "They don't want to put an airplane up that they're going to have to deal with again," he told Reuters.

"They want this thing resolved. They want to do it in an efficient, appropriate, scientific, analytic way. It is not in their best interests to rush a system."

John Goglia, a former NTSB board member, said he expected the steel containment box would work as expected and the plane could be returned to service in April.

"I will give the Boeing engineers the benefit of the doubt that they have designed a box that will handle what the battery can give it," he said. Reported by guardian.co.uk 4 hours ago.

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