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November 2011 Archives

Boeing 787 Dreamliner N787BA ZA001

Thursday, December 1, ZA001 will ferry to Palmdale, California.

It will be the aircraft's last flight for a while, as the first 787 will be decommissioned as a test aircraft, Boeing confirms. 

Its Rolls-Royce Trent 1000 engines will be removed and it will remain in long-term storage before finding its way to a permanent spot in a museum, likely not far from the first 757, 747 and 737.

It's a coincidental bookend of sorts, its ferry coming a day after Boeing and its largest union reached a landmark deal to secure 737 Max production in Renton. Much of the program's life was defined in-part by the contentiousness between labor and management.

ZA001 may also be the single most expensive test asset in commercial aviation history, with the aircraft's estimated cost exceeding $4 billion, say company sources.

Its flying life as a globe-trotting test aircraft will conclude just 15 days shy of its second birthday as a flying machine and its extended gestation in Everett filled the two and a half years that preceded. It was a strange way to come into the world for this first carbon fiber jetliner, wound from looms, rather than forged from metal. 

Those who assembled it felt it almost maddening at times, rife with frustration and the stress of the push to speed it towards flight test. 

The machinists and engineers could make a washing machine fly if they had to, and there were days that making ZA001 into a living, breathing aircraft seemed to feel that way.

Then-787 chief systems engineer Mike Sinnett held his blackberry up to ZA001's cooling fans, running for the first time in June 2008, on the other end was David Hess, then-Hamilton Sundstrand CEO, whose electrical power system had brought the aircraft to life.

When it came time for its first factory gauntlet in April 2009, ZA001 proved incredibly hard to fool, stubbornly refusing to raise its landing gear. A flip of the gear handle would not suffice, its deeply integrated computer systems had to be tricked into believing it was flying.

"Hot diggity dang, TM, it works!" were the words from then-787 Chief Pilot Mike Carriker at the controls of ZA001 on December 15, 2009 as the jet climbed away from Paine Field for the first time. 

Assembled, disassembled, re-assembled and disassembled and reassembled a few more times after that, the amount of changes made to its structure and fasteners and the lack of initial documentation made its future as a member of All Nippon''s fleet - any fleet - a non-starter. 

It officially left Boeing's production inventory in March 2009, though the official disclosure, along with a $2.5 billion charge to its earnings along with ZA002 and ZA003, shifted the first three 787s to research and development duty in August of that same year.

ZA002 lives on as a demonstration aircraft for Boeing Charleston, while ZA003 will take the lead on the Dream Tour over the next half year.

Though its service was brief in comparison to the company's other first models in its near 100-year history, ZA001's impact will be felt for decades, having laid the foundation for the company's technological and financial future.
American Airlines Boeing 737-800 N875NN

Just breaking now, The Seattle Times reports that the IAM and Boeing have reached a sweeping deal to place the 737 Max final assembly line in Renton, having secured a new four-year contract as well as a settlement of the National Labor Relations Board complaint against the company's second 787 final assembly line in Charleston.

UPDATE 2:28 PM: The IAM and Boeing have confirmed the deal, saying that once a December 7 ratification vote takes place, the union will instruct the Obama administration that its grievances have been resolved and the NLRB dispute will be dropped.

UPDATE 4:16 PM: Reactions are pouring in from around Washington, from the State's two US Senators, the Mayor of Renton, Snohomish County Executive (PDF) and SPEEA

My first pass at the story:
The union leadership has recommended its members approve the new four-year contract, which includes a $5,000 ratification bonus, a 2% cost of living wage increase each of the four years on the contract, pensions for new hires, new health care plans and preservation of medical benefits for retirees.

"Boeing has assessed the business case for locating production of the 737 MAX in Renton in light of the economics of a proposed new labor agreement and the company is prepared to locate 737 MAX production in Renton provided the economics contained in that proposal are achieved," said Boeing

Here are the complete details of the contract that being shared with the union's membership.

This is a breaking story and will be updated.

Airbus just announced that A320 MSN001 - fitted with Sharklets - has completed its first flight from its Toulouse, France base. Video of the flight itself isn't yet available, though Airbus has released footage of the installation process of the new fuel-saving wingtip treatments.

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Photo Credit Airbus
Air India Boeing 787 Dreamliner ZA236

US Federal Aviation Administration certification of the General Electric GEnx-1B-powered 787 is set to slide to early 2012 due to the lack of availability of a production aircraft to satisfy final regulatory requirements, sources confirm.

While Boeing has completed a portion of its extended operations (ETOPS) and functionality and reliability (F&R) testing on a Block 4 GEnx test aircraft ZA005 and ZA006, the FAA mandates a portion of the required 300h F&R campaign to be undertaken on a production aircraft.

Boeing and GE had intended to certify the Block 4 GE-powered 787 variant in the fourth quarter 2011.

Boeing declined to comment on the GEnx 787 certification schedule.

Boeing will employ Airplane 35 a GEnx-powered 787 for Air India as its confirming production article for testing, though the slow process of change incorporation has pushed the aircraft's first flight to the first half of December, sliding the completion of the FAA's Part 25 requirements.

The delay has pushed Air India's first delivery into 2012, after its latest schedule had it being delivered in the fourth quarter of 2011, already delayed from 2009.

The aircraft is expected to transition from the company's Everett, Washington factory to its flight test base at Boeing Field in Seattle later in December, say program sources.

ZA005 remains an active test aircraft, conducting flight tests of the GEnx-1B's first performance improvement package (PIP1), expected to deliver a 1.4% improvement in specific fuel consumption, due to an increase in the number of low pressure turbine (LPT) blades.

The Block 4 GEnx-1B engine configuration received FAA certification in March 2008, and the PIP 1 configuration was certified in August. A second PIP for the GEnx-1B is expected to achieve engine certification next year.

Test aircraft ZA006 is currently having its instrumentation removed in preparation for its coming relocation to Boeing's Global Services & Support facility in San Antonio, Texas for refurbishment.

Boeing has delivered two Rolls-Royce Trent 1000-powered 787s, both to All Nippon Airways and aims to deliver a combined 15 to 20 747-8s and 787 in 2011, two-thirds of which will be 787s.

The slow pace of aircraft change incorporation has continued to put pressure on Boeing's delivery schedule, with its internal planning showing five more deliveries in 2011. However, program sources caution that only one or two 787s for ANA will be ready for delivery before the end of December.
American Airlines Boeing 737-800 N869NN

After months of speculation about its seemingly impending bankruptcy, American Airlines officially filed Chapter 11 protection this morning to restructure its business. The filing comes after years of network issues, hemorrhaging cash and labor disputes, as well as ordering massive amounts of aircraft - perhaps more than any other airline in the world.

According to Boeing and the airline's recent US Securities and Exchange Commission filings, American Airlines holds firm orders for a total of 15 777 aircraft, split between 9 777-300ERs and 6 777-200ERs, as well as orders for 143 outstanding 737-800s.

Of its record 460 aircraft order in July, only the 100 737-800s have been officially added to Boeing's backlog, part of that 143 narrowbodies still to deliver.  In the near-term the consensus thus far points to the bankruptcy hastening the departure of the MD-80s from American's fleet. 

UPDATE: Airbus says the 130 current generation A319 and A321 aircraft that were a part of the July order are now a part of its backlog as firm orders.

American Airlines Senior Vice President Craig Kreeger says of the record aircraft buy: "That order is rock solid. Airbus and Boeing will give us the youngest fleet in the industry within a few years ... and that remains an important part of our strategy."

Though even with that assurance, longer-term questions remain about the massive number of unfirmed orders waiting to be put on Airbus and Boeing's books, all of which are dependent on the process of American's restructuring.

Boeing issued the following statement earlier today:
We anticipate as part of American's reorganization that new, fuel-efficient airplanes will be a key part of their ongoing success, so we expect these Boeing airplanes to be a part of it.

We have seen a number of our customers go through the bankruptcy process and successfully reorganize. We hope it will be an opportunity for American to do the same and emerge stronger from the process.

When we entered into our recent agreements with American, we were confident that these assets at issue will be core to their operation in almost any scenario. We have no reason to doubt that today.
Of its orders that are not yet firm, American holds 130 A320neos and 100 737 Max aircraft. Further, American has unfirmed orders from Boeing for 42 787-9s, which are dependent on approval of a new agreement with its pilots. The airline also has purchase rights and options for 365 more A320 family aircraft, 40 737-800s and 60 737 Maxs, and 58 787-9s

All told, American Airlines holds firm, unfirmed commitments, options and purchase rights for 1081 aircraft, 795 of which currently stand as commitments to Boeing and Airbus.
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Following last week's roll-out of the first Airbus A320 fitted with Sharklets - and the new addition of its shark teeth - there were a lot of questions about what modifications were required to actually fit the new winglets to the narrowbody. 

The extent of the modifications made to A320 MSN001 should provide an indication of why a retrofit program may prove to be extremely costly for in-service pre-2012 A320s. 

The flight testing had initially been slated to begin in October, though the installation of the required structure for the Sharklets proved "tedious", with additional work needed in the original 1987-model narrowbody, which has been changed multiple times during its life as a flight test aircraft.

To equip an already-built A320 for flight test, Airbus had to remove the wing's flaps and slats to then remove the wing skin for internal reinforcement and installation of flight test instrumentation. While there are no changes to the wing's spar configuration, the outer spar and most ribs are strengthened with added material.

Of the ribs in the wing of an A320, Rib 27, the outer-most, has been fully redesigned to offer compatibility with the current wing fences and the option to fit the Sharklet at a later date. All of the ribs outboard of Rib 8 have been strengthened after Airbus re-studied the higher bending yaw and torque loads that would come from the installation of the new wingtip treatment.

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Further, Airbus is also strengthening the aircraft's center wing box in some local areas, though rather than make second modification for the updates to the structure for the A320neo starting in 2015, the airframer will add "all the modifications in pretty much one pass" on the first Sharklet-equipped A320, says Tom Williams, Airbus executive vice president programmes.

"So we think we'll have it done in a way that will take care of both Sharklet and Neo without having to have two iterations of it," he adds of the incremental approach to the new variant's development.

Additional inboard rib and spar reinforcement for the added maximum takeoff weight and new CFM Leap-1A and Pratt & Whitney PW1100G engines will be incorporated when the A320neo goes into production well ahead of the October 2015 service entry with Qatar Airways.

The strengthened Sharklet center wing box will mean higher structural weight in those areas, though Williams says an airframe-wide weight-reduction plan of around 440lbs (200kgs) will make the reinforcement weight neutral. 

"If you take a delivery of an aircraft last year (2010) and an aircraft next year (2012)," Williams said in April, "You'll not be able to tell the difference between fuel burn and performance of those aircraft; whether they're Sharklet-ready aircraft or not. So, I think it's a pretty good incorporation of some very sound engineering work."

The new Sharklet-ready wings are expected to enter the production system in early 2012 and will be delivered to customers with wingtip fences before being modified with the new winglets following their EASA certification late next year.

Photo Credit Airbus

Part Two in a series on the Pratt & Whitney Canada PT6 turboprop. Read Part One.
BOULDER CITY -- Journalists are advised never to get emotionally entangled in a story, and certainly not physically. Though this assignment found your correspondent unavoidably invested.

I'm about to get thrown out of a perfectly good aircraft with five other people.

"Why gamble with your money when you can gamble with your life???" asks Skydive Las Vegas, with two extra question marks added for emphasis.

Based at Boulder City Airport southeast of The Strip, and just south of Lake Mead, Skydive Las Vegas has been asking that provocative question of its customers since 1993.

When you think of business aviation, red carpets, plush leather cabins and twin turbofans tend to come to mind. Now picture a Pacific Aerospace P-750 XSTOL, a single-engine Pratt & Whitney Canada PT6A-34A-powered turboprop with bench seating and bare metal floors.

Quantifying the impact of business aviation on the economy is often a difficult and abstract task. Despite being one of the lesser-seen faces of business aviation, the skydiving operations at SLV and its single aircraft and its single engine directly support more than two dozen jobs.

Admittedly, there's not a lot of sex appeal in a half-century old engine design, just a whirring certainty for SLV, which can fly as many four flights an hour; each climbing to 15,000ft, and dropping as many as 16 tandem skydivers at a time.

The aircraft's thick camber wing and its 750hp (560kW) engine, can carry more than 4,000lbs, a payload in excess of the P-750's own empty weight, just 3,100lbs.

Today, I'm strapped to Kelly Corcoran for our tandem jump, along with five of SLV's professional skydivers for some special formation falling.

Our walk to the aircraft is a euphemism uncomfortably referred to at SLV as the 'the green mile walk', a tongue-in-cheek way of disarming, or in some cases arming, a person's concerns about free falling.

After its human payload is headed for Earth, it's a race to the ground. A 3,000fpm descent puts the PT6-powered prop back on the ground before the last jumper's heels hit dirt on the edge of the airport.

The P-750 and its PT6 engine, says SLV owner and manager Brent Buckner, was a natural choice for the job, as the New Zealand-built aircraft is custom designed for skydiving, equipped with a factory-fitted aft door closing mechanism, eliminating the need for an extra crew member to fly along to close the door after jumpers have departed.

"This was the first airplane designed from the ground up for skydiving," says Buckner. "Every other jump airplane that exists today is a modification, it's been modified and changed to accommodate skydiving and the mission. 

"This one was designed with skydiving in mind, everything from the performance aspects of it to the internal construction to the specially designed jump door. This is the only aircraft that comes out of the factory skydive ready anywhere in the world."

Separated by nearly 5,900nm, just getting the P-750 from the factory in Hamilton, New Zealand to Boulder City Airport was a saga in itself. The aircraft was fitted with FAA-approved cabin fuel tanks for its island-hopping delivery, raising the gross weight of the aircraft to 10,000lbs, providing a sense of the carrying capacity of aircraft's structure.

The P-750 replaced its PT6-114A-powered Cessna Caravan as its lead aircraft. While the company keeps a 1966 Cessna 182J as a backup, the P-750 is SLV's workhorse, providing around 50% less maintenance and a higher time between overhaul than the Caravan, 3,600h compared to 4,000h.
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Spotters in Hamburg captured A350 forward fuselage Section 13/14 being loaded into the Beluga SuperTransporter on Monday. The four-panel Section 13/14 is fabricated and assembled by Premium Aerotec in Nordenham, Germany, another wholly-owned EADS subsidiary and sent by boat to Hamburg for equipping. 

UPDATE: Pictured in the photo is MSN1.

Judging by the photograph, the section was being shipped from Hamburg Airport to St. Nazaire where it will be joined with Aerolia's Section 11/12, the A350's nose and flight deck. The fully joined forward fuselage will be reloaded onto the Beluga for shipment to final assembly in Toulouse. 

Airbus will first activate its final assembly line with the A350 static airframe, dubbed 'ES' by the airframer, followed by the first test aircraft MSN1. After being assembled, ES will be tested in the L34 facility in Toulouse.

Airbus said MSN001's Section 13/14 had been handed over to the Hamburg facility on October 20, while Premium Aerotec said its "first A350 XWB fuselage section" made the 12hr boat journey to Hamburg on November 10 - not saying explicitly if that was ES or MSN001. The announcement came the same day the airframer delayed the new majority-composite jet's entry into service to the first half of 2014. It not clear from the photo if this particular Section 13/14 is ES or MSN001.

Photo Credit Helmut
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The original A320 prototype rolled out of a hangar in Toulouse this morning, sporting Airbus-designed winglets or "sharkets", which will enter service with Air New Zealand starting next year. The coming flight test evaluations represent a near-final configuration in a long series of evaluations undertaken by Airbus to take its original wing fence design and replace it with a full-fledged winglet. The wing fence design was first introduced with the A320-200 model in November 1988.

Airbus returned to evaluations of wingtip treatments for the A320 family in early 2006, announcing it would flight test two designs. The first, a standard angled winglet and the second and a parabolic blended winglet design from Winglet Technologies. The angled winglet was flight tested in April 2006 and the parabolic design followed on MSN001 in July of that same year.

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Airbus turned to Aviation Partners for a better winglet design after the 2006 angled and parabolic trials failed to achieve the desired improvement in performance. The Seattle-based Aviation Partners is better known for the its joint venture with Boeing, providing winglets for the 737, 757 and 767 family aircraft. The company offered a scimitar blended winglet to Airbus for the A320 family, flight testing the design in December 2008

JetBlue, eager to get its hands on the fuel saving winglets for its flee, lent an aircraft to Airbus for flight testing of both the angled and parabolic winglets designs during the initial trials on MSN2755 in June and September 2006, as well as the Aviation Partners scimitar design aboard MSN1904 in January 2010

Airbus made its winglet plan official with its selection of its own design at the 2009 Dubai Air Show, branding its own configuration as "sharklets". At June's Paris Air Show, Airbus also agreed to evaluate a retrofit winglet program for existing A320 family aircraft, though few details of the program have been firmed up.

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Photos Credit Airbus (1, 2, 5), Christophe Ramos (3) & Yannick Delmarre (4)

TOULOUSE -- The familiar Rolls-Royce Trent 900 flying in the number two engine position under the wing of the first A380 has been replaced by Trent XWB as the engine-maker and Airbus are approaching the start of the powerplant's 175h flight test program. 

With 1,200h of testing accumulated across eight engines at test facilities in five countries, Chris Cholerton, R-R director of the Trent XWB programme, said specific fuel consumption tests are tracking ahead of expectation for typical early build engines and that it is the company's expectation that the A350's engine will be the "world's most efficient civil turbofan." 

The 118in (300cm) fan, designed to produce 84,000lbs of thrust for the A350-900, has been installed on A380 MSN001 with a multi-million dollar bespoke pylon that features on one end an A350 engine interface, and an A380 wing interface on the other. 
  
The heavily instrumented engine has already begun ground runs on the A380, and will relay 1,200 individual parameters, the most for a civil programme by Rolls-Royce, will measure and twice as many as any previous evaluation. The instrumentation alone adds 600kg (1,300lbs) of weight to the test engine.

Once the new majority-composite aircraft is flying, each engine for the A350 flight test program will be less instrumented than the certification engine as the 1,300lbs of instrumentation will be spread across the aircraft's two engines. Both A350 MSN001 and MSN003 will be fully instrumented test aircraft. 
 
On the A380's flight deck, test pilots have a mechanical link installed between the A380's throttle quadrant and the A350's, positioned at the rear of the pedestal. In the cabin of the A380, flight test engineers have live access to all the data streaming off of the engine, as well as access to the Trent's electronic engine control (EEC) software, which will be able to be changed in flight. 



While Airbus only says the Trent XWB flying test bed would make its first flight in the "coming weeks", the Rolls-Royce says a minor design change could slide that target further by "a few weeks".

During the engine's required 150h endurance testing, which wrapped up in September, Cholerton said R-R discovered damage on the engine's "rotating air seal that separates the [intermedia pressure] turbine from the back of the [low pressure] turbine"

"That's an issue we can easily resolve," he said, adding an updated design has already been manufactured. 

If Rolls opts to install the modification before beginning its flight trials the engine will have to be removed from the A380's wing.

"We may elect to change that prior to flight, because we can, it's simple to do," he said. "We can do it here in Toulouse. We can still be flying the flying test bed over a year ahead of first flight. We want to test the final production standard of part, that's a good thing to do for our maturity objectives."
Lion Air Commitment for up to 380 Boeing 737s

AFP is reporting out of Jakarta, Indonesia this morning that low-cost carrier Lion Air, who served as launch customer for the Boeing 737-900ER, has placed a record $21.7 billion order for 230 737s, including 201 737 Max aircraft.

The order is said to include options for 150 additional aircraft.

According to the reports, the announcement was paired with President Barack Obama's arrival in Indonesia and comes just days after Boeing broke its own order record with Emirates' $18 billion purchase of 50 777-300ER.

Boeing has not yet confirmed the report, nor has it disclosed the list price of any of its 737 MAX models.

Lion AIr joins American Airlines as the second disclosed customer to commit to the 737 MAX, whose commitments stand at 700 from nine customers. Boeing has not yet to firmed any orders for its recently launched CFM International Leap-1B powered 737.

UPDATE 9:35 AM: Boeing confirms the order, which currently stands as a commitment for 230 737 family aircraft, with options for 150 more.

UPDATE 10:34 AM: My first pass at the story: Lion Air commits to up to 380 Boeing 737s

Photo Credit Boeing
Japan Airlines Boeing 787 Dreamliner JA822A/N1003W ZA177

Boeing's Airplane 23, ZA177 for Japan Airlines, ferried to Everett on November 13 with little fanfare.

Yet this particular 787 returned quite different from when it left the Pacific Northwest in March. The aircraft completed eight months of change incorporation at Boeing's Global Support & Services facility in San Antonio, Texas.

The site, which sits adjacent to Lackland Air Force Base, is being used to modify six 787; refurbishing the three commercially viable test aircraft, three production aircraft, as well as the 747-8F test fleet. 

Boeing has not yet decided if it will expand San Antonio's scope beyond these first six 787s.

The duration of ZA117's stay in San Antonio provides an indication of both the scope and pacing of the 787 change incorporation operation that is taking place in Texas and Washington State. 

Further, it also provides a broad measurement of the top of Boeing's learning curve for modifying 787s, as aircraft assembled after Airplane 23 will require less re-work.

When the facility was first inaugurated in early-March, Boeing was bullish on how long it would take for a 787 to be modified and brought into full post-certification compliance before being outfitted with a revenue interior:
"We're not far away," says David Pickering, director of field operations at the Everett site. "This signifies a point in the program where this airplane is getting darn close. A few months worth of work down here and managing the end of flight test, and then we're looking at interiors." 
Pickering adds Boeing will know if additional aircraft will be coming to San Antonio at the conclusion of flight test around "early summer" in June or July. 
Airplane 23, also known as ZA177, is expected to remain in San Antonio for change incorporation until mid-summer, before returning to Everett for final installation of the aircraft's interior and repainting with JAL's new colors.
With Z24 to be released later this month, Boeing's latest delivery and production schedule, there are strong suggestions the pace of change incorporation in Everett and San Antonio has slowed 2011 deliveries further, pushing early aircraft into 2012. 

While in Texas, Airplane 23 underwent extensive changes including wholesale replacement of its environmental control system air-conditioning packs and modification of ducting and baffling in the aircraft's cabin, as well as motor and fan changes and related software.

Further, modifications were made to the aircraft's flight control system hardware and software, changing out the outboard ailerons, outboard and inboard flaps and flaperons, as well as making changes to the elevator and rudder systems.

The aircraft now features a new wiring configuration, along with the fully certified version of the updated electrical power distribution system that was changed after the November 2010 fire aboard test aircraft ZA002.
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With its E-Jet sales surging and regional competitor Bombardier focused on the clean-sheet 125 to 149-seat CS100 and CS300, Embraer is turning its focus to the evolution of its existing commercial aircraft with a new engine ready by 2018, currently dubbed the EV.

Flightglobal reports out of the Dubai Air Show (PDF Daily) elaborate on the Brazilian airframer is plans to focus on a re-engined version of the E-175, E-190 and E-195, with a potential fourth member of the EV family with a further stretch of the E-195 to 130 seats. The fifth, a re-engined E-170, the smallest member of the E-Jet family, is less likely, says Cesar de Souza e Silva, president of Embraer Commercial Aviation, unless scope clauses in the US are relaxed.

"If that does not happen, then we may not go ahead with the 170," he says.

The move toward a re-engined E-Jet sets up a major engine competition between General Electric and its CF34-10E replacement engine, Passport, and Pratt & Whitney's PW1000G. Only those two engines were mentioned by Embraer, while the 16,000-25,000lb Rolls-Royce Advance2 (PDF) and its 2016 and 2017 service readiness was not included.

The aiframer is currently studying a new wing for the family, as well as an updated flight deck, full fly-by-wire and implementation of composite materials.

Low Cost and Regional Aviation News reports Cesar says the EV "could be similar to when Boeing produced the 737NG with almost an all-new aircraft inside the same skin."

Rendering Credit Embraer
Emirates Boeing 777-300ER A6-ECZ

Many say that Emirates is to the 777 as Southwest is to the 737 and Sunday's order for 50 more 777-300ER aircraft cemented that status further. The order, the largest in Boeing's history, is worth up to $26 billion when factoring in the 20 additional options, though the company's largest customers receive heavy discounts for their purchases.

Emirates is known for using the Dubai Air Show for its splash orders, spending an estimated $34.2 billion (at list prices) for 70 Airbus A350s, 11 A380s and 12 777-300ERs in 2007.

With 95 777s in operation today and another 41 777-300ERs on order, Emirates has accounted for 9.7% of the program's total deliveries since 1995. That share will grow to 10.2% in March 2012 when the airline takes delivery of the 1,000th 777, the airline's 102nd of the type. When factoring in the 50 new orders, Emirates is responsible for 24% of the 777's backlog, which stands today at 375.

Emirates also holds the largest share of the A380 backlog at 41%, 73 on order, and the second largest for the A350 at 12.3% with 70 on the books.

To look at the historical ordering patterns of Boeing's largest narrowbody customer, Southwest behaves similarly to the aircraft-maker's largest widebody customer. On an backlog-to-backlog comparison, the 92 outstanding orders held by Southwest represents 4.2% of Boeing's future 737 deliveries.

According to its orders and delivery website, Southwest has placed direct orders with Boeing for 676 737s (of all generations). Though the most frequently occurring order quantity may surprise: Three. Yes, in that total there are huge blocks of orders for 63, 59 and 94 aircraft, but Southwest's Red DNA - its steady methodical growth - has defined its time as a Boeing customer. 

Similarly, even with Sunday's mega-order for 50 777s, Emirates' direct buying behavior matches Southwest's, with a median order total of just 11 777 aircraft at a time since 1992.

With their massive stakes in the future of the Boeing backlog, both customers have already laid out their respective capacity bridges to the company's future products. The launched and yet-to-be-defined 737 Max and yet-to-be-launched but more defined 777-9X have met different reactions by the airframer's biggest customers.

The two airlines diverge when it comes to providing public input for Boeing's new development programs. Former Southwest CEO Herb Kelleher's comments to Aviation Week on the eve of the surprise American Airlines 737 re-engining decision was largely seen as the subtle cue for the future of the narrowbody which has forever been the centerpiece of the low-cost carrier's fleet. 

Emirates' propensity for public commentary with its aircraft suppliers' product strategies are well documented. President Tim Clark's displeasure with the latest iteration of the A350-1000 and its advice to Boeing about the future of the 777-9X, the composite winged 777-300ER successor, are hallmarks of its methods of persuasion. 

The Dubai-based carrier's own relationship with Boeing remains fundamentally different from Southwest's. Despite the mega order and the deep involvement in the -9X's development, 

Applying a Red or Blue label to Emirates isn't as straightforward as it seems. While Emirates could be called Red, with its tightly integrated growth strategy with the Emirate of Dubai, it exists in a developing (immature) market, where innovating its products rather than processes yields a high return. For its relationship with Boeing and Airbus, the relationship is zero-sum: "All I have to do is pick up the phone and order more Boeing 777s," Clark warned Airbus in 2010 regarding delays to the A350

Though Emirates eagerness to serve as launch customer for the -9X stands in contrast to Southwest's reservation of judgement over the 737 Max: "We are just now being briefed on what it does, what it doesn't do, and it's just too early to give you an answer on either our evaluation of that or what we might do," said Southwest CEO Gary Kelly on the airline's third quarter 2011 earnings call.

For Boeing, there remains a marked difference between the inception of the 737 Max and the 777-9X and how the company has developed each product. Both are intended to be incremental evolutions of today's products, with an estimated three years between them, but how each have come about with the input of the airframer's largest customers could not be more different.

Travel Day: CDG-IAD, originally uploaded by flightblogger.

PARIS -- It was a sprint from one flight to another at De Gaulle after a spontaneous strike by the Air France gate agents in Toulouse delayed my flight north by two hours. The run between terminals ended shortly before this photo was taken and with minutes to spare and more than 100 passengers still left to board ten minutes before our departure time. You may recognize the aircraft in the photo, it's F-HPJA, MSN033, the first Airbus A380 delivered to Air France. The seven-plus hour flight to Dulles will be my first extended opportunity to churn through all of yesterday's A350 briefings, which were rife with the lessons gleaned from the A380 program. Much more still to come. See you on the other side of the pond.

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TOULOUSE - Airbus has shifted final assembly of the first A350 XWB to the first quarter of 2012, with service entry of the new majority composite widebody with launch customer Qatar Airways to the first half of 2014, parent EADS has announced in its third quarter results.

Further, EADS has announced a €200 million charge on the program.

The company has cited the "maturity of the A350 XWB main components" as Airbus primary focus, though no other details about the reasons for the slip have been released yet.

Few details are expected to be released at this point by EADS, though a small contingent of journalists (including this one) is in Toulouse, site of the A350 final assembly line, for a comprehensive day of briefings that is expected to explain the current state of the program.

UPDATE 10:34 CET: Airbus A350 XWB program chief Didier Evrard says the start of assembly of the static test specimen (ES), the first A350 to be brought together in Toulouse, is paced by the complexity of the aircraft's center fuselage panels and fixed trailing edge, supplied by Spirit AeroSystems and GKN, respectively.

The second aircraft assembled in Toulouse will be MSN001, the first A350 to fly, followed by an identical flight test aircraft in MSN003, while the fatigue aircraft (EF1, 2 & 3) will come fourth and subsequently MSN002, which is the airframer's interior test bed.

Photo Credit Airbus

Travel Night: IAD-AMS-TLS, originally uploaded by flightblogger.

Greetings from KLM Flight 652. This 2006 model Airbus A330-200 (PH-AOF) will take me across the Atlantic tonight to Amsterdam headed for Toulouse to spend a few days with Airbus. Thursday morning will feature a comprehensive day-long briefing on the A350 XWB, which coincidentally coincides with the EADS third quarter earnings release.

The last time I was in Toulouse, Airbus was still selecting supplier partners for the aircraft and today those suppliers are feverishly working to complete and deliver parts to final assembly. The program's schedule will be the centerpiece of the discussions on Thursday, but beyond that the spectre of the A380 and 787 loom large. Seeing how the company and its relationship with its diverse engineering corps, suppliers and customers interact and solve the program's challenges are seen as the key to learning the lessons of the last two clean sheet widebody jetliners. More as the week unfolds. Time to fly.

ANA-JA801A-Boeing-787-881-OKJ_560.jpgAll Nippon Airways saw its first significant 787 operational hiccup Sunday, as the newly introduced aircraft suffered a malfunction that prevented that the main gear from extending on its the crew's first attempt.

A photograph taken of JA801A while on approach to Okayama, the first of two destinations served by the 787 from Tokyo's Handed Airport by ANA, show the main landing gear doors in the retracted position, while the nose gear extended normally.

The Wall St. Journal indicated that a failed hydraulic valve was at fault, being replaced on site. It is not know if the first of two 787s ANA is operating has re-entered scheduled service.

Photos taken of the aircraft following landing at Okayama, which show the nose and main landing gear body doors hanging free from the aircraft, indicates indicates the crew selected an alternate gear swing to achieve full extension.

Boeing and ANA have not yet responded to a request for comment.

ANA began its first scheduled routes on 1 November between Tokyo-Haneda airport and Okayama and Hiroshima.

The 787's landing gear is hydraulically actuated by the center 5000psi hydraulic system. The center system and its twin electric-motor-driven hydraulic pumps actuates the flaps, nose gear and steering, main gear and flight controls. One of the two center system pumps is constantly running, while the second is available during high demand phases of flight.

Left and right engine driven primary demand pumps are responsible for flight control actuation, both of which are engine-driven pumps.

Each main landing gear has four different hydraulic valve modules, each responsible for a different part of the sequence of raising and lowering of the 787's main landing gear and associated body doors. 

Photo Credit FlyTeam.jp User Mosochiku 妄想竹さん
El Al 4X-EKS

There's an old joke in aircraft design that the perfect engine is the one that burns no fuel and makes no noise. Until they become available, airframers, engine makers, suppliers and novel inventors work feverishly to squeeze every ounce of propulsive and acoustic efficiency out of an aircraft. 

Isaiah Cox, CEO of WheelTug, believes he has found a way to deliver that engine, at least for a small part of each trip away from the gate. Cox is banking that little changes can be very green; environmentally and economically friendly.

We're "saving the engines to do what they do best", he says.

In Barcelona this morning, Cox announced El Al Israel Airlines will become launch customer for WheelTug's engineless taxi system, aiming to be in operational service aboard the first of its 14 Next Generation 737 aircraft in the second quarter of 2013 after the technology is certified with an FAA supplemental type certificate (STC). 

Photo Credit Andrew W. Sieber

So, what is it like to fly the 787?
737-MAX8-crop_560.jpgBoeing Commercial Airplanes CEO Jim Albaugh has announced that the company will fit a 68in CFM Leap-1B engine on its 737 MAX family. In addition, the design will add fly-by-wire "one control surface" and the larger fan will prompt a 6-8in extension of the nose landing gear.

Albaugh also says that the company now holds "north of 600 commitments" for the re-engined narrowbody. UPDATE: This has grown from five to eight customers.
737 Max-Albaugh Slide.jpgUPDATE: In August when the 737 MAX was officially launched,  Albaugh said: "Certainly with the 66 [inches] there's no modifications, and I think even with the 68 [inches] a very low probability we'll have to touch the front gear."

The question of whether or not a nose blister for the larger gear comes into the fray, however, a year ago Boeing said it had essentially cracked the problem by relocating equipment from the forward electronics equipment bay and creating a larger nose landing gear wheel well for the extended strut. Also, company sources point to the spoilers as the recipient of the fly-by-wire upgrade.

UPDATE 1:30 PM ET: Boeing has just put out a release saying the 737 MAX will achieve firm configuration in 2013, with first flight of the type to follow in 2016.

Photo & Slide Credit Boeing
LOT-767-300_1.jpgLOT-767-300_2.jpgLOT-767-300_3.jpgLOT-767-300_4.jpgIt ain't a miracle, it's engineering.

LOT Polish Airlines flight 16 from Newark made a gear-up landing at Warsaw airport around 1:42 PM local time with 230 aboard. The 1997 Boeing 767-300ER (SP-LPC) sustained heavy damage upon landing, none of the 230 aboard were injured.

UPDATE: The video has been pulled from YouTube, though the screenshots have replaced the video taken from Polish TV. 

UPDATE 11:24 AM ET: Reuters has video (embedding disabled) from a different angle at the moment of touchdown on the runway.