SaBatAir – Aircraft Operator (UPS) Lithium Battery Transport Risk Mitigations

Alex McCulloch

14 November 2019

• UPS International Dangerous Goods Manager since 1998.

• IATA Dangerous Goods Board Chairman and active observer at the International Civil Aviation Organization (ICAO) Dangerous Goods Panel.

• 26+ years of employment at UPS• Previously worked for UK Civil Aviation

Authority (Deputy-head of Dangerous Goods Office)

Alex McCulloch

UPS AIRCRAFT FLEET• Boeing 747-400 = 13• Boeing 747-8F = 10*• MD-11 = 37• Boeing 767-300ER = 62**• Airbus A300-600 = 52• Boeing 757-200 = 75• Total Aircraft = 249

Additional aircraft on order:• *Boeing 747-8F, +18• **Boeing 767-300ER, +13

– 10 new production, – 3 BCF (Boeing Converted

Freighters)

+ Full charter aircraft (ranging from Boeing 767 to ATR 42)

UPS Aircraft Fleet

UPS “Small Package” Express Operation

• Customer dangerous goods approval process– Evaluation of all dangerous goods products.– Evaluation of projected shipment volumes (origin and

destination)– Customer visit.– Internal approval process. UN38.3 test summary review.– Specific additional internal approval process for lithium metal

batteries.– Specific dangerous goods contract with customer.– Repeat business.– Customer suspension for incidents / non-compliance.6

Lithium Battery Air Transport – Mitigation Measures

Regulatory requirements:• As for any other cargo, UPS must meet all air (ICAO/IATA)

dangerous goods transport regulatory requirements, including:• All personnel dangerous goods trained.• Check for package damage or leakage on initial acceptance.• Carry out UPS DG acceptance audit (UPS HMMS System).• Load ULD, taking account of DG segregation requirements.

–New lithium battery segregation requirements.• Apply DG “load tag” to Unit Load Device (ULD).• Notify aircraft captain (NOTOC) of all DG on board aircraft and

loading position (UPS HMMS System).7

Lithium Battery Air Transport – Mitigation Measures

• Cross-functional team formed.• Fibre-reinforced plastic panels.• Withstand intense fires for at least

four hours (650°C)• 40+ fire tests• Initially deployed 1,300 by end 2015• ULD inventory = 44,000+ units• 24,000+ FRC’s in use (over 50% of

total ULD inventory)• Additional 20,000+ FRC’s scheduled

UPS Unit Load Device (ULD) - Fire Resistant Containers (FRC’s)

8

Lithium Battery Air Transport – Mitigation Measures

• Continuous improvement– In ULD fire detection– In ULD fire suppression

• UPS tests demonstrate that FRC’s can mitigate gas buildup and contain a lithium battery fire

• FRC’s already enhance safetyand we continue to improve:– Venting– Durability– Fiberglass strands/weave

UPS ULD Fire Resistant Containers - Facts

9 Seal

Clamps

Door durability

Fiberglass weave

• Lighter20 kgs lighter per ULD= Reduced fuel burn

• Stronger x 300% stronger than polycarbonatex 200% stronger than aluminium

• More durable= Less maintenance. Cost savings

• Target air gateways (airports) with international overwater flights– Priority usage for lithium battery shipments.

ULD – UPS Fire Resistant Containers

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ULD – UPS Fire Resistant Containers - Hybrid• Replacement of old curtain/net open-front ULD’s.• Worked with our supplier on a design that fits both our cargo/freight and

small package operations.• Hybrid door design has a narrow roll-up door for our small package

operations, and two swing doors for wider fork-lift access for heavier freight.• This FRC ULD also offers full fire containment protection.

• Fiberglass blankets.• Palletized cargo.• Designed and tested to withstand fires for at least four hours.• Implemented on international over water routes for shipments of

electronics, lithium battery shipments or unknown contents.

Fire Containment Covers – FCC’s

12FCC fire test

Flight deck improvements

Emergency VisionAssurance System

Full-Face Oxygen Masks

Operator Risk Assessment:• Dangerous Goods Policy

• UN3090 and UN3480 not accepted as lightly regulated shipments. Handled as fully regulated dangerous goods. Visible in transport.

• Evaluation of volume of shipments, by origin IDG country. • Audit evaluation. • Incident / non-compliance evaluation.• Additional measures / training (internal and customer) put in place as

needed.• Aircraft equipment / fire suppression (evaluation).• Determination of risk and additional measures which may be needed.

Including local measures:14

Lithium Battery Air Transport – Mitigation Measures

• Based on volumes and incident data:– Additional training.– Additional personnel communication.

• Posters.• Daily briefing programme to include lithium batteries.

– Additional X-ray screening, specifically looking for undeclared lithium batteries.

– “Open box” inspections.– “Watched Shipper” programme. Daily evaluation of products being

shipped.– Shipper suspension.

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Additional Local Mitigation Measures

• Know the regulations; – Ensure your people are trained and current– Observe 30% state of charge (UN3480)– Regulations are very dynamic – stay informed!

• Know where your batteries come from– Be wary of counterfeit batteries– Confirm UN 38.3 test reports / test summaries– Does the battery manufacturer have ongoing quality

assurance efforts?• Know your air carriers’ policies• Have a question? ASK!• See also IATA Lithium Battery Guidance Document (IATA website)

Advice for Shippers

www.ups.com/assets/resources/media/pack_ship_batteries.pdf

http://www.ups.com/assets/resources/media/pack_ship_batteries.pdf

WHY IS THIS IMPORTANT?

Thank you! – Questions?

SaBatAir – Aircraft Operator (UPS) Lithium Battery Transport Risk Mitigations����Alex McCullochAlex McCullochSlide Number 3UPS Aircraft FleetUPS “Small Package” Express OperationSlide Number 6Slide Number 7UPS Unit Load Device (ULD) - Fire Resistant Containers (FRC’s)UPS ULD Fire Resistant Containers - FactsULD – UPS Fire Resistant ContainersULD – UPS Fire Resistant Containers - HybridFire Containment Covers – FCC’sFlight deck improvementsSlide Number 14Slide Number 15Advice for ShippersWHY IS THIS IMPORTANT?Thank you! – Questions?