MODULE 3

BASIC INSPECTOR AND AUDIT COURSE

CONCEPTS OF AIRWORTHINESS
Presented by DGCA 2019
Monday, July 22, 2019 Basic Inspector Course 2016 1
REFERENCES:
AIRCRAFT CERTIFICATION
CASR Part 21
CERTIFICATION PROCEDURES FOR
PRODUCT AND PARTS
 DEFINITION
( PART 1 Revision 1 - DEFINITIONS AND ABBREVIATIONS)

“PRODUCT”
Means an aircraft, aircraft engines, or propeller.
In addition, for the purposes of subpart L only, it
includes components and parts of aircraft, of
aircraft engines, and of propellers; also parts,
materials and appliances, approved under the
Technical Standard Order (TSO) system

Erlana Ichsan H
DGCA - April 2014
GENERAL
Procedural Requirements For
1. Issuance of Type Certificate (TC)
2. Change/Supplement to Type Certificate (STC)
3. Issuance of Production Certificate (PC)
4. Issuance of Airworthiness Certification (C of A)
5. Issuance of Export Airworthiness Approval (Export C of
A Airworthiness Approval Tag)
6. Issuance of Technical Standard Order (TSO)
7. Procedural Requirements for a Approval of Part
Manufacturing (PMA)

Erlana Ichsan H
DGCA - April 2014
GENERAL
ISSUED FOR Aircraft, Engines and Propellers

TYPE CERTIFICATE - CONSIST OF:

1. Type Design
2. Data Sheets (TCDS)
3. Operation Limitations
4. Applicable Regulation with which the Director Records
Compliance.
5. Any other condition or limitations

Erlana Ichsan H
DGCA - April 2014
TYPE CERTIFICATED AIRCRAFT PROCESS
TC is A document issued by a DGCA to define the design of an aircraft type and to
certify that this design meets the appropriate airworthiness requirements. Type
Certificate Data Sheet (TCDS) means the data approved by DGCA attached to the Type
Certificate include operation limitation of the aircraft type.

CONTINUED
OPERATIONAL
SAFETY

AIRWORTHINESS
APPROVAL
PRODUCTION
APPROVAL
TYPE DESIGN

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 TYPE CERTIFICATE MARKING
• AIRCRAFT
 TYPE CERTIFICATE MARKING
• ENGINES
 TYPE CERTIFICATE MARKING
• PROPELLERS
CERTIFICATION BASIS
CASR
SUBJECT
PART
23 Airworthiness Standard : Normal, Utility, Acrobatic and Commuter Category
Aeroplanes
25 Airworthiness Standard : Transport Category Aeroplanes
27 Airworthiness Standard : Normal Category Rotorcraft
29 Airworthiness Standard : Transport Category Rotorcraft
31 Airworthiness Standard : Manned Free Ballons
33 Airworthiness Standard : Aircraft Engine
34 Fuel Venting and Exhaust Emission Requirements for Turbine Engine Powered
Airplanes
35 Airworthiness Standards: Propellers
36 Noise Standards: Aircraft Type and Airworthiness Certification
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DGCA - April 2014
CERTIFICATION BASIS
CASR Part 23 - for airplanes in the normal, utility, acrobatic, and
commuter categories.
a. The normal category is limited to airplanes that have a
seating configuration, excluding pilot seats, of nine or less, a
maximum certificated takeoff weight of 12,500 pounds or
less, and intended for non-acrobatic operation.

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CERTIFICATION BASIS
CASR Part 23 - for airplanes in the normal, utility, acrobatic, and
commuter categories.
b. The utility category is limited to airplanes that have a seating
configuration, excluding pilot seats, of nine or less, a maximum
certificated takeoff weight of 12,500 pounds or less, and intended
for limited acrobatic operation.
CERTIFICATION BASIS
CASR Part 23
c. The acrobatic category is limited to airplanes that have a
seating configuration, excluding pilot seats, of nine or less, a
maximum certificated takeoff weight of 12,500 pounds or
less, and intended for use without restrictions, other than
those shown to be necessary as a result of required flight
tests.

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CERTIFICATION BASIS
CASR Part 23
c. .
d. The commuter category is limited to propeller driven,
multiengine airplanes that have a seating configuration,
excluding pilot seats, of 19 or less, and a maximum
certificated takeoff weight of 19,000 pounds or less.
CERTIFICATION BASIS
• CASR 25
Airworthiness Standard : Transport Category Aeroplanes
CERTIFICATION BASIS
CASR Part 27
• for normal category rotorcraft with maximum
weights of 6,000 pounds or less.

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TYPE
CERTIFICATES

Erlana Ichsan H
DGCA - April 2014
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 Type Certificate
A Type Certificate (TC) is the design
approval for a new (or new model)
aircraft, engine or propeller

It certifies that the product’s design

complies with the DGCA airworthiness
standards

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DGCA - April 2014
 Type Certificate Validation
A type certificate may be issued for a product that is manufactured in a
foreign country if it is to be imported into the Republic of Indonesia if –

• The country in which the product was manufactured certifies that the
product has been examined, tested, and found to meet -
▪ The applicable aircraft noise, fuel venting and exhaust emissions
requirements
▪ The applicable airworthiness requirements

• The applicant has submitted the technical data, concerning aircraft noise
and airworthiness

• The manuals, placards, listings, and instrument markings required by the

applicable airworthiness (and noise, where applicable) requirements are
presented in the English language

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DGCA - April 2014
Type
Certificate
Validation

Erlana Ichsan H
DGCA - April 2014
 PRODUCTION
CERTIFICATE (PC)

Erlana Ichsan H
DGCA - April 2014
Who May Apply:

1. Holder of a Type Certificate

2. Holder of a licensing agreement with

right to the benefits of that Type
Certificate

3. Holder of a STC

Erlana Ichsan H
DGCA - April 2014
PRODUCTION CERTIFICATION

is certification of an ORGANIZATION to reproduce /

manufacture a design certificated product or part.

The certificate issued to the organization is called as :

PRODUCTION CERTIFICATE (PC) or Production Under
Type Certificate Only or Approved Production Inspection
System (APIS) for they who manufacture a PRODUCT
(aircraft, engine or propeller) ;

TECHNICAL STANDARD ORDER AUTHORIZATION (TSOA)

for they who manufacture a TSO PART ; and

PART MANUFACTURER APPROVAL (PMA) for they who

manufacture a replacement part.
Erlana Ichsan H
DGCA - April 2014
 Production Certificate
Eligibility
Any person may apply for a production certificate if he holds, for the product
concerned, a -
(1) Current type certificate;
(2) Right to the benefits of that type certificate under a licensing agreement; or
(3) Supplemental type certificate.

Quality Control
The applicant must show that he has established and can maintain a
quality control system for any product, for which he requests a production
certificate, so that each article will meet the design provisions of the
pertinent type certificate.

24 Erlana Ichsan H
DGCA - April 2014
 Production Certificate
 A Production Certificate (PC)
is the approval of the quality
control system controlling
production of an aviation
product

 The purpose of a PC is to
make sure that every product
produced conforms to its
approved type design

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DGCA - April 2014
 Production Certificate
( continued )
 A PC covers :
➢A new aircraft, engine or propeller
➢Modified or redesigned aircraft or component
➢Parts
 A PC allows the applicant to manufacture the
product for sale without having DGCA
physically inspect each aircraft or component
produced
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DGCA - April 2014
Changes in Type Certificate

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DGCA - April 2014
Design Change Classification
Changes in type design are classified as
minor and major.

A "minor change" is one that has NO

appreciable effect on the weight, balance,
structural strength, reliability, operational
characteristics, or other characteristics
affecting the airworthiness of the
product.
All other changes are "major changes"
Erlana Ichsan H 28
DGCA - April 2014
Design Changes Approval
APPROVAL CHANGES
Amended TC  Major Changes
Approval the applicant must submit
Supplement TC substantiating data and necessary
Approval descriptive data for inclusion in the
type design.
21-09 Approval  MinorChanges
may be approved under a method
acceptable to the DGCA before
submitting to the DGCA any
substantiating or descriptive data.
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DGCA - April 2014
Supplemental Type Certificate
Issue of STC
A STC consists of –
1. The approval by the Director General
of a change in the type design of the
product; and
2. The type certificate previously issued
for the product.

Difference Amended TC and STC:

 The main difference is who applies :
1. Only a TC holder can apply for
an amended TC
2. Everyone else must apply for
an STC
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DGCA - April 2014
Supplemental Type Certificate
Privileges
The holder of a supplemental type certificate may –
a. In the case of aircraft, obtain airworthiness
certificates;
b. In the case of other products, obtain approval for
installation on certificated aircraft; and
c. Obtain a production certificate for the change in the
type design that was approved by that
supplemental type certificate.

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DGCA - April 2014
Change to Product
CHANGES IN:
 Design Configuration
 Power
 Weight

CHANGES TO AIRCRAFT:
 Number of Engines
 Different Principal of Population

CHANGES TO ENGINE:
 Principal of Operation

CHANGES TO PROPELLER:
 Number of Blades
 Principal of Pitch Change Operation

Erlana Ichsan H
DGCA - April 2014
Change to Product - cont

CLASSIFICATION OF CHANGES

MINOR No Appreciable effect on: Weight, balance, structural strength,

reliability operation characteristics, or other characteristics effecting
the Airworthiness

MAJOR All other changes

ACOUSTICAL Changes which may Increase the NOISE LEVEL CASR Part 36

Erlana Ichsan H
DGCA - April 2014
Change to Product - cont

REQUIRED DATA FOR CHANGES

 MINOR Approval under a method ACCEPTABLE to the Director

 MAJOR Submit. Substantive data and necessary descriptive DATA for

inclusion in Type Design
Other Type of Change to Product

 Airworthiness Directive Under CASR Part 39:

To correct an unsafe condition of the product resulting in
design changes

 DGAC Approval on Form 43-337

 Amendment of Original Type Certificate by TC Holder

 Supplemental Type Certificate (STC)

Major Change, but not great enough to require a new
application for a Type Certificate

Erlana Ichsan H
DGCA - April 2014
CONCEPTS OF AIRWORTHINESS
Initial and Continuing Airworthiness

Bandung, 02 February 2016

By Erlana DKUPPU
Airworthiness Certification

37 Erlana Ichsan H
DGCA - April 2014
What is an “airworthy”?
• Airworthy means Conform to type
design and condition for safe operation.
DEFINITION:
Certify as airworthy (to):

• To certify that an aircraft or parts thereof

comply with current airworthiness
requirements after maintenance has been
performed on the aircraft or parts thereof.
Definition:
Sign a maintenance release (to)
• To certify that maintenance work has been completed
satisfactorily in accordance with the applicable Standards of
airworthiness, by issuing the maintenance release referred to
in Annex 6.
• Aviation Dictionary, McGraw-Hill:_______________
RTS mean the completion of all applicable maintenance
records and forms after maintenance has been performed on
an aircraft that will allow the aircraft to be flown legally.
•
AIRWORTHINESS CERTIFICATION
 Unlike design and production approval
airworthiness certification is approval of an
individual aircraft
 A standard airworthiness certificate means
that an aircraft :
1. Conforms to an approved type design
2. Is in “condition for safe operation”

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DGCA - April 2014
Airworthiness Certification
(continued)

 Each civil aircraft must have an airworthiness

certificate before flight
 An aircraft will need an airworthiness
certificate when it is :
➢ New - ready for operation
➢ Not yet completed or certified, but must be
flown (flight tested)
➢ Damaged, but must be flown
➢ Brought in from another country
 C OF A CLASSIFICATION AND CATEGORY

- Standard Classification. A Standard Airworthiness Certificate

may be issued for an aircraft that fully complies with all the
requirements applicable to: Normal, Utility, Acrobatic,
Transport, Commuter, Glider, and Balloon categories.
– Part 23 Airworthiness Standards : Normal, Utility, Acrobatic,
and Commuter Category Aeroplanes
– Part 25 Airworthiness Standards : Transport Category
Aeroplanes
– Part 27 Airworthiness Standards : Normal Category
Rotorcraft
– Part 29 Airworthiness Standards : Transport Category
Rotorcraft
• Special Classification. A Special Airworthiness Certificate,
may be issued for an aircraft that does not meet the
requirements for a Standard Airworthiness Certificate.
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DGCA - April 2014
Airworthiness Certification _Airworthiness
Certificate/ Certificate of Airworthiness (C of A) means A document issued by
a DGCA to an individual aircraft and the aircraft meets the appropriate
requirements.___(continued)

 Standard certificates are issued to aircraft with type

certificates in these categories :
➢ Normal
➢ Utility
➢ Acrobatic
➢ Commuter
➢ Transport
➢ Balloon
➢ Glider
 Special Classification
1. Restricted. A Special Airworthiness Certificate may be issued for an aircraft
in the restricted category that meets the requirements of CASR section
21.185.
2. Experimental. A Special Airworthiness Certificate may be issued for
experimental purposes for any category aircraft, including an amateur-built.
Research and development, Showing compliance with regulations,
Crew training, Exhibition, Air racing, Market surveys, and Operating
amateur built aircraft.
3. Flight Permits. A Special Airworthiness Certificate may be issued for an
aircraft that may not currently meet applicable airworthiness requirements,
but is capable of safe flight, and meets the requirements of CASR sections
21.197 and 21.199.
Flying the aircraft to a base where repairs, alterations, or
maintenance are to be performed, or to a point of storage,
Delivering or exporting the aircraft, Production flight testing new
production aircraft, Evacuating aircraft from areas of impending
danger, Conducting customer demonstration flights in new
production aircraft that have satisfactorily completed production
flight tests.

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DGCA - April 2014
Special Airworthiness Certificate

 Include operating limitations, generally

applicable to not-standard aircraft,
printed on the back of the certificate
 may be accompanied by additional
operating limitations for the aircraft
category
• A Special Airworthiness Certificate, may be
issued for an aircraft that does not meet the
requirements for a Standard Airworthiness
Certificate.
APPLICATION: ORIGINAL AND RECURENT AIRWORTHINESS

1. Airworthiness Certificate, DAC Form 21-21

2. Airworthiness Inspection Check List (Annual Inspection) DAC
Form PK-02-01.
3. Aircraft available for inspection and review the aircraft,
aircraft records, inspection records and technical data any
other data necessary to establish conformity to its type
design.
4. Using the type certificate data sheet, aircraft specification, or
aircraft listing, as applicable, determine that the aircraft is
eligible by make and model.
5. Determine that the aircraft is properly registered iaw CASR
Part 47 and that registration marks are properly displayed in
accordance with CASR Part 45.
ORIGINAL AND RECURENT AIRWORTHINESS
CERTIFICATION

1. Application for Airworthiness Certificate, DAC Form 21-21

2. Airworthiness Inspection Check List DAC Form PK-02-01.
3. Aircraft available for inspection and review the aircraft,
aircraft records, inspection records and technical data any
other data necessary to establish conformity to its type
design.
4. Using the TCDS, aircraft specification, or aircraft listing, as
applicable, determine that the aircraft is eligible by make and
model.
5. Determine that the aircraft is properly registered iaw Part 47
and that registration marks are properly displayed iaw Part 45.
6. Determine that the aircraft identification plate is iaw Part 45.
7. Review the inspection/ maintenance records.

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DGCA - April 2014
Validity
CERTIFICATE DURATION
Standard One Year, so long as the aircraft is
◼ Indonesian Registered
◼ Properly maintenance

Special
Restricted & Limited One year – same as Standard

Experimental Depends on the purpose

◼ R & D or flight test : one year or less
◼ Amateur-built : same as Standard

Special Flight Permit Time limited, as specified

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DGCA - April 2014
 Export
Airworthiness
Approval
(“Class I”)
 Export
Certificate of
Airworthines
Certifying Exports
 Airworthiness approval of exports :
 CASR Part 21, Subpart L – Export Airworthiness
Approvals
 Products with export certification can go anywhere
 Once out of Indonesia, PK registration markings are
removed
 Indonesian registration and airworthiness
certificates are returned
Export Airworthiness Approval

CLASS PRODUCT
I Complete Aircraft, Engine, Propeller

II ▪ Any part, material or appliance manufactured under

a TSO in the “C” series
▪ Major component whose failure would jeopardize the
safety of a Class I product
III Anything else : any part or component
▪ Not Class I or II
▪ Included standard parts, such as AN, NAS, and SAE
hardware

TWO KINDS OF THE EXPORT AIRWORTHINESS APPROVAL ARE:

C OF A for EXPORT AND AIRWORTHINESS APPROAL TAG
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DGCA - April 2014
Export

PRODUCT EXPORT APPROVAL

Aircraft, engine, propeller Export certificate of Airworthiness (Export C

(“Class I”) of A)

Anything else
(“Class II & Class III”) Airworthiness Release Certificate (ARC)

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DGCA - April 2014
AUTHORIZED RELEASE CERTIFICATE
(ARC)

DAC FORM 21-18

AIRWORTHINESS APPROVAL TAG

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AUTHORIZED RELEASE CERTIFICATE

1.APPROVAL FOR RETURN TO SERVICE OF

PRODUCTS AND PARTS
“The use of Form 21-18 for this purpose is optional but the DGAC recommends
its use”.
This will help aviation authorities and the industry to ensure complete
traceability and ease the movement of products and parts through the
aviation system”

2.EXPORT AIRWORTHINESS APPROVALS OF

CLASS II AND III PRODUCTS (AND PARTS
THEREOF)

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GENERAL
 Air agencies certificated under part 145, part 121 or part 135
with an approved continued airworthiness maintenance
program are authorized to issue a Form 21-18 for approval for
RTS.
 Form 21-18 does not constitute approval to install a product,
part, or appliance on a particular aircraft, aircraft engine, or
propeller.
 The issuer should retain a copy of Form 21-18 for a period of 2
years after the work is approved for return to service, unless
the work is repeated or superseded.
 The repair station (AMO) should retain a copy of the document
for 2 years.

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INSTRUCTIONS FOR COMPLETING FORM 21-18 FOR
EXPORT AIRWORTHINESS APPROVAL

Block 14. Airworthiness Approval. Place a check in the “Approved

design data and are in a condition for safe operation” box if the
products, parts, and appliances were manufactured using DGCA-
approved design data and found to be in a condition for safe
operation.
Block 15. Authorized Signature. The authorized DGCA Inspector or
Designated.
Block 16. Approval/Authorization No. Enter the approval
/authorization number of the authorized representative
/organization identified in Block 15.
Block 17. Name.
Block 18. Date. Enter the date (month (three-letter
designator)/day/year) the Form 21-18 is signed and the
airworthiness or conformity determination is made.
Blocks 19 through 23. Shade, darken, or otherwise mark to preclude
inadvertent or unauthorized use.

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AIRWORTHINESS OF
COMPONENTS
TSO and PMA PART
 Technical Standard Order (TSO)
Authorization

 (TSO) Authorization is a design and production

approval issued by the Director General and is a
minimum performance standard for specified articles
(for the purpose of this subpart, articles means
materials, parts, processes, or appliances) used on
civil aircraft.

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 TSO Marking
(1) The name and address of the manufacturer.
(2) The name, type, part number, or model designation of the article.
(3) The serial number or the date of manufacture of the article or both.
(4) The applicable TSO number.
The Technical Standard Order (TSO)

TSOs have been established for many types of aircraft

parts such as:
▪ Engines part ,
▪ Landing gear parts,
▪ Environmental system components,
▪ and many avionics.
Certifications Procedures For Products &
Parts Technical Standard Order (TSO)

TSO Authorization is a design and production approval issued by the Director

General and is a minimum performance standard for specified articles (for the
purpose of this subpart, articles means materials, parts, processes, or
appliances) used on civil aircraft.

TSO A minimum performance standard for Specified

Articles
 Materials  Parts
 Process  Appliances

TSO Authority DGAC design & production Approval

(TSOA)

LETTER OF TSO
DGAC design Approval for Foreign Manufacture Articles
needs a certificate of Airworthiness for export Erlana Ichsan H
DGCA - April 2014
Certifications Procedures For Products &
Parts Technical Standard Order (TSO)
• TSOs are divided into categories and identify the testing required to
cover a wide range of environmental conditions such as heat,
temperature, altitude, vibration, etc.
• If a TSO is available that is suitable for a part, a manufacturer will
typically test the part in a FAA-approved laboratory to the
requirements of the TSO.
• If the part successfully passes all the tests, then the manufacturer
will receive a letter from the FAA stating the part is approved per
the TSO.
• This TSO approval letter means the part is eligible for installation in
any aircraft via an STC or TC as long as the operating environment
of the part in the aircraft is within the TSO criteria.
•
PMA Part
• Parts Manufacturer Approval (PMA) is a
design and production approval to produce
a modification or replacement part for sale
for installation on a type certificated
product.
PMA Part
PMA Part MARKING
PMA Part
Parts Manufacturer Approvals Parts
▪ is both a design approval and a production
approval.
▪ It is issued for the production of modification or
replacement parts, which includes materials,
parts, processes, and appliances.
▪ is a design and production approval to produce
a modification or replacement part for sale for
installation on a type certificated product.

Erlana Ichsan H
DGCA - April 2014
 Part Manufacturer Approval
• PMA regulations not apply to the following:
1. Parts produced under a type or
production certificate.
2. Parts produced by an owner or operator
for maintaining or altering his own
product.
3. Parts produced under an TSO.
4. Standard parts (such as bolts and nuts)
conforming to approved specifications.

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SUSPECTED UNAPPROVED PART
(SUP)
Erlana Ichsan H
DGCA - April 2014
Suspected Unapproved Part (SUP)
Suspected Unapproved Part (SUP)
A suspected part, component, or material not meeting the
requirements of an “approved part.”
(Reasons may include findings such as a different finish, size,
color, improper (or lack of) identification, incomplete or
altered paperwork)
Unapproved Part
A part that does not meet the requirements of an “approved
part”.
Approved parts
Parts are produced iaw the means outlined in part 21,
maintained iaw parts 43, and meet applicable design
standards.
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DGCA - April 2014
Approved, Unapproved, or
Suspect
Approved Part :
• Properly designed
• Properly produced
• Properly maintained
• Properly documented (examples: data plates, ID plates,
Inspection stamp, number purchase order etc.)
• A part that has been designed, produced, and maintained in
accordance with applicable regulations
• Produced in accordance with a PMA
• in accordance with a TSO
• Produced during the TC or STC application process

Erlana Ichsan H
DGCA - April 2014
Approved, Unapproved, or Suspect
Approved Part :
• Produced under a TC without a separate production authorization, and an
approved APIS.
• Produced under a PC (including by a license if produced under PC
authority)
• Produced in accordance with an approval under a BAA.
• Produced as standard parts that conform to established industry.
• Produced by an owner or operator for the purpose of maintaining or
altering their own product supported by acceptable data, process and
quality system approved by an authority.
• Produced under STC by Production Approval Holder.
• Repaired or Overhauled by an AMO (ARC attached).
• Approved in any other manner acceptable by an authority.

Erlana Ichsan H
DGCA - April 2014
Approved, Unapproved, or Suspect
Unapproved Part :
• A part that does not meet the requirements of an approved part.
• Parts that have not been designed, produced in accordance with the
applicable regulations
• Parts shipped directly to the user by a manufacturer, supplier, or
distributor, where the parts were not produced under the authority
production approval.
• A new parts that have passed through a PAH quality system that are
found not to conform to the approved design/data.
• Parts that have been maintained, rebuilt, altered, overhauled, or
approved for return to service by persons or facilities not authorized to
perform such service under part 43 and/or part 145.
• Parts that have been maintained, rebuilt, altered, overhauled, or
approved for return to service that are found not conform to approved
data

Erlana Ichsan H
DGCA - April 2014
Approved, Unapproved, or Suspect

• Unapproved Part :
• Replacement parts produced by a
manufacturer that has failed to obtain a PMA.
• Counterfeit parts : a part made or altered so
as to imitate or reassemble an “approved
parts” without authority or right, and the
intent to missed or defraud by passing the
imitation as original or genuine.
Erlana Ichsan H
DGCA - April 2014
Approved, Unapproved, or Suspect
• Suspected unapproved part (SUPs):
• A part, component, or material that is
suspected of not meeting the requirements of
an “approved part.” a part that for any reason,
may not be “approved”.
• Indicators of SUPs have included : a different
finish, size, color, improper identification,
incomplete or altered documentation.

Erlana Ichsan H
DGCA - April 2014
 Erlana Ichsan H
DGCA - April 2014
 Erlana Ichsan H
DGCA - April 2014
 Erlana Ichsan H
DGCA - April 2014
Examples of unapproved
parts :
- Counterfeit identification
plates
- Counterfeit labels
- Scrap bins containing parts
for sale
- Unapproved repair
- Marking old parts look like
new
- Life limited parts past limit
- Part did not fit
- Sold as new suffered
impact damage
- Size and marking is
different
- Etc.
Erlana Ichsan H
DGCA - April 2014
ANY QUESTION?