Direktorat civilnog vazduhoplovsta

Investigation & surveillance of a flight test organisation

Investigation & surveillance of a flight test organisation

WI.DOA.00147-001

Name Prepared by: Verified by: Reviewed by: Approved by: Stanislav Kacujani Veljko Basari Nenad Petrovi Neboja Starevi

Validation Validated Validated Validated Validated

Date dd/mm/2011 dd/mm/2011 dd/mm/2011 dd/mm/2011

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Direktorat civilnog vazduhoplovsta

Investigation & surveillance of a flight test organisation

DOCUMENT CONTROL SHEET

Process Area Main Process Scenario Process Main Process Owner Reference documents a) Procedures PR.DOA.00071 - DOA Initial investigation b) Internal documents Organisation approval Design Organisation Approval DOA Initial investigation DOA initial investigation phase 3: Detailed review of handbook Roger SIMON

Abbreviations ADOA: Alternative Procedures to DOA AMC: Acceptable Means of Compliance C: Certification Directorate DOA: Design Organisation Approval DOAA: Design Organisations Administrative Assistant DOAH: Design Organisation Approval Holder DOATL: Design Organisation Approval Team Leader DOATLM: Design Organisation Approval Team Leader Manager DOATM: Design Organisation Approval Team Member DOH: Design Organisation Handbook F.1.2: EASA Products Applications Management Section EDOM: Design Organisation Manager EDOS: Design Organisations Secretary EASA: European Aviation Safety Agency EC: European Commission FAQ: Frequently asked questions GM: Guidance Material IMS: Integrated Management System NAA: National Aviation Authorities NDOM: National Design Organisation Manager PCM: Project Certification Manager PE: Panel of experts S: Approvals and Standardisation Directorate

Log of issues Issue 001 Issue date 11/05/2011 Change description First Issue

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Investigation & surveillance of a flight test organisation

Table of content
Scope.......................................................................................................................................................4 Referential................................................................................................................................................4 List of subject related questions...............................................................................................................5 3.2. Organisation...................................................................................................................................5 3.1.1. General..................................................................................................................................5 3.1.2. Interfaces................................................................................................................................6 3.1.3. Competences.........................................................................................................................6 3.1.4. Facilities and tools..................................................................................................................7 3.1.5. System monitoring..................................................................................................................7 3.2. Procedures....................................................................................................................................8 3.2.1. Safety provisions....................................................................................................................8 3.2.2. Flight test operations..............................................................................................................8 3.2.3. Flight test crew.......................................................................................................................9 3.2.4. Configuration management Maintenance............................................................................9 3.2.5. Flight Test Instrumentation (FTI)..........................................................................................10 3.2.6. Risk and safety management...............................................................................................10 3.2.7. Limitations............................................................................................................................11 3.2.8. Flight test programme, flight test order, flight test cards, flight test reports........................11 3.2.9. Demonstration of compliance...............................................................................................12 3.2.10. Post flight activities.............................................................................................................12 3.2.11. Flight conditions; Permit to Fly............................................................................................12 Bibliography.............................................................................................................................................13 RECORDS..............................................................................................................................................14

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Direktorat civilnog vazduhoplovsta

Investigation & surveillance of a flight test organisation

Scope
This work instruction defines the subjects to be reviewed by DOATL when investigating the flight test activities performed by design organisations, for the purpose of development and/or certification activities. It can also be used to prepare an audit of organisations applying for the privilege to approve flight conditions and permit to fly. The DOATL will adapt his own questionnaire and plan the auditing activities according to the extent of flight test activities needed under the scope of work of the organisation. He will do it with the support of a flight test expert or a PCM with a good knowledge of flight testing.

Referential
21A.4(a), 21A.20, 21A.33, 21A.35(a), 21A.35(b), 21A.55, 21A.239(a), 21A.239(b), 21A.239(c), 21A.243(a), 21A.243(b), 21A.243(c), 21A.243(d), 21A.245(a), 21A.245(b), 21A.251, 21A.257(a), 21A.257(b), 21A.263(c), 21A.265, 21A.701, 21A.707, 21A.708, 21A.709, 21A.710, 21A.711, 21A.713, 21A.723, 21A.725 21A.727, 21A.729 and related GMs and AMCs

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Investigation & surveillance of a flight test organisation

List of subject related questions

3.2. Organisation
3.1.1. General
Part 21 21A.251 21A.701 Question What is the actual or intended scope of flight testing? Comment Identification in accordance with Part 21 subpart P and NPA criteria. It needs to match the requested scope of work or existing Terms of Approval. In the DOA handbook or in a separate document linked to the handbook. It is expected that the head of flight test has direct line of communication with the Head of the Design. CVEs in flight test organisation?

21A.243

Where is the flight test organisation and processes documented? What is the reporting line between the Head of Flight Test and the head of design organisation?

Is the flight test organisation employing personnel making decisions affecting airworthiness and environmental protection? (See GM to 21A. 243 (d)). Is the DOA holder contracting the flight test activities to an external entity?

Such relation must be documented and appropriate procedures defined (see below).

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Investigation & surveillance of a flight test organisation

3.1.2. Interfaces
Part 21 21A.4 21A.239 21A.243 21A.245 21A.257 Question If any activities are sub-contracted, where is the interface between the DOA holder and the sub-contractor documented? Where is the interface between flight test organisation and design office documented? Where is the interface between flight test organisation and office of airworthiness documented? Where is the interface between the flight test organisation and the production organisation documented? Where is the interface between the flight test organisation and the maintenance organisation documented? Where is the interface between the design organisation / flight test organisation and EASA documented? Where is the interface between the design organisation / flight test organisation and the local authorities documented? Where is the interface between the flight test organisation and the organisation in charge of conformity inspection documented? Comment Mandatory if applicable.

Mandatory. Mandatory for certification activity. Mandatory if production organisation involved. Mandatory if maintenance organisation involved. Mandatory (Flight Conditions, Safety occurrences). Mandatory for Permit to Fly.

Mandatory, in order to attest conformity of test specimen and conformity with approved flight conditions.

3.1.3. Competences
Part 21 21A.243(d) 21A.245(a) 21A.55 Question Where is the management of the competences of the personnel working for the flight test organisation documented? How competences are assessed and maintained (Test pilots, flight test engineers)? Comment Procedure should be referenced in handbook. CVs, job description, training records, people authorized to assess, people authorized to nominate. Competences for the whole scope of work must be established and documented. Need to be documented. See details in GM No 1 to 21A.243(d), paragraph 3.3.

How competences are linked to the scope of work? How is the scope of authorisation defined (for pilots, flight test engineers)? Where are the data related to personnel competences recorded? In case the flights are performed by a subcontractor, are the previous questions covered in the interface document?

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Investigation & surveillance of a flight test organisation

3.1.4. Facilities and tools

Part 21 21A.245 Question Are specific facilities allocated to the flight test organisation? What are the specific tools used by the flight test organisation (telemetry, flight data recorders, spin recovery equipments, ballast, flight test installation)? Who is in charge to take care of the serviceability of these equipments? For telemetry check radiofrequency approval with local NAA Check storage condition in comparison with design requirements and also protection against inadvertent operation before or after installation on the plane. The record should be available at least for 5 years and for all open projects. Comment

Where is the calibration process documented?

Who is in charge of calibration and maintenance of test facilities and specific tools? How are related activities managed and recorded? Perform at least a check on parachutes/ pyrotechnic device to see if the labels of calibration are visible and not expired

What are the specific safety equipments (parachutes, pyrotechnic devices.) used by the flight test organisation? Who is in charge to take care of the serviceability of these equipments? How are related activities managed and recorded? Are safety facilities such as fire brigade inside or outside company, and are the contacts available to flight test people? Where are documented the aspects described above? Fire extinguishers, sand, fuel barrier and so on should be available inside the company or the hangar if tests are done inside. Fire brigade trucks /service could be located outside. Contacts should be available to flight test people.

3.1.5. System monitoring

Part 21 21A.239(a) 21A.265 Question How is the system monitoring of the flight test organisation performed? Who is in charge to manage the corrective actions? How is reporting to the Head of Design organisation performed? Comment

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Investigation & surveillance of a flight test organisation

3.2. Procedures
3.2.1. Safety provisions
Part 21 21A.708 GM Question Where are safety provisions documented, like: Minimum crew onboard? Communication rules and devices? Prototype safety features (emergency egress, ballast, pyro)? Accompanying aircraft? Fire brigade if necessary on ground? Flight data recording and transmission to the ground? Monitoring of the flight by ground crew? Equipment on board like oxygen, parachutes, helmets? Reserved aerospace and/or preliminary information to air traffic control services? Decision to interrupt of test flight? Secured area and sealed access for aircraft ready for test flight? First aid present at time of initials take off and landing of prototype? Accident procedure (telephone numbers, persons to contact) available for the ground staff? Flight briefing (including Limitations, as per 6.2.7) Weather evaluation (observations, verbal, computerized..) and possible resulting operational limitations Comment

3.2.2. Flight test operations

Part 21 21A.708 GM Question Are flight tests subject to categorization? Where is this documented? Where is the communication with the local authority prior to the flights (ATC, Airworthiness) documented? Where are tasks and duties related to the airspace and/or operational restrictions documented? Are the communications during flight test recorded? Comment See proposed categories in available publication (see bibliography).

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Investigation & surveillance of a flight test organisation

3.2.3. Flight test crew

Part 21 21A.245 Question Who is in charge to verify that the flight test crew is properly skilled to perform a specific flight test? How is crew qualification/experience requirements established for each flight test? What kind of training/exposure is required before starting a flight test campaign? Comment (see bibliography).

3.2.4. Configuration management Maintenance

Part 21 21A.708 GM Question How is the airworthiness status of the aircraft established and captured at time of handover to the design organisation (aircraft configuration review report by POA, CAMO or Part M)? How is aircraft configuration managed by the flight test organisation? How is current configuration captured? In case of configuration change, how is the data transferred to the organisation in charge to implement the change? Who is in charge to establish and declare conformity of the modified aircraft with the latest design specifications and approved flight conditions? How the test crew is made aware of a configuration change? If any ground test is required before flight test (such a maintenance acceptance procedure), who is doing it? Who is recording the result, and where? How are communicated to the flight crew the results of the ground testing? How is crew satisfied that required maintenance has been performed? How is defined maintenance of experimental or modified engines? How is the test aircraft secured after conformity has been declared? The configuration of test aircraft shall not be modified after conformity declaration. The test crew must be made aware of a configuration change. Comment There should be an acceptance procedure in act, i.e. if this documentation is not existing or lacking information , then it should not be accepted. For example, are the weight and cg data systematically reviewed each time the configuration is changed?

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Investigation & surveillance of a flight test organisation

3.2.5. Flight Test Instrumentation (FTI)

Part 21 21A.33 21A.35 Question How is the flight test instrumentation defined? How is the design of the flight test Instrumentation (FTI) transferred to the organisation in charge to implement it on the test aircraft? Who is in charge to manage / perform calibration of the test instrumentation? How is maintenance of the calibrated equipment within its due time interval before recalibration performed and recorded? Who is in charge to establish and declare conformity of the flight test instrumentation? The conformity of the 3 following items should be detailed: Original aircraft prior to modification (to the original TC) Modification added (to the new Supplemental type design) FTI (to the specific requirements coming from flight testing) The FTI should never cause hazard to the crew/aircraft and this should also be documented How are recorded the related activities and associated statements or decisions? Comment

3.2.6. Risk and safety management

Part 21 21A.708 GM Question Who are the persons involved in the safety review process? Where is this process documented? How are hazards identified? How is risk assessment performed? How are mitigating procedures established? Who is making the final decision to accept the flight test plan? Who is in charge to establish analysis, calculations, tests or other means used to determine under which conditions or restrictions the aircraft can perform safely a flight? Who is in charge to perform the independent technical verification of this safety assessment and associated substantiations? Comment (see bibliography).

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Part 21 Question Is the safety review process conducted every time the aircraft configuration is changing? Comment

3.2.7. Limitations
Part 21 21A.708 GM Question As an output to the safety review process, mitigating procedures could decide upon limitations (operational, airspace, maintenance). How are these limitations communicated to the flight test crew? How are these limitations managed along the flight test campaign? How are flight new test limitations coming from flight test result reported to the design Office/ applicable to future flights? Comment It could be through an experimental Aircraft Flight Manual and as far as practical, made visible to the Crew, through placards.

There should be at least a record of existing limitations, with expiration date or expiration procedure detailed.

3.2.8. Flight test programme, flight test order, flight test cards, flight test reports
Part 21 21A.33 21A.35 21A.239(a) GM 21A.708 GM Question Who are the persons in charge to prepare and approve the flight test programme? What are the verifications performed before the flight test order is signed? Who is responsible to verify compliance of the flight test programme and flight test order with the approved flight conditions? Who are the persons in charge to take the data from the flight test programme and to prepare flight test cards, if flight test cards are used? Who is in charge to verify compliance of the flight test order with the approved flight test programme? Who are the persons in charge to prepare and approved the flight test report? Is there a safety briefing performed before each test flight? Where is the scope defined? Where is it recorded? Who is participating? Comment

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Investigation & surveillance of a flight test organisation

3.2.9. Demonstration of compliance

Part 21 21A.20 21A.239(b) Question Who checks that the test identified in certification test plan are adequate to demonstrate compliance with the applicable airworthiness standards, including Human Factors evaluation, if necessary? Are the flight test pilot and/or flight test engineer playing a role in the demonstration of compliance? Are the flight test pilot and flight test engineer playing a role in the CVE function? What are the compliance documents signed by the CVEs? Flight test programme? Flight test report? Flight test cards? Comment

3.2.10. Post flight activities

Part 21 21A.727 Question How is the post flight debrief documented and actions before next flight recorded? What is the reporting process for safety related events occurring during the flight test campaign? What is reported to the Agency? Comment Where is it recorded? Who is participating? Are maintenance problems and preliminary flight test results separated?

3.2.11. Flight conditions; Permit to Fly

Part 21 21A.701 21A.707 21A.709 21A.710 21A.711 21A.713 21A.723 21A.727 21A.729 Question Who is in charge to apply for the approval of flight conditions? (if the DOA holder doesnt have the privilege) Who is in charge to apply for the permit to fly (if the DOA holder doesnt have the privilege)? How approved flight conditions and permit to fly are communicated to the pilot on command or to the person authorising the flight? Who is in charge to monitor the validity of the Permit to Fly (duration, changes, compliance with approved flight conditions)? Where is documented the record process related to flight conditions and permit to fly? Check evidence that the permit to fly form is on board the aircraft during the test flights, and, as necessary, the approved flight conditions. Comment

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Bibliography
Useful information on the subjects addressed in this work instruction can be found in the following documents: EASA NPA Flight testing 2008-20 CAA UK CAP553 FAA Order 4040.26 French DGAC : Dcret n 99-52 du 20 janvier 1999 art. 1 Journal Officiel du 27 janvier 1999 French DGAC : Arrt du 1er juin 1999 portant cration dun manuel doprations pour lexercice des activits ariennes dessais et de rceptions French DGAC : Arrt du 1 juin 1999 relatif aux brevets, licences et qualifications des personnels navigants professionnels de laronautique civile (personnels dessais et de rceptions)

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RECORDS

Appendix A : Operational Documents

Record
FO.DOA.00088: DOA audit record (landscape) FO.DOA.00144: DOA audit record (portrait)

Step / Related to
See Section 4 of this Work Instruction

Appendix B : External Documents

Record Step / Related to

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