UNDERSECRETARIAT FOR DEFENCE INDUSTRIES

C130 E/B Avionics Modernization Project (AMP)

AW Certification Process and Difficulties
 CONTENT
• C-130 AMP Scope
• C-130 AMP AW Certification Activities
• General AW Certification Objectives
• C-130 AMP Certification Content and Standarts
• C-130 AMP Certification Management
• C-130 AMP STC Process
• C-130 AMP Documents
• C-130 AMP Special Conditions
• C-130 AMP Risk Acceptance Process
• C-130 AMP DOCA and POCA Activities
• C-130 AMP Flight Tests
• C-130 AMP Major Difficulties
• C-130 AMP Lessons Learned
• C-130 AMP Targets
 C-130 AMP Scope
SSM contracted with TAI upgrading of 13 TuAF
C-130 Hercules E/B in order to have a
convenient configuration to comply with the
international aviation requirements.

Contract Effectivity : February 2007

 C-130 AMP Scope
 117 LRU for 23 system: Avionics System Integration,
 Flight Management System (FMS) design/development and
Integration instead of Navigator in the cockpit
 Link-16 Implementation
 Mission Planning Ground Station design/ development and delivery
 NVIS Lighting System
 RVSM
 RNP-1
 RNAV/GPS Approach
 CAT II/ILS Approach Operations
 + 6 E model C-130
C-130 AMP Scope
 C-130 AMP Scope
To change from Analog to Glass Cockpit
C-130 AMP AW ACTIVITIES AND
CERTIFICATION PROCESS
 General AW Certification Objectives

 Our objectives for Military

Airworthiness Certification are,
 Develop the Military
Regulations and Processes in
parallel with Civil Aviation
Regulations and Processes
 System based Safety approach SSM Internal Procedure
instead of Product based SSM-YN-3500-09
IR 21 Adapted to SSM
Safety approach Internal Processes
 C-130 AW Certification Content

• Issueance of STC (Supplementary

Type Certificate) at the end of
Prototype Phase

• Issueance of A/W Certificate for

each A/C in both Prototype &
Serial Production A/C.
C-130 AW Certification Standards
FAR-25 &
Certification Basis Certification Review Items (CRI) (36
each)

Evaluation of Contractor’s Design &

Production Organization with IR 21 Subpart J&G
DOCA/POCA studies

Evaluation of Environmental RTCA DO-160E

Conditions MIL-HDBK-810F

Evaluation of Software Safety RTCA DO-178B

Evaluation of System Safety MIL-HDBK-882C

 C-130 AW Certification Management

AW CERTIFICATION BOARD
(3 MIL+3 CIVIL)

Project Certification
Coordinator
(CIVIL)

FLIGHT
STRUCTURAL/ ORGANIZASTIONAL
AVIONICS PERFORMANCE SAFETY ELECTRICAL
HYDRO. MECH SOFTWARE MAINTENANCE APPROVALS
(10 ENG.) (12 (12 ENG.) (5 ENG.)
(11 ENG.) (12 ENG.) (12 ENG.) (3 ENG)
ENG+PİLOTS)

• Over 70 Engineers (Civilian+Military) are working for AW Certification Process.

 C-130 AMP STC Process

Organizational Approvals

Planning Certification Basis Planning Compliance Review

(Certification Strategy) (FAR 25+Special Conditions) (Certification Plan) (Artifacts+Data+Noncompliances)

Certification Board Decision Noncompliances-Risk Acceptance

Supplemental Type Certificate (Risk Identification+Mitigation Methods Panel Compliance Declarations
+Risk Acceptance)
 C-130 AMP AW Documents
SSM
AW Crtf. Regulation
3500-09

C-130 AMP Certification Project Based

Strategy Detailed Government Internal Plan

C-130 AMP Contract and Certification

Basis
(Incld. Special Conditions)
C-130 AMP Design and
C-130 AMP Project Project Based
Production
Certification Plan Detailed Government-Contractor Plan
Organization Manuals
C-130 AMP System Certification Plans
(ATA Chapters)

C-130 AMP Compliance Documents/Evidences

 C-130 AMP AW Documents
C-130 AMP
Certification Strategy • Project Content and Product Specifications
• Project AW Certification Content
• Contractor Info
• AW Certification Organization (IPTs, Panels,
Certification Board etc.)
• Responsibilities and Tasks (Project Cert.
Coord, Panel Coord., Board Members, etc.)
• Resources (Personnel, Training, Tools etc.)
• AW Certification Process (STC, AWC, DOCA,
POCA)
• AW Certification Schedule
• Resolution of Conflicts
• Meetings
• AW Certification Risk Management
GOVERNMENT • Internal Audits
PROJECT AW HANDBOOK! • …
 C-130 AMP Special Conditions
B – Flight C – Structures
C-01 Aeroelastic stability
B-03 Human Factors Flight Deck requirements
C-02 Tests for pressurized cabins
B-04 RVSM
B-05 CAT II
B-06 RNP-1
B-07 RNAV/GPS D - Design & Construction
B-09 Military Operations D-03 Trim Systems
D-05 Two-way voice communication
D-06 Control Surface and System
Loads
D-07 Minimum Recommended Speed
D-08 Door Indications
D-09 Installation of CVR
D-10 Pressure Differential Indicator
D-11 Airspeed indicating system
D-12 Control Systems
 C-130 AMP Risk Acceptance Process

• Each noncompliance will increase flight safety risk by some

amount! So each noncompliance has been considered and
accepted individually in C-130 AMP.
United States Air Force
(USAF) Airworthiness Bulletin • C-130 Certification Board will issue a STC after concurrence
(AWB)-013A
Risk Identification and
on risk assessment and formal risk acceptance by TuRAF.
Acceptance for Airworthiness
Determinations
FREQUENCY OF OCCURRENCE FC CLASSIFICATION
Quantitative
Definition Qualitative CATASTROPHIC HAZARDOUS MAJOR MINOR NSE
[P per FH]
Frequent - -3
P ≥ 10 1 3 6 10 N/A
Probable Probable Failure Conditions are
those anticipated to occur one or
-5 -3
more times during the entire 10 ≤ P < 10 2 5 9 16 N/A
operational life of each
aeroplane.
Remote Unlikely to occur to each
aeroplane during its total life but
may occur several times when -7 -5
10 ≤ P < 10 4 8 13 18 N/A
considering the total operational
life of a number of aeroplanes of
the same type.
Extremely Unlikely to occur when
Remote considering the total operational
-9 -7
life of all aeroplanes of the same 10 ≤ P < 10 7 12 15 19 N/A
MIL-STD-882C type, but nevertheless has to be
considered as being possible.
Extremely Extremely Improbable Failure
Improbable Conditions are those so unlikely
that they are not anticipated to -9
P < 10 11 14 17 20 N/A
occur during the entire
operational life of all aeroplanes
of one type.
 C-130 AMP DOCA Activities
07 / 2008
03 / 2007 05 / 2007 07 / 2007 05 / 2008
02 / 2012
05 / 2011

Presentation
Presentationof
of the
the DOCA
Initiation Preparation
Preparation Investigation
Investigation Conclusion
Conclusion
investigation
investigationplan
plan

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

DOCA Final
Report
 C-130 AMP POCA Activities
03 / 2007 06/2007 02/2008 09 / 2008 10 / 2008
09/2009 11/2009

Initiation Preparation Investigation Plan Investigation Conclusion POCA

09/2011 09/2011 POCA Final

Report

Continued Surveillance Continued Surveillance POCA is the approval showing that a

2010 2011 quality system is in place ensuring that
the product, part or appliance is in
compliance with the approved type
POCA CS Report POCA CS Report design data and is in a condition for
2010 2011 safe operation.
 Flight Tests
• Certification Board issues Technical Evaluation
Report for Flight Permits based on safety clearances
given by each panel.
• First flight was performed in May 2011,
• Totally 16 Flight Permits were given so far.
Total
Flight Total Flight Flight Total (Flight
Taxi Taxi Total (sorti hour)
(sorti (Flight (Sorti
(number) (number) (hour) number)
number) hour) number)

Phase 1-
Development
2 4 5:27 0 0 0 4 5:27

Phase 2-
Development
1 19 39:49 2 8 16:02 27 55:51

Certification-
Qualification 0 21 52:39 0 20 46:08 41 98:47
(Non-FMS)

Certification-
Qualification 1 6 16:50 0 0 0:00 6 16:50
(FMS)

TOTAL 4 50 114:45 2 28 62:10 78 176:55

Major Difficulties-Project Schedule
PROBLEM:
• Urgent needs for Project Schedule with a limited number of certification
specialists.
SOLUTION:
• It was decided to assign the Project Manager as a member of Certification Board.
• Close cooperation was established with the Project Team and Certification Team.
• Daily workshops with the Contractor teams in the Contractor Facilities.
• «Safety First » approach has been accepted by all project parties.
 Major Difficulties-Vibration Qual.
PROBLEM:
• Some of the installed equipment might not satisfy FAR 25.1309 with respect to the
vibration qualification requirements.
• Some equipment have been qualified using sine sweep vibration tests, whereas
the vibration environment of the C-130 is considered to be reflected by the
random vibration tests as specified by MIL-STD-810F.
SOLUTION:
• MOC 0 would be possible, either a formal report (“declaration of no objection”
based on experience) referring to C-130B/E including the respective DDP (or CofC)
has to be issued by the equipment manufacturer,
• MoC 1 and MoC 2 showing compliance could be possible by comparable
calculations of the performed DO-160 sinusoidal tests.
• MoC 6 would be possible for all equipment in case there is an approved flight test
plan for the equipment under test and the corresponding flight test report,
including all test procedures applicable for this scope.
• OR RİSK ACCEPTANCE !
 Major Difficulties-Software Levels
PROBLEM:
• Some of the installed equipments software is not RTCA/DO178B compliant or
compliance level is below the criticality level. (coming from Sytem Safety Analysis).
• For Example; according to System Safety Studies APN-241 RADAR Equipment
software is DAL B. However, APN-241 RADAR software is developed according to
DO-178B Level D.

SOLUTION:
• A CRI addressing this issue is created.
• A software safety case including service history, similarity analyses is prepared for
each non-compliant critical equipments.
• Some software safety cases are considered as satisfactory and approved by
Software Certification Panel.
• For the other equipments a Risk Assessment Process followed at Aircraft level.
 Lessons Learned
• Do not put specified LRUs in contractual documents .
• Include Airworthiness related requirements, processes and tasks explicitly in
contractual documents.
• Do not bound air system delivery and specified certificates (TC/STC/AWC) in
contractual documents.
(Define Flight Release Processes in the contracts to allow for limited or restricted flight
operations if needed. )
 Lessons Learned
Before the contract signature:
• Agree on AW Certification requirements and their MOCs. Changes are
always possible!
• Agree on AW Certification evidences for Project Milestones (PDR, CDR, TRR,
FTRR, etc.)
• Harmonize AW Certification Schedule with Project Schedule .
• Put contract provisions to ensure government access to the data.
 Lessons Learned
• Use all Military and Civil supporting tools to reflect“best engineering
practices” in the certification basis.

• Use Approved, Practical and Valid (follow NATO AWWG, EDA MAWA, USAF
TAA, NATO FINAS etc.!!) policy and processes.
 C-130 AMP Targets
• STC and AW Certificate,
• 1 st Delivery and Serial Production Start,
at the end of 2013
 Thank You…

Seçil AYDIN
Certification Coordinator for C-130 E/B Modernization Program
TURKEY Certification Coordinator for JSF Program
Quality Test and Certification Department
Ministry of National Defence-Undersecretariat for Defence Industries (SSM)
Tel: +90 312 411 93 27
Fax: +90 312 411 93 86
e-mail: saydin@ssm.gov.tr