Maintenance check flights (MCF) Manual

Transcription

1 X Airlines MAINTENANCE CHECK FLIGHT MANUAL MCF MANUAL JUT 1/15/2013 Maintenance check flight means a flight carried ut t prvide reassurance f the aircraft s perfrmance r t establish the crrect functining f a system that cannt be fully established during grund checks MCF Manual Page 1 f 41

2 Table f Cntents Table f Cntents... 2 List f Effective Pages... 5 Recrd f revisin... 6 Recrd f Temprary revisin... 8 Intrductin... 9 Purpse... 9 Distributin... 9 Effective Date... 9 Practical Use f this Manual... 9 Operatr s Declaratin General cnsideratins Intrductin Definitins Specific requirements fr Maintenance check flights (MCF) Flight prgram (CFS) Maintenance check flight manual (MCF) Cnditins requiring a maintenance check flight Requested by maintenance data Requested by the peratr (elective) Requested by the maintenance rganisatin Requested t regain airwrthiness Apprpriate maintenance release befre the maintenance check flight Requested by the peratr Requested by the maintenance rganizatin Requested t regain airwrthiness Flight authrizatin Prcess t develp a flight prgramme and prcedures Cntents f the flight prgramme and prcedures Aircraft status Requirements abut the status f the aircraft prir t departure (e.g. MEL, CDL) fr the maintenance check flight Fuel lading Weight and balance MCF Manual Page 2 f 41

3 Specific test and safety equipment Crew selectin and ther persns n bard Selectin summary: Flight crew qualificatins Experience and recency Training Flight crew training curse Simulated abnrmal situatins in flight Curse cnsideratins Curse syllabus Persns n bard The rle f bserving engineers Crew cmpsitin and persns n bard Task Specialist assigned duties Flight time limitatins and rest Briefings Briefing participants Specific pre-flight briefing tpics Risk management Risk assessment Safety meeting Event reprting Lessn learnt Aircraft status Summary f maintenance Flight prgramme, specific prcedures and limitatins Crew members respnsibilities and crdinatin Crew Resurce Management Headphne and Flight Deck Speaker Use Synptic Display Calluts Infrmatin t ATC Pst-flight briefing External cnditins Terrain MCF Manual Page 3 f 41

4 ATC, airspace Airprt (runway, equipment)/perating site Dcumentatin Specific dcumentatin n bard In-flight recrdings Result f the maintenance check flight and related data Accurate recrding f required maintenance actins after the flight Annexes Pilts briefing sheet MCF Schedule MCF Lad Sheet MCF Training Syllabi List f MCF authrized crews MCF Manual Page 4 f 41

5 List f Effective Pages PAGE REVISION DATE PAGE REVISION DATE PAGE REVISION DATE 1 0/0 2 0/0 3 0/0 4 0/0 5 0/0 6 0/0 7 0/0 8 0/0 9 0/0 10 0/0 11 0/0 12 0/0 13 0/0 14 0/0 15 0/0 16 0/0 17 0/0 18 0/0 19 0/0 20 0/0 21 0/0 22 0/0 23 0/0 24 0/0 25 0/0 26 0/0 27 0/0 MCF Manual Page 5 f 41

6 Administratin and Cntrl f MCF Manual Recrd f revisin REVISION NO. DATE OF REVISION REASON OF REVISION PERFORMED BY 0/0 FIRST EDITION JUT MCF Manual Page 6 f 41

7 Highlights f changes First editin. MCF Manual Page 7 f 41

8 Recrd f Temprary revisin TEMPORARY REVISION NO. DATE OF REVISION REASON OF REVISION PERFORMED BY MCF Manual Page 8 f 41

9 Intrductin Purpse This manual cntains the plicy, prcedures, and criteria fr Maintenance Check Flights and recertificatin f airwrthiness. Distributin This manual is distributed t selected ffices n special mailing list. X Flight Operatins X Dispatch X CAMO X Part 145 Belp X Part 145 X FOCA Effective Date This manual is effective February 15, Practical Use f this Manual The Maintenance Check Flight Manual is meant t assist in the preparatin and safe executin f check flights. Where there is cnflict between this Manual and the equivalent dcumentatin prvided by the aircraft manufacturer, the manufacturer s dcumentatin has precedence. MCF Manual Page 9 f 41

10 Operatr s Declaratin We, the undersigned, declare that: The Operatins Manual Parts A, B, C, D, and assciated dcuments have been established and will be maintained in full cmpliance with the prvisins f COUNCIL REGULATION (EEC) 3922/91 ANNEX III (EU-OPS), and in particular Annex VIII theref, cntaining the requirements f Specialised Operatins (Part- SPO). The Maintenance Check Flight Manual cmplies with the terms and cnditins f the cmpany s Air Operatr Certificate; We are respnsible fr the cntent f the Maintenance Check Flight Manual and cnfirm that besides COUNCIL REGULATION (EEC) 3922/91 (and JAR-FCL 1, where applicable) all relevant natinal rules and regulatins as well as ICAO standards and prcedures are reflected in the different chapters; We knw and understand the cntent and meaning f the Maintenance Check Flight Manual and will perfrm ur duties in full accrdance with it; The detailed knwledge f the relevant cntent is mandatry t all cncerned flying, grund and managing persnnel wh shall perfrm their duties accrdingly. We undertake t ensure that they cmply with the instructins given in the Maintenance Check Flight Manual; and We are aware f the fact that the Federal Office fr Civil Aviatin des nt apprve / accept the Maintenance Check Flight Manual as such, but nly specific parts theref, as shwn n the respective cmpliance list. The respnsibility fr the cmpleteness and the crrectness f the Maintenance Check Flight Manual remains therefre slely with X Airlines. MCF Manual Page 10 f 41

11 1. General cnsideratins Intrductin A significant number f aviatin accidents and serius incidents ccur during nn-revenue flights. Amng them, a particular case is maintenance check flights (MCFs). These flights, under the cntrl f the peratr, may be required t assist in the identificatin f a defect, t cmplete certain maintenance instructins, t verify that maintenance has been prperly perfrmed, r t avid peratinal disruptins after majr maintenance. In 2011 EASA created a rulemaking grup with the participatin f experts frm industry and aviatin authrities and tasked it with the develpment f a Ntice f Prpsed Amendment (NPA). Als, in accrdance with the resulting text prpsed in this NPA, maintenance rganisatins may be able t release the incnclusive maintenance t allw fr a maintenance check flight when this is required by the aircraft maintenance manual, r a permit t fly may be required if there is a need t perfrm a maintenance check flight but, in accrdance with the maintenance rganisatin requirements, the aircraft cannt be released. During the perfrmance f a maintenance check flight and in rder t fulfill its bjective, there is ften the need t perate the aircraft differently frm what is the nrmal aircraft peratin (e.g. trying t reprduce in flight a fault discvered n grund fr trubleshting). Perfrming this flight withut additinal precautins may nt be safe. Definitins CAMO Cntinuus Airwrthiness Management Organisatin Check Flight a pst-certificatin flight carried ut as ne f the prcesses t ensure that the aircraft cntinues t cmply with the applicable airwrthiness requirements. CFS Check Flight Schedule. A check flight prgramme. Elective Check Flight a Check Flight required by the peratr, e.g. t fulfill part f the end f lease cnditins. Maintenance check flight means a flight carried ut t prvide reassurance f the aircraft s perfrmance r t establish the crrect functining f a system that cannt be fully established during grund checks. Mandated Check Flight a Check Flight mandated by the Authrity mainly assciated with the issue f a Certificate f Airwrthiness (C f A) fr used aircraft imprted frm utside the Eurpean Unin. Maintenance Organisatin the s called Part 145 rganisatin. MCF Manual Page 11 f 41

12 Test Flight a pre-certificatin flight, usually carried ut by the manufacturer. Test Flights are nt dealt with in this manual. MCF Manual Page 12 f 41

13 Specific requirements fr Maintenance check flights (MCF) Applicability SPO.SPEC.MCF.100 Befre cnducting maintenance check flights, the peratr shall determine the applicable level f the maintenance check flight, as fllws: Level A maintenance check flights are flights intended t be perfrmed using the standard perating prcedure fr rutine flights. Level B maintenance check flights are maintenance check flights ther than level A. E.g.: Stick shaker/pusher activatin (belw the minimum standard speeds), abnrmal landing gear extensins. Flight prgram (CFS) Applicability SPO.SPEC.MCF.105 Befre cnducting a level B maintenance check flight with a cmplex mtr-pwered aircraft, the peratr shall develp a written flight prgram (CFS). Maintenance check flight manual (MCF) Applicability SPO.SPEC.MCF.110 Operatrs intending t cnduct level B maintenance check flights with cmplex mtrpwered aircraft shall describe these peratins and assciated prcedures in the peratins manual r in a dedicated maintenance check flight manual. The manual shall be updated when necessary. All affected persnnel shall be made aware f the manual and its changes that are relevant t their duties. Cmmercial peratrs shall submit the manual and its updates t the cmpetent authrity. Cnditins requiring a maintenance check flight There is the fllwing pssibilities: Requested by maintenance data As required by the aircraft maintenance manual (AMM) r any ther maintenance data issued by the design apprval hlder fr the cntinuing airwrthiness f the aircraft; r Requested by the peratr (elective) MCF Manual Page 13 f 41

14 after scheduled maintenance r unscheduled maintenance including repainting, as required by the peratr; r handback f it frm r t a lessr fr cntractural reasns; r Requested by the maintenance rganisatin as required by the maintenance rganizatin fr verificatin f a successful defect rectificatin; r Requested t regain airwrthiness t assist with fault islatin r trubleshting. Apprpriate maintenance release befre the maintenance check flight Depending n the aircraft defect and the status f the maintenance activity perfrmed befre the flight, different scenaris are pssible and are described belw: Requested by maintenance data The aircraft maintenance manual (AMM), r any ther maintenance data issued by the design apprval hlder, requires that a maintenance check flight is perfrmed befre cmpletin f the maintenance rdered. In this scenari, a certificate f release t service after incmplete maintenance when in cmpliance with M.A.801(g) r 145.A.50(e) shuld be issued by the maintenance rganisatin and the aircraft can be flwn fr this purpse under its airwrthiness certificate. Requested by the peratr Based n its wn experience and fr safety cnsideratins and/r quality assurance, an peratr may wish t perfrm a maintenance check flight after the aircraft has undergne certain maintenance while maintenance data des nt call fr such flight. Therefre, after the maintenance has been prperly carried ut, a certificate f release t service is issued and the aircraft airwrthiness certificate remains valid fr this flight. Requested by the maintenance rganizatin After trubleshting f a system n grund, a maintenance check flight is prpsed by the maintenance rganisatin as cnfirmatin that the slutin applied has restred the airwrthiness f the aircraft. During the maintenance perfrmed the maintenance instructins were fllwed fr the cmplete restratin f the system and therefre a certificate f release t service is issued befre the flight. The airwrthiness certificate is valid fr the flight. An pen entry requesting this flight may be recrded in the aircraft technical lg. Requested t regain airwrthiness An aircraft system has been fund t fail, the dispatch f the aircraft is nt pssible in accrdance with maintenance data and the satisfactry diagnsis f the cause f the fault MCF Manual Page 14 f 41

15 can nly be perfrmed in flight. The prcess fr this trubleshting is nt described in the maintenance data and therefre scenari (3.4.1) des nt apply. Since the aircraft cannt fly under its airwrthiness certificate because it has nt been released t service after maintenance, a permit t fly issued in accrdance with Regulatin (EC) N 1702/2003 is required. Flight authrizatin Maintenance check flights, as defined in the Regulatin n Air Operatins, are carried ut under the cntrl and respnsibility f the aircraft peratr. During the flight preparatin, the flight and the pst-flight activities and fr the aircraft hand ver, the prcesses requiring the invlvement f the maintenance rganisatins r their persnnel shuld be agreed in advance with the peratr. When the decisin t undertake a Maintenance Check Flight has been made, the Psthlder Flight Operatin and the Psthlder Cntinuus Airwrthiness will brief the Technical Pilt wh will then prepare the necessary dcumentatin and supervise the rganisatin f the flight. The Maintenance Check Flight rder must be signed by the Psthlder Flight Operatin and the Psthlder Cntinuus Airwrthiness. Preparatin f the aircraft fr, and recvery frm, a Check Flight is the respnsibility f the CAMO and, where applicable, ther maintenance rganisatins. Prcess t develp a flight prgramme and prcedures Check Flight Schedules are presented in a frmat such that the results are recrded directly n the Schedule. Additinal specific material t enable the cnduct and analysis f results f Check Flights is smetimes needed. This culd be in the frm f a dedicated Supplement r Appendix t the Aircraft Flight Manual. This additinal material culd include perfrmance charts fr use in analysing the perfrmance climbs referenced in sme Schedules. These charts give the perfrmance in terms f rate f climb, whereas the main perfrmance sectin f the Flight Manual will nrmally express climb perfrmance in terms f gradients. In sme cases it might be pssible t calculate the scheduled perfrmance frm the gradient charts, but great care is necessary t ensure that the chart is applicable t the check flwn, i.e. it refers t the same airspeed, pwer setting and engine air bleed cnditin and that it can be cnverted t prvide 'grss' rather than 'net' perfrmance. Where the Schedule requires a climb t be carried ut with the inperative engine at idle rather than fully shutdwn, the gradient charts in the main perfrmance sectin f the Flight Manual are nt applicable. They assume a fully shutdwn engine and the effect f an idling engine (which can be very significant) will nly be taken int accunt in any additinal rate f climb charts prepared fr that purpse. MCF Manual Page 15 f 41

16 As part f the generic prcedures, the tests in the Schedules nrmally require the aircraft t be flwn beynd VMO and MMO and hence utside the nrmal Flight Manual Limitatins. Additinal material in the Flight Manual permitted such excursins fr the purpse f airwrthiness flight testing. In the absence f such a statement in the Flight Manual fr the specific aircraft, wners/peratrs shuld cnsult manufacturers t determine a basis fr small excursins beynd declared AFM limits. Additinal material may als include stall speeds in terms f indicated airspeed if the perfrmance sectin f the Flight Manual nly gives them in terms f CAS r EAS. Where quted in the Schedules, values are usually indicated values, careful cnsideratin f the aircraft standard and cnfiguratin is essential t ensure the Schedule is applicable. Subsequent mdificatins, service bulletins r AD's may invalidate a previusly valid Schedule. Cntents f the flight prgramme and prcedures The prcedure cntaining the checks t be perfrmed in flight shuld be thrughly develped by the peratr using applicable current data wuld be available as read-andd checklist, including: In-flight briefings; Limits (nt t be exceeded); Specific-entry-cnditins; Task sharing and call-uts; Cntingency plans; Infrmatin t additinal crew and ATC. The detailed CFS will always be the respnsibility f, and under the cntrl f, the peratr, agreed with the peratr s CAMO and, where necessary, in liaisn with the applicable maintenance rganisatin. Fr a Maintenance Check Flight, the CFS will be determined by the functins and tests required by the maintenance rganisatin in cnjunctin with the CAMO. It shuld be nted that maintenance data may specify the functins and tests that need t be perfrmed during Maintenance Check Flights and the flight cnditins required t enable the flight t be safely and prperly cnducted. It is imprtant that the peratr ensures that they btain all relevant infrmatin f this type, and that the flight crew wh will cnduct the flight are prvided with the infrmatin and briefed accrdingly. Fr bth Elective and Maintenance Check Flights, where nly checks fr functinality f equipment used by crew during rutine peratins are required, the schedule may cnsist f a simple list f checks t be perfrmed, the rder f the checks and the required flight cnditins. Where the checks require peratin utside nrmal Standard Operating Prcedures (SOPs), the CFS shuld be cnstructed with the relevant cnditins appertaining. MCF Manual Page 16 f 41

17 It is the respnsibility f the peratr t ensure that the checks and limitatins n the CFS are crrect fr the aircraft under check. The prime surce f infrmatin is the Aircraft Flight Manual, and in the event f cnflict this shuld be taken as verriding. 2. Aircraft status Applicability SPO.IDE.A/H.140 The aircraft shall be equipped with a cckpit vice recrder in accrdance with the applicable requirements fr the aircraft s nrmal peratin NCC.IDE.A.160 r CAT.IDE.A.185. Applicability SPO.IDE.A/H.145 The aircraft shall be equipped with a flight data recrder in accrdance with the applicable requirements fr the aircraft s nrmal peratin NCC.IDE.A.165 r CAT.IDE.A.190. Requirements abut the status f the aircraft prir t departure (e.g. MEL, CDL) fr the maintenance check flight The same prvisins as fr nrmal flights apply. It is ften nt wrth prceeding with a Check Schedule when perating with unserviceable equipment, albeit in accrdance with the MEL. Depending n their nature, such unserviceabilities may render the checks invalid and, pssibly mre significantly, yu must bear in mind that the first failure has, in effect, already ccurred and thus the prbability f a secnd failure is that much mre likely. Such situatins may als invlve knck-n effects that are nt readily apparent when the subject is first cnsidered. It is highly beneficial t have a list f the existing Deferred Defects List n the check aircraft available at the briefing stage since their significance can then be cnsidered in the calm f the briefing rm. Fuel lading Fuel minima: Min Blck fr the intended flight + fuel required per each apprach. A selectin f en-rute alternate must be planned and at least tw destinatin alternate. Weight and balance The imprtance f weight and balance, and in particular knwing the exact lcatin f the CG, cannt be veremphasised. Dangerus flight characteristics are usually assciated with an aircraft s CG being beynd established limits. When intentinally appraching thse limits, especially fr the first time, disciplined prcedures fr determining the psitin f the CG are essential. Weighing the check aircraft in its precisely laded pretake-ff cnditin is the recmmended methd fr achieving this. If this is nt practical, in the case f large aircraft fr instance, accurate weight and balance data, based n a recent weighing, an inventry f cnfiguratin changes and a validated lading system, may be acceptable. The after landing cnditin is determined similarly. The precise MCF Manual Page 17 f 41

18 weight and balance f the aircraft at specific pints can then be derived by cnsidering fuel burn and elapsed time frm engine start. Like with all flights preparatin, a weight and balance cmputatin must be perfrmed. When the aircraft has been repainted, a weighing is required and a new basic weight and arm reflected n the new weighing reprt. The nrmal weight and balance cmputatin sheet might nt be used in that case and a specific weight and balance cmputatin sheet must be prepared. As the center f gravity will usually be frward, lad and secure weight ballast cmpsed f stne bag in the carg hld. Specific test and safety equipment Mandatry equipment test as per manufacturer dcumentatin (AFM) have t be perfrmed, including safety equipment and escape systems. MCF Manual Page 18 f 41

19 3. Crew selectin and ther persns n bard Selectin summary: Gd Cmmunicatr Technically inquisitive Determined t get answers Gd flying ability Admits errrs and learns Takes respnsibility Patient Makes balanced judgments Defaults twards Safety Team player Skills: Observatin Interpretatin Analysis Cmmunicatin Use f ALL senses Airmanship and Teamwrk Mtr skills Lgical Flexible Cnsistent Apprach Aptitude: Creative Persistent Variable Asking Learning Attitude Telling Knwing Under cnfidence Right Over Cnfidence Manage these paradxes T achieve the right balance INTEGRITY Experience: Better risk evaluatin Better Priritisatin f task Less errrs Aircraft Thery Rle Knwledge: A Technical Flight Crew is a crew f 3: 2 Pilts Prerequisites: rated and current n Aircraft type with at least 6 mnth experience 1 Technical Flight Engineer (TFE) Prerequisites: A third pilt, r A Flight Engineer wh has fllwed a familiarizatin curse n the type, r A Maintenance Engineer wh has successfully fllwed the applicable maintenance type rating curse as per Part 147 r equivalent, r MCF Manual Page 19 f 41

20 A Flight Operatins Engineer wh has fllwed a familiarizatin curse n the type Flight crew qualificatins Applicability: SPO.SPEC.MCF.115 The peratr shall select the flight crew members fr level B maintenance check flights as fllws: Fr flights with cmplex mtr-pwered aircraft Fr flights with cmplex mtr-pwered aircraft, the pilt-in-cmmand shall: (a) hld a valid type rating, have cmpleted a minimum f flight hurs as pilt-incmmand n aircraft with similar characteristics, and have fllwed a training curse in accrdance with SPO.SPEC.MCF.120; r (b) hld a valid test pilt rating. Fr flights with ther-than-cmplex mtr-pwered aircraft Fr flights with ther-than-cmplex mtr-pwered aircraft, the pilt-in-cmmand shall: (a) have cmpleted a minimum f flight hurs flwn as pilt-in-cmmand in the apprpriate aircraft categry r, in the case f single pistn-engine aircraft, sailplane r balln, have cmpleted a minimum f 300 flight hurs flwn as pilt-in-cmmand in the apprpriate aircraft categry, and hld a valid type r class rating with a minimum f 50 hurs n type r class as pilt-incmmand; r (b) hld a valid test pilt rating; r (c) hld a valid type r class rating and a minimum ttal experience f 500 flight hurs as pilt-in-cmmand and shall have fllwed a training curse in accrdance with SPO.SPEC.MCF.120. Experience and recency The pilt-in-cmmand shall nt perfrm a level B maintenance check flight unless he/she has carried ut a maintenance check flight within the preceding 24 mnths. Recency as pilt-in-cmmand n a level B maintenance check flight is regained after perfrming a level B flight as bserver r pilt mnitring r after acting as pilt-incmmand in a full flight simulatr level B maintenance check flight. 4. Training MCF Manual Page 20 f 41

21 The difficulties (and decrease in safety) f MCFs d nt lie in the abnrmal r emergency situatins that may arise frm the MCF itself. These situatins are cmmnly practiced during type ratings and recurrent trainings by all pilts. The real challenge is t mitigate the likelihd f such abnrmal r emergency situatins by prper preparatin and flight perfrmance and t be able t cpe with them adequately. And the difference with rutine flights lies with the different envirnment, pre-flight and during flight in additin t the increased wrklad during flight. Pre-flight, it is necessary t prepare, check, have an exhaustive walk-arund, understand the maintenance achieved n the aircraft and the purpse f the flight. During flight the wrklad is higher than usual because f specific maneuvers, cckpit cmmunicatin and ATC cmmunicatin (especially when n dedicated flight test aera ATC is used: accurate frequency mnitring and multiple frequency changes are necessary). Flight crew training curse Applicability SPO.SPEC.MCF.120 A typical manufacturer curse is the Technical Flight Familiarisatin Curse ffered by Airbus which may be run at the manufacturer's premises r at the Operatr's base and is a five day curse cnsisting f 3 mdules: A tw day grund schl Tw fur-hur full flight simulatr sessins t: train key checks in nrmal peratins analyse sme abnrmal situatins One fur-hur flight in an aircraft t train key prcedures. Classrm training shuld cver the fllwing: Crew respnsibilities and task sharing Flight preparatin and authrisatin Pre-flight briefing Recrding f in-flight parameters Risk Management - peratinal and safety aspects f flight check prfile and risk mitigatin Aircraft-type specifics and use f special system checklists in flight Full flight Simulatr Training shuld prvide demnstratin and practice f representative system test sequences and pssible utcmes. The imprtance f adherence t all applicable manufacturers recmmended flight check prfiles shuld be stressed and where apprpriate demnstrated. Simulated abnrmal situatins in flight SPO.SPEC.MCF.130 MCF Manual Page 21 f 41

22 The requirement laid dwn in SPO.OP.185 is nt applicable fr maintenance check flights when the simulatin f abnrmal situatins in flight is required t meet the intentin f the flight and is identified in the flight prgramme. Level B maintenance check flights training curses shall be cnducted in accrdance with a detailed syllabus. The peratrs f cmplex mtr-pwered aircraft shall describe this training in the manual referred t in SPO.SPEC.MCF.110. The training curse shall be cnducted as fllws: In a full flight simulatr fllwed by at least ne maintenance check flight as cpilt r bserver befre acting as pilt-in-cmmand n a maintenance check flight; r During a flight in an aircraft demnstrating maintenance check flight techniques. The training curse referred t abve, fllwed n ne aircraft categry is cnsidered valid fr all aircraft types in that categry. Cnsidering the aircraft used fr the training and the aircraft t be flwn during the maintenance check flight, the peratr shall specify if differences r familiarisatin training is required and the cntents f such training Curse cnsideratins The training curse stipulated in SPO.SPEC.MCF.120 (5.3.1) shuld cmprise grund training fllwed by a demnstratin f techniques fr the checks in flight and failure cnditins in a full flight simulatr (FFS) r aircraft during dedicated flight r Maintenance Check Flight level B. In a demnstratin perfrmed in an aircraft, the trainer shuld nt simulate a failure cnditin that culd induce a safety risk, e.g., unexpected engine failure. The grund training shuld cver the specified training syllabus (see AMC2 SPO.SPEC.MCF.120). The flight demnstratin shuld include the techniques fr the mst significant checks cvered in the grund training. As part f this demnstratin, the pilts under training shuld be given the pprtunity t cnduct checks themselves under supervisin. The grund training and flight demnstratin shuld be prvided by experienced flight crew with test r maintenance check flight experience. Flight demnstratins shuld be instructed by any f the fllwing persns: A qualified test pilt; r An aircraft manufacturer s pilt experienced in cnducting pre-delivery check flights; r A type rated pilt, currently authrised by the peratr, t cnduct maintenance check flights. Upn successful cmpletin f the training a recrd shuld be kept. MCF Manual Page 22 f 41

23 Curse syllabus In the case f aerplanes and helicpters, the training curse syllabus includes the fllwing subjects: Legal aspects: regulatins cncerning maintenance check flights. Organisatin f maintenance check flights: crew cmpsitin, persns n bard, definitin f tasks and respnsibilities, briefing requirements fr all participants, decisin-making, ATC, develpment f a flight prgramme. Envirnmental cnditins: weather and light requirements fr all flight phases. Flight preparatin: aircraft status, weight and balance, flight prfile, airfield limitatins, list f checks. Equipment and instrumentatin: n bard access t varius parameters. Organisatin n bard: CRM, crew crdinatin and respnse t emergency situatins. Grund checks and engine runs: review f checks and assciated techniques. Taxi and rejected take-ff: specificities and techniques. Techniques fr checks f varius systems: Aerplanes: flight cntrls, high speed and lw speed checks, autpilt and autthrttle, depressurisatin, hydraulic, electricity, air cnditining, APU, fuel, anti-ice, navigatin, landing gear, engine parameters and relight, anemmetry. Helicpters: engine pwer tpping, track and balance, high wind start, autpilt, perfrmance measurement, hydraulic, electricity, air cnditining, APU, fuel, anti-ice, navigatin, landing gear, engine checks and relight, autrtatin, anemmetry. Review f failure cases specific t these checks. Pst-flight analysis. Persns n bard SPO.SPEC.MCF.125 With the cabin altitude greater than 10,000 ft, use xygen. If passengers r bservers are carried, there shuld be prtable xygen sets available fr their use. The rle f bserving engineers Manufacturer s typically recmmend that all flights where aircraft systems will be intentinally degraded shuld be carried ut with an apprpriately qualified and experienced aircraft engineer (r alternatively a third pilt wh has been trained t the same level as the designated aircraft cmmander) ccupying ne f the flight deck supernumerary seats. The rle f this third persn shuld be clearly defined in relatin t the primacy f the perating flight crew and the aircraft cmmander in particular. MCF Manual Page 23 f 41

24 Crew cmpsitin and persns n bard The minimum flight crew shall be tw pilts, whenever the aircraft has at least tw pilt statins. Fr level B maintenance check flights n cmplex mtr-pwered aircraft, a task specialist is required in the flight crew cmpartment assist the flight crew t cnduct the maintenance check flight if permitted by the aircraft cnfiguratin. Ntwithstanding the abve and cnsidering the wrklad f the flight crew based n the flight prgramme, when the peratr can justify as part f its risk analysis that the flight crew wuld nt require additinal assistance, the peratr may fly withut a task specialist in the flight crew cmpartment. The peratr shall identify the need fr additinal task specialists as required fr the intended flight. The peratr shall define in its manual the plicy fr ther persns n bard. As a general principle, nly persnnel essential t cmplete the flight (crew and task specialists) shuld be n bard. Task Specialist assigned duties A task specialist is trained and briefed as necessary t perfrm his/her intended functins. Based n this, the peratr is able t determine if a task specialist is suitable t assist the flight crew in the cckpit perfrming functins, such as: Assistance n grund fr flight preparatin; Assistance in navigatin; Assistance in radi cmmunicatin/radi navigatin means selectin; Reading f checklists; and Mnitring f parameters. If a task specialist s assigned duties are nt directly related t the flight peratin but related t the maintenance check (e.g. reprting frm the cabin n a certain vibratin r nise), the required training and briefing shuld be adequate t this functin. Flight time limitatins and rest Operatrs subject t Subpart FTL f Annex III (Part-ORO) shall apply this subpart when assigning crew members t maintenance check flights. Apprpriate additinal time shuld be rstered fr pre-flight briefing fr all thse persns wh will ccupy flight deck seats prir t the cmmencement f a nn-standard flight. MCF Manual Page 24 f 41

25 5. Briefings Pre-briefings, during which team members are made aware f details fr the planned peratin, shuld be cnducted prir t the varius verall flight phases and then prir t each individual flight. All participants, shuld attend pre-flight briefings as shuld the relevant manager r authrising fficer. Fr certain maintenance check flights, the data btained r verified in flight will be necessary fr assessment r cnsideratin after the flight by the maintenance rganisatin prir t issuing the maintenance release. Fr this purpse, when the persnnel f the maintenance rganisatin cannt perfrm these functins in flight, the maintenance rganisatin may rely n the crew perfrming the flight t cmplete these data r t make statements abut in-flight verificatins. In this case the maintenance rganisatin shuld appint the crew persnnel playing such a rle and brief them n their functins befre the flight. Briefing participants A briefing between the Operatr and the maintenance rganisatin will be held t establish the technical requirements. The Operatr will hld a briefing between the relevant services: Flight Operatins Airwrthiness Management Maintenance Organisatin Grund Operatins Lessee/lessr Specific pre-flight briefing tpics Applicability SPO.SPEC.MCF.140 Prir t any Check Flight, a full pre-brief shuld be cnducted between the CAMO, maintenance rganisatin and flight peratins, during which the flight crew shuld be made aware f the specific reasns fr the Check Flight. In particular, specific nte shuld be made f any maintenance tasks that have a direct effect n the aircraft s handling r perfrmance. The briefings shuld include details f the data t be recrded, and the requirement t accurately recrd any defects r requests fr maintenance. MCF Manual Page 25 f 41

26 Risk management The perating crew and any ther persnnel legitimately n the flight deck fr airwrthiness functin / check flight is the final line f defense in risk management, where the principal risk is lss f cntrl. The peratr will be respnsible fr ensuring that its crew thrughly understands the CFS, the techniques t be used, the flight cnditins required and all ther aspects f the cnduct f the flight. Cnsideratins t fly with ptentially unreliable systems: When a maintenance check flight is intended t check the prper functining f a system r equipment, this shall be identified as ptentially unreliable, and apprpriate mitigatin means shall be agreed prir t the flight in rder t minimise the risks t flight safety. Identify which check pints carry mre risk Plan hw t fly them and then stick t yur plan Decide and brief break ff pints If things dn t lk right they are prbably wrng s stp Take care with breaks in the sequence Risk assessment Risk management is nrmally cnducted thrugh a safety review prcess in which a flight check plan is examined by prject and nn-prject persnnel in rder t draw ut ptential hazards and recmmend mitigating (r minimising) prcedures. It shuld cnsider the risks t ther airspace users and persns n the grund and water as well as t the aircraft under check. Risk management can be carried ut infrmally, hwever, mst benefit will be gained thrugh frmalising the prcess and writing dwn the utcmes in a risk management plan. Mre infrmatin available at Appendix. Factrs: 1. Required crew experience; 2. Required meterlgical cnditins; 3. Required FTO review and apprval levels; 4. Supprt and safety equipment. Safety meeting hazards are identified; an assessment is made f the risks invlved; mitigating prcedures are established t reduce r eliminate the risks; and a cnscius decisin is made, at the apprpriate level f authrity, t accept residual risk. Risk level table: MCF Manual Page 26 f 41

27 Hazard Outcme Categry Subjective Prbability f Occurrence Prbable Pssible Unlikely Remte Catastrphic UNACCEPTA HIGH Medium Lw BLE Critical HIGH HIGH Medium Lw Marginal Medium Medium Medium Lw Acceptable Lw Lw Lw Lw Factrs Affecting Flight Check Risk Ratings: Sme factrs which may be wrth taking int cnsideratin when assigning flight check risk ratings are as fllws: team s prficiency with, currency n and familiarity with the aircraft and the type f checks being cnducted. e existence f any previus check prgram, the thrughness theref and the relevant results. techniques and wrklads. etc.). Aircraft internal envirnment (temperature, pressurisatin level etc.). sequencing. Risk Level Examples: Examples f tests which culd be cnsidered t carry different risk levels, initially and unmitigated, are gruped belw. These are typical examples nly and are prvided fr general guidance. The actual risk categry fr each test cnditin must be evaluated n a case-by-case basis. High Risk: Tests that culd be cnsidered t invlve high risk factrs are as fllws: Stall Characteristics: MCF Manual Page 27 f 41

28 deep stalls. h unprved pusher systems that are masking ptential High speed tests abve VNE/VMO/MMO. VMCA tests at lw altitude, particularly dynamic VMCA. Flight cntrl malfunctin testing during take-ff and landing phases f flight, and asymmetric deplyment f rll cntrls at high speeds. Maximum energy RTOs where wheel brake fires are a pssibility. Autpilt malfunctin tests at lw altitudes. Nsewheel steering malfunctin tests. Dynamic lateral-directinal testing (Dutch rlls) n aerplanes that are unstable under certain cnditins. Pilt Induced Oscillatins testing. Medium Risk: Tests that culd be cnsidered t invlve medium risk factrs are as fllws: Any tests invlving lw altitude peratins (e.g. grund curse pressure errr crrectin testing). Tests invlving frmatin flying. Aerbatic maneuvres. Actual V1 fuel cuts fr take-ff perfrmance. Inflight unusable fuel tests that result in engine flameut. Stall speed, r glide perfrmance, measurement with the engine actually inperative. Lw speed and high speed stability and cntrl tests. Emergency electrical pwer landings at night using standby instruments and/r reduced lighting (bth external and internal). Emergency descents t demnstrate high altitude special cnditins (pssible physilgical effects). Abnrmal flight cntrl cnfiguratin testing. Includes pitch and rll discnnects r manual reversin fr hydraulic systems. MCF Manual Page 28 f 41

29 Abnrmal peratin f nbard systems. Flights invlving Full Authrity Digital Engine Cntrl testing (Electrmagnetic Interference, sftware, etc.). Terrain Awareness Warning Systems grund prximity warning systems (GPWS/EGPWS). Lw Risk: Examples f lw risk testing culd be as fllws: Basic system functin tests (electrical, hydraulic, fuel, envirnmental, anti-ice, avinics etc.) nt invlving abnrmal r emergency cnditins. High altitude airspeed calibratins (e.g. GPS). Climb perfrmance/speed pwer etc. Event reprting Cnsider whether any f the defects bserved warrant further, frmal reprting under either Cmpany reprting schemes r the Mandatry Occurrence Reprting (MOR) scheme. Lessn learnt 6. Aircraft status Due t incmplete maintenance, it is advisable t pen a new entry n the aircraft technical lg t identify the need fr a maintenance check flight. This new entry shuld cntain r refer, as necessary, t data relevant t perfrm the maintenance check flight, such as: aircraft limitatins due t incmplete maintenance, maintenance data reference and maintenance actins t be perfrmed after the flight. Summary f maintenance A summary f the maintenance perfrmed n the aircraft and the pssible effects during flight will be described in the pilts briefing sheet and discussed with the Technical Pilt. 7. Flight prgramme, specific prcedures and limitatins There may be ccasins when the requirements f the Check Flight Schedule appear t cnflict with Limitatins r advice in the Flight Manual (AFM); in all such cases, the AFM must take pririty. Specific dispensatins may, when necessary, be given in an AFM Supplement, (Flight Testing and Training), and crews shuld make themselves familiar with this Supplement befre carrying ut Check Flights. Nte: MCF Manual Page 29 f 41

30 Assciate warnings and limits with check t be dne Hard limits need clear DO NOT EXCEED warnings Avid writing a check sequence ver tw pages Make them easy t handle. Nt t big r detailed Crew members respnsibilities and crdinatin The pilt in cmmand f the Check Flight shuld ensure that the crew is suitable fr the task and adequately instructed. Ensure back-up fr all prcedural tasks n the flight deck. Crew Resurce Management Crew Resurce Management Crew resurce management is the applicatin f team management cncepts and the effective use f all available resurces t perate a flight safely. In additin t the aircrew, it includes all ther grups rutinely wrking with the aircrew wh are invlved in decisins required t perate a flight. These grups include, but are nt limited t, airplane dispatchers, flight attendants, maintenance persnnel, and air traffic cntrllers. Situatinal awareness, r the ability t accurately perceive what is ging n in the flight deck and utside the airplane, requires n ging questining, crsschecking, cmmunicatin, and refinement f perceptin. It is imprtant that all flight deck crewmembers identify and cmmunicate any situatin that appears unsafe r ut f the rdinary. Experience has prven that the mst effective way t maintain safety f flight and reslve these situatins is t cmbine the skills and experience f all crewmembers in the decisin making prcess t determine the safest curse f actin. The general principles f CRM, as applicable t the nrmal peratinal envirnment, can be easily extended t take in the additinal supprt teams that will be invlved in flight checking. -It-Off: The knck-it-ff (time-ut) (KIO) principle can be usefully applied t flight check peratins. A KIO call instigates an immediate halt t test prceedings and establishes the aircraft in a benign, straight and level, r climbing, state while situatinal awareness is recvered r the surce f a prblem is investigated. A psitive decisin regarding recmmencement r terminatin f the srtie is then made. Pre-established cmpany rules shuld nrmally be in place regarding wh can make a KIO call and when ne shuld be made althugh the best methd is usually the mst cnservative i.e. any team member shuld be encuraged t make the call when they nte any limit exceedence, r dangerus trend tward such. Headphne and Flight Deck Speaker Use Headphne and Flight Deck Speaker Use In the airplane, headphnes r bm micrphnes/headsets are wrn during takeff until the tp f climb and frm the start f descent thrughut apprach and landing. During cruise, flight deck speakers may be used. Speaker vlume shuld be kept at the MCF Manual Page 30 f 41

31 minimum usable level adequate t avid interference with nrmal crew flight deck cnversatin, but still ensure receptin f relevant cmmunicatins. Synptic Display Synptic Display Synptic displays are prvided as a means f assisting the flight crew in rapidly understanding the status f the airplane systems. Hwever, crews shuld nt rely slely n the displays fr determining airplane status. The flight crew is encuraged t select a display at any time they feel it is the mst efficient way t get desired infrmatin. Synptic displays shuld nly be used as necessary t get the desired infrmatin and then turned ff. The clarity and simplicity f displayed infrmatin enable the flight crew t btain necessary infrmatin frm a brief scan. If the flight crew elects t use synptic displays in cnjunctin with accmplishment f prcedures, they must assure n distractin frm the intended task results. This is particularly true when accmplishing nn-nrmal prcedures. Under certain cnditins, system faults can result in missing synptic infrmatin. Therefre, decisins regarding nn-nrmal situatins shuld be based n EICAS messages and ther flight deck effects and indicatins. In every case where a nn-nrmal prcedure results in a need fr memry items, they shuld be cmpleted befre selecting a synptic display. Accmplishment f necessary prcedures shuld take pririty ver use f synptic displays. Calluts Calluts Bth crewmembers shuld be aware f altitude, airplane psitin and situatin. Avid nnessential cnversatin during critical phases f flight, particularly during taxi, takeff, apprach and landing. Unnecessary cnversatin reduces crew efficiency and alertness and is nt recmmended when belw 10,000 feet MSL / FL100. At high altitude airprts, adjust this altitude upward, as required. The Pilt Mnitring (PM) makes calluts based n instrument indicatins r bservatins fr the apprpriate cnditin. The Pilt Flying (PF) shuld verify the cnditin/lcatin frm the flight instruments and acknwledge. If the PM des nt make the required callut, the PF shuld make it. The PM calls ut significant deviatins frm cmmand airspeed r flight path. Either pilt shuld call ut any abnrmal indicatins f the flight instruments (flags, lss f deviatin pinters, etc.). One f the basic fundamentals f Crew Resurce Management is that each crewmember must be able t supplement r act as a back-up fr the ther crewmember. Prper adherence t standard calluts is an essential element f a wellmanaged flight deck. These calluts prvide bth crewmembers required infrmatin abut airplane systems and abut the participatin f the ther crewmember. The absence f a standard callut at the apprpriate time may indicate a malfunctin f an airplane system r indicatin, r indicate the pssibility f incapacitatin f the ther pilt. MCF Manual Page 31 f 41

32 The PF shuld acknwledge all GPWS vice calluts during apprach except altitude calluts while belw 500 feet AFE. The standard callut f "CONTINUE" r "GO-AROUND" at minimums is nt cnsidered an altitude callut and shuld always be made. If the autmatic electrnic vice callut is nt heard by the flight crew, the PM shuld make the callut. Nte: If autmatic calluts are nt available, the PM may call ut radi altitude at 100 feet, 50 feet and 30 feet (r ther values as required) t aid in develping an awareness f eye height at tuchdwn. Standard Phraselgy A partial list f recmmended wrds and phrases fllws: Thrust: SET TAKEOFF THRUST SET GO-AROUND THRUST SET MAXIMUM CONTINUOUS THRUST SET CLIMB THRUST SET CRUISE THRUST Flap Settings: FLAPS UP FLAPS ONE FLAPS FIVE FLAPS FIFTEEN FLAPS TWENTY FLAPS TWENTY-FIVE FLAPS THIRTY Airspeed: 80 KNOTS V1 ROTATE SET KNOTS SET VREF PLUS (additive) SET FLAPS SPEED MCF Manual Page 32 f 41

33 Infrmatin t ATC Liaise with ATC t ensure that they are aware f yur requirements. Pst-flight briefing Pst-flight briefings, whereby the success r therwise f the missin and any safety lessns are drawn ut while still fresh in the grup s memry are als wrthwhile. 8. External cnditins Weather and light cnditins Ref: OM A chap Weather minima: daylight nly and actual and frecast WX fr take-ff, destinatin and alternate are at least 1000ft ceiling and min visibility fr apprach 1500m RVR. On flights, where external visual reference n take-ff is required, the required wx cnditins will be specified by the Psthlder FOP accrding t the circumstances, but may nt be lwer than the published circling minimum where the check flight takes place. Ensure that the weather is suitable fr the checks t be carried ut, e.g., there is little pint in carrying ut perfrmance climbs in heavy turbulence r in clud since bth will reduce the perfrmance, perhaps requiring a re-fly. Never carry ut stalls r high-speed runs when there is significant atmspheric turbulence arund; remember that the nrmal margins are significantly erded and the assciated gusts may put the aircraft utside its certificated envelpe. Be aware that after flight thrugh icing cnditins, sme ice may remain n unprtected areas and this can have significant effects n handling and perfrmance. Check Flights shuld be carried ut in day VMC and with a well-defined visible hrizn since gd attitude awareness may be necessary fr precise cntrl and in the remte event f extreme attitudes being reached, e.g. an unexpected and prnunced wing drp at the stall; in additin ensure that there is sufficient vertical clearance frm clud fr any recvery t be cmpleted visually. Check Flights shuld nt be carried ut at night. Terrain Fr multi-engine aircraft, the single-engine climb shuld nt be carried ut belw the minimum safety height f 3000 ft AGL. ATC, airspace Experience shws that it is best and mst expeditius nt t carry ut Check Flights in cntrlled airspace where ATC requirements will necessarily take pririty. It is usually best t exit and re-enter cntrlled airspace in accrdance with ATC and cmpany nrmal perating prcedures. MCF Manual Page 33 f 41

34 A special airspace dedicated fr check flight shuld be requested if pssible in rder t reduce the wrklad. Airprt (runway, equipment)/perating site The selectin f the perating site shuld take in t accunt: Ease f access Facilities: Licensed airfield with apprpriate runways, facilities and perating envirnment. Significant air-traffic prblems r busy airspace envirnment. Limited apprach and departure lanes r apprach and departure lanes require cmplicated navigatinal prcedures t negtiate. Emergency, crash recvery, fire fighting and medical services available and n stand-by. Sme flight supprt r flight fllwing available. Runway status (cntaminatin, NOTAM) MCF Manual Page 34 f 41

35 9. Dcumentatin Specific dcumentatin n bard List f Dcuments required prir t cnduct f a Check Flight: 1 Certificate f Registratin 2 Either: C f A (and ARC) r Permit t Fly (if in date) 3 Aircraft Flight Manual (r POH), including apprpriate Supplements if applicable 4 Weight and Balance Statement 5 Radi Statin Licence and Certificate f Apprval 6 Nise Certificate 7 Certificate f Insurance 8 Either: Aircraft Technical Lg Or: Lgbk fr Aircraft/Engine/Prpeller In-flight recrdings The Check Flight Schedule will prvide details f instrument readings t be recrded. Recrding the climb data shuld nt be started until the aircraft is stabilised in the climb at the crrect speed and with the pwer set. It is als necessary t establish the weight f the aircraft at a pint apprximately midway in each measured climb. This can be determined by reference t fuel gne indicatrs, n a time and cnsumptin basis r, where their accuracy is gd enugh, by reference t direct fuel gauge readings. It is acceptable t recrd the weight at the beginning and end f the climb and t use the average f the tw fr data reductin. Result f the maintenance check flight and related data Fllwing the Check Flight, it is essential that the utcme be reprted fully and frmally. The fllwing prcesses shuld be cmpleted as a minimum: Ensure that the Check Flight Schedule has been cmpleted and all the apprpriate data blcks filled. If apprpriate, calculate the perfrmance. Cmplete the Check Flight Reprt. Transfer the defects frm the Schedule t the aircraft Technical Lg. Cnsider whether any f the defects bserved warrant further, frmal reprting under either Cmpany reprting schemes r the Mandatry Occurrence Reprting (MOR) scheme. MCF Manual Page 35 f 41