Advisory Circular (AC) Flight Test Considerations For The Approval Of The Design Of Aircraft Modifications File No. 5009-6-513 AC No. 513-003 RDIMS No. 528350-V3 Issue No. 01 Issuing Branch Aircraft Certification Effective Date 2004-12-01 1.0 INTRODUCTION... 2 1.1 Purpose... 2 1.2 Guidance Applicability... 2 1.3 Description of Changes... 2 1.4 Termination... 2 2.0 REFERENCES... 2 2.1 Reference Document... 2 2.2 Cancelled Document... 2 3.0 BACKGROUND AND DISCUSSION... 2 4.0 FLIGHT TEST... 2 4.1 General... 2 4.2 Flight Characteristics... 3 4.3 Performance... 3 4.4 Flight Deck Design... 4 4.5 Flight Guidance...4 4.6 Navigation Systems... 5 4.7 System Operation... 5 4.8 Aeroplane or Rotorcraft Flight Manual Changes... 6 5.0 FLIGHT TEST TECHNIQUES... 6 6.0 REQUEST FOR ADDITIONAL INFORMATION... 7 7.0 HEADQUARTERS CONTACT... 7
1.0 INTRODUCTION 1.1 Purpose The purpose of this Advisory Circular (AC) is to provide general guidance on the flight test considerations associated with the approval of the design of aircraft modifications 1.2 Guidance Applicability This document is applicable to all Transport Canada personnel, delegates and industry. 1.3 Description of Changes This document, formerly AMA No. 513.05/1, is reissued as an AC. With the exception of minor editorial changes, the content is unaltered. 1.4 Termination This document does not have a terminating action. It will however, be reviewed periodically for suitability of content. 2.0 REFERENCES 2.1 Reference Document It is intended that the following reference material be used in conjunction with this document: Chapter 513 of the Airworthiness Manual (AWM), paragraph 513.05(1) Approval of Modification and Repair Designs, Obligations of an Applicant. 2.2 Cancelled Document As of the effective date of this document, AMA No. 513.05/1 dated 10 June 2003 is cancelled. 3.0 BACKGROUND AND DISCUSSION Chapter 513 of the Airworthiness Manual (AWM) contains procedures for the approval of the design of an aircraft modification. To show that the modified aircraft meets the applicable airworthiness standards, flight tests may be required to demonstrate compliance with standards of airworthiness or to determine that the characteristics of the aircraft are not degraded to an unacceptable level. Some examples of design changes which would require flight-testing are set out in the following sections. 4.0 FLIGHT TEST 4.1 General Flight test assessments are usually required for aircraft modifications that could affect airworthiness in areas such as: Flight Characteristics; Performance; Flight Deck Design; Flight Guidance; Navigation Performance; System Operation; and Aeroplane or Rotorcraft Flight Manual changes. 2004-12-01 2 of 7 AC 513-003 Issue 01
4.2 Flight Characteristics Flight tests are normally required when a modification may affect aircraft flight characteristics including the following: controllability and manoeuvrability; trim; stability (dynamic and static); stalls; spinning (where applicable); ground or water handling characteristics; and miscellaneous flight requirements (vibration and buffeting, high speed characteristics and out-of-trim characteristics). Some modifications in which flight characteristics are affected include: 4.3 Performance changes to the primary or secondary control surface size, surface travel limits, surface actuation systems or balance mechanisms; powerplant changes affecting the thrust or power level, thrust line, nacelles, pylons, thrust reverser system, propeller or rotor; the addition of, or change to, fairings, radomes, finlets, antennae, cargo pods, aerial spray equipment or other externally mounted equipment; increase in the maximum take-off weight or maximum landing weight; and extension of the forward or aft CG limit. Flight tests are normally required when a modification has some effect on the aircraft lift, drag, installed thrust, maximum weight, ground friction characteristics or braking effectiveness. The effect of the modification on the aircraft performance must be determined in the following areas: (h) (j) stall speeds; installed power or thrust; take-off and landing speeds; take-off and landing distances; accelerate-stop distances; take-off, approach and landing climb performance; airspeed indicator position error; altimeter position error; helicopter hover performance (IGE and OGE); and helicopter climb performance. Examples of modifications which will normally require flight testing because of the impact on performance include: new or revised take-off or landing flap settings; externally mounted equipment; powerplant changes (new rated power or thrust characteristics); engine nacelle, engine intake, or pylon changes affecting installed thrust; 2004-12-01 3 of 7 AC 513-003 Issue 01
4.4 Flight Deck Design tire, brake, anti-skid and aerodynamic lift dump systems affecting deceleration performance; externally mounted equipment which may influence the pitot-static system position errors; and changes to the pitot static system installation. Modifications affecting pilot compartment view, aircraft flight instruments, flight controls, powerplant instruments, warning and caution panels, system controls and displays and pilot workload normally require a flight test assessment. Some examples include the modification to or addition of: (h) (j) radios or avionic systems; head-up displays (HUD); electronic flight instrument displays; electronic engine instrument displays; instruments or controls; flight crewmember seats, including alternate pilot seat operations; instruments or equipment affecting pilot compartment view; lighting systems; 4.5 Flight Guidance bubble windows; and helicopter hoisting, hook controls and release systems. Modification of hardware or software in automatic flight control systems, auto-thrust, auto-brake or auto-land systems and flight director systems may require a flight test assessment. The requirement for flight test can only be determined after a comprehensive analysis is conducted to identify the effect of the modification on all other systems interfacing with the modified component. Some examples of flight guidance system modifications which may require flight testing include software or hardware changes which affect: the pitch, yaw or roll rate commanded by the system; the airspeed at which control laws are phased in and out; the location of the command bars on flight director systems (e.g. go-around); the limits for control surface deflections; the limits for engagement and disengagement of autopilot, auto-thrust, auto-brake and auto-land systems; new technology digital systems; and actuator travel changes and hard-over characteristics. Since the examples provided in 4.5 cannot be comprehensive, a flight evaluation becomes necessary when a modification made to the flight guidance equipment is likely to change the aircraft characteristics in the normal or failure modes in any approved configuration. 2004-12-01 4 of 7 AC 513-003 Issue 01
4.6 Navigation Systems Flight testing of navigation system modifications includes tests to establish system accuracy and performance in order to demonstrate that the modified equipment performs its intended function and that the aircraft will operate satisfactorily using the installed equipment. Systems include ADF, VOR, INS, Omega, Loran, Doppler, Tacan, Satellite Navigation and for the purpose of this advisory, precision navigation and guidance systems such as ILS, MLS and TCAS. Examples of the modifications which can affect navigation system performance and accuracy include: 4.7 System Operation addition of externally mounted equipment which may partially obscure a transmitter, antenna, sensor or receiver; the relocation of antennae, transmitter and receiving sensors; the replacement of navigation system equipment with components that have different specifications; electrical modifications or the addition of systems which may cause electromagnetic interference with the existing navigation systems; and a software or hardware update to permit Cat II or steep approaches or both. Flight tests may be required after modification of any aircraft system not previously discussed. When considering the need for flight tests the failure cases should be assessed to the level where the failure is assumed to occur after dispatch of the aircraft with systems inoperative as permitted in the Master Minimum Equipment List. Examples of modified systems which may need to be assessed through a flight test program include: (h) (j) (k) (l) (m) air conditioning and pressurisation systems; communication systems; cockpit voice recorder and flight data recorder; electrical power systems; fire protection systems; fuel systems (including engine fuel and control); hydraulic systems; ice and rain protection systems; landing gear; lighting systems (internal and external); oxygen systems; pneumatic systems; and airborne auxiliary power systems. In most cases the primary objectives of the flight test assessment of the modified system are: to confirm that the modified system performs its intended function and has satisfactory operating characteristics; to confirm that the modified system does not interfere with the function of other aircraft systems; and 2004-12-01 5 of 7 AC 513-003 Issue 01
to ensure that appropriate procedures are documented for the new equipment as well as any changes to the procedures for other aircraft systems. 4.8 Aeroplane or Rotorcraft Flight Manual Changes The flight manual usually (but not always) needs to be amended as part of a modification approval. Typically, a supplement is produced which includes changes or additions to the basic flight manual information that results from the modification. AC 513.05/2 provides additional guidance on the format and content of the flight manual supplement. A flight manual supplement, flight manual amendment or new flight manual is required if one or more of the following conditions are met: flight testing has shown that operating limitations for the modified aircraft are changed. Examples of this category are: (ii) (iii) (iv) (v) (vi) reduction in maximum operating airspeeds; changes to the weight or CG envelope; changes to engine operating limitations; reduction in maximum operating altitude; the modified aircraft can only be operated in a restricted role, i.e. day VFR, no icing, etc; and changes to system limitations, e.g. minimum autopilot engage altitude is increased. flight testing has shown, or system changes have necessitated changes to normal, abnormal, or emergency procedures; or performance characteristics have been changes by the modification such as: (ii) (iii) (iv) pitot static systems calibrations; stall speeds; take-off or landing performance or both; and climb performance. 5.0 FLIGHT TEST TECHNIQUES Many of the flight test techniques recommended for determining compliance with the certification basis of the aircraft are described in various FAA Advisory Circulars (AC) as outlined below, or later revisions thereof: AC 23-8A Chg. 1 (08-30-93) Flight Test Guide for Certification of Part 23 Airplanes. AC 25-7A (03-31-98) Flight Test Guide for Certification of Transport Category Airplanes. AC 27-1A (07-30-97) Certification of Normal Category Rotorcraft. AC 29-2B (07-30-97) Certification of Transport Category Rotorcraft. Guidance for the flight test instrumentation requirements, manoeuvres and data reduction methods is also provided in the above mentioned advisories. In addition to the FAA ACs several ACs have been published to provide flight test guidance for some specific tests. These ACs normally relate to the airworthiness manual applicable to the type of aircraft under consideration, e.g. (AC 525/1 refers to stall testing on a transport category fixed wing aircraft). These ACs are listed in AC 500/00 of this Manual. 2004-12-01 6 of 7 AC 513-003 Issue 01
6.0 REQUEST FOR ADDITIONAL INFORMATION It is recommended that the Transport Canada Regional Aircraft Certification office be contacted to determine the acceptability and completeness of the proposed tests prior to conducting the flight test. TCCA may need to conduct a flight test assessment of the modified aircraft, so early notification is recommended. The following address can be used for inquiries: Transport Canada Place de Ville Ottawa, Ontario K1A 0N8 Attention: Chief, Flight Test (AARDC) Phone: (613) 952-4315 Fax: (613) 996-9178 7.0 HEADQUARTERS CONTACT For more information please contact: Policy Standards Coordinator (AARDH/P) Phone: (613) 990-3923 Facsimile: (613) 996-9178 E-mail: AARDH-P@tc.gc.ca Original signed by Maher Khouzam Maher Khouzam Chief, Regulatory Standards Aircraft Certification Branch 2004-12-01 7 of 7 AC 513-003 Issue 01