Attachment_07o_3710.1X.pdf

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER EAST

PSC BOX 8021

CHERRY POINT NC 28533-0021

FRCEASTINST 3710.1X CH-i Code 6.ODB—CDW

NOV 102015

FRC EAST INSTRUCTION 3710.1X

CHANGE TRANSMITTAL 1

From: Commanding Officer, Fleet Readiness Center East

Subj: AIR OPERATIONS PROCEDURES MANUAL

Ref: (a) COMNAVAIRFORINST 4790.2 CH-l

End: (1) Revised Page ii

(2) Revised Page 5-8

(3) Revised Page 5-9

(4) Revised Page A-i

1. Purpose. To transmit pages 5-8 and 5-9 which provide Missing Fastener Procedures for aircraft in the flight phase following re-work. Appendix A was modified to include FRC East 3710/12, “FOD Hazard/Missing Fastener Report,” and the Table of Contents to include the Missing Fastener Procedures paragraph.

2. Action. Remove pages ii, 5-8, 5-9 and A-i of the Air Operations Procedures Manual and insert enclosures (1) through

(4) respectively.

V. E. CLARK

Distribution: Electronic only, via the FRC East Master List Web page:

https://mynavair.navair.navy.mil/portal/server.pt/community/issc toois/i742/index.cfm?processHyperLink=true&crt=

“UNSURPASSED SERVICE TO THE FLEET AND RELENTLESS FOCUS ON QUALITY~ ENVIRONMENT

AND OCCUPATIONAL HEALTH AND SAFETY”

DEPARTMENT OF THE NAVY

FLEET READINESS CENTER EAST

PSC Box 8021

CHERRY POINT NC 28533-0021

FRCEASTINST 3710. 1X

Code 6.0DB-Cow

JUL 162015

FRC EAST INSTRUCTION 3710.1X

From: Commanding Officer, Fleet Readiness Center East

Subj: AIR OPERATION PROCEDURES

End: (1) Air Operations Procedures Manual

1. Purpose. To issue procedures and practices for the Flight Check Office (Code 6.003) Air Operations at Fleet Readiness Center East (FRC East)

2. Cancellation. FRCEASTINST 3710.1w

3. Summary of Changes. The incorporated changes focus heavily on using Optimized Organizational Maintenance Activity (OOMA) in the Safe For Flight process, particularly with respect to ensuring aircraft documentation is up to date. Training and qualification requirements for civilian Plane Captain and Ground Turn artisans have been modified, as well as personal protective equipment requirements while on the flight line.

4. General. This instruction is designed to supplement the Naval Air Training and Operating Procedures Standardization manuals and applicable directives covering general flight operations procedures and specific procedures for each type!

model/series aircraft maintained by FRC East.

5. Scope. This instruction is applicable to all military and civilian personnel involved with aviation maintenance and flight operations, inclusive of all activity on the flight line and ramp areas at FRC East.

6. Action. All military and civilian personnel involved with aviation m4ntenance and flight operations at FRC East shall be familiar and comply with this instruction.

7. Required Forms. Refer to enclosure (1), Appendix A.

‘UNSURPASSED SERVICE TO THE FLEET AND RELENTLESS FOCUS ON QUALITY, ENVIRONMENT

AND OCCUPATIONAL HEALTH AND SAFETY’

FRCEASTINST 3710 . lx

JUL 182015

8. Records Management. Records created as a result of this instruction regardless of media and format, will be managed per SECNAV Manual 5210.1, Department of the Navy Records Management Manual.

9. Instruction Responsibility. The Flight Check Officer (Code 6.0DB) shall review this instruction annually.

V. E. CLARK

Distribution: II

FRCEASTINST 3710. 1X

jui~ 162015

AIR OPERATIONS PROCEDURES MANUAL

This is a CONTROLLED DOCUMENT. The contrOlled version is available on the FRC East Master List Web page. Personnel may download directives as required. Appropriate Fleet Readiness Center East personnel are informed of all updates as they occur and are required to use the current version. Outdated copies should be discarded to avoid unintended use.

Enclosure (1)

RECORD OF CHANGES

JUL 162015

CHANGE DATE OF

DATE ENTERED ENTERED BYNUMBER CHANGE

TITLE

TABLE OF CONTENTS

FRCEASTINST 3710. lX

JUL 162015

PAGE

Chapter 1 Transfer of Aircraft General Responsibilities Procedures

Low/High Power Fixed Wing Ground Rotor Engagement/Tilt Rotor Prop General Background Personnel Authorized Personal Protective Equipment Procedures for Fixed Wing Ground Helicopter Rotor Engagement/Tilt Engagement Qualifications Requirements Responsibilities

Flight Check Office (Code 6.

Responsibilities QAS Responsibilities FCP Requirements Currency Minimum Aircrew Requirements Mixed Aircrew in Multi-Place Formation Flights Briefings Crew Day Ferrying Aircraft Flight Line Procedures Conduct of the Flight Post Check Flight

1-1 1-1 1-3

Turn and Helicopter Rotor Engagement

2-1 2-1 2-1 2-1

Turn and Rotor Prop Rotor

2-2 2-4 2-5

3-5 3-6 3-6 3-6 3-6 3-7

3-9

Chapter 2

Chapter 3

Ground Run/Rotor Engagement Requirements 2-7 References 2-7

Functional Check General 3-1 General Functional Check Flight Requirements....3-l Procedures 3-1

0DB)

Aircraft and

3-2 3-4 3-5 3-5 3-5

NATOPS Program 3-9 Plight Check Office Tool Control 3-10 References 3-11 i

FRCEASTINST 3710.lX CH-l

NOV 10 2015

TITLE PAGE

Chapter 4 Training/Qualification Requirements General 4-1 Aircrew Training/Qualification Requirements 4-i Plane Captain Training Responsibilities 4-3 Flight Personnel (Non-crew) Requirements 4-6 Safe For Flight Personnel 4-6 References 4-7

Chapter 5 Flight Line Operations General 5-1 Scope 5-1 Towing Aircraft 5-1 Mishap Reporting 5-3 Destructive Weather 5-4 Work Stands/Fall Protection 5-6 Personal Protective Equipment (PPE) 5-6 Training Requirements 5-7 Flight Line Boundaries 5-7 Missing Fastener Procedures 5-8 References 5-8

Chapter 6 Aviation Life Support/Flight Equipment Shop General 6-1 Flight Check Office (Code 6.0DB) and Quality Assurance (Code 6.4) Responsibilities 6-1 Depot and Intermediate Level ALSS 6-1 Monthly Maintenance Plan 6-2 Flight Equipment Budget 6-2

Appendix A Required Forms A-i ii

JUL 162015

CHAPTER 1

Transfer of Aircraft

1. General. The transfer of aircraft from production to flight check is a three-phase process. This chapter outlines procedures for the transfer of aircraft from the type/model!

series (T/M/S) Industrial Integrated Product Team (IPT) to the Flight Check Office (Code 6.0DB), also referred to as Maintenance Control, and finally, the customer.

2. Responsibilities

a. Aircraft Line IPTs. Will ensure the following tasks are complete:

(1) Inspection of the aircraft.

(2) Current Weight and Balance prior to Functional Check Flight (FCF).

(3) Weight and Balance annotated in the Aircraft Discrepancy Book (ADB)

(4) Document shortages that are not flight critical on the FRC East 4855/107, “Flight Limitations Sheet.”

(5) Ensure that all previous FRC East 3710/1 “Flight Test Discrepancies,” accompany the aircraft.

(6) Ensure the FRC East 4855/107 lists outstanding discrepancies and accompanies the aircraft.

(7) Ensure the FRC East 4855/41, “Removal and Reinstallation List,” accompaflies the aircraft.

(8) Conduct required fuel samples and properly record them in FRC East 13471/1, “Aircraft Fuel Sample Log.”

(9) Certify that the aircraft is ready for transfer to Flight Check by signing and stamping Block 9 of the OPNAV 4790/141, “Aircraft Inspection and Acceptance Record.” This ensures that all of the above requirements have been met.

1-1

FRCEASTINST 3710. lX

b. IPT Quality Assurance Specialist

(1) Review the aircraft records to ensure inspections, technical directives, power plant changes, airframe changes, and required repairs have been completed and properly documented.

In those instances where required entries cannot be completed prior to the first flight, all documentation, including references, will be reviewed to ensure that the limitations are correct and that the required information is available.

(2) Review documentation of the work prescribed by the quality characteristics lists, aircraft rework control, handwritten shop orders, discrepancy work orders, technical engineering instructions, FRC East 4855/107, and the OPNAV 4790/38, “Preflight/Daily/Turnaround/Postf light Maintenance Record,” for proper documentation, certification, and/or verification as applicable.

c. Maintenance Control Coordinator (Code 6.2) . Will sign OPNAV 4790/141 in Block 10. The Flight Folder will be screened and made safe for flight in Maintenance Control prior to release. All log sets and applicable records shall be centrally located in the Logs and Records section of the Planning and Estimation Branch (Code 6.2.2.2)

(1) safe for Flight Process for Induction of Aircraft

(a) Review AIDE inspection dates and times from the workload report and add flight time from the delivery flight (to include all special inspections required)

(b) Review discrepancies in the AIDE and any other discrepancies written up by the aircrew delivering the aircraft.

(c) Ensure the Daily and Turnaround (D&T) Inspection is performed and signed off on OPNAV 4790/38.

(d) Ensure the Part A is filled out and Blocks 9, 10, and 11 are signed on OPNAV 4790/141.

Ce) Ensure the work order is stamped and the D&T Inspection and Part A are filed in the folder for that aircraft and retained by maintenance personnel in the Production Trades Division (Code 6.2.1).

1-2

(2) Safe For Flight Process For Post Production FCF and

Departing Aircraft

(a) Ensure Logs and Records are complete and delivered to the custody of the Planner and Estimator (P&E) (Code 6.2.2.2) located in Maintenance Control for transfer with the aircraft.

(b) Review all discrepancies discovered by previous aircrew.

(c) Ensure the D&T Inspection is performed and OPNAV 4790/38 is signed off by a certified Plane Captain.

(d) Screen both the Optimized Organizational Maintenance System and Autonomic Logistics Information System for overdue inspections and/or components prior to ground run/rotor engagement.

(e) Ensure Part A is filled out and Blocks 9, 10, and 11 are signed on the OPNAV 4790/141.

(f) Ensure the work order is stamped and the D&T Inspection and Part A are filed in the folder for that aircraft with the P&E (Code 6.2.2.2).

3. Procedures

a. For all pre-induction aircraft, appropriate T/M/S military personnel will ensure the following tasks are completed:

(1) The IPT Plane Captain will complete pre-induction inspections and document the results on the FRC East 4720/7, “OCM/SDLM Discrepancy Worksheet,” or FRC East 3710/1.

(2) Coordinate with the IPT P&E representative to ensure a work order document is completed for D&T Inspections when an induction flight is possible.

(3) A Plane Captain will complete a D&T Inspection for the induction flight when applicable. Document DaT on OPNAV 4790/38, and submit to the Maintenance Control Coordinator (Code 6.2.) with a completed OPNAV 4790/141.

1-3

b. For post-rework aircraft, appropriate T/M/S military personnel will complete the following tasks:

(1) After the Production Trades Division (Code 6.2.1) completes aircraft rework, a military Plane Captain will perform an inspection and document the results on FRC East 4720/7 or FRC East 3710/1 prior to first flight. The Plane Captain will provide Maintenance Control with the discrepancies found during the inspection.

(2) After every FCF, pilots and aircrew will document all discrepancies found on FRC East 3710/1. All OPNAV 3710/4, “Naval Flight Records (NAVFLIR5),” will be turned in to the Operations Clerk in the Flight Check Office (Code 6.0DB)

c. For production-sold aircraft, flight test personnel will complete the following tasks:

(1) Ensure OPNAV 3710/4 is completed.

(2) Ensure proper documentation of vibration analysis, Inches Per Second analysis, and engine performance.

(3) Complete and sign the Naval Air Training and Operating Procedures Standardization Functional Test Flight Checklist Book.

(4) Sign the last FCF complete on FRC East 3710/1.

d. Prior to aircraft final delivery to customer, the following tasks shall be completed:

(1) Each T/M/S IPT shall complete a thorough inspection of the aircraft to ensure its readiness for squadron acceptance.

(2) Each T/M/S IPT shall provide squadron aircrew with assistance readying aircraft for flight.

(3) For aircraft that are being picked up by fleet customers, Maintenance Control shall ensure that a Plane Captain from the receiving squadron performs and signs off the D&T Inspection on OPNAV 4790/38 and Block 9 of OPNAV 4790/141.

(4) Maintenance Control shall ensure that a qualified

1-4 individual signs Block 10 (Safe for Flight) of OPNAV 4790/141.

The signature of a qualified Marine or signature of a qualified civilian is the only approved methods for signature of Block 10.

Block 10 should not be signed until all logbooks are screened and completed by Logs and Records personnel (Code 6.2.2.2) and then delivered to the P&E (Code 6.2.2.2) located in Maintenance Control. Logbooks should be mailed or handed over to the unit picking up the aircraft. If completed, aircraft are delivered to the customer by FRC East personnel; the logbooks will go with the aircraft unless arrangements are made to mail the logbooks to the unit.

(5) For aircraft that are being picked up by fleet customers, Maintenance Control shall ensure that an aircraft commander from the receiving squadron signs for the aircraft in Block 11 of OPNAV 4790/141.

(6) Maintenance Control shall ensure that the work order preparing the aircraft for flight is stamped and completed prior to the aircraft commander signing for the aircraft.

1-5

JUL 15 2Q15

CHAPTER 2

Low/High Power Fixed Wing Ground Turn and Helicopter Rotor Engagement/Tilt Rotor Prop Rotor Engagement

1. General. This chapter provides local procedures and personnel qualification requirements for the ground runup and rotor engagement of aircraft. It describes the standardized production sequence of events to be followed in order to ensure the airworthiness of each aircraft prior to ground operations/ flight. The process requires teamwork and unity of effort between Production Trades Division (Code 6.2.1), Examination and Evaluation (E&E) (Code 6.2.2.1), Planning and Estimation (Code 6.2.2.2), Flight Check Office (Code 6.0DB), also referred to as Maintenance Control, and Quality Assurance (QA) (Code 6.4) while the aircraft progresses through each step. Thorough document reviews by QA and production Industrial Integrated Product Team personnel shall ensure all required actions have been certified and verified when required. These reviews will be conducted and completed during Phase Break Reviews in order to reduce the amount of time required for the initial Safe for Flight (5FF) certification (tagging) and expediting the Functional Check Flight phase.

2. Background. Reference (a) provides authority to the Commanding Off icer to authorize certain military and civilian personnel to perform low/high power fixed wing ground runs and engage rotors during helicopter ground checks.

3. Personnel Authorized. Ground check of helicopters/tilt rotors, to include rotor engagement and low/high power fixed wing ground turns are authorized for military and civilian employees who are qualified according to references (a) and (b) Ground turn artisans shall be listed in the civil certification tracker. Individuals who are qualified for ground check, rotor engagement of helicopters, and/or start of Auxiliary Power Plants (APP) during ground checks, shall be trained by qualified military air crew, and have the appropriate license signed by an approving authority.

4. Personal Protective Equipment. Personnel performing engine start, rotor engagement, manning the fire bottle, or in a aircraft with the rotors engaged, Auxiliary Power Units (APU)

2-1

JUL 152015

online, or engine online shall wear flame retardant clothing (flight suit or equivalent) and appropriate aircrew helmet or maintenanbe cranial.

5. Procedures for Fixed Wing Ground Turn and Helicopter Rotor Engagement/Tilt Rotor Prop Rotor Engagement

a. Upon completion of the assembly rig and test phase and prior to ground check, the associated aircraft document review will be performed by the Plane Captain and a QA Representative.

b. Prior to rotor engagement or low/high power ground run, a qualified Plane Captain and Maintenance Control will coordinate to determine special inspection requirements, maintenance requirements, and log book status. The responsible Plane Captain shall notify Maintenance Control when they are aware’ of the aircraft entering the ground check phase.

c. A qualified civilian or military Plane Captain will perform a pre-flight inspection and complete OPNAV 4790/38, “Preflight/Daily/Turnaround/Postflight Maintenance Record.” All noted discrepancies shall be worked off as required.

Discrepancies encountered during ground runs shall be recorded on FRC East 3710/1, “Flight Test Discrepancies,” and reviewed by E&E and QA for disposition prior to being corrected.

Disposition examples: Noted But Not Corrected, Add-A-Line, Hand Written Shop Order, or Discrepancy Work Order.

d. A foreign object damage check inspection shall be performed prior to initial rotor engagement or high power run.

e. Rotor engagement or low/high power runs will be preformed by a qualified military Naval Air Training and Operating Procedures Standardization (NATOPS) Test Pilot or a qualified FRC East ground turn artisan utilizing the published NATOPS procedures.

f. A ground turn qualified artisan or military functional check pilot will perform the Ground Check items in accordance with reference (a) and shall ensure all discrepancies are listed on FRC East 3710/1. All discrepancies listed shall be reviewed by E&E and QA for disposition prior to performing required maintenance. Discrepancies shall be corrected, certified, and

2-2 verified as required by references (b) and (c) . Following ground turns, all discrepancies shall be noted and corrected as required.

g. All maintenance actions required to certify aircraft 5FF shall be completed during the Ground Check phase. All non-safety of flight discrepancies and maintenance actions required shall be listed on FRC East 4855/107, “Flight Limitations Sheet.” Military flight crew members and Maintenance Control Representatives shall have the final determination on Mission Essential Subsystem Matrix applicability.

h. Prior to FCF, a pre-f light inspection shall be completed by the military Crew Chief/Plane Captain responsible for the aircraft. All noted discrepancies shall be listed on FRC East 3710/1. Noted discrepancies shall be dispositioned by E&E and QA and worked off as required by references (b) and (c) . The responsible first line supervisor/Plane Captain shall notify the military Crew Chief/Plane Captain when the aircraft is available for inspection.

i. All operators turning up aircraft or engaging rotors, must have the appropriate current certification(s) and designation(s) on file with the Flight Check Office (Code

6.0DB)

j. A Plane Captain shall be present outside of aircraft in view of qualified personnel in pilot seat during start up.

k. All work operations pertaining to rotor engagements and engines must be certified on the appropriate work document, and where applicable, verified by the Quality Assurance Specialist (QAS) prior to engine turn up.

1. All aircraft shall be tied down as prescribed by the current NATOPS manual. No deviation is permitted.

m. A complete preflight in accordance with the NATOPS manual shall be conducted prior to engine start or rotor engagement.

n. A qualified fireguard shall man the fire bottle, and be briefed by the aircraft commander on their responsibilities.

The fireguard will be posted in accordance with appropriate

2-3

FRCEASTINST 3710 lx

NATOPS during APP and main engine start. Once rotor speed has stabilized, the fireguard is free to enter the aircraft at the direction of the aircraft commander. The aircraft commander is responsible for ensuring that the fireguard is posted with fire bottle prior to engine shutdown and rotor stop.

o. Only individuals that are required for system checks during rotor engagement should be in the immediate vicinity of the helicopter.

6. Qualification Requirements

a. Training. In order to qualify for ground run, and rotor engagement of helicopters, personnel must be a Plane Captain in type/model/series (T/M/S) and be familiar with the ground operating procedures outlined in the appropriate NATOPS manuals and complete the applicable ground turnup syllabus. Training on the following procedures will be given by civilian or military personnel authorized to ground runup and engage rotors: -

(1) Preflight, engine start, rotor engagement, and shutdown.

(2) Appropriate maintenance checks (run-card requirements)

(3) Emergency procedures.

(4) Voice communications.

(5) Hand and arm signals.

b. Examination. A designated QA representative will examine personnel applying for ground turnup/rotor engagement qualification. The examination will require the applicants to:

(1) Demonstrate a working knowledge of appropriate NATOPS procedures and ground emergencies by passing written ground turn open and closed book examinations.

(2) Demonstrate the ability to preflight, start engines and/or APU, engage rotors, and perform the appropriate maintenance checks by practical examination from an appropriate T/M/S NATOPS instructor.

2-4

FRCEASTINST 3710.lX

c. Waivers. No waivers will be considered for the above requirements.

d. Annual Recertification. The renewal evaluation may be accomplished within 60 days preceding expiration of a current evaluation and is valid for 12 months. Any qualification which does not meet the renewal criteria at the end of 12 months will expire and require the completion of a new syllabus in order to recertify.

e. Currency. Currency is defined as at least one operation of that qualification in a 45-day period. Operation of an APP shall be tracked by completing an FRC East 12410/55, “On-the-Job Training Record,” once during the 45-day period. The FRC East 12410/55 shall be sent to the Aircraft Mechanics Branch (Code 6.2.1.1/Shop 91101) Training Leader for entry into Employee Master Maintenance Application (EMMA) . After 45 days without an operation, the artisan will need to complete an operation of that qualification with another cu~rent qualified artisan in attendance before the delinquent artisan is able to perform that task on their own. After 60 days without an operation of that type of qualification, the artisan shall perform two operations of that type of qualification with a NATOPS Instructor or Assistant NATOPS Instructor before the artisan is able to perform that task on their own. If the steps outlined above are not complete and the artisan has not complied within 120 days, the qualification process must be restarted. The definition of that qualification process is the completion of the refresher syllabus and all tests that are required for that qualification.

All annual requalification requirements remain in effect for the appropriate qualifications.

7. Responsibilities

a. Industrial Execution Department (Code 6.2)

(1) The Production Trades Division Director (Code 6.2.1) is responsible for the execution of a training program and ensuring that personnel are qualified to be examined.

(2) The cognizant supervisor or his/her representative will submit a FRC East 4855/65, “Special Process Certification,” to the Flight Check Office (Code 6.003) to identify individuals

2-5 who require certification/recertification. To ensure timely recertification, initiate action prior to expiration of an individual’s certification.

(3) Supervisors will ensure that only fully qualified personnel are permitted to conduct ground turnup or rotor engagement.

(4) Supervisors will ensure that OPNAV 4790/158, “Plane Captain Designation,” provided by the Assistant Civil Certification Program Managers (Code 6.0DB) for artisans performing Ground Turning/Engine Run-Up and APU Operation Qualification, is utilized in order to comply with the 45-day currency requirements in accordance with reference (d) . The qualification currency tracking system document report will be submitted to the Assistant Civil Certification Program Managers from the shop supervisors on or before the 15th ôf every month.

The Assistant Civil Certification Program Managers will then give that information to the Civil Certification Program Manager. This qualification currency tracking system document is for the entire command and will be maintained by the Civil Certification Program Manager for official record of currency.

b. Flight Check Office (Code 6.0DB)

(1) Upon satisfactory completion of the examination, the Flight Check Office, hereafter referred to as Flight Check, will prepare the appropriate license for the approving authority’s signature in accordance with reference (b) . After signature, a copy of the license and the FRC East 4855/65 will be sent to the cognizant QAS Representative, and then sent to the Production Training Specialist (Code 6.2.2) for entry into EMMA.

(2) Flight Check will maintain a file on each individual qualified to perform ground turnup or rotor engagement, to include a copy of the test administered, a completed FRC East 4855/65, and the original license signed by the approving authority.

(3) The Flight Check Officer (Code 6.0DB) will assign an Assistant Civil Certification Program Manager with the responsibility for the Plane Captain Designation identified on OPNAV 4790/158. All civilian qualifications will be tracked in

EMMA.

2-6

8. Ground Run/Rotor Engagement Personnel Requirements

a. Ground Run/Rotor Engagement Personnel shall:

(1) Ensure a Plane Captain is present during start up of aircraft and throughout duration of the turnup.

(2) Ensure a fire bottle is manned during start up and shutdown of aircraft.

(3) Ensure all tools and equipment are accounted for prior to start up. -

(4) Ensure a thorough FOD walk is conducted prior to start up.

(5) Complete a thorough pre and post turn-up walk around of the aircraft.

9. References

a. OPNAVINST 3710.7U, NATOPS General Flight and Operating Instructions

b. COMNAVAIRFORINST 4790.2B CH-l, Naval Aviation Maintenance Program

c. FRCEASTINST 4855.80, Quality Assurance Procedures

d. NAVAIRINST 3750.SC, Naval Air Systems Command Safety Program

2-7

CHAPTER 3

Functional Check

1. General. This chapter establishes policies and procedures covering the Functional Check Flights (FCF) of all aircraft at Fleet Readiness Center East (FRC East) . Since the FCF is an extension of the quality evaluation process and an integral part of repair, all FCFs of in-process aircraft will be performed by FRC East pilots/aircrews. Exceptions will be authorized in writing only by the Commanding Officer or Director of Operations. Flight Check personnel are responsible to provide evaluation and feedback of flight check data to the Quality Assurance Specialist (QAS) and Flight Check Office (Code 6.0DB) personnel for coordination of corrective action in the processing cycle.

2. General Functional Check Flight Requirements. In accordance with the current reference (a) , all aircraft at FRC East under Fleet Support custody and those completing Standard Depot Level Maintenance (SDLM)/Integrated Maintenance Concept (IMC) require at least one FCF prior to being sold. Other Fleet Support aircraft will receive at least one FCF, if required, prior to being sold. These flights will be for the purpose of determining the quality of work and airworthiness of the particular aircraft. Reference (a) defines the conditions requiring functional check flights.

3. Procedures

a. When all maintenance necessary for flight is completed, a mandatory foreign object damage (FOD) inspection (shakedown) and document review shall be performed by the Plane Captain and QAS representative prior to aircraft acceptance for first flight. No maintenance shall take place after the FOD check is verified by Quality Assurance (QA) other than the Daily and Turnaround (D&T) Inspection. If maintenance is required due to discrepancies found during the D&T Inspection, the Flight Check Office (Code 6.0DB), also referred to as Flight Check or Maintenance Control, shall inspect disturbed areas for FOD per reference (a) . The responsible production supervisor and QA Representative will sign FRC East 4855/106, “Aircraft Acceptance for Vt Flight Checklist,” at this time. Flight Crew, civilian Plane Captain, QA, and Maintenance Control will hold required

3-1 briefs, pre and post all FCF flights in accordance with reference (a) and sign the FCF brief logbook located in Maintenance Control.

b. A designated Plane Captain will perform a D&T and preflight inspection as required by references (a) and (b) Designated personnel will perform Safe for Flight (5FF) certifications and complete the final document review prior to first flight, signing Block 10 of the OPNAV 4790/141, “Aircraft Inspection and Acceptance Record,” certifying the aircraft 5FF in accordance with reference (a) . Marine aircrews will preflight the aircraft and Aircraft Commander shall sign Block 11 of the 4790/141, assuming responsibility for aircraft.

c. Military aircrews will complete the FCF Checklist ensuring all discrepancies are properly listed on FRC East 3710/1, “Flight Test Discrepancies,” and reviewed for disposition by Examination and Evaluation and QA.

d. The QA representative will review the FRC East 3710/1 to ensure required discrepancies have been certified and verified.

e. Designated 8FF personnel shall screen the flight discrepancies prior to subsequent FCFs. Designated 5FF personnel will review completed maintenance and determine the requirement for D&T Inspections and special/periodic inspections in accordance with the curtent reference (a)

4. Flight Check Office (Code 6.0DB) Responsibilities

a. When an aircraft is delivered to Flight Check, a designated flight crew will inspect the aircraft prior to the flight.

b. A flight schedule shall be prepared the day prior, after notification of aircraft availability. The Operations Clerk will arrange for aircrews as directed by the Flight Check Officer. A written flight schedule will be prepared and signed by the Commanding Officer or authorized designee prior to the launch of the first aircraft scheduled. The flight schedule constitutes approval for all flights, and pertinent notes will annotate if the flight is for pilot proficiency, induction, first flight, etc. The flight schedule will list the pilot in command and other crew members in multi-place aircraft.

3-2

C. Designated 5FF personnel will sign Block 10 on OPNAV

4790/141 and Block 12 on OPNAV 4790/38, “Preflight/Daily /Turnaround/Postflight Maintenance Record,” after review of the Aircraft Flight Folder and OPNAV 4790/38. Flight check personnel with 5FF designation will also ensure that a full log set is compiled and maintained in a central location prior to releasing the corresponding aircraft for flight. The Aircraft Flight Folder shall include:

(1) FRC East 3710/1

(2) FRC East 4855/24 and the 301 Rework Control Listing from the Ground Check Phase

(3) FRC East 4855/106

(4) FRC East 4855/107

(5) DO 365-4

(6) OPNAV 4790/38 and OPNAV 4790/141

(7) Aircraft Production Order

(8) Compass Cards

(9) FCF Checklist

(10) Hydraulic Sample Results

(11) Load sheets (ordnance)

(12) Noted But Not Corrected Listings

(13) Oil Sample Results

(14) Rotor Track and Balance printouts and iterations per second printouts (rotary wing)

d. Oil consumption shall be documented in the Aircraft Discrepancy Book (ADB) for applicable T/M/S aircraft prior to releasing the aircraft for flight.

3-3

JUL 162015.

e. The Optimized Organizational Maintenance Activity System shall be screened and updated for all equipment currently installed on the aircraft prior to it being released as Safe for Flight.

f. All logbooks should be accounted for and physically present in Logs and Records prior to ground turn/rotor engagement, but shall be accounted for and located in Logs and Records prior to flight. The AIDE shall be located in Flight Check during the flight portion of the FCF.

g. A face to face brief in Maintenance Control shall be conducted at the start of every fly day. Required personnel for the meeting include: Quality Assurance, the Aircraft Commander, any civilian Plane Captains supporting the FCF evolution that day, and the Maintenance Controller who screened the 301. The purpose of the meeting is to review maintenance performed, ensure all maintenance requirements/inspections are completed, and to review how long until the next hourly/calendar based inspection requirement is due. The brief/debrief portion of the FCF checklist shall be filled out when applicable.

h. The Flight Check Officer, or representative, will:

(1) Ensure all flight crewmembers meet the Naval Air Training and Operating Procedures Standardization (NATOPS) and physiological requirements prior to flight.

(2) Ensure OPNAV 3710/4, “Naval Flight Record (NAVFLIR),” is completed for each flight through MSHARP (computer program to electronically list flight times)

5. QAS Responsibilities. In accordance with quality assurance procedures identified in reference (b), a QAS will:

a. Review all documents relative to the preflight (e.g., checklist, work sheets, servicing records, work definition documents/quality characteristics lists, etc.) for certification, verification, and proper documentation.

b. Ensure that discrepancies recorded on FRC East 3710/1 from previous FCFs have been corrected, certified, and verified.

Discrepancies that do not result in a “down” status that have

3-4 not been corrected will remain open, and listed on FRC East 4855/107, “Flight Limitations Sheet.”

c. Ensure all preflight types I, II, and applicable III quality characteristics have been certified and verified.

d. Verify that the documentation reflects that all preflight requirements have been completed, certified/verified.

e. Ensure that all paperwork and documentation is stamped and delivered complete to the Maintenance Control Coordinator (Code 6.2) . If all documentation is not complete, it shall be returned to the QAS to be corrected before the aircraft is released for FCF.

f. A type/model/series (T/M/S) cognizant QAS shall provide FCF brief/debrief to Functional Check Pilot (FCP) in the Flight Check ready room, and sign the brief logbook for all Ground Turns and FCFs. The QAS shall sign the test card when complete.

6. FCP Requirements. All Aircraft Commanders must have successfully completed a FCF Syllabus and be designated in writing by the Commanding Officer prior to performing an FCF.

For pilots checking into FRC East, qualifications from another command will be reviewed by the Flight Check Officer (Code 6.003) or Aviation Safety Officer (Code 6.00) . No syllabus is required if it is determined that the pilot is currently qualified as an Aircraft Commander and FCP.

7. Currency. In accordance with reference (c) -

8. Minimum Aircrew Requirements. As per applicable T/M/S NATOPS manual.

9. Mixed Aircrew in Multi-Place Aircraft and Formation Flights

a. Mixed aircrew (pilot qualified in model and qualified observer) may be used for FCF5 and for ferry flights if not restricted by the particular T/M/S NATOPS manual. For first flights on production aircraft, two qualified pilots will occupy the seats in multi-place aircraft. When one of the pilots is not qualified in that T/M/S, the pilot qualified in the model will be on the controls during all critical phases of flight.

3-5

b. Formation flight may be flown with dissimilar aircraft provided it is thoroughly briefed. Although not all inclusive, the below listed items will be briefed by the formation lead:

(1) Airspeeds

(2) Separation

(3) Rendezvous procedures

(4) Emergency procedures

(5) Communication/lost communications procedures

(6) Mixed aircrew and formation flight will be considered only when flight safety and mission accomplishment would be enhanced.

10. Briefings. Before each flight the FCF aircrew shall receive a brief from the cognizant QAS to flight. The brief shall include a review of FCF cards and items to be included/excluded from the flight.

11. Crew Day. The crew day for all pilots/aircrew will be 12 hours. For single piloted aircraft, the crewday is limited to

7.5 hours total flight time for the day, which may be extended by permission of the Commanding Officer in accordance with reference (d)

12. Ferrying Aircraft. Prior to ferrying an aircraft to or from FRC East, each aircrew member must be thoroughly knowledgeable about reporting requirements, sending arrival messages, and down aircraft procedures. Ferry crews will maintain contact with the Flight Check Office (Code 6.0DB),

(252) 464-9270, Operations Duty Officer (ODO) , (252) 349-3722, or Director of Operations (252) 665-4055, while en route to provide aircraft and aircrew “safe on deck” notification.

13. Flight Line Procedures

a. Production Trades Division (Code 6.2.1) Personnel.

Verify preflight, perform limited servicing, launch, recover, and postf light on all aircraft in accordance with the applicable NATOPS manual, Periodic Maintenance Requirement Card (AR-62) and Preflight Maintenance Requirement Card. Discrepancies found on

3-6 preflight will be noted on FRC East 3710/1. This form will be placed with the aircraft records for the pilot’s information.

The work leader for the aircraft will be notified of discrepancies requiring corrective action prior to flight.

b. Preflight. Aircraft scheduled for initial and subsequent FCFs and aircraft exercise flights will be preflight inspected by a plane captain/crew chief. This requirement does not relieve the Maintenance Control of the responsibility to ensure a documented D&T Inspection, performed by a qualified Plane Captain, has been completed. In conjunction with the foregoing, the following is applicable:

(1) The plane captain/crew chief will ensure the preflight of all aircraft to be flown by Flight Check (Code 6.0DB) personnel is accomplished.

(2) Aircraft needing an exercise flight while assigned to the Planner and Estimator (P&E) (Code 6.2.2.2) shall have a D&T Inspection performed and documented by the military Plane Captain for that flight in those instances where production priorities/workload will not allow the responsible production shop supervisor to provide a Plane Captain to perform the required tasks.

c. Minimum Ground Crew Requirement. During the launch and recovery of aircraft, the minimum number of plane captains required will be as follows.

(1) One plane captain for the AV-S/TAV-S.

(2) Only a qualified H-46 crew chief will perform the duties of launch and recovery for the H-46 helicopter.

(3) Only a qualified H-53 crew chief will perform the duties of launch and recovery for the H-53 helicopter.

(4) An ODO will be assigned by the Flight Check Office (Code 6.0DB) to monitor inbound and outbound aircraft, and track all flights in a logbook after normal business hours.

14. Conduct of the Flight. The purpose of the flight is to determine if the airframe, power plant, and accessories are functioning properly while subjected to the flight environment.

3-7

Further, such flights are conducted to determine dynamic reaction, air loading, and signal propagation which is not possible in ground and shop tests. The pilot must apply the FCF specifications conscientiously while keeping in mind the mission of the aircraft and being alert for any malfunction.

a. Regulations. The pilot must comply with all air traffic regulations as described in the current reference Ce)

b. Area. The flight will be conducted in the local area, clear of normal air traffic, but such that a prompt landing may be made on a suitable field in case of emergency. Particular care must be exercised to remain clear of all target areas and to comply with local airspace restrictions as described in reference (e)

c. Data. Functional check flights will be confined to verifying completed maintenance and collecting data. The data should be recorded directly while in flight, using checklists as described in specific NATOPS manuals for the aircraft.

d. Radio Procedures. A radio check will be made with Camel Base on UHF 293.825 prior to leaving the line. The takeoff and landing will be conducted on primary tower frequency. Under no circumstances will FRC East aircraft take off on local flights without two-way radio contact with the tower and functioning intercom system where applicable.

e. Survival Gear. Survival gear will be worn in accordance with the current reference (d) and current NATOPS manuals in all types of aircraft. In addition, the survival radio AN/PRC-149 or URT-33 will be carried.

f. Weather Minimums. All FCF will be conducted under visual flight rules (VFR) conditions during daylight hours.

(1) The following weather criteria will be used for fixed-wing aircraft check flights:

(a) Initial flights after completion of SDLM/IMC, crash damage repair, overhaul, or engine removal/reinstallation:

5000 feet broken or better, five miles visibility, maintain VFR, no night flights.

3-8

(b) Aircraft requiring re-flights (second and subsequent flights) 2500 feet broken or better, three miles visibility, no night flights.

(c) Aircraft requiring functional check flights when no repair has been performed on engines or flight controls (i.e., modification or exercise flights) require circling Tactical Air Navigation minimums with a suitable alternate.

Night and instrument flights may be flown only on exercise and ferry missions.

(2) Helicopters will be flown in visual flight rule conditions. Helicopters that intend to go to forward flight shall have weather equal to or greater than 1000 feet and three miles visibility. If it is required to fly in weather less than the minimums indicated in this instruction, the Helicopter Aircraft Commander shall notify the Director of Operations (Code 6.0DB) who shall obtain the Commanding Off icer’s approval in accordance with reference (d) . After completion of the check flight requirements, and the aircraft has been pre-sold, night and instrument flights may be flown.

16. Post Check Flight (Code 6.0DB) . Upon completion of a flight after repair, the pilot will meet with Production Trades Division (Code 6.2.1) Aircraft Mechanic Work Leader, the QAS of the aircraft involved, if necessary, other personnel, e.g.

artisans, Production Support Engineer, etc. The pilot must report any deviations from the normal operation of equipment and record them on FRC East 3710/1. Flight re-checks will not be made unless discrepancies can only be checked satisfactorily in flight. In cases where re-flight is necessary, a full internal fuel load is specified unless the Aircraft Commander directs otherwise. The FCP will make the decision concerning re flights.

17. NATOPS Program. The Flight Check Officer (Code 6.0DB) is responsible for the implementation of the NATOPS Program. A Staff Noncommissioned Officer (SNCO) is assigned as the NATOPS SNCO and is responsible for the update of applicable NATOPS publications. The NATOPS SNCO will be assisted by the operations clerk in maintaining aircrew qualification jackets.

3—9

a. Publication/orders

(1) Reference (d) establishes the procedures for the NATOPS program. It provides the procedures to be used for change recommendations, NATOPS evaluations, and qualification jackets.

(2) The NATOPS monthly status report, received from the Naval Tactical Doctrine Activity, provides a quick reference to all NATOPS publications, changes, aircraft type model managers, and their Defense Switched Network telephone numbers.

b. NATOPS Qualification. Aircrews assigned to FRC East shall be experienced and current in the aircraft they are assigned to fly.

c. NATOPS and Instrument Flight Evaluations. The Flight Check Off icer (Code 6.0DB) will supervise and administer the requirement for NATOPS and instrument evaluations. Flight evaluations for aircraft will normally be conducted by NATOPS evaluators from fleet units for the type aircraft to be used.

When, fleet evaluators are not feasible, members of the NATOPS and Instrument Flight Boards may be used as evaluators.

d. Aircrew Proficiency Flights. At the discretion of the Director of Operations (Code 6.0DB), aircraft that completed necessary depot maintenance may be flown to assist aircrews in meeting annual minimums, as well as maintaining annual instrument/NATOPS currency. Where possible, the aircraft used should be restricted to those aircraft delivered to the custody of the P&E (Code 6.2.2.2). It is the responsibility of the Flight Check Office (Code 5.0DB) to coordinate with the P&E (Code 6.2.2.2) and the Industrial Execution Department (Code 6.2) for use of aircraft after it has been sold.

18. Flight Check Office Tool Control. The assigned Noncommissioned Officer in Charge shall:

a. Ensure maintenance of the tool custody inventory records for all tools and a master inventory of tools contained in all tool control kits.

b. Provide the initial logbook for tool checkout procedures.

3-10

c. Establish a permanent tool marking system to identify tools.

d. Ensure a daily inventory of all tools has been completed by the Tool Control Program Noncommissioned Officer.

e. Perform routine monthly inspections of the Tool Control Program.

19. References

a. COMNAVAIRFORINST 4790.2E CH-l, Naval Aviation Maintenance Program

b. FRCEASTINST 4855.80, Quality Assurance Procedures

c. NAVAIRINST 3750.SC, Naval Air Systems Command Safety Program

d. OPNAVINST 3710.7U, NATOPS General Flight and Operating Instructions

e. AirStaO 3710.SL, Air Operations Manual

3-11

FRCEASTINST 37l0.1X

CHAPTER 4

Training and Qualification Requirements

1. General. This chapter establishes the requirements for training and qualification as outlined in references (a) and

(b) . The Flight Check Officer (Code 6.0DB) will supervise and track the training requirements for all aircrew and Plane Captains and ensure that completed training requirements are recorded in logbooks, Naval Air Training and Operating Procedures Standardization (NATOPS) qualifications jackets, and service record books as appropriate.

2. Aircrew Training/Qualification Requirements

a. Read and Initial Folder. When applicable, each pilot shall be current with the Read and Initial Folder.

b. Command Indoctrination. The Aviation Safety Officer (Code 6.0DB) shall ensure newly assigned personnel are briefed on the hazards and risks associated with the operations and environments unique to Fleet Readiness Center (FRC East) and Marine Corps Air Station Cherry Point.

c. Aircrew Ready Room Training. Aircrew will receive formal ground training applicable to the mission or task at the minimum rate of two hours per month. All training shall be documented and kept by the Operations Clerk in the Flight Check Office (Code 6.0DB), also referred to as Flight Check.

d. Pilot Simulator Minimums. Aircrew personnel shall complete a minimum of one simulator flight dedicated to basic mission/NATOPS/emergency procedures in accordance with the applicable Training and Readiness Manual or annually in each aircraft type in which they are qualified. It is highly recommended that aircrew complete an Emergency Procedures Simulator event once a quarter. Some aircraft require a simulator event to complete an annual NATOPS examination. It is highly recommended that all NATOPS and instrument checks be conducted in, or include, a simulator to maximize emergency procedure realism.

4-1

e. Monthly NATOPS Emergency Procedures Quiz. On a monthly basis, each pilot/naval flight officer and crew chief will take a written emergency procedures examination.

f. Naval Aviation Survival Training Program (NASTP) Aircrews needing initial and refresher flight physiology and water survival training will be scheduled by the individual by contacting the Aviation Survival Training Center, Cherry Point at 466-7422. The maximum interval between training, measuring from the last day of the month in which the evaluation was conducted, not to exceed four years. Wat’er Survival Training is also available at the Naval Air Station, Norfolk, Virginia.

Training will be scheduled by contacting the Naval Air Station Norfolk, Aviation Physiology Section at (757) 444-1329/3083.

g. NATOPS Evaluation. This is an evaluation of individual pilot or crew member standardization, consisting of an open book examination, a closed book examination, an oral examination, and an evaluation flight. Each air crewman must achieve a grade of qualified.

h. Instrument Ground School. All naval aviators and naval flight officers assigned to duty involving flight operations or training flights will complete an annual Instrument Ground School (IGSY (either in a formal class or by using the Fleet FRC East IGS briefcase) and complete a written examination with a grade of qualified. Pilots must satisfactorily complete the ground school and written examination no earlier than 60 days prior to the instrument evaluation flight.

i. Instrument Flight Evaluation. Renewal of current instrument ratings for all naval pilots and instrument qualification for naval flight officers will be accomplished prior to the end of the aviator’s/flight officerTs evaluation month and no sooner than 60 days prior to the first day of their evaluation month.

j. Aviation Physical Examination. Flight personnel will initiate an aviation physical examination annually in accordance with reference (a) . The aviation physical examination is scheduled by contacting Aviation Medicine at 466-0368 or nhccherrypoint-aer@med.navy.mil.

4-2

k. Minimum Flying Hours. All FRC East pilots and aircrew are responsible for ensuring that they achieve their minimum annual flight hours in accordance with reference (a) . As described in reference (a) , failure to meet minimum flight hour requirements due to extended duty, grounding, or unavailability of assets will require a waiyer. The Flight Check Officer will prepare and submit all waivers annually.

1. Emergency Egress Training, Flight and Ground Crew Resource Management (CRM) Training

(a) Ejection Seat. Static ejection seat training will be conducted as a part of the regular NASTP Refresher Training.

(b) Non-Ejection Seat. Egress training for other than ejection seat equipped aircraft will be conducted annually with the NATOPS Check.

(c) Ground CRM. All aircrew shall complete CRM Ground Training annually in accordance with reference (c)

3. Plane Captain Training Responsibilities

a. General. Personnel assigned as Plane Captain will be responsible for the launch and recovery of aircraft, to include completion and documentation of the Daily and Turnaround (D&T) Inspection.