N0042119R0011__Airworthiness_Brief.pdf

Presented to:

Presented by:

CAS Aircraft Airworthiness

Prospective Offerors/Industry Partners

Specialized and Proven Aircraft Program Office

26 March 2019

PMA-226

DISTRIBUTION A. Approved for public release: distribution unlimited.

What is a NAVAIR IFC?

DISTRIBUTION A. Approved for public release: distribution unlimited. 2

• A formal document that provides assurance of airworthiness & safety of flight and ensures risk has been identified, mitigated and/or accepted at the appropriate level, within acceptable bounds for the intended mission

• Flight clearances provide flight / operating limitations and/or restrictions for specific configurations and store loadings.

– Does not account for every applicable limit or restriction

– Does not replace good headwork or common sense by the pilot / aircrew

Flight Plan

• How do I get a Navy Flight Clearance?

– Contract

– PAO Assessment / Determination

– Physical Configuration Audit

– Interim Flight Clearance

• Flight Clearance Data Requirements

• Wiring Assessment

• EMC SOFT and RADHAZ testing

• Continuing Airworthiness

• References

• Questions

3DISTRIBUTION A. Approved for public release: distribution unlimited.

How do I get a NAVY Flight Clearance?

NOTE: Adversary fighter activities are considered PUBLIC operations as they are outside of the purview of the FAA.

• Five primary elements of the USN Flight Clearance Process:

– Contract

– Public Aircraft Operations (PAO) Assessment/Determination and

Declaration

– Physical Configuration Audit (PCA)

– Interim Flight Clearance (IFC)

– Continuing Airworthiness (AW)

4DISTRIBUTION A. Approved for public release: distribution unlimited.

Contract

• Contains but not limited to the following:

– Service being provided

– Who’s in the binding agreement with the government

– How Continuing Airworthiness oversight is being provided

– Liability/Indemnity

– Government Furnished Equipment (GFE) list

5DISTRIBUTION A. Approved for public release: distribution unlimited.

PAO Assessment / Determination (1 of 2)

• PMA-226, Airworthiness and CYBERSAFE (AIR 4.0P), Test and Evaluation (AIR 5.0)

– Responsible for PAO Assessment and Determination

• PAO Assessment

– Used to determine if the contracted operation with its mission specific equipment is civil or public

– Uses U.S. Armed Forces PAO decision tool

– Input includes but not limited to the following:

• Detailed Mission Description

• Contract

• Contract Data Requirements List (CDRL)

• FAA Airworthiness Certificates and Operating Limits

• FAA Major Repair and Alteration, Form 337s

• FAA Statement of Compliance with AW Standards, Form 8110-3s

• Documentation for Unapproved Installations (Installations that do not have FAA approval documents or are not approved by the FAA)

• Carry-on Equipment

• Persons on board

• Program Letter for Special Experimental or Restricted Certificates

• Insurance Documentation

• PAO Declaration Letter provided by PMA-226 to Owner/Operator

• Owner/Operator provides declaration to FAA, as required by FAA

6DISTRIBUTION A. Approved for public release: distribution unlimited.

PAO Assessment / Determination (2 of 2)

• Examples of PAO missions:

– Mission is outside of FAA approved Operating Limits

(e.g. Adversary Fighter)

– Mission is in support of an inherently military requirement (e.g. Dropping of Ordnance, Launching Targets, Electronic Attack(EA)/Electronic Warfare (EW) etc.)

7DISTRIBUTION A. Approved for public release: distribution unlimited.

Physical Configuration Audit (PCA)

• PMA-226

• To establish existing aircraft pedigree

• Conducted on-site

• Formal Examination of the as-maintained configuration

(e.g PAO Airworthiness Checklist) to identify non-conformances, if any

• Examination of aircraft as configured for PAO

• Various types of audits: Engineering drawings, specifications, technical data and tests, Quality Assurance, processes and procedures and others as necessary, to determine existing aircraft pedigree for the intended mission

8DISTRIBUTION A. Approved for public release: distribution unlimited.

Continuous Maintenance Record Coverage Critical to Support Pedigree / Airworthiness

Interim Flight Clearance (1 of 3)

• PMA-226 Class Desk, supported by AIR 4.0P and NAVAIR Technical Competencies

– Responsible for all CAS Flight Clearances

• Technical Area Expert (TAE) Data requirements

– A list comprised of engineering technical data required to certify aircraft airworthiness for a flight clearance release

– Include but not limited to: Test plans, test reports, analyses, Failure Modes

Effects Criticality Analyses (FMECA), drawings, model specifications and other source data applicable to hardware and software (Primarily those NOT approved by the FAA)

• TAE Data review

NOTE: Throughout the process TAEs may request additional information/data needed to substantiate airworthiness for the Flight Clearance approval process.

• Identify Limitations, Warnings and Cautions

• IFC Released (AIR 4.0P signs IFC)

9DISTRIBUTION A. Approved for public release: distribution unlimited.

Interim Flight Clearance (3 of 3)

• AIR 4.0P can accept Airworthiness documentation from others as a basis for their AW certification

– FAA

– Other military branches

– Foreign Military - If there is recognition between foreign nation and the United States

Government

– Recognized foreign nation Civil Airworthiness Authority (AA)

• AIR 4.0P will work with TAEs and the CAS Class Desk to determine if an AW basis can be established based on artifacts provided

Note: If a Safety of Flight hazard is identified, a Systems Safety Risk Acceptance (SSRA) is developed to document the hazard for formal acceptance.

• TAEs will assess areas for which an AW basis can’t be established

– Lack of data

– No AW basis exists

Note: CAS Class Desk must be notified of any IFC content changes for reassessment and IFC revision as needed.

10DISTRIBUTION A. Approved for public release: distribution unlimited.

Interim Flight Clearance (2 of 3)

• FAA Airworthiness Documentation:

– Type Certificate(TC): Approved aircraft design

– Supplemental Type Certificate (STC): Required for modifications to aircraft design

– Current FAA Type Cert Data Sheet (TCDS)

– Flight Manuals and Flight Manual Supplements

– FAA Approved Maintenance Plan

– FAA Form 8110-3s: Statement of Compliance with the Federal Aviation Regulations

– FAA Form 337s: Major Repair and Alteration

– Approved Minimum Equipment List (MEL) if applicable

– Restricted Certificate has similar limitations to Experimental. Key difference is government personnel could be carried on aircraft with Restricted Certificate

– Experimental Certificate: Modifications performed on aircraft with Experimental Certificate are NOT validated by the FAA. This certificate requires further review of aircraft pedigree/design

• Program Letter submitted to FAA for application of Experimental Certificate

– Identifies aircraft configuration

– States intended purpose

• Operating Limitations provided by FAA in conjunction with Experimental Certificate

NAVAIR leverages FAA to establish DoN Airworthiness (IFC)

Flight Clearance Data Focus (1 of 2)

• FAA approved data: Data specifically approved by the FAA or FAA-delegated representatives. These data may include:

– Aircraft Manuals, Procedures

– FAA Registration Certificate

– Program Letter

– Operating Limitations

– FAA Airworthiness Certificate. If a Special Certification, include Operating Limitations

– Copy of FAA Letter authorizing current aircraft inspection program

– Copy of FAA Letter authorizing aircraft to operate under provisions of the approved Minimum

Equipment List (MEL)

– Type Certificate data and Specification sheets

– FAA Form 337s and 8110-3s

– Supplemental type Certificates (STC)

– Airworthiness Directives (ADs)

– Copy of Current Maintenance Program

– FAA Designated Engineering Representative (DER) data

– FAA Designated Alteration Station (DAS) data

– Configuration Summary: A spreadsheet that lists all the FAA approved modifications with detail on specific aircraft

12DISTRIBUTION A. Approved for public release: distribution unlimited.

Flight Clearance Data Focus (2 of 2)

• OEM documents

– Aircraft Manuals, Procedures, etc.

– Model specifications

• Military Documentation

– Manuals

– Airworthiness Certification

– Technical Directives (TCTOs, AFCs, Bulletins, etc.)

• Test plans

• Test reports

• Engineering analyses

• Models and Simulations

• FMECA

• Engineering Drawings

• Any other source data applicable to hardware and software modifications

Testing & Assessment Requirements Prior to IFC Release (1 of 2)

• Evaluation for operation of mission specific electronic equipment

– Determination of Safe Distances for:

• Hazards of Electronic Radiation to Personnel (HERP)

• Hazards of Electronic Radiation to Ordnance (HERO)

• Hazards of Electronic Radiation to Fuel (HERF)

– Electromagnetic Interference/ Electromagnetic Compatibility Safety of Flight Test (EMC SOFT)

• Equipment operating in all modes and at all frequencies that will be used in flight

14DISTRIBUTION A. Approved for public release: distribution unlimited.

Testing & Assessment Requirements Prior to IFC Release (2 of 2)

• Aircraft Validation and Verification (Val/Ver) Electrical Wiring Interconnect System (EWIS) assessments

– Conducted on wiring associated with aircraft modifications not approved by FAA

– May be required at four different stages within the modification process

• 30%, 60%, 90%, and 100% of completion

• Dependent on availability of engineering documentation

• Assessments for CAS aircraft are typically conducted at 100% completion

– All terminations are made

– Wire bundles and cables are completely installed and secured

– All of the equipment has been installed

– Quality Assurance (QA) function has accepted the installation

15DISTRIBUTION A. Approved for public release: distribution unlimited.

IFC Process and Sequence of Events (1 of 2)

• Conduct a Planning Meeting (Class Desk, Contractor)

– To occur immediately post contract award

– Develop an Engineering Data Requirements Agreement Plan (EDRAP)

• Identify TAEs based on aircraft modification requiring review and approval

– Plan for Data Requirements

• PCA (Class Desk, Contractor)

– Initial PCA to determine aircraft pedigree

– Final PCA post modification completion

– Schedule and conduct

• To occur post contract award

• Aircraft must be available for inspection

• Communicate early and often (All)

– Class Desk: actively coordinate and communicate with TAEs, AIR-4.0P, Contractor

– Program/Contractor: Provide ALL required data early enough to allow for sufficient review

16DISTRIBUTION A. Approved for public release: distribution unlimited.

IFC Process and Sequence of Events (2 of 2)

• Testing/Assessments

– Determine requirement (Class Desk, TAEs)

– Schedule tests (PMA, Class Desk, Contractor, TAE)

• Typically occur post completion of required aircraft modification (or as required by TAEs)

• Electronic equipment (EA/EW Pods) must be available and approved for carriage prior to EMC SOFT testing

• Class Desk submits complete IFC request to the AIR 4.0P Airworthiness Office

– A complete request means adequate planning & coordination with Stakeholders (Program, Airworthiness, Customer, Operator, Support Personnel, TAEs/Competencies) is in place and all data is ready and available

– Data includes all flight clearance references and any additional data required per EDRAP for review and release of an IFC by TAEs and Airworthiness authority

– Met all known TAE requirements

• IFC Review (TAEs, Class Desk)

– Provide concurrence

• May require additional discussions and documentation

• IFC Release (AIR 4.0P)

17DISTRIBUTION A. Approved for public release: distribution unlimited.

Continuing Airworthiness Oversight

• Ensures contractor “maintains” airworthiness through approved air and maintenance operations over the life of contract. Required by:

– Contract

– DCMA INST 8210.1C w/ CH1 (NAVAIRINST 3710.1G CH 1)

• Government Flight Representative (GFR) conducts initial and semiannual audits to:

– Approve Contractor Ground, Flight Operational Procedures (GOPS / FOPS) and Safety Program

– Review Pilot and Maintenance Records to assure continued compliance with approved Procedures

• NAVAIR Aircraft Maintenance Management Team will conduct

Aircraft Maintenance Inspections (AMI) to provide an outside evaluation of the contractors maintenance and assess the overall risks associated with the contract

– Before flight operations

– Every two years thereafter

18DISTRIBUTION A. Approved for public release: distribution unlimited.

Reference List

a) Advisory Circular 43-201A: Standardized Procedures for Obtaining Approval of Data Used in the Performance of Major Repairs and Major Alterations.

b) Advisory Circular 00-1.1A: Public Aircraft Operations.

c) Advisory Circular 91-91 Maintaining Public Aircraft.

d) FAA Order 8300.16.

e) Title 14, Code of Federal Regulations.

f) DCMA INST 8210.1C (NAVAIRINST 3710.1G) w/ CH1

Contractor’s Flight and Ground Operations, 5 April 2017.

g) NAVAIRINST 13034.1F – Flight Clearance Policy for Air

Vehicles and Aircraft Systems.

h) Department of Defense (DoD) Directive 5030.61 DoD

Airworthiness Policy.

19DISTRIBUTION A. Approved for public release: distribution unlimited.

QUESTIONS?