1 Flight Safety Foundation Symposium Vancouver, 08-09 February 2011 A Process for Control and...

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Flight Safety Foundation SymposiumFlight Safety Foundation Symposium Vancouver, 08-09 February 2011Vancouver, 08-09 February 2011

A Process for Control and Conduct of Functional Check Flights

Cathay Pacific Airways

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Introduction

• Who we are

• What we do

• Why we are here in YVR

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IntroductionIntroduction

Who we are –• Flight Technical Section in Flight Operations Department

• Manager – Aeronautical Engineering Background

• 5 Ex-military Line Pilots (RAF, RAAF), 4 are TPS Graduates

• Simulator Specialist Engineer

• Operations Development Engineer

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What we do –• Cathay Pacific Test Flying

Check Flights – periodicLease acceptance/return flights – infrequentCabin IFE/Power EMI tests - infrequent

• Flight Simulator EvaluationNew simulator Company acceptanceEvaluation for Regulatory Qualification

• Management of AFM Configuration

• Projects on ad-hoc basis

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Why we are here in YVR –• Shocked and saddened by Perpignan accident

• FT Section has considerable airline test flight experience• A300-600, A330, A340-300, A340-600• B747 Classic, B747-400, B777-200/300/300ER

• No major incidents over many years

• Competent and willing to contribute to discussion on improved Check Flight safety

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Hong Kong Check Flight SchemeHong Kong Check Flight Scheme

Why we have check flight scheme in HKG -• Reason for scheme

• Basic scheme details

• Reporting responsibility

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Reason for scheme -• Scheme mandated by HKG Civil Aviation Dept.

• Known as Airworthiness Flight Test Scheme

• Follows UKCAA Scheme, still in effect for non-EASA aircraft

• CX finds benefit in these ‘Quality Control’ checks

• No other scheduled/regular post-maintenance flight test

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Basic scheme details -• Series test required for each new aircraft (HKCAD)

(Doubles as customer acceptance test for CX)

• First annual test required for each new aircraft (rate may be reduced with HKCAD agreement)

• Sample test of each fleet required(For CX fleets, 3 – 4 aircraft per year, on rotating basis)

• Approx. half number of test flights compared with operators conducting post-maintenance test flights after D Check(D-Check frequency approx. 5 yrs)

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Reporting responsibility –• “Approved Pilots” individually approved by HKCAD to submit

reports on test flights

• Pilots employed by CX, test flight flown as agent of HKCAD

• Pilots directly responsible to HKCAD for reporting

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Check Flight ConsiderationsCheck Flight Considerations

Threats, potential errors increased RISK!• Non-standard OPS

• Conducted infrequently

• Tests near edges of flight envelope or system limits

• Weather

• ATC environment

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Increased RISK Risk Mitigation Methodology

Considerations –• Who does the testing

• What is tested

• Where & when the testing is conducted

• How the test process is controlled

• Process documentation – Section Policy & Procedures Manual (PPM)

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Who does the testing –• Crew selection

• Crew training

• Crew currency

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Who does the testing / Crew selection –• FT Section test pilots

• Ex-military line pilots with military post-maintenance test exp.

• Senior Check/Training pilots (1-2 in each fleet)

• Flight test crew includes trained flight test observer(need not be pilot)

• Crew selected on basis of known methodical, disciplined nature

• Numbers balanced considering task size, experience dilution, roster disruption

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Who does the testing / Crew training –• PPM self-study

• Comprehensive flight test briefing by CAD-approved trainer

• 1 Sim practice as PNF

• 1 Test flight as PNF

• 1 Sim practice as PF

• 1 Test flight as PF

• Consolidation test flight(s)

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Who does the testing / Crew currency –• If PPM currency requirements not satisfied, simulator practice

required prior to test flight

• Simulator practice should include entire scheduled crew(Approved Pilot, PNF, FT Observer)

• When one crew member under training, other crew members should be experienced

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What is tested –• Test selection

• Test schedule format

• Additional HKCAD tests

• Ad-hoc tests during flight ?

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What is tested / Test selection –• Tests taken from manufacturers’ production test manuals

• Manufacturers’ test manuals used within well-developed manufacturers’ flight test safety environment

• Manufacturers’ production test manuals clearly suitable for crews conducting frequent, regular test activities at the manufacturers’ facilities

• Manufacturers’ production test manuals not considered entirely suitable for airline crews conducting infrequent test activities

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What is tested / Test schedule format –• Locally-developed test schedules expanded –

Limits/Warnings/Cautions/Notes added to strengthen local flight test safety environment

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What is tested / Test schedule format –• Locally-developed test schedules expanded (contd)–

Initial and Completion conditions added

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Step-by-step procedure and result recording

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Carefully phrased instructionsSimple changes can be important –

Condition, followed by Action

e.g. After 3 min at idle, shutdown ENG 2NOT

Shutdown ENG 2 after 3 min at idle

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What is tested / Additional HKCAD tests –• Engine in-flight relight tests

In-flight relight envelope data used

• Second segment and final segment climb performanceManufacturers’ gross performance data supplied for specific

ranges of weight and altitude

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What is tested / Ad-hoc tests during flight ? –• NO in-flight ad-hoc tests are conducted!!

• If issue arises where in-flight test considered useful for issue resolution – Issue/system reviewed with Engineering and manufacturerRisk assessment conducted / risk mitigation developedTest drafted / reviewed / practised (simulator)

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Where & when the testing is conducted –• Daylight hours

• Critical tests in VMC(Low speed / high speed/Mach / backup power etc.)

• ‘Non dynamic’ weather(No test in/near storms, typhoons etc – defer as appropriate)

• Reserved test or low-use airspace

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Where & when the testing is conducted –• ATC is, and must be considered as, an integral part of a

successful test

• ATC brief (phone/fax) in addition to slot notificationRequirements for non-deviating headings (perf climbs)Requirements for block altitudes

• Crew use flight profile also sent to ATCATC info notes included

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Check Flight ConsiderationsCheck Flight ConsiderationsWhere & when the testing is conducted –• Typical

flight profile

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How the test process is controlled –• Test process fully documented in FT Section Policy &

Procedures Manual – PPM a ‘living’ document

• PPM contains information to ensureRegulatory complianceCompany complianceGovernmental compliance (e.g. Immigration requirements)

• PPM contains information to educate non-TP-trained crew on essential elements of flight test methodologyProduction flight test, NOT experimental flight test

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How the test process is controlled –• Compliance information drawn from

Air Navigation OrderAir Operator’s Certificate documentCompany OPS Manuals

• Initial effort required to research and set up framework for compliance

• Compliance not burdensome in operation

• New test crew not required to ‘reinvent the wheel’!

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How the test process is controlled –• In-flight test procedures

Assigned crew rolesNo independent testingSwitch/knob confirmation prior operationAny crew member may call for temporary halt

• In-flight standard proceduresPeriodic reversion to SOPs ‘Re-baseline’ of OPS

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Concluding CommentsConcluding Comments

In the experience of Cathay Pacific Airways -

• Are trained test pilots / FTEs required for safe conduct of check flights?No

• Are trained test pilots / FTEs required to administer a check flight scheme?No

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Concluding CommentsConcluding Comments

• Has Cathay Pacific Airways benefited from having trained test pilots / FTEs set up the scheme philosophy and framework?Definitely Yes – Cathay Pacific Airways has safely

conducted check (airworthiness) flights for many years;Where in-flight systems failures occurred, risk mitigation methodology enabled safe returns to base

• Should development of any new Regulatory framework for check flights involve test pilots, FTEs, and experienced industry teams?Cathay Pacific Airways’ experience would suggest Yes

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Concluding StatementConcluding Statement

• Cathay Pacific Airways is ready, willing, and, we believe, competent to assist the industry in its quest to improve the safety of check flight operations

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AcknowledgementsAcknowledgements

General Manager Operations, Cathay Pacific AirwaysCapt. Russell Davie

Former Flight Technical Section ManagersCapt. John CarrodusCapt. Terry Farquharson

Current members of Flight Technical SectionAirbus Team Boeing Team

Henry De Courcier John O’Halloran Ian McClelland Dave Lohse Matt Fullwood

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