Flight Safety Foundation Symposium
Vancouver, 08-09 February 2011
A Process for Control and Conduct of
Functional Check Flights
Cathay Pacific Airways
1
Introduction
• Who we are
• What we do
• Why we are here in YVR
2
Introduction
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
3
Introduction
What we do –
• Cathay Pacific Test Flying
Check Flights – periodic
Lease acceptance/return flights – infrequent
Cabin IFE/Power EMI tests - infrequent
• Flight Simulator Evaluation
New simulator Company acceptance
Evaluation for Regulatory Qualification
• Management of AFM Configuration
• Projects on ad-hoc basis
4
Introduction
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
5
Hong Kong Check Flight Scheme
Why we have check flight scheme in HKG • Reason for scheme
• Basic scheme details
• Reporting responsibility
6
Hong Kong Check Flight Scheme
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
7
Hong Kong Check Flight Scheme
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)
8
Hong Kong Check Flight Scheme
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
9
Check Flight Considerations
Threats, potential errors
increased RISK!
• Non-standard OPS
• Conducted infrequently
• Tests near edges of flight envelope or system limits
• Weather
• ATC environment
10
Check Flight Considerations
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)
11
Check Flight Considerations
Who does the testing –
• Crew selection
• Crew training
• Crew currency
12
Check Flight Considerations
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
13
Check Flight Considerations
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)
14
Check Flight Considerations
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
15
Check Flight Considerations
What is tested –
• Test selection
• Test schedule format
• Additional HKCAD tests
• Ad-hoc tests during flight ?
16
Check Flight Considerations
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
17
Check Flight Considerations
What is tested / Test schedule format –
• Locally-developed test schedules expanded –
 Limits/Warnings/Cautions/Notes added to strengthen local
flight test safety environment
18
Check Flight Considerations
What is tested / Test schedule format –
• Locally-developed test schedules expanded
 Initial and Completion conditions added
(contd)–
19
Check Flight Considerations
What is tested / Test schedule format –
• Locally-developed test schedules expanded (contd)–
 Step-by-step procedure and result recording
20
Check Flight Considerations
What is tested / Test schedule format –
• Locally-developed test schedules expanded
 Carefully phrased instructions
Simple changes can be important –
Condition, followed by Action
e.g.
(contd)–
After 3 min at idle, shutdown ENG 2
NOT
Shutdown ENG 2 after 3 min at idle
21
Check Flight Considerations
What is tested / Additional HKCAD tests –
• Engine in-flight relight tests
 In-flight relight envelope data used
• Second segment and final segment climb performance
 Manufacturers’ gross performance data supplied for specific
ranges of weight and altitude
22
Check Flight Considerations
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 manufacturer
 Risk assessment conducted / risk mitigation developed
 Test drafted / reviewed / practised (simulator)
23
Check Flight Considerations
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
24
Check Flight Considerations
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 notification
 Requirements for non-deviating headings (perf climbs)
 Requirements for block altitudes
• Crew use flight profile also sent to ATC
 ATC info notes included
25
Check Flight Considerations
Where & when the testing is conducted –
• Typical
flight
profile
26
Check Flight Considerations
How the test process is controlled –
• Test process fully documented in FT Section Policy &
Procedures Manual – PPM a ‘living’ document
• PPM contains information to ensure
 Regulatory compliance
 Company compliance
 Governmental compliance (e.g. Immigration requirements)
• PPM contains information to educate non-TP-trained crew on
essential elements of flight test methodology
 Production flight test, NOT experimental flight test
27
Check Flight Considerations
How the test process is controlled –
• Compliance information drawn from
 Air Navigation Order
 Air Operator’s Certificate document
 Company 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’!
28
Check Flight Considerations
How the test process is controlled –
• In-flight test procedures
 Assigned crew roles
 No independent testing
 Switch/knob confirmation prior operation
 Any crew member may call for temporary halt
• In-flight standard procedures
 Periodic reversion to SOPs
 ‘Re-baseline’ of OPS
29
Concluding 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 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
31
Concluding 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
32
Acknowledgements
General Manager Operations, Cathay Pacific Airways
Capt. Russell Davie
Former Flight Technical Section Managers
Capt. John Carrodus
Capt. Terry Farquharson
Current members of Flight Technical Section
Airbus Team
Boeing Team
Henry De Courcier
John O’Halloran
Ian McClelland
Dave Lohse
Matt Fullwood
33