Pilatus Aircraft Certification EC/Utility Aircraft POPA ...pilatusowners.org/wp-content/uploads/2016/07/2016-06-18-POPA... · Pilatus Aircraft Certification. POPA Convention 2016

1POPA Convention 2016 June 18, 2016

EC/Utility AircraftPilatus Aircraft CertificationDietmar BretscherDirector Utility Aircraft

Pilatus Aircraft Ltd, Stans

POPA Convention 2016


POPA Convention 2016Pilatus Aircraft Certification


Utility Aircraft

• Application to the Certifying Authority followed by agreement on Programme and Certification Basis

• Definition of the Type Design / Aircraft Design Completion• Showing of Compliance to the agreed Certification Basis

Means of compliance include:

• Verification of Compliance - independentActivity performed by Compliance Verification Engineers (CVE)

• Declaration of compliance and application to the Certifying Authority (EASA) for a Type Certificate – approval

Type CertificationSummary of Activities

Statements, Design Reviews, Calculations & Analysis, Safety Assessments, Human Factors Assessment, Equipment Qualification/Vendor Data, Tests Results


Utility Aircraft

1. Summary of Activities

Type CertificationSummary of Activities

Definition of Change / Aircraft

Design

Testing(lab/rig, ground/flight)

Build Showing Compliance

Compliance Verification

Declaration of Compliance

witnessing

Approved Design Data

Approval (Type Certificate)

Agreement of ProgrammeCertification Basis

Deliver

Au

tho

riti

es


Utility Aircraft

1. Certification Rules

2. Certification Process

3. Foreign Country Validations

4. Pilatus Examples

TOPICS


Utility Aircraft

Abbreviations

EASA European Aviation Safety Agency CS Certification Specification

FAA Federal Aviation Administration (USA) FAR Federal Aviation Regulation

TC Transport Canada

FOCA Federal Office of Civil Aviation (Switzerland)

CVE Certification Verification Engineer (Pilatus)

AFM Airplane Flight Manual POH Pilot Operating Handbook

AMM Airplane Maintenance Manual SB Service Bulletin

SRM Structural Repair Manual SADD Statement of Approved Design Data

IPC Illustrated Parts Catalogue SL Service Letter

VFR Visual Flight Rules IFR Instrument Flight Rules

DO Design Organization PO Production Organization

DAS Design Assurance System


1. Certification Rules


Utility Aircraft

1. Pilatus Aircraft Ltd : Privileges and Obligations• Design Organization (DO) & Production Organization (PO)

2. Certification Basis• Airworthiness Standards• Additional requirements, clarifications or accepted deviations

by the certifying or validating authorities3. Environment Protection (noise and aircraft engine emissions)4. Operational Suitability Data (OSD)

• Pilatus Objectives and Requirements (… fit for purpose …)• Design Principles, Best Practice, Experience, …• Customer Requirements and Expectations, “Brand”, …

Certification Rules1.


Utility Aircraft

Pilatus Aircraft Ltd – Privileges1.1Design Organization


Utility Aircraft

• Each holder of a type certificate shall comply with:• 21A.3 Failures, Malfunctions and Defects• 21A.3B Airworthiness Directives• 21A.4 Coordination between design and production• 21A.55 Record keeping• 21A.57 Manuals• 21A.61 Instructions for continued airworthiness• 21A.14 Demonstration of capability

• These obligations are overviewed by EASA (FOCA) in the frame of the annual DO Approval Surveillance Audit.

Pilatus Aircraft Ltd – Obligations1.1as a Type Certificate holder


Utility Aircraft

Pilatus Aircraft Ltd 1.1Design Organization Approval

SCOPE


Utility Aircraft

Pilatus Aircraft Ltd1.1Production Organization


Utility Aircraft

Pilatus Aircraft Ltd1.1Production Organization Approval

SCOPE


Utility Aircraft

• Airworthiness Standards• Normal, Utility, Acrobatic, and Commuter Category Airplanes

• FAA : FAR 23 (current : Amendment 23-62, 31 January 2012)• EASA : CS 23 (current : Amendment 4, 15 July 2015)

• Additional Requirements, Clarifications or accepted Deviations(Certification Basis, Special Conditions, Exemptions, Equivalent Safety Findings)

• Certification Review Item (CRI), Issue Paper (IP),Compliance Question Form (CQF), Certification Action Item (CAI)

• Certification Basis : defined a dedicated CRI/IP

Certification Basis1.2


Utility Aircraft

• Examples (see Type-Certificate Data Sheets)• PC-12 : application in 1986 / Type Certificate issued in 1994

• FAR 23 (Amdt. 23-1 to -42 / 62) and 22 CRIs & 2 CQFs• PC-24 : application in 2012 / Type Certificate planned for 2017

• CS 23 (Amdt. 1 to 3) and approx. 91 CRI’s

• Application until Certificationfor new aircraft and significant major change• no change of certification basis if below 3 years if longer then newer airworthiness standard (if available) applies

Certification Basis1.2Pilatus Examples


Utility Aircraft

• https://www.easa.europa.eu/system/files/dfu/CS-23%20Amdt%203.pdf• hhttp://rgl.faa.gov/Regulatory_and_Guidance_Library/rgFAR.nsf/MainFrame?OpenFrameSet

• Subpart A – General (§§ 23.1 – 23.3)• Subpart B – Flight (§§ 23.21 – 23.255)• Subpart C – Structure (§§ 23.301 – 23.575)• Subpart D – Design and Construction (§§ 23.601 – 23.871)• Subpart E – Powerplant (§§ 23.901 – 23.1203)• Subpart F – Equipment (§§ 23.1301 – 23.1461)• Subpart G– Operating Limitations and Information (§§ 23.1501 – 23.1589)

Certification Basis1.2Airworthiness Standards – Subparts


Utility Aircraft

Certification Basis1.2Airworthiness Standards – Example FAR 23 (Amdt. 23-1 to 62)


Utility Aircraft

• Example : PC-12/47E• Type-Certificate

Data Sheet (TCDS)

Certification Basis1.2Additional Requirements, Clarifications or accepted Deviations


2. Aircraft Certification Process


Utility Aircraft

1. Development and Certification of a new Aircraft (Type Design)

2. Change to (existing) Type Design• Minor existing rules apply, no involvement of authorities• Major existing rules apply, authorities are involved and approve

• Significant latest rules apply• Substantial new Type Certificate

3. Documents and Approved Design Data

Aircraft Certification Process2.


Utility Aircraft

Development and Certification of a new Aircraft

2.1


Utility Aircraft

• Minor• existing rules apply, no involvement of authorities

• Major• existing rules apply, authorities are involved and approve• Master Certification Program (agreement with authorities)• Significant

• latest rules apply• requires update of Certification Rules (at least for the change)

• Substantial• new Type Certificate

Change to (existing) Type Design2.2Levels / Classification


Utility Aircraft

Change to (existing) Type Design2.2Pilatus DO Process


Utility Aircraft

• Certification Compliance List (CCL)• For each rule (FAR/CS paragraph; CRI, IP, CQF,

CAI) a compliance statement is required• Detailed substation is provided in Engineering

Reports (reference)• Engineering Change (EC)

• For each change a top level description is provided

• Lists all affected parts and drawings• Lists affected rules with compliance statement

and substantiation/Engineering Report

Engineering Report• Show compliance to

the Certification Basis by detailed substantiation

• Contain test results, analysis, calculations, human factors and safety assessments, …

Documents2.3


Utility Aircraft

• Original PC-12 Certification Compliance List of 1994• FAR 23.903 (Example)• Signed by Pilatus• Approved by FOCA

• without PilatusDesign Organization Approval

Documents2.3Certification Compliance List


Utility Aircraft

• Summary Engineering Report for PC-12 NG (2008)• Signed by Pilatus• Approved by Pilatus CVE’s

• with PilatusDesign Organization Approval



Utility Aircraft

• Summary Engineering Report for PC-12 NG (2008)

• Updated Certification Compliance List

• FAR 23.903 (Example)



Utility Aircraft

Documents2.3Engineering Report: Structural Analysis

Load Cases• Global Finite Element Model (GFEM) of the PC-12

Required to calculate loads and stresses


Utility Aircraft


• Flutter Model PC-12 (based on GFEM)


Utility Aircraft


• Static Wing Structural Test (original)


Utility Aircraft

Documents2.3Engineering Report: Safety Assessments

Severity(or effect of the failure

condition)

Probability of occurrenceAcceptable

Not acceptable

Class II(PC-6)

Class III(PC-12)

Class IV(PC-24)

CAT High Potential for loss of the aircraft, multiple fatalities.

Extremely Improbable

<10-7

per flight hour<10-8


per flight hour

More than Extremely Improbable

HAZLarge Reduction in functional capabilities or safety margins that can cause serious or fatal injuries.

Extremely Remote

<10-6



per flight hour

More than Extremely Remote

MAJ

Significant reduction in functional capabilities or safety margins that will cause physical discomfort or a significant increase in workload, possible injuries or fatalities.

Remote <10-5



per flight hour More than remote

MIN

Slight reduction in functional capabilities or safety margins that will cause an increase in workload or require use of emergency procedures.

Probable <10-3



per flight hourMore than probable


Utility Aircraft

• Parts List and Drawings (incl. processes and tests)• how to build an aircraft

• AFM/POH, AMM, IPC, SB• how to operate, maintain

and modify an aircraft• SRM, SADD

• how repair an aircraft

• SL, …• for information

Documents2.3Approved Design Data


3. Foreign Country Validations


Utility Aircraft

• Development and Certification of a new Aircraft (Type Design);Change to (existing) Type Design• Prime Certifying Authority is EASA (was FOCA until 2006)

• Validation required by foreign country in order to register the aircraft in that country• Always for new Type Designs; some countries require validations of all

major changes• Some countries define additional requirements, clarifications or accepted

deviations (new certification basis)• Change to Type Design (initially by EASA, validation by foreign country)• Certain options have to be installed (from factory or by SB)

Foreign Country Validations3.Process


Utility Aircraft

• Agencies covering several countries• EASA : European Aviation Safety Agency

Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxemburg, Malta, Norway, Poland, Portugal, Slovak Republic, Slovenia, Spain, Sweden, Switzerland, The Netherlands, United Kingdom

• CIS : Commonwealth of Independent StatesArmenia, Azerbaijan, Belarus, Georgia, Kazakhstan, Kyrgyzstan, Moldova, Russia, Tajikistan, Turkmenistan, Ukraine, Uzbekistan

• Level of Involvement• Full evaluation including dedicated certification basis (new requirements)• …• Acceptance of other countries Type Certification

Foreign Country Validations3Level of Involvement


Utility Aircraft

Foreign Country Validations3.PC-12

• Including• EASA• CIS


4. PC-12 Examples


Utility Aircraft

1. PC-12 Certification Steps• FOCA, FAA, EASA• PC-12 (basic, IFR, 4’100 kg MTOW, FIKI)

PC-12/45PC-12/47PC-12/47E

Change to Type Design2. IPECO Crew Seat (PC-12/47)3. PC-12 NG (PC-12/47E)4. PC-12 Model 2016

PC-12 Examples4.


Utility Aircraft

PC-12 Certification Steps4.1Basic Certification, Change to Type Design

23.12.05

14.12.05

/474740 kg

24.3.95

27.2.95

PC-124100 kg

13.7.94

PC-12IFR

15.7.94

30.3.94

PC-12BASICVFR

4000 kg

USFAA

SwissFOCA

EASA

28.7.95

29.6.95

PC-12Icing

31.7.96

4.6.96

/454500 kg

23.6.06 23.6.06 23.6.06

28.3.08

Part of EASA

/47EAPEX

28.3.08


Utility Aircraft

PC-12 Certification Steps4.1Type Certification : EASA & FAA

Type-Certificate Data Sheet


Utility Aircraft

• Vertical Structural Dynamic Test (60°) FAR § 23.592Simulation of Emergency Landing Condition at Stall Speed

• PC-12 : 19.0g / 0.050s 61kcas• PC-12/45 : 21.6g / 0.044s 65kcas• PC-12/47 : 22.9g / 0.042s 67kcasLumber spine loads (1500 lbs limit)

• Horizontal Head Injury Criteria (HIC) TestSimulation of Aircraft Overrun during Take Off and Landing Simulation of Emergency Landing without Landing Gear or on Non-Prepared Runways

• all : 26.0g / 0.050sHIC < 1000 (due to head impact)

IPECO Crew Seat (PC-12/47)4.2Dynamic Seat and Head Injury Criteria


Utility Aircraft

IPECO Crew Seat (PC-12/47)

Vertical Structural Dynamic Test (60°)


EC/Utility Aircraft

New IPECO pilot seat (PC-12/47)

Vertical Structural Dynamic Test (60°)


Utility Aircraft

IPECO Crew Seat (PC-12/47)

Horizontal HIC Test


EC/Utility Aircraft

New IPECO pilot seat (PC-12/47)

Horizontal HIC Test


Utility Aircraft

Determine Impact Location by plotting the Head Trajectory in the Interior Drawing re-evaluation

with component changes

Component test (head dummy only)

IPECO Crew Seat (PC-12/47)4.2Determination of all Impact Locations


Utility Aircraft

• Major Changes• Primus Apex and associated Components & Systems *)• ESIS (Electronic Standby Instrument System) *)• PGDS (Power Generation and Distribution System) *)• Engine (PT6A-67P)• Digital CPCS (Cabin Pressure Control System)• Digital ECS (Environmental Control System) Controller

Note *) : significant

• Several other minor changes were done as well

PC-12 NG (PC-12/47E) 4.3Changes to Type Design


Utility Aircraft

• P02 : 2004 – 2006• 107 flying hrs

• MSN 545, 1001, 1002 :2006 – 2008• 776 flying hrs

PC-12 NG (PC-12/47E) 4.3Flying Hours


Utility Aircraft

• Dedicated Engineering Reports per change

• Summary Reports for other subjects

PC-12 NG (PC-12/47E) 4.3Engineering Reports > 150

APEX

PGDS Engine CPCS ECS ESIS 23.1309

Structural Substantiation

Aerodynamic & Performance

Fuel


Utility Aircraft

• Major Changes• Removal of Standby Compass• 5-blade Composite Propeller• Primus Apex Build 10

• Several other minor changes• External aerodynamic changes• Pax door• Removal of clock• …

PC-12 Model 2016 4.4Changes to Type Design


Utility Aircraft

• Flight test program for Model 2016 (117.5 hrs)• 5-blade propeller & aerodynamic improvement: 68.5 flying hrs• APEX Build 10: 49.0 flying hrs

• Number of Engineering Reports updated or created (57):• Certification Programs: 3• Top Level Reports: 5• APEX Build 10: 15• 5-blade propeller: 15• Performance: 19

• Updated AFM/POH, AMM, IPC

PC-12 Model 2016 4.4Flying Hours / Engineering Reports


Utility Aircraft

• L3 ESIS displays heading independently (and more reliably).• With the introduction of the L3 ESIS which provides an

independent display of magnetic heading, the centrepost mounted whisky compass is no longer needed.

PC-12 Model 20164.4Removal of Standby Compass


Utility Aircraft

Master Certification Programme

• Agreement with Certifying Authority regarding Programme and Certification Basis

major non-significant

• Signed by Pilatus• Verified by Pilatus• Accepted by EASA



Utility Aircraft

Pilatus Configuration Management


Changed Drawingsand Parts Lists

Engineering Reports, Approvals, …


Utility Aircraft

Major Change Approval Summary

• Signed and Verified by Pilatus

Pilatus to EASA



Utility Aircraft

EASA & FAA Approval



Utility Aircraft

• Propellers receive specific Type Certificate (FAR 35 / EASA CS-P) issued by FAA/EASA• Supplier Testing by Hartzell

• EASA/FAA have to validate the propeller Type Certificate

• Pilatus has to certify the new propeller as part of the Aircraft Type Certificate• Major Change• with EASA/FAA

PC-12 Model 20164.55-Blade Composite Propeller


Utility Aircraft

• The applicant must demonstrate, by tests or analysis based on tests or experience on similar designs, that the propeller can withstand the impact of a 4-pound bird at the critical location(s) and critical flight condition(s) of a typical installation without causing a major or hazardous propeller effect.

• Test Condition• 4 lbs bird / Impact Location 8 inches from tip• NP = 1700 RPM / 1200 SHP / 76 KTASImpact Velocity = 392 kts & Impact Angle = 17.4 degreesConditions simulate take-off rotation, as the airplane accelerates into a advancing bird. Results in the bird hitting the blade at the highest angle (not cutting the bird).

5-Blade Composite Propeller 4.5Testing : FAR 35.36, Bird Impact


Bird Impact Testing


EC/Utility AircraftBird Impact Testing


Lightning Testing

All Hartzell composite blades have successfully passed direct effects lightning tests to:

– 1,000,000 volts– 100,000 amps

Our propellers have been tested and include features and components that provide a level of protection for airframe electrical components from indirect lightning effects


Deicer Testing

Hartzell designs, manufactures and certifies it’s own fluid anti-ice and electro-thermal deice systems

Impingement and accretion analysis is performed using LEWICE

Certification is accomplished using FAA approved analytical and convection testing capabilities− Thermal (IR) temperature measurements− Wind tunnel (600 ft/s) to verify deicer surface

temperatures at the applicable speed conditions


Propeller Stress Testing

Dedicated test lab − Blade, Hub & component fatigue testing− Focused on testing propeller

components to comply with FAR Part 35 and 23 requirements

In-flight Vibration Testing− Accomplished by strain gaging

propeller and telemetry system− Perform propeller loads/stresses for all

unique aircraft/propeller installation


Utility Aircraft

In-flight Vibration Testing on PC-12 (MSN 545)



Utility Aircraft

Propeller Pressure Survey Testing


• Controlling oil pressure never drops to zero and never exceeds the maximum governing pressure

• Flyweights and spring act against the oil pressure

• Examples are from the 4-blade aluminum propeller testing on PC-12 P02 (1994)

• Same testing repeated with the 5-blade composite propeller on a similar application


Utility Aircraft


Propeller Pressure Survey (4-blade)

• max power:Vs Vmo Vs

5-blade composite propeller


Utility Aircraft

Propeller Pressure Survey (4-blade)• max power: Vs Vmo Vs



EC/Utility Aircraft