1 Flight Safety Foundation Symposium Vancouver, February 2011 A Process for Control and Conduct of Functional Check Flights Cathay Pacific Airways

2 Introduction Who we are What we do Why we are here in YVR

3 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

4 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

5 Introduction Why we are here in YVR – Shocked and saddened by Perpignan accident FT Section has considerable airline test flight experience A , A330, A , A B747 Classic, B , B /300/300ER No major incidents over many years Competent and willing to contribute to discussion on improved Check Flight safety

6 Hong Kong Check Flight Scheme Why we have check flight scheme in HKG - Reason for scheme Basic scheme details Reporting responsibility

7 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

8 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)

9 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

10 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

11 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)

12 Check Flight Considerations Who does the testing – Crew selection Crew training Crew currency

13 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

14 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)

15 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

16 Check Flight Considerations What is tested – Test selection Test schedule format Additional HKCAD tests Ad-hoc tests during flight ?

17 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

18 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

19 Check Flight Considerations What is tested / Test schedule format – Locally-developed test schedules expanded (contd) –  Initial and Completion conditions added

20 Check Flight Considerations What is tested / Test schedule format – Locally-developed test schedules expanded (contd) –  Step-by-step procedure and result recording

21 Check Flight Considerations What is tested / Test schedule format – Locally-developed test schedules expanded (contd) –  Carefully phrased instructions Simple changes can be important – Condition, followed by Action e.g. After 3 min at idle, shutdown ENG 2 NOT Shutdown ENG 2 after 3 min at idle

22 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

23 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)

24 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

25 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

26 Check Flight Considerations Where & when the testing is conducted – Typical flight profile

27 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

28 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’!

29 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

30 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

31 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

32 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

33 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