**Executive Summary**
This document outlines the Civil Aviation Requirements (CAR) Section II, Series T, Part II, specifically concerning flight testing of aircraft for which a Certificate of Airworthiness has previously been issued. The amendment is effective forthwith as of April 1, 1976, and details the applicability, definitions, circumstances, and procedures related to flight testing. It also includes the criteria for pilot qualifications to undertake test flights.
**Key Points / Main Content**
* **Applicability and Definitions:**
* The document specifies the conditions for flight testing of aircraft with existing Certificates of Airworthiness.
* "Approved" means approved by the Director General of Civil Aviation (DGCA).
* "Flight Test" means flying an aircraft, without passengers, to ensure aircraft handling, performance, and equipment function properly.
* **Circumstances Necessitating Flight Testing:**
* Flight testing is required upon renewal of the Airworthiness Review Certificate (ARC).
* Also required after maintenance, repair, or modification affecting operational or flight characteristics.
* If fuel consumption, engine power, or navigational equipment performance is doubtful and cannot be checked on the ground.
* Subsequent to an engine change, unless specific ground testing procedures are followed and acceptable to the DGCA (with limitations based on the number of engines changed).
* To determine the cause of a defect for maintenance rectification.
* DGCA may require flight testing at any frequency.
* **Certification and Procedure:**
* Operators must specify flight test circumstances in their manuals.
* Adverse performance during test flights must be reported to the Regional Airworthiness Office.
* A certifying staff member must determine if a flight test is necessary before issuing a Certificate of Release to Service.
* Maintenance and inspection documents must be completed and certified before the flight test.
* A certificate stating the aircraft is fit for flight must be issued before the test flight.
* Operators must have an approved routine test flight schedule.
* **Flight Test Report and Monitoring:**
* A flight test report detailing results and defects must be completed by the pilot-in-command.
* Scheduled airlines should monitor aircraft performance against flight plans and investigate variations.
* **Pilot Requirements for Test Flights:**
* Specific pilot license and experience requirements are detailed for passenger and aerial work aircraft, as well as for private category aircraft.
* Glider pilots conducting test flights must have a Glider Pilot Licence and a current Flight Instructor Rating.
* DGCA may approve other suitable pilots.
* **Submission of Certificate:**
* A Quality Control Manager/Chief Instructor / Continuing Airworthiness Manager must submit a certificate to the Regional Airworthiness Office at the time of renewal of the ARC.
**Impact Analysis**
**Aircraft Operators**
*Impact:* Must ensure that flight testing is conducted according to the specified circumstances and procedures. Operators also need to include flight test procedures in their operations and maintenance manuals.
*Action Required:* Update manuals, training programs, and procedures to align with the requirements.
**Maintenance Personnel / Certifying Staff**
*Impact:* Responsible for ensuring aircraft are fit for flight and for properly documenting maintenance, repairs, and modifications. They must determine if a flight test is necessary before issuing a Certificate of Release to Service.
*Action Required:* Familiarize themselves with the new procedures and ensure compliance before certifying aircraft for flight.
**Flight Crew (Pilots)**
*Impact:* Need to meet the specified license and experience requirements to conduct flight tests. Pilots are also responsible for completing detailed flight test reports and reporting any adverse performance.
*Action Required:* Ensure they meet the pilot qualification requirements, complete flight test reports accurately, and report any performance deviations.
**Scheduled Airlines**
*Impact:* They need to monitor aircraft performance and investigate variations in flight performance to make sure their aircraft meet the required safety standards.
*Action Required:* Scheduled airlines should review and update their maintenance and operations procedures. This ensures the airline has effective systems for monitoring and evaluating aircraft performance during revenue flights. They also need to ensure staff are properly trained in data collection, analysis, and reporting, and need to establish clear processes for investigating and rectifying any identified performance deviations.
**Director General of Civil Aviation (DGCA)**
*Impact:* DGCA retains the authority to require flight testing at any frequency and approves ground testing procedures.
*Action Required:* Ensure compliance with DGCA requirements.
**Quality Control Manager/Chief Instructor / Continuing Airworthiness Manager**
*Impact:* Responsible for submitting a certificate to the Regional Airworthiness Office at the time of renewal of the ARC.
*Action Required:* Ensure compliance with DGCA requirements.
Key Entities Referenced
Director General of Civil Aviation: Regulatory authority, approval from which is required.
Civil Aviation Requirements (CAR): Aviation regulations; CAR Section 2, Series T, Part II specifically deals with flight testing of aircraft for which a Certificate of Airworthiness has been issued.
Certificate of Airworthiness: A document certifying that an aircraft meets airworthiness standards, and the policy defines the conditions necessitating flight testing for aircraft with previously issued certificates.
Airworthiness Review Certificate (ARC): A certificate related to the renewal of Certificate of Airworthiness. The document refers to issuance of ARC for aircraft.
Certificate of Release to Service (CRS): A certificate of maintenance release. The document refers to issuance of CRS for aircraft.
CAR Section II Series T Part II is proposed to be amended. The propose
amendments are shown in subsequent affected paragraphs.
The text of the amendment is arranged to show deleted text, new or amended text as
shown below:
(a) deleted text is marked with strikethrough;
(b) new or amended text is highlighted in grey;
(c) an ellipsis (…) indicates that the remaining text is unchanged in front of or
following the reflected amendment
CIVIL AVIATION REQUIREMENTS
SECTION 2 - AIRWORTHINESS
SERIES 'T', PART II
1st APRIL, 1976 EFFECTIVE: FORTHWITH
Subject: Flight Testing of aircraft for which a Certificate of Airworthiness has
previously been issued.
1. APPLICABILITY:
1.1 This part of Civil Aviation Requirements (Section 2-Airworthiness) specifies the conditions
for the flight testing of aircraft for which a Certificate of Airworthiness has previously been
issued.
2. DEFINITIONS:
(a) "Approved" means approved by Director General of Civil Aviation.
(b) (b) "Flight Test" means the flying of an aircraft, without any passenger on board, for the
purpose of ensuring that: -
(i) the aircraft handling characteristics have not deteriorated with time;
(ii) the aircraft performance remains as scheduled; and
(iii) aircraft and its equipment function properly.
3. CIRCUMSTANCES NECESSITATING FLIGHT TESTING:
3.1 An aircraft shall be flight tested under the circumstances mentioned below:
(a) At the time of renewal of Certificate of Airworthiness (including six monthly renewal of
Certificate of Airworthiness) issue of Airworthiness Review Certificate (ARC) of aircraft
operated by operators and subsequent to a major inspection schedule/ as specified by
the manufacturer in case of scheduled airlines.
Note: The scheduled airlines, which have a system (vide para 7 of this part of the CAR) of
meticulous flight monitoring of each revenue flight, for the guidance of their operating
crew and also have a flight performance evaluation cell in their engineering organisation,
acceptable to DGCA, need not subject individual aircraft to test flight for the purpose of
renewal of C of A, issue of ARC except under the circumstances detailed below in sub-CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
paras (b) to (e). The performance cell Continuing Airworthiness Manager should furnish
a certificate during every C of A renewal issue of ARC certifying that the aircraft
performance has been continuously monitored and the performance is satisfactory. The
procedures to be adopted by the performance evaluation cell shall be documented in the
organization approved CAME.
Rev 4, ----- 2017
(b) Subsequent to maintenance, repair, or modification which affect operational or flight
characteristics of the aircraft.
(c) For the purpose of evaluation in respect of fuel consumption engine power and
performance of radio/ radar/ navigational equipment or instruments whenever these are
doubted and cannot be satisfactorily checked on ground.
(d) (i) Subsequent to change of an engine.
(ii) (i) On a twin engined aircraft a test flight after an engine change may not be carried
out provided satisfactory engine ground testing procedure subsequent to an engine
change and acceptable to Director General of Civil Aviation is evolved prior to
availing of this relaxation. However, if two engines are changed a test flight is
necessary.
(iii) (ii)On three engined aircraft, after a single engine change a test flight may not be
carried out provided satisfactory engine ground testing procedure subsequent to an
engine change and acceptable to Director General of Civil Aviation is evolved prior to
availing of this relaxation. However more than one engine change will require a Test
Flight.
(iv) (iii) On a four engine aircraft, after one or two engine changes, a test flight may not be
carried out provided satisfactory engine ground testing procedure subsequent to
engine change and acceptable to Director General of Civil Aviation is evolved prior to
availing of this relaxation. However if more than two engines are changed, a test
flight is necessary.
Note: - Engine change would mean removal of any engine and its replacement by :
(i) an overhauled engine
(ii) an engine removed from any other position of the same aircraft or any other
aircraft.
(Reinstallation of the same engine on the same aircraft in its original position would
not constitute an engine change for this purpose, provided the engine has already
been flight proven and the entire installation of the engine is double-checked and
certified.)
(e) To satisfactorily determine the cause of a defect so as to assess the maintenance
required to rectify the defect.
Rev 4, ----- 2017 2CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
3.2 Notwithstanding the circumstances mentioned in para 3.1 above, DGCA may require any
aircraft or any type of aircraft to undergo such flight-testing and at such frequency as
considered necessary.
3.3 Operator of an aircraft shall, for each type of aircraft operated by it, specify in its approved
Quality Control and/or Maintenance System Manual, Continuing Airworthiness
Management Exposition / Maintenance Organisation Manual ( CAME / MOM ), the
circumstances under which a flight test is to be performed. This shall not only include the
circumstances laid down in para 3.1 above, but also any other currently known. Further
procedures to be observed by maintenance personnel for the flight testing shall also be
included in the exposition/ manual.
3.4 Whenever the performance of an aircraft during the test flight or at other occasions, is
adversely commented upon by the flight crew, the same shall be reported to Regional
Airworthiness Office promptly, along with the remedial measures envisaged to rectify the
situation.
3.5 An person appropriately authorized certifying staff licensed/approved to certify the issue
the Certificate of Release to Service (CRS) as per CAR 145 / CAR M "Flight release (vide
CAR Section 2 Series 'F') of an aircraft, shall prior to certifying, determine whether or not
the circumstances are such that a flight test is necessary.
4. CERTIFICATION BEFORE FLIGHT TEST:
4.1 Before a flight test is made, the documents covering the maintenance repair, modification
and inspection shall be completed in all respects and certified in accordance with the
approved procedures listed in Quality Control Manual/ Maintenance System Manual, (
CAME / MOM ) and shall be produced before the pilot of the aircraft, if required.
4.2 When the requirements of para 4.1 have been met, and before the test flight, a certificate,
to the effect that the aircraft is fit for the flight, shall be issued in duplicate on a proforma,
by an authorized certifying staff licensed/ approved individual who is permitted to issue
Certificate of Release to Service Flight Release (vide CAR Section 2 Series 'F'). One
copy shall be delivered to the pilot test flying the aircraft and the other copy shall be
retained by the operator.
4.3 The licensed individual certifying staff who signs the pre test flight certification documents
shall also ensure that the document shows the purpose of test flight and the information
required to be observed/ recorded during the test flight by the flight crew. The pilot test
flying the aircraft shall also be briefed on these aspects.
5. PROCEDURE DURING TEST FLIGHT:
5.1 Operators shall, for each type of aircraft operated by them, provide in an approved routine
test flight schedule, the detailed procedure to be followed/ observed while performing the
flight test.
5.2 It shall be the responsibility of the operator to keep the test flight schedule, vis-a-vis
manufacturer's/ DGCA's requirements, up-to-date.
Rev 4, ----- 2017 3CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
5.3 As far as practicable, the routine test flight will be conducted at maximum all-up-weight,
authorised for the type of aircraft, keeping in view the limitation imposed by the factors
like aerodrome altitude/ temperature, runway length etc.
5.4 The routine test flight procedure will at least ensure: -
(i) that “all-engine-operating climb performance is within acceptable limits, specified by the
manufacturer/ DGCA, while effecting climb at the "best climbing speed".
(ii) that the cruise speed at the cruising engine power, is within the range specified;
(iii) that the stalling speed has not increased beyond the figure specified by the
manufacturer/ DGCA.
(iv) that through normal operating range of the aircraft no abnormal vibrations exist;
(v) that flight controls operate and respond normally and satisfactorily.
Note: - The stalling characteristics of the aircraft if required to be checked, must be checked
at a safe altitude.
(vi) The radio/ radar equipment functions correctly as installed in the aircraft and the
operating range is satisfactory.
6. FLIGHT TEST REPORT:
6.1 A flight test report appropriate to the flight test performed shall be completed by the pilot-
in-command or by any other flight crewmember of the aircraft, authorised by the operator.
The report shall detail the result of the flight test and record all defects experienced and
adjustments made during the flight, besides recording of instruments readings as called
for in the report (schedule).
6.2 The pilot-in-command shall be responsible for recording the result of the test flight and for
making such comments in writing as considered necessary for a further test flight.
6.3 A flight test report and record of defects and adjustments shall be made in the flight
logbook of the aircraft or other equivalent document approved by the Director General.
7. MONITORING OF FLIGHT PERFORMANCE OF AIRCRAFT OPERATED BY
SCHEDULED AIRLINES:
7.1 The scheduled airlines may evolve a system within there their "Operations Section"
preparing flight plans, for the convenience of operating crew, for conducting each revenue
flight, based on the performance data documented by the manufacturers. Under this
system, operating crew should be expected to report back on the actual performance of
aircraft during flight vis-a-vis the prepared plan. Significant variations in aircraft's
performance shall be investigated by the operator so that corrective measures are initiated
promptly.
Rev 4, ----- 2017 4CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
7.2 Additionally, scheduled airlines will have aircraft performance monitoring cell in their
"Engineering Section" CAMO for keeping the performance of each aircraft under
continuous surveillance by regularly analysing the flight data like ROC, cruising speed,
fuel consumption, range of Radio/ Radar equipment etc., collected from revenue flight
reports for detecting any persisting shortfall in the performance of any aircraft.
7.3 In consultation with the manufacturers of aircraft/ DGCA, scheduled airlines shall specify
in their Quality Control/ Maintenance System Manual Continuing Airworthiness
Management Exposition the acceptable “shortfall for the guidance of their maintenance
staff.
7.4 On learning of the "shortfall" DGCA may order such further flight test or such other
corrective action as considered necessary.
8. EVALUATION OF TEST FLIGHT REPORTS:
8.1 The "Rate of Climb" figure read off the aircraft instrument, during the climbing phase of the
test flight, is related to test conditions, viz., mean altitude, mean temperature and mean
weight. This will be termed as "observed actual climb performance" figure.
8.2 The "expected climb performance" figure corresponding to test conditions (mean altitude,
mean temperature and mean weight) shall be obtained from the relevant manual of the
aircraft, like Flight Manual, Operations Manual, Pilot's notes.
8.3 The “observed actual climb performance" figure (para 8.1) shall in no case be lower by
more than 3% (in terms of ft. per minute) of the "expected climb performance" figure (para
8.2) for the purpose of acceptance of test flight report.
8.4 In case necessary graphs for deriving "expected climb performance" figure corresponding
to test conditions are not readily available, then appropriate "ROC correction factor" graph
(Appendix to this CAR) be used either graph meant for constant speed propellers or for
fixed pitch propellers, as applicable for determining the correction factor corresponding to
mean altitude and mean temperature test conditions, stipulated in Flight Manual/
Operations Manual/ Pilots' notes, before ROC, thus corrected partly, is further corrected
for test conditions of mean weight as described in the following para 8.5.
8.5 As the mean weight of the aircraft at the test conditions is invariably different from the
maximum authorised all-up-weight for which ROC is specified in Flight Manual/
Operations Manual/ Pilots' notes, the following expression may be used for applying
weight correction to obtain the finally corrected 'expected climb performance' figure:
_________________________________________________________________
R.O.C
(Partly corrected,
after applying
correction factor
obtained from
Expected R.O.C. Approx.) X Maximum AUW
Rev 4, ----- 2017 5CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
(finally corrected) = __________________________________________________
Mean weight
(at test condition)
8.6 The finally corrected "expected climb performance" figure shall then be compared with
"observed actual climb performance" figure as described in para 8.3 above, for the
purpose of acceptance of test flight report.
9. CERTIFICATION AFTER FLIGHT TEST:
9.1 When a satisfactory flight test has been performed and subsequent defects, if any, are
rectified and certified an endorsement to this effect shall be made in the Pilot's Defect
Report/ Maintenance documents/ aircraft log book by licensed/approved person
certifying staff responsible for issuing Certificate of Release to Service (CRS) as per
CAR 145 / CAR M. "Flight Release" (vide CAR Series 'F').
9.2 Thereafter the usual Certificate of Release to Service (CRS) "Flight Release" may be
issued.
10. FLIGHT CREW REQUIREMENTS:
For the purpose of flight tests, the number of flight crew to be carried on board shall be as
specified in the flight manual.
The flight crew requirements for the purpose of flight test shall be as follows:
10.1 PASSENGER AND AERIAL WORK AIRCRAFT
The pilot carrying out the flight test shall be in possession of:-
10.1.1 FOR SINGLE ENGINED AIRCRAFT
(i) a valid Commercial Pilot's Licence/ Senior Commercial Pilot Licence/ Airline
Transport Pilot Licence endorsed for the type of aircraft; with
(ii) at least 500 hours total flying time as Pilot-in-Command (PIC) which shall include :
(a) atleast 100 hours as PIC on type; of which
(b) at least 10 hours shall be as PIC on type or similar aircraft types within a
period of six months immediately preceding the date of flight test.
10.1.2 FOR TWIN ENGINED AIRCRAFT
(i) a valid Commercial Pilot's Licence/Senior Commercial Pilot Licence/ Airline
Transport Pilot Licence endorsed for the type of aircraft; with
Rev 4, ----- 2017 6CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
(ii) at least 1000 hours total flying time which shall include :
(a) atleast 500 hours flying time as PIC on twin engined aircraft; of which
(b) at least 100 hours shall be as PIC on type; and
(c) atleast 10 hours as PIC on type or similar aircraft types within a period of six
months immediately preceding the date of flight test.
10.2 PRIVATE CATEGORY AIRCRAFT
10.2.1 The pilot carrying out flight test of aircraft fitted with Piston engine with Maximum Take-
off Weight (MTOW) not exceeding 3000 kgs. and categorised as private aircraft in the
C of A, shall be in possession of:-
(a) atleast a valid Private Pilot's licence (PPL) endorsed for the type of aircraft; with
(b) at least 500 hours total flying experience which shall include:-
(i) atleast 200 hours as PIC, of which
(ii) at least 100 hours shall be on type; and
(iii) atleast 10 hours as PIC on type or similar aircraft types within a period of
six months immediately preceding the date of flight test.
10.2.2 Test flight of aircraft other than piston engined aircraft having maximum take-off weight
exceeding 3000 kgs shall be carried out as per the para 10.1.
10.2.3 Notwithstanding what has been specified, here in before, DGCA may consider permitting
private owners to carry out the flight test on their own aircraft, after considering their
total flying experience and type, thereof.
10.3 Gliders: Test flight of gliders including powered gliders shall be conducted by Glider
Pilot licence (GPL) holders with current Flight Instructor Rating on the relevant type.
10.4 Notwithstanding the above, any other suitable person pilot may be permitted to carry
out test flights with the prior approval of DGCA.
Note: No pilot shall carry out test flight after 1st May 1997 unless he meets the requirements
of Para 10 through 10.2.2, as applicable.
11. SUBMISSION OF CERTIFICATE AT THE TIME OF RENEWAL OF CERTIFICATE OF
AIRWORTHINESS: ISSUE OF AIRWORTHINESS REVIEW CERTIFICATE.
11.1 The Quality Control Manager/Chief Instructor / Continuing Airworthiness Manager of an
approved organisation or Chief Engineer/ Engineer in charge of other organisations shall
submit a certificate to the Regional Airworthiness Office at the time of renewal of
Certificate of Airworthiness issue of ARC of the aircraft, stating that Test Flight/
Evaluations of revenue flights were carried out as and when required vide this part of
Rev 4, ----- 2017 7CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
CAR Series 'T' and the flight results did not reveal any deterioration in aircraft's
performance/revealed deterioration in aircraft's performance which was within acceptable
limits.
Director General of Civil Aviation
Rev 4, ----- 2017 8CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
Rev 4, ----- 2017 9CIVIL AVIATION REQUIREMENTS SECTION 2-AIRWORTHINESS
SERIES 'T' PART II 1ST APRIL, 1976
Rev 4, ----- 2017 10