GOVERNMENT OF INDIA

DIRECTOR GENERAL OF CIVIL AVIATION

TECHNICAL CENTRE, OPP SAFDURJUNG AIRPORT, NEW DELHI

CIVIL AVIATION REQUIREMENTS

SECTION 2 – AIRWORTHINESS
SERIES T PART II
ISSUE III, 1ST APRIL 1976 EFFECTIVE: FORTHWITH

F. No. 11-690/T-II/2017-AI(2)
DGCA-25012(07)/8/2021

Subject: Flight testing of aircraft for which a Certificate of Airworthiness has

previously been issued.

1. APPLICABILITY:

1.1 This Civil Aviation Requirements 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) "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) Subsequent to a major inspection schedule/ as specified by the manufacturer in

case of scheduled airlines.

Note: Scheduled airlines, which have a system (vide para 7 of this 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 issue/ extension of ARC except under the circumstances detailed below

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in sub-paras (c) to (e). The Continuing Airworthiness Manager should furnish a

certificate during every issue/extension 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.

(b) At the time of issue/ extension of ARC for aircraft other than those operated by a
scheduled airline in the following cases:

i) The ARC has expired; or

ii) The aircraft has not flown in the preceding 15 days prior to the expiry
date of ARC.

(c) Subsequent to maintenance, repair, or modification which affects operational or

flight characteristics of the aircraft.

(d) For the purpose of evaluation in respect of fuel consumption, engine power,
performance of radio/ radar/ navigational equipment or instruments, whenever
these cannot be satisfactorily checked on ground.

(e) Subsequent to change of engine.

(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 both the engines are
changed a Test Flight is necessary.

(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.

(iii) On a four engine aircraft, after one or two engine change, 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.

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(f) To satisfactorily determine the cause of a defect so as to assess the maintenance

required to rectify the defect.

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 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 flight test 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 appropriately authorized certifying staff issue the Certificate of Release to

Service (CRS) as per CAR 145 / CAR M 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 (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 who is permitted to issue Certificate
of Release to Service. 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 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:

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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.

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.

(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.

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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 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.

7.2 Additionally, scheduled airlines will have aircraft performance monitoring cell in their
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 Continuing Airworthiness Management Exposition the acceptable
“shortfall for the guidance of 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 be within the limit
prescribed by TC holder. In case this is not provided by the TC holder, then the climb
performance shall not 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.

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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
(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 certifying staff
responsible for issuing Certificate of Release to Service (CRS) as per CAR 145 /
CAR M.

9.2 Thereafter the usual Certificate of Release to Service (CRS) may be issued.

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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 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 Airline Transport Pilot Licence endorsed
for the type of aircraft; with

(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; and

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(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 pilot may be permitted to carry out
test flights with the prior approval of DGCA.

11. SUBMISSION OF CERTIFICATE AT THE TIME OF ISSUE OF AIRWORTHINESS

REVIEW CERTIFICATE.

11.1 The Chief Instructor/ Continuing Airworthiness Manager of an approved

organisation shall submit a certificate to the Regional Airworthiness Office at the
time of 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 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.

(Arun Kumar)
Director General of Civil Aviation

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