UNDERSECRETARIAT FOR DEFENCE INDUSTRIES

C130 E/B Avionics Modernization Project (AMP)

AW Certification Process and Difficulties

CONTENT

• C-130 AMP Scope • C-130 AMP AW Certification Activities • General AW Certification Objectives • C-130 AMP Certification Content and Standarts • C-130 AMP Certification Management • C-130 AMP STC Process • C-130 AMP Documents • C-130 AMP Special Conditions • C-130 AMP Risk Acceptance Process • C-130 AMP DOCA and POCA Activities • C-130 AMP Flight Tests • C-130 AMP Major Difficulties • C-130 AMP Lessons Learned • C-130 AMP Targets

C-130 AMP Scope

SSM contracted with TAI upgrading of 13 TuAF C-130 Hercules E/B in order to have a convenient configuration to comply with the international aviation requirements.

Contract Effectivity : February 2007

C-130 AMP Scope 117 LRU for 23 system: Avionics System Integration,

Flight Management System (FMS) design/development and Integration instead of Navigator in the cockpit

Link-16 Implementation

Mission Planning Ground Station design/ development and delivery

NVIS Lighting System

RVSM

RNP-1

RNAV/GPS Approach

CAT II/ILS Approach Operations

+ 6 E model C-130

C-130 AMP Scope

C-130 AMP Scope To change from Analog to Glass Cockpit

C-130 AMP AW ACTIVITIES AND CERTIFICATION PROCESS

Our objectives for Military Airworthiness Certification are,

Develop the Military Regulations and Processes in parallel with Civil Aviation Regulations and Processes

System based Safety approach instead of Product based Safety approach

SSM Internal Procedure SSM-YN-3500-09

IR 21 Adapted to SSM Internal Processes

General AW Certification Objectives

C-130 AW Certification Content

• Issueance of STC (Supplementary Type Certificate) at the end of Prototype Phase

• Issueance of A/W Certificate for each A/C in both Prototype & Serial Production A/C.

C-130 AW Certification Standards

Certification Basis

Evaluation of Contractor’s Design & Production Organization with

DOCA/POCA studies

FAR-25 &

Certification Review Items (CRI) (36 each)

IR 21 Subpart J&G

RTCA DO-160E

MIL-HDBK-810F

RTCA DO-178B Evaluation of Software Safety

Evaluation of System Safety MIL-HDBK-882C

Evaluation of Environmental Conditions

C-130 AW Certification Management

AW CERTIFICATION BOARD(3 MIL+3 CIVIL)

Project Certification Coordinator

(CIVIL)

SOFTWARE (12 ENG.)

SAFETY(12 ENG.)

FLIGHT PERFORMANCE

(12 ENG+PİLOTS)

ELECTRICAL(5 ENG.)

AVIONICS (10 ENG.)

MAINTENANCE (12 ENG.)

STRUCTURAL/HYDRO. MECH

(11 ENG.)

ORGANIZASTIONAL APPROVALS

(3 ENG)

• Over 70 Engineers (Civilian+Military) are working for AW Certification Process.

C-130 AMP STC Process

Compliance Review(Artifacts+Data+Noncompliances)

Certification Basis(FAR 25+Special Conditions)

Noncompliances-Risk Acceptance(Risk Identification+Mitigation Methods

+Risk Acceptance)

Panel Compliance DeclarationsCertification Board Decision

Supplemental Type Certificate

Organizational Approvals

Planning (Certification Strategy)

Planning (Certification Plan)

C-130 AMP AW Documents

SSM AW Crtf. Regulation

3500-09

C-130 AMP Contract and Certification Basis

(Incld. Special Conditions)

C-130 AMP System Certification Plans (ATA Chapters)

C-130 AMP Project Certification Plan

C-130 AMP Certification Strategy

C-130 AMP Design and Production

Organization Manuals

Project Based Detailed Government Internal Plan

Project Based Detailed Government-Contractor Plan

C-130 AMP Compliance Documents/Evidences

C-130 AMP AW Documents

C-130 AMP Certification Strategy • Project Content and Product Specifications

• Project AW Certification Content • Contractor Info • AW Certification Organization (IPTs, Panels,

Certification Board etc.) • Responsibilities and Tasks (Project Cert.

Coord, Panel Coord., Board Members, etc.) • Resources (Personnel, Training, Tools etc.) • AW Certification Process (STC, AWC, DOCA,

POCA) • AW Certification Schedule • Resolution of Conflicts • Meetings • AW Certification Risk Management • Internal Audits • …

GOVERNMENT PROJECT AW HANDBOOK!

C-130 AMP Special Conditions

B – Flight

B-03 Human Factors Flight Deck

B-04 RVSM

B-05 CAT II

B-06 RNP-1

B-07 RNAV/GPS

B-09 Military Operations

C – Structures

C-01 Aeroelastic stability requirements

C-02 Tests for pressurized cabins

D - Design & Construction

D-03 Trim Systems

D-05 Two-way voice communication

D-06 Control Surface and System Loads

D-07 Minimum Recommended Speed

D-08 Door Indications

D-09 Installation of CVR

D-10 Pressure Differential Indicator

D-11 Airspeed indicating system

D-12 Control Systems

C-130 AMP Risk Acceptance Process

• Each noncompliance will increase flight safety risk by some amount! So each noncompliance has been considered and accepted individually in C-130 AMP.

United States Air Force

(USAF) Airworthiness Bulletin

(AWB)-013A

Risk Identification and

Acceptance for Airworthiness

Determinations

MIL-STD-882C

FREQUENCY OF OCCURRENCE FC CLASSIFICATION

Definition Qualitative Quantitative [P per FH]

CATASTROPHIC HAZARDOUS MAJOR MINOR NSE

Frequent - P ≥ 10

-3 1 3 6 10 N/A

Probable Probable Failure Conditions are those anticipated to occur one or more times during the entire operational life of each aeroplane.

10-5

≤ P < 10-3

2 5 9 16 N/A

Remote Unlikely to occur to each aeroplane during its total life but may occur several times when considering the total operational life of a number of aeroplanes of the same type.

10-7

≤ P < 10-5

4 8 13 18 N/A

Extremely Remote

Unlikely to occur when considering the total operational life of all aeroplanes of the same type, but nevertheless has to be considered as being possible.

10-9

≤ P < 10-7

7 12 15 19 N/A

Extremely Improbable

Extremely Improbable Failure Conditions are those so unlikely that they are not anticipated to occur during the entire operational life of all aeroplanes of one type.

P < 10-9

11 14 17 20 N/A

• C-130 Certification Board will issue a STC after concurrence on risk assessment and formal risk acceptance by TuRAF.

C-130 AMP DOCA Activities

07 / 2008

02 / 2012

Initiation Preparation Presentation of the investigation plan

Investigation Conclusion

03 / 2007

Preparation Presentation of the investigation plan

Investigation Conclusion

05 / 2007 07 / 2007 05 / 2008 05 / 2011

DOCA Final

Report

DOCA

Phase 2 Phase 1 Phase 3 Phase 4 Phase 5

C-130 AMP POCA Activities

Initiation Preparation Investigation Plan Investigation Conclusion

POCA Final Report

POCA

10 / 2008 09 / 2008 06/2007 03 / 2007 09/2009

02/2008 11/2009

Continued Surveillance 2010

Continued Surveillance 2011

09/2011 09/2011

POCA CS Report 2010

POCA CS Report 2011

POCA is the approval showing that a quality system is in place ensuring that the product, part or appliance is in compliance with the approved type design data and is in a condition for safe operation.

Flight Tests

• Certification Board issues Technical Evaluation Report for Flight Permits based on safety clearances given by each panel.

• First flight was performed in May 2011,

• Totally 16 Flight Permits were given so far.

Total Flight (sorti

number)

Total (Flight hour) Taxi

(number)

Flight (sorti

number)

Total (Flight hour)

Taxi (number)

Flight (Sorti

number)

Total (hour)

Phase 1-Development

2 4 5:27 0 0 0 4 5:27

Phase 2- Development

1 19 39:49 2 8 16:02 27 55:51

Certification-Qualification (Non-FMS)

0 21 52:39 0 20 46:08 41 98:47

Certification-Qualification

(FMS) 1 6 16:50 0 0 0:00 6 16:50

TOTAL 4 50 114:45 2 28 62:10 78 176:55

Major Difficulties-Project Schedule

PROBLEM:

• Urgent needs for Project Schedule with a limited number of certification specialists.

SOLUTION:

• It was decided to assign the Project Manager as a member of Certification Board.

• Close cooperation was established with the Project Team and Certification Team.

• Daily workshops with the Contractor teams in the Contractor Facilities.

• «Safety First » approach has been accepted by all project parties.

Major Difficulties-Vibration Qual. PROBLEM:

• Some of the installed equipment might not satisfy FAR 25.1309 with respect to the vibration qualification requirements.

• Some equipment have been qualified using sine sweep vibration tests, whereas the vibration environment of the C-130 is considered to be reflected by the random vibration tests as specified by MIL-STD-810F.

SOLUTION:

• MOC 0 would be possible, either a formal report (“declaration of no objection” based on experience) referring to C-130B/E including the respective DDP (or CofC) has to be issued by the equipment manufacturer,

• MoC 1 and MoC 2 showing compliance could be possible by comparable calculations of the performed DO-160 sinusoidal tests.

• MoC 6 would be possible for all equipment in case there is an approved flight test plan for the equipment under test and the corresponding flight test report, including all test procedures applicable for this scope.

• OR RİSK ACCEPTANCE !

Major Difficulties-Software Levels PROBLEM:

• Some of the installed equipments software is not RTCA/DO178B compliant or compliance level is below the criticality level. (coming from Sytem Safety Analysis).

• For Example; according to System Safety Studies APN-241 RADAR Equipment software is DAL B. However, APN-241 RADAR software is developed according to DO-178B Level D.

SOLUTION:

• A CRI addressing this issue is created.

• A software safety case including service history, similarity analyses is prepared for each non-compliant critical equipments.

• Some software safety cases are considered as satisfactory and approved by Software Certification Panel.

• For the other equipments a Risk Assessment Process followed at Aircraft level.

Lessons Learned

• Do not put specified LRUs in contractual documents .

• Include Airworthiness related requirements, processes and tasks explicitly in contractual documents.

• Do not bound air system delivery and specified certificates (TC/STC/AWC) in contractual documents.

(Define Flight Release Processes in the contracts to allow for limited or restricted flight operations if needed. )

Lessons Learned

Before the contract signature:

• Agree on AW Certification requirements and their MOCs. Changes are always possible!

• Agree on AW Certification evidences for Project Milestones (PDR, CDR, TRR, FTRR, etc.)

• Harmonize AW Certification Schedule with Project Schedule .

• Put contract provisions to ensure government access to the data.

Lessons Learned

• Use all Military and Civil supporting tools to reflect“best engineering practices” in the certification basis.

• Use Approved, Practical and Valid (follow NATO AWWG, EDA MAWA, USAF

TAA, NATO FINAS etc.!!) policy and processes.

C-130 AMP Targets

• STC and AW Certificate,

• 1 st Delivery and Serial Production Start,

at the end of 2013

Thank You…

Seçil AYDIN Certification Coordinator for C-130 E/B Modernization Program TURKEY Certification Coordinator for JSF Program Quality Test and Certification Department Ministry of National Defence-Undersecretariat for Defence Industries (SSM) Tel: +90 312 411 93 27 Fax: +90 312 411 93 86 e-mail: saydin@ssm.gov.tr