GOVERNMENT OF INDIA CIVIL AVIATION REQUIREMENTS
CIVIL AVIATION DEPARTMENT SECTION 2 - AIRWORTHINESS
SERIES 'A' PART IV
ISSUE I, DATED 28th AUGUST, 1996.
File No. 11/690/96-AI(2) EFFECTIVE : FORTHWITH
Subject: Airworthiness Regulation and Safety Oversight of
Engineering Activities of Operators.
1. OBJECTIVE:
1.1 Safety oversight of engineering activities of operator and
maintenance organisation is a function to ensure effective
implementation of the safety related airworthiness rules,
regulations and requirements contained in the various
National documents and Standards and Recommended Practices
and associated procedures contained in the ICAO Annexes to
the Convention and other related documents particularly
Annexes 1,6,8. The safety oversight airworthiness programme
is aimed to detect the weaknesses in the engineering
activities of the operators, maintenance and other related
organisations so that necessary corrective measures can be
taken in time before they become a potential safety hazard
and that the capability of the organisation to exercise
airworthiness control be maintained at or above the level
required by the regulations.
1.2 All maintenance work on aircraft engaged in public transport
operations shall be performed by approved organisations.
All work performed by an approved organisation shall be
regulated by its Quality Control Organisation which shall be
headed by an approved Quality Control Manager. The approved
organisations shall ensure that aircraft are maintained in
accordance with the specified approved procedures and the
maintenance work is done by licensed or approved persons.
1.3 Directorate General of Civil Aviation lays down the
standards and procedures for ensuring compliance with
various airworthiness requirements and continuous monitoring
of approved organisations. These requirements are aimed to
implement the standards and recommended practices laid down
in the ICAO Annexes 1, 6 and 8.
1.4 DGCA regional and sub-regional officers carry out
surveillance checks to ensure that the standards laid down
are enforced. The Regional and Sub-Regional offices give
feed-back to headquarters regarding any weaknesses in the
systems, and also suggested corrective actions. DGCA
headquarters, thereafter, takes necessary corrective action
under the Aircraft Rules/CAR to remove the system
deficiencies.
1.5 This Civil Aviation Requirement briefly outlines the salient
airworthiness requirements and the system under which the
airworthiness control and the safety oversight is required
to be exercised on the engineering activities by the
operators and the DGCA officers. The CAR is issued under
the provisions of Rule 133A of the Aircraft Rules, 1937 and
Section A of the Aircraft Act, 1934 for information,
guidance and compliance by the concerned agencies.
2. APPLICABILITY:
All Indian operators engaged in Scheduled air transport
services for carriage of passengers, mail or cargo and
maintenance organisations engaged in maintenance of aircraft
and approved in accordance with CAR Section 2 Series 'E'
shall comply with the requirements of this CAR. The
airworthiness oversight and safety requirements are equally
applicable to the operators of Non scheduled
(Passenger/Cargo) air transport service who should follow
the requirements as applicable, keeping in view the scope
and extent of their operations. For new organizations
seeking permission to commence operations or maintenance
activities, it shall be a prerequisite for grant of the
approval to furnish information confiming that they have
established the necessary system and have adequate qualified
manpower and infrastructure to implement the airworthiness
regulation and in-house oversight of their engineering
activities as stipulated in this CAR. Concerned DGCA
officers shall also exercise the safety oversight of
engineering activities of the organisations as described in
this CAR.
3. AIRWORTHINESS AND SAFETY REGULATION - OVERVIEW:
Various statutory/regulatory documents, namely the Aircraft
Act 1934, the Aircraft Rules 1937, Aeronautical Information
Publication (AIP), Civil Aviation Requirements (CAR),
Aeronautical Information Circular (AIC), stipulate the
safety and airworthiness requirements applicable to
different type of operations and maintenance activities,
which shall be complied with by the concerned organisation.
In addition implementation of the following salient
airworthiness and safety requirements shall be closely
monitored by the organisation and DGCA officers to enhance
safety of operations.
3.1 MAINTENANCE APPROVAL:
3.1.1 Rule 155A of the Aircraft Rules, 1937 requires that an
operator shall have access to an adequate organisation for
maintenance of aircraft. Rule 133B specifies the conditions
for approval of an organisation. Besides requirement of
maintenance organisation, in accordance with Rule 134 of the
Aircraft Rules, no person shall operate any air transport
service in India without obtaining the necessary permit for
operating such services. The operating permit shall be
maintained current and valid and the operations shall be
conducted within the scope and provisions of the permit.
3.1.2 The organisation shall demonstrate, before grant of the
approval/permit their capability to satisfactorily maintain
the aircraft and safely operate the air transport services
sought to be operated. It is the responsibility of the
operator to satisfy the DGCA that their maintenance support
arrangements are to a satisfactory standard. The operator
may have his own maintenance organisation approved by the
DGCA in accordance with Rule 133B or may contract his
maintenance work to another DGCA approved organisation. The
approved organisation shall have to have his own approved
maintenance programme, quality control and safety oversight
setup. It shall be ensured that the manpower,
infrastructure, facilities, systems and maintenance
operating capability does not degrade below the required
level at any time and is enhanced continuously commensurate
with expansion of activities.
3.1.3 In accordance with Rule 140 of the Aircraft Rules, 1937 all
operators shall comply with the stipulated engineering,
inspection manual and safety requirements to ensure that the
passenger and the aircraft are protected at an adequate
level of safety throughout the operation.
3.1.4 Leased Aircraft: The requirements for maintenance and safe
operation of foreign aircraft leased for operation by or on
behalf of Indian operators for public transport are laid
down in CAR Section 3, Series 'C' Part I under the provision
Rule 133A of the Aircraft Rules, 1937 and Section 5A of The
Aircraft Act, 1934.
3.2 MAXIMUM AGE FOR IMPORTANT OF AIRCRAFT:
3.2.1 The maximum permissible age and cycle flying hours of
aircraft for import into India Shall be in accordance with
CAR Section 2 Series 'F' Part XX and CAR Section 3 Series
'C'.
3.3 REGISTRATION OF AIRCRAFT:
In accordance with Rule 5 of the Aircraft Rules, 1937, no
person shall fly or assist in flying any aircraft unless it
has been registered in accordance with Rule 30 of the
Aircraft Rules, 1937. The procedure for registration is
detailed in CAR Section 2, Series 'F' Part I. Further, the
aircraft shall bear its nationality and registration marking
and the name and address of the owner affixed thereon in
accordance with Rule 37 of the Aircraft Rules, 1937.
3.4 AIRCRAFT TYPE CERTIFICATE:
3.4.1 To be eligible for issue of Indian Certificate of
Airworthiness (C of A), each aircraft either manufactured
in India or elsewhere shall conform to Type Design and shall
be in a condition for safe operation. In accordance with
Rule 49 of the Aircraft Rules, 1937 and CAR Section 2,
Series 'F' Part II, aircraft designed and manufactured in
India, shall be type certificated by DGCA, India. Aircraft
imported into India, must conform to Type Design under the
regulations of Federal Aviation Administration of USA (FAA),
European Airworthiness Consortium (JAA) or any other
authority acceptable to DGCA, India.
3.4.2 For cargo operations, tne aircraft shall be certified in
the category by the Airworthiness Authority of The Country
of eport manufacture and acceptable to DGCA.
3.4.3 The Aircraft proposed to be utilized by the operators shall
be fitted with all the mandatory instruments andequipments
and in accordance with the Type Certificate and such
equipment as specified in CAR Section2.
3.5 AIRWORTHINESS:
3.5.1 In Accordance with Rule 15 of the Aircraft Rules, 1937, no
aircraft registered in India shall be flown unless it has a
current and valid C of A issued/revalidated in accordance
with Rule 50 of the Aircraft Rules, 1937 unless it is flown
for the purpose of flight test for C of A renewal in the
close vicinity of the departing aerodrome. The procedure
for issue and revalidation of C of A is detailed in CAR
Section 2, Series 'F' Part III & IV.
3.5.2 All aircraft shall be maintained in a continuous state of
airworthiness and meet the applicable airworthiness
requirements including those relating to identification,
equipment, mandatory modification, applicable maintencnce
schedules, replacement of components when due, failing which
the C of A shall stand suspended or deemed to be suspended
in accordance with Rule 55 the Aicraft Rules, 1937 CAR
Section 2 Series 'F' Part V.
3.5.3 It shall be ensured by the operator that all instruments,
systems, equipment and accessories on board the aircraft are
serviceable unless these are covered under an approved
Minimum Equipment/Configuration Deviation List (MEL/CDL).
The MEL/CDL shall be prepared by the operator based on the
Master Minimum Equipment List and got approved by the DGCA
in accordance with CAR Section 2, Series 'B' Part I.
3.5.4 Maintenance support arrangements shall only be provided by
the organisations approved by the DGCA for the specific type
of work in accordance with CAR Section 2, Series 'E'. Such
arrangements shall be reflected in the Quality Control
manual of the operators.
3.5.5 The approved organisation shall provide, for the use and
guidance of its personnel, Engineering Organisation
mannual, Quality Control Manual, Maintenance System Manual,
which shall contain details of information concerning
policies, procedures, practices and quality control method
relating to activities of the operator and containing such
further information as may be specified by the DGCA.
3.5.6 The approved Maintenance Organisations shall maintain their
capability at or above the standard based on which initial
approval was accorded by the DGCA. To ensure that the
operator has continued capability to conduct engineering
functions commensurate with the scope of approval, the
Quality Control Division of the organisation shall carry out
detailed audit frequently and submit report to the concerned
office of the DGCA. The DGCA officers shall also conduct
frequent surveillance checks. Discrepancies detected must
be rectified forthwith, failing which approval of the firm
may be revoked.
3.5.7 The operaor shall submit the following information while
applying for renewal of approval of the Organisation.
a. continued compliance of applicable Aircraft Rules, CARs
and AICs.
b. In-house safety audit team reports highlighting the
discrepancies of the operator along with the action taken
report carried out within 60 days prior to expiry of the
validity of approval.
3.5.8 The operator shall maintain his aircraft in a continued
state of airworthiness and shall ensure that all maintenance
is being performed according to the approved maintenance
programme, methods, standards and techniques specified in
the Maintencance/Quality Control Manual. Detailed
requirements for maintenance, certification and continued
maintenance programme laid down in Rule 60 of the Aircraft
Rules, 1937 and CAR Section 2 Series 'F' Part III and IX
shall be complied with.
3.5.9 The approved organisation shall have the maintenance
programme of the aircraft approved prior to commencement of
operations. The operator can base his programme on the
manufacturers' Maintenance Planning Document (MPD) or any
DGCA approved programme and shall have adequate facilities
in terms of trained manpower, adequate inventory,
reliability monitoring system, shop facilities etc. The
maintenance programme once approved, shall be updated based
on DGCA/Manufacturers instructions, SBS, in service
experience etc.
3.6 OUALITY CONTROL:
3.6.1 The approved organisation shall have a full-fledged
Quality Control Department headed by a Quality Control
Manager assisted by Deputy Quality Control Manager(s) and
adequate mumber of trained technical officers.
3.6.2 The Quality Control department shall have dedicated cells
for:
a. delay, defect and engineering incident investigation
b. relibility analysis, engine performance monitoring and
component life control
c. compliance of servive bulletins and modifications,
maintenance of technical records, schedules, issue of
technical circulars and distribution of technical data.
3.6.3 The Quality Control cell shall have a proper system of
maintaining the records of each AME/approved authorised
person (including foreign AMEs, if employed) in order to
ensure that:
a. the licences are maintained current/valid.
b. the licences are endorsed for the type of aircraft;
c. authorsation/approvals are current/valid. For this
purpose a fool proof system of record keeping in proper
formats, preferably a computer based system, shall be
established and followed.
3.6.4 The operator shall ensure compliance of all applicable
Mandatory SBs/Mods and Airworthiness Directives and proper
record be maintained to show current status, repeat and
terminating actions.
3.6.5 The QC department shall ensure that all certifications are
executed by appropriately licenced/approved persons and
according to procedures specified in the approved Quality
Control Mannual.
3.6.6 The QC department shall ensure that carried forward defects
and deferred maintenance are properly attended in time.
3.6.7 QC department shall ensure that vendors hold DGCA approval.
3.6.8 The various allied/support shops shall comply with
regulations regarding cleanliness, approved schedules,
documents, calibration and adequacy of test benches and
availability of approved inspector-in-charge and sufficient
numnber of licensed/approved personnel, as applicable.
3.6.9 The QC cell shall associate with Flight Safety Department
to investigate engineering incidents & take such corrective
measures promptly as called for.
3.6.10 The storage facilities shall be adequate in terms of
protection of part, control of shelf life, storage
conditions etc.
3.6.11 Negative trends in the maintenance/inspection programme
noted during routine surveillance or by continuing
surveillance programme shall be immediately arrested and
action taken to reverse the trend. Examples of situations
indicating negative trends include increase in the
following:
- Aircraft delays
- Premature removal rates
- Number of engine shut down rates,
- Number of short term escalations,
- Deferred maintenance (MEL) items and length of time
they remain deferred.
- Repeat Pilot Reports etc.
3.6.12 The operator shall have a sound airworthiness performance
monitoring system. This function provides for collecting and
analysing operational and airworthiness data. This
monitoring is done through:-
a. Emergency responding which includes identifying critical
situations like in Flight Shut Down (IFSD), uncontained
engine failure, depressurization etc.
b Day to Day Monitoring: Scheduled operators shall conduct daily
meeting to discuss morning launch delays and activities of
the previous day. Other operators may conduct these
meetings at less frequent intervals.
c Long term monitoring: This system shall include appropriate
means of reporting and accounting operational and
airworthiness data at specified intervals to reveal trend
related information and take corrective action. Typical
example of the data used to monitor airworthiness
performance are:-
- Pilot reports complied ATA codewise.
- Inspection findings complied ATA codewise, Failure
rates compled ATA codewise.
- Tear down/strip reports
- Pre-mature removal rate (Including engine)
- Engine shut down rate
- Deferred items (MEL)
- Mechanical Defect summeries.
- Mechanical Reliability Reports.
3.7 ENGINEERING PERSONNEL:
3.7.1 In accordance with Rule 54 of the Aircraft Rules, 1937,
all manufacturing/maintenance work performed on civil
registered aircraft shall be carried out and certified by
appropriately licensed AMEs and/or authorised/approved
persons. The operator shall have sufficient number of AMEs
holding licences issued by DGCA in various categories in
accordance with Rule 61 of the Aircraft Rules, 1937 and CAR
Section 2 Series 'L' Part I. The engineers should be
supported by sufficient number of trained experienced
technicians in each trade. However, DGCA may allow
appropriately qualified/licenced foreign engineers to carry
out and certify maintenance work of Indian registered
aircraft to enable engineers of the operator to acquire
necessary maintenance experience and licence.
3.7.2 An operator employing any foreign AME shall obtain for him
the required security clearance through DGCA before the AME
is scheduled for maintenance work. The AME should also be
given thorough familiarisation about Indian rules,
regulations, CARs, operators' control manual and facilities
avaiable at bases and enroute stations. After the Quality
Control Manager is satisfied with and has certified, the
foreign AME has to pass an oral check by a DGCA board in
accordance with AIC 17 of 1994 and then only the AME will be
authorised to certify the aircraft.
3.7.3 An operator employing appropriately licenced AME from any
other domestic airlines shall familiarise him with
differences in the aircraft in their fleet if any, and the
QC Manual/Procedure. The AME shall be deputed for
inspection certification work only after he has passed an
oral check conducted by DGCA board as per AIC 17 of 1994.
3.7.4 Where the AMEs are required to be trained on a particular
type of aircraft, the operator shall get the training
programme approved along with the names of AMEs.
3.7.5 Revoke of licence/approvals:
In accordance with Rule 61 of the Aircraft Rules, 1937, any
licence, authorisation, approval or Certificate of
Competency may be cancelled, suspended or endorsed, if the
holder has not performed the work in a careful and competent
manner or the holder has signed for work not licenced to
deal with or it is undesirable that the holder should
continue to exercise his privileges granted under this rule.
3.8. LITERATURE:
3.8.1 The Q.C Manual maintenance System Manual,
Maintenance/Overhaul/Structural Manuals, Illustrated Parts
Catalog, Wiring Manual, Service Bulletins, Airworthiness
Directives and related guidance materials shall be kept and
amended to keep them upto date by the Q.C. department. The
operator shall remain on the mailing list of the
manufacturers and Airworthiness Authorities of country of
manufacture of aircraft, engine and equipment installed
thereon for the purpose of receiving SBs, ADs and regular
amendments to the various documents.
3.8.2 A master folder of each type of regulatory/policy
document viz. CARs, AICs, Airworthiness Advisory Circulars,
SBs etc. shall be maintained by the QC Office for reference
of QC personnel and AMEs. All publications, documents,
maintenance schedules, forms shall be frequently screened
for completeness.
3.9 A master copy of approved maintenance shedules/Special
Inspection shcedules shall be kept in the QC Department.
Whenever a new inspection item or routine functional check
of any component is introduced, it should be immediately
included in the relevant maintenance schedule so that it
could be carried out at the required periodicity. There
shall be a check for completed inspection schedules to
ensure that all items of inspection are duly certified and
carried out.
3.10 The QC department shalkl maintain up to date Mandatory
Modification list in respect of each type of aircraft,
engine, system operated alongwith the applicability and
compliance status.
3.11 Major repairs/Modification shall be accomplished with
approved drawing and by approved persons as envisaged in
Rule 52 the Aircraft rules, 1937.
3.12 GENERAL:
3.12.1 The operator shall have his own facilities for replay of
Cockpit Voice Recorder. For readout of FDR/DFDR he should
have his own facilities or make approved arrangement
acceptable to DGCA.
3.12.2 The operator shall have necessary technical literatue
tools, special tools, appropriately licensed AMEs, battery
cart/GPU, trestles, jacks, trained manpower etc. for
carrying out the required maintenance.
3.12.3 The operator shall have facilities and approved persons or
satisfactory arrangements with DGCA approved firm to carry
out additional structural inspection of aging aircraft to
keep them in a continued state of airworthiness.
3.12.4 The operator engaged in operations with twin engined
aircraft shall ensure compliance of the requirement relating
to etop operations.
3.12.5 Before commencing operations to a new station or
establishing a night halt station, the Q.C. Manager shall
carry out and ensure that all facilities as envisaged in CAR
Section 3, Series 'E' Part I and Section 2, Series 'E' Part
IX are available. A certificate to that effect shall be
forwarded to the concerned Regional Airworthiness Office by
the Q.C. Manager.
3.12.6 The operator shall have a system of frequent exchange of
information between Operations and Engineering Department to
improve co-ordination and understanding of operational and
airworthiness matters. A record of such discussions shall
be maintained.
3.13 The DGCA issues Airworthiness Advisory Circulars, Air Safety
Circulars Bulletins to the industry for guidance and advice
in order to enhance safety of aircraft operations. The
orgnaisations shall go through these materials and take
action wherever required.
3.14 The operator has to arrange or conduct training whenever a
new aircraft type is inducted or new AMEs are recruited.
The organisation must, therefore, have the training
programme approved and ensure its compliance.
3.15 The DGCA conducts AME licence examination periodically. All
organisations shall, therefore, train their maintenance
personnel and have them appear in the said examinations, so
as to ensure sufficient qualified AMEs on their employment.
4. IMPLEMENTATION OF AIRWORTHINESS OVERSIGHT PROGRAMME:
Effective safety regulation and oversight of airworthiness
functions can be achieved only by joint efforts on the part
of the operators, maintenance organisations and the
regulatory authority. It is, therefore, essential that in
addition to the airworthiness programme of the DGCA, the
operators and maintenance organisations should also have
their in-house surveillance programme commensurate with the
type and scale of their operations activities.
Broadly, the surveillance programme may be conducted on the
following lines:
4.1 The operators and maintenance organisatons shall lay down
their policies and procedures for compliance of the
airworthiness, safety, training and internal safety audit
programme in their engineering procedures and training
manuals. The responsibility of implementation of the
policies and procedures contained in these manuals shall be
assigned and division of responsibility for this purpose
shall be clearly reflected in the relevant manuals.
4.2 The day-to-day safety regulation and in-house monitoring of
the airworthiness functions of the operator and the
maintenance organisations shall be exercised by the Quality
Control Manager and by his inspectors and dedicated staff.
Necessary check lists should be devised for carrying out
such monitoring. There shall be a proper system of
documentation and record keeping of the deficiencies
observed and corrective measures taken.
4.3 In addition to the day-to-day monitoring, periodic in-house
safety audit shall be carried out by the dedicated safety
audit team of the operator and the maintenance organisations
to ensure that the airworthiness safety regulations are
complied with. Corrective action shall be taken immediately
by the Chief of Flight Safety in consultation with the
Quality Control Manager on the deficiencies observed during
the audit. Relevant record and data in proper format shall
be maintained in this regard.
4.4 In order to discharge the responsibility for safety oversight
in accordance with ICAO Annex 6, Aircraft Act, 1934,
Aircraft Rules, 1937, and the CARs made thereunder,
surveillance of all airworthiness and safety functions
including training, shall also be carried out by the DGCA
officers viz. officers of the Regional and Subregional
Airworthiness offices directly supervising the activities of
the organisations working in their area of control.
Deficiencies observed shall be intimated to the operator
concerned for immediate corrective action. Director of
Airworthiness (DAW) of the region concerned shall ensure
that necessary actions are taken on the observations made.
4.5 The DGCA safety audit teams or other nominated officers shall
carry out safety audit or special checks of the operators
and the maintenance organisation periodically. The
deficiencies observed by the team during the audit shall be
brought to the notice of the concerned organisation for
prompt corrective action. The DAW in the DGCA Headquarters
shall take appropriate measures to ensure that necessary
actions are taken by the operator or the maintenance
organisation to remove the deficiencies and to implement the
safety recommendations. Where punitive action is required
to be taken for serious lapses, the DAW (Hdqrs.) shall
initiate the same promptly.
5. INDUSTRY CONSULATATION AND REVIEW OF IMPLEMENTATION OF THE
AIRWORTHINESS REGULATION AND OVERSIGHT PROGRAMME:
Review of implementation of the airworthiness regulation and
oversight programme shall be carried out as and when
required by the DGCA Headquarters jointly with the operator
and maintenance organisations to asses functioning and
effectiveness of the programmes. The DAW (Hdqrs.) shall co-
ordinate the review. This would also provide an opportunity
to the organisations to learn from the experience of others
and to improve their own systems. During the review, it
would also be assessed whether the national rules,
regulations, procedures and requirements are adequate and
effective in the implementation of the relevant ICAO
Standards and Recommended Practices and if found necessary,
appropriate amendaments would be suggested.
(H. S. KHOLA)
DIRECTOR GENERAL OF CIVIL AVIATION