Aviation Australia Major Defects PDF

Major Defects Introduction to Major Defects A major defect is described as a defect that has caused, or that could cause: A primary structural failure A control system failure An engine structural failure A fire in an aircraft. CASA stat...

Major Defects Introduction to Major Defects A major defect is described as a defect that has caused, or that could cause: A primary structural failure A control system failure An engine structural failure A fire in an aircraft. CASA states that if a person connected to the operation or the carrying out of maintenance discovers a major defect in the aircraft, the person must report the defect to the Certificate of Registration (CofR) holder and to CASA. If a person discovers a defect in an aircraft in the course of complying with an AD, the person must report the defect to CASA. A person must not prevent another person from reporting a major defect. © Aviation Australia CASA Online Defect Reporting Portal Link to the CASA Defect Reporting Service (DRS). 2024-10-01 B-10c Aviation Legislation Page 300 of 328 CASA Part 66 - Training Materials Only  Major Defect Reporting Part 42 covers major defects that are discovered by an AMO during maintenance of an aeronautical product when the existence of the major defect was not apparent prior to the aeronautical product being removed from an aircraft. It is not applicable to an AMO that is carrying out maintenance on, or an investigation of, an aeronautical product that has a known defect on behalf of a CAMO or operator. In addition to the requirement to report the major defect to CASA, if an AMO knows the identity of the owner and/or previous user of the aeronautical product, then the AMO should also report the defect to the owner and/or previous user. Part 145 covers major defect reporting by an AMO. An acceptable internal occurrence reporting system will enable free and open reporting of potentially unsafe occurrences. This will establish a just culture, which will ensure that employees are not inappropriately punished for reporting or for co-operating with occurrence investigations. Conditions under which punitive disciplinary action is considered (e.g. illegal activity, negligence or wilful misconduct) are clearly defined and documented. The functionality of the just reporting culture policy will be widely disseminated and understood within the organisation, and documentation of the reporting and investigation process will confirm the effectiveness of its application. The acceptable internal reporting process will be a closed loop, ensuring that actions are taken internally to address maintenance errors and safety hazards. Feedback to reporters, on both an individual and a more general basis, ensures their continued support for the scheme. 2024-10-01 B-10c Aviation Legislation Page 301 of 328 CASA Part 66 - Training Materials Only  CASA defect report form Major Defect Reporting Procedures An acceptable means of compliance for the requirements of major defect reporting is that the reports submitted to the Registered Operators (ROs) or CASA must state the following details: Describe the defect The date on which the defect was discovered The circumstances under which the defect was discovered The action that has been taken or that is proposed to be taken: To rectify the defect, or To prevent the defect from recurring A description of what the person making the report considers the cause of the defect. 2024-10-01 B-10c Aviation Legislation Page 302 of 328 CASA Part 66 - Training Materials Only  If the defect is in an aircraft, the following information is required: The type, model, serial number and registration mark of the aircraft The type, model and serial number of the aircraft’s engine, if relevant If the aircraft has a propeller, the type, model and serial number of the aircraft’s propeller, if relevant to the defect, and Time in service of, number of landings or number of cycles completed by the aircraft since new. If the defect is in an aeronautical product, the following information is required: The identity of the product, including (if applicable) the part number and serial number of the product Time in service or the number of cycles completed by the product since new If the product has been overhauled, the time in service or the number of cycles completed by the product since its most recent overhaul, and If the product is a turbine engine, the number of cycles completed by the engine since new. A Part 145 AMO may use the internal occurrence reporting system to identify and report any major defect maintained by the AMO in accordance with Part 42. The AMO must submit major defect reports to CASA within two days. CASA states that the person must take reasonable steps to ensure the defective item is kept in a state that will allow CASA to investigate the defect. CASA may give notice that the aircraft, part of the aircraft or the aircraft component is no longer required to be kept. Defective items are normally kept for a period of one year from the day on which the defect was reported to CASA unless CASA gives notice. An authorised person may investigate any matter connected with any defect in an Australian aircraft, including testing an aircraft or any aircraft component installed or provided in an aircraft. CASA may request and hold any document or component during the investigation. 2024-10-01 B-10c Aviation Legislation Page 303 of 328 CASA Part 66 - Training Materials Only  Damaged undercarriage 2024-10-01 B-10c Aviation Legislation Page 304 of 328 CASA Part 66 - Training Materials Only  Flight Tests Introduction to Flight Tests Flight test means the process of developing and gathering data during operation and flight of an aircraft and then analysing that data to evaluate the flight characteristics of the aircraft. It does not mean a practical test of a person’s knowledge and practical flying skill. Definitions Certification Flight Testing means flight tests conducted for the purpose of demonstrating, or verifying, compliance with the applicable airworthiness standard. Production Flight Testing means flight tests conducted for the purpose of ensuring each individual aircraft conforms to its Type Design and is in a condition for safe operation. Experimental/Developmental Flight Testing involves flight tests conducted for the purpose of defining or expanding an aircraft’s flight envelope. CASA has powers to permit operation of an aircraft that may not meet airworthiness requirements. The legislation requires that permission is given only if there is a reasonable expectation that an aircraft will be capable of safe flight for the intended purpose. Flight Test After Modification Australian aircraft are often subject to modification. Modifications that may have flight type implications include any that influence the performance or handling characteristics of the aircraft, any systems change that may affect aircraft operation or have consequences for the pilot and crew, and anything that requires amendment to the Aircraft Flight Manual. Such changes to an aircraft will require flight testing to ensure continued safety and certification compliance. 2024-10-01 B-10c Aviation Legislation Page 305 of 328 CASA Part 66 - Training Materials Only  Flight Test Assessments Flight test assessments take place in areas which include, but are not limited to, the following: Aircraft performance: comprises stall speed measurement, climb rates and gradients, cruise range and endurance, descent or glide rates and gradients, and take-off and landing distances. For rotary wing aircraft, hover and autorotation capabilities are included. Flight handling: qualities include stability, controllability and manoeuvrability, trim, and stalling and spinning characteristics. Aircraft systems: includes piloting and operational features of aircraft controls, systems and avionics, the Human-Machine Interface (HMI). Assessment of aircraft instrumentation and independent test instrumentation used during flight testing is also included. Human factors: includes ergonomic, workload and operational environment aspects. 2024-10-01 B-10c Aviation Legislation Page 306 of 328 CASA Part 66 - Training Materials Only  Extended Diversion Time Operation Introduction to Extended Diversion Time Operation Extended-range Twin-engine Operations Performance Standards (EDTO, previously ETOPS) covers aircraft fitted with all types of engines. In simple terms, EDTO/ETOPS approval allows airlines to operate over a route that contains a point farther than one hour’s flying time from an adequate airport at the approved one-engine inoperative cruise speed for twin-engined aircraft and 180 minutes for four-engined aircraft, regardless of whether such airports are separated by water or land. ETOPS began in the piston-engine aircraft era 2024-10-01 B-10c Aviation Legislation Page 307 of 328 CASA Part 66 - Training Materials Only  EDTO Flights The operator’s EDTO flights are conducted in accordance with the aircraft manufacturer’s approved standards for EDTO. These standards present aircraft design, configuration, maintenance tasks, crew procedures and dispatch limitations for EDTO. There are certain operational criteria: 60 minutes to 120 minutes, and 120 minutes to 180 minutes. ETOPS 240 and beyond are now permitted on a case-by-case basis. Aviation Australia 60 minutes non-EDTO route 2024-10-01 B-10c Aviation Legislation Page 308 of 328 CASA Part 66 - Training Materials Only  Aviation Australia Enlarged area of operation eliminating dog leg tracking EDTO Approval An Australian aircraft can operate over an extended range, but it must meet EDTO configuration standards and be issued the following: Type Certificate issued by the NAA in the country of manufacture CASA Type Acceptance Certificate EDTO Configuration, Maintenance and Procedures Manual (CMP) The CMP is a document that contains the configuration minimum requirements for each approved aircraft, including: Special inspections Hardware life limits Minimum Equipment List (MEL) constraints Maintenance practices found necessary by CASA to establish the suitability of an airframe- engine combination for extended range operation. 2024-10-01 B-10c Aviation Legislation Page 309 of 328 CASA Part 66 - Training Materials Only  EDTO Maintenance Procedures Maintenance procedures were created to ensure the safety and reliability of EDTO flights, including: Engine condition monitoring Oil consumption monitoring EDTO pre-flight checks Verification procedures Task identification Training and documentation Operator reporting requirements. Identical maintenance must not be undertaken at the same maintenance visit on multiple similar elements in EDTO-significant systems without certain precautions being taken. EDTO-related tasks should be identified on the operator’s routine work documentation and related instructions. EDTO-related procedures, such as the involvement of centralised maintenance control, should be clearly defined in the CAMO’s maintenance program. An EDTO service check should be developed to verify that the status of the aircraft and certain critical items are acceptable. This check should be accomplished and signed off by an EDTO-qualified maintenance engineer immediately prior to an EDTO flight. The Technical Log should be reviewed and documented as appropriate to ensure that: Proper MEL procedures have been followed Deferred items have been carried forward and maintenance checks have been carried out System verification procedures have been properly performed. Rectification of Aircraft Defects A verification program or procedures must be established to ensure corrective action following an: Engine shutdown Primary system failure and adverse trends Any prescribed events which require a verification flight or other action and establish means to assure their accomplishment. 2024-10-01 B-10c Aviation Legislation Page 310 of 328 CASA Part 66 - Training Materials Only  EDTO-Significant Systems Aircraft systems critical to safety over extended ranges have been classified, for approval purposes, as EDTO-significant systems. EDTO-significant systems are the aircraft’s propulsion systems and any other aircraft systems whose failure or malfunction could adversely affect the safety of an EDTO flight, or whose functioning is specifically important to continued safe flight and landing during an EDTO aircraft diversion. Bernie Lagas EDTO significant systems Also, systems that may affect the proper functioning of the engines to the extent that it could result in an in-flight shutdown or uncommanded loss of power. Some of these systems include, but are not limited to: Hydraulic Pneumatic Ice protection Cargo fire protection Fuel systems Engine indicating systems Engine controls Fire detection systems. 2024-10-01 B-10c Aviation Legislation Page 311 of 328 CASA Part 66 - Training Materials Only  Fire detection elements 2024-10-01 B-10c Aviation Legislation Page 312 of 328 CASA Part 66 - Training Materials Only  EDTO Reliability Program The program should be designed with early identification and prevention of EDTO-related problems as the primary goal. The program should be event-oriented and incorporate reporting procedures for significant events detrimental to EDTO flights with the following items: In-flight shutdowns Diversions or turnbacks Uncommanded power changes or surges Inability to control the engine or obtain desired power Problems with systems critical to EDTO Any other event detrimental to EDTO Digital fuel system 2024-10-01 B-10c Aviation Legislation Page 313 of 328 CASA Part 66 - Training Materials Only  EDTO Maintenance Training Maintenance training should focus on the special nature of EDTO: This program should be included in the normal maintenance training program. The goal of this program is to ensure that all personnel involved in EDTO are provided the necessary training so that the EDTO maintenance tasks are properly accomplished, and to emphasise the special nature of EDTO maintenance requirements. EDTO maintenance training EDTO Parts Control The operator should develop a parts control program that ensures the correct parts and configuration are maintained for EDTO. 2024-10-01 B-10c Aviation Legislation Page 314 of 328 CASA Part 66 - Training Materials Only  Weather Operations Introduction to Weather Operations Issues such as All-Weather Operations (AWO), Reduced Vertical Separation Minima (RVSM), etc, are operational issues, not used by all organisations. They do, however, have specific maintenance requirements in order to maintain their accuracy. As such, any of these maintenance requirements must be included in the Maintenance Program. AWO refers to the requirements for Instrument Landing Systems (ILS) and requires both airborne and ground-based equipment to be installed. Procedures must ensure that aircraft low-visibility status is downgraded if maintenance was carried out by a person not adequately trained, qualified and authorised. All weather operations (AWOPS) The objective of AWO is to provide a level of safety when landing in low-visibility conditions, equivalent to that of ‘normal’ operating conditions. Category II and Category III constitute the main part of AWO. The system also consists of Category I, which includes landing and taxiing in low-visibility conditions. Although ICAO, CASA, FAA and EU regulations are slightly different, all refer to the same concepts for Category II and Category III operations. The main difference between Category II and Category III operations is that Category II provides sufficient visual reference to permit a manual landing at Decision Height (DH). Category III does not provide sufficient visual references and requires an automatic landing system. 2024-10-01 B-10c Aviation Legislation Page 315 of 328 CASA Part 66 - Training Materials Only  DH is a specified altitude in the precision approach at which a missed approach must be initiated if the required visual reference to continue the approach has not been established. Approach path: decision height Category I A Category I operation is a precision approach operation with a DH lower than 200 ft, but not lower than 150 ft, and a Runway Visual Range (RVR) not less than 1480 ft. 2024-10-01 B-10c Aviation Legislation Page 316 of 328 CASA Part 66 - Training Materials Only  Category II Category II includes supplementary airworthiness requirements for the performance of ILS precision approaches with DHs below 200 ft, down to 100 ft. An aircraft with basic airworthiness approval for Instrument Flight Rules operation is eligible to perform ILS precision approaches down to a decision height of 60 m (200 ft). This is assuming that the necessary airfield ILS receiver(s) and instruments and their installation are operational and have been approved. Category II Category III Category III supplementary airworthiness requirements regulate the performance of ILS precision approaches with DHs below 100 ft or with no DH. 2024-10-01 B-10c Aviation Legislation Page 317 of 328 CASA Part 66 - Training Materials Only  Maintenance Requirements Maintenance should include: Confirmed defect with corrective action carried out Unconfirmed defect but with corrective action Aircraft dispatch under MEL conditions Unable to correct defect and not under MEL conditions Unable to perform the required test. Procedures must ensure that aircraft low-visibility status is downgraded if maintenance was carried out by a person other than one who is trained, qualified and authorised. The dispatch status of the aircraft must be recorded in the aircraft’s Technical Logbook with reference to the MEL (if any): Rectified defects should be cleared accordingly Revalidation of the aircraft’s AWO status must be carried out. After an adjustment or a repair is made on the system, a revalidation of the aircraft should be made by the corresponding AMM ground test. For example, if an autopilot computer is replaced and its functions must be tested, then the entire auto-land system must also be tested. A prominent placard should be displayed on the aircraft, denoting the current aircraft status. Approved aircraft maintenance planning document 2024-10-01 B-10c Aviation Legislation Page 318 of 328 CASA Part 66 - Training Materials Only  The operator must have the CASA-approved Aircraft Maintenance Planning Document (MPD) in place, which is necessary for supporting AWO. Any operator wishing to conduct auto-land operations – whether for low-visibility operations or normal – will require CASA approval. CASA requires an assessment of the following matters: Aircraft certification and equipment Continuing airworthiness and maintenance procedures Demonstration of achievement of required accuracy Internal reporting system of results of auto-lands Crew and maintenance training and procedures Qualification, recency and standards of aircraft and engineering flight crews Operations Manual material. 2024-10-01 B-10c Aviation Legislation Page 319 of 328 CASA Part 66 - Training Materials Only  CASA Dictionary Learning Objectives 10.8 Module 10c CASA dictionary terms (S). 2024-10-01 B-10c Aviation Legislation Page 320 of 328 CASA Part 66 - Training Materials Only  CASA Dictionary Glossary Act Act means the Civil Aviation Act 1988. Aerobatic Manoeuvres Aerobatic manoeuvres, for an aircraft, means manoeuvres of the aircraft that involve: Bank angles that are greater than 60°, or Pitch angles that are greater than 45° or are otherwise abnormal to the aircraft type, or Abrupt changes of speed, direction, angle of bank or angle of pitch. Airborne Collision Avoidance System Airborne Collision Avoidance System means a system fitted to an aircraft to provide information to its pilot for avoiding collisions with other aircraft. Aircraft Engineer Licence Aircraft Engineer Licence means any of the following licences granted under Regulation 66.025 or 66.026: Subcategory A1 Subcategory A2 Subcategory A3 Subcategory A Subcategory B1. Subcategory B1.2 Subcategory B1.3 Subcategory B1.4 Category B2 Category C. 2024-10-01 B-10c Aviation Legislation Page 321 of 328 CASA Part 66 - Training Materials Only  Aircraft Registration Identification Plate Aircraft registration identification plate: see Regulation 45.010. Airship Airship means a powered, lighter‑than‑air aircraft. Amateur Built Aircraft Acceptance Amateur Built Aircraft Acceptance (ABAA) means a document given by CASA or an authorised person as a type approval for an amateur‑built aircraft. APMA APMA means Australian Parts Manufacturer Approval. Appliance Appliance means any instrument, mechanism, equipment, part, apparatus, appurtenance, or accessory, including communication equipment, that is used or intended to be used in operating or controlling an aircraft in flight, is installed in or attached to the aircraft and is not part of an airframe, engine or propeller. Approved Approved means approved by CASA. 2024-10-01 B-10c Aviation Legislation Page 322 of 328 CASA Part 66 - Training Materials Only  Authorised Instrument Approach Procedure Authorised instrument approach procedure, for an aerodrome in Australian territory, means an instrument approach procedure that is: Designed by a certified designer or authorised designer and published in the AIP or given to CASA under Part 173, or Prescribed by an instrument issued under Regulation 201.025 for this paragraph. For an aerodrome in a foreign country, an instrument approach procedure is authorised by the national aviation authority of the country. For an aerodrome in Australian territory, an authorised instrument departure procedure means an instrument departure procedure that is: Designed by a certified designer or authorised designer and published in the AIP or given to CASA under Part 173, or Prescribed by an instrument issued under Regulation 201.025 for this paragraph. For an aerodrome in a foreign country an instrument departure procedure is authorised by the national aviation authority of the country. CAR CAR means the Civil Aviation Regulations 1988. CASR CASR means the Civil Aviation Safety Regulations 1998. Category Category, in relation to the type certification of aircraft, means a grouping of aircraft based upon intended use and operating limitations (for example, Transport, Normal, Utility, Acrobatic, Limited, Restricted and Provisional). Certificate of Airworthiness Certificate of Airworthiness means a Standard Certificate of Airworthiness or a Special Certificate of Airworthiness. 2024-10-01 B-10c Aviation Legislation Page 323 of 328 CASA Part 66 - Training Materials Only  European Aviation Safety Agency European Aviation Safety Agency (EASA) means the European Aviation Safety Agency established by Regulation (EC) No. 1592/2002 of the European Parliament and the Council of the European Union. Export Airworthiness Approval Export airworthiness approval means: For a Class I product: An export certificate of airworthiness or an authorised release certificate For a Class II or Class III product: An authorised release certificate. Federal Aviation Regulations FARs means the Federal Aviation Regulations in Chapter 1 (Federal Aviation Administration, Department of Transportation) of Title 14 of the Code of Federal Regulations as published by the Office of the Federal Register National Archives and Records Administration of the United States of America. Foreign Air Transport AOC Foreign air transport AOC means an AOC that authorises the operation of an aircraft for a foreign air transport operation. Foreign Air Transport Operation Foreign air transport operation means an air transport operation that is conducted by a foreign operator using any aircraft for: A flight into or out of Australian territory, or A flight wholly within Australia that is undertaken as part of a flight into or out of Australian territory. It does not include the following: The operation of an aeroplane or rotorcraft under a permission under Section 25 (non‑scheduled flights by foreign registered aircraft) or Section 27A (permission for operation of foreign registered aircraft without AOC) of the Act. An air transport operation authorised by a New Zealand AOC with ANZA privileges that is in force for Australia. 2024-10-01 B-10c Aviation Legislation Page 324 of 328 CASA Part 66 - Training Materials Only  Foreign Air Transport Operator Foreign air transport operator means a person who holds a foreign air transport AOC. Foreign certificate, for a foreign operator, means an air operator certificate issued by the national aviation authority of the foreign country in which the foreign operator has its principal place of business or place of permanent residence. Foreign Operator Foreign operator means an operator that is not an Australian operator. Foreign Supplemental Type Certificate Foreign supplemental type certificate: see Regulation 21.114. Foreign type certification basis, for an aircraft, aircraft engine or propeller, means the airworthiness standards and any special conditions or other conditions with which the aircraft, aircraft engine or propeller must comply for the issue of a foreign type certificate. Human Factors Principles Human factors principles mean principles concerned with the minimisation of human error and its consequences by optimising the relationships within systems between people, activities and equipment. Licensed Aircraft Maintenance Engineer Licensed aircraft maintenance engineer (LAME) means an individual who holds an aircraft engineer licence that is in force. Low‑Visibility Approach Low‑visibility approach means an approach using minima for a runway that are below the Category I precision approach minima for the runway published in the AIP. Low‑Visibility Operation Low‑visibility operation means: A low‑visibility take‑off, or A low‑visibility approach. 2024-10-01 B-10c Aviation Legislation Page 325 of 328 CASA Part 66 - Training Materials Only  Low‑Visibility Take‑Off Low‑visibility take‑off means a take‑off with a runway visual range of less than 550 m. Major Defect Major defect means: In relation to an aeronautical product that is not fitted to an aircraft: a defect of such a kind that the aeronautical product, if fitted to an aircraft, may affect the safety of the aircraft or cause the aircraft to become a danger to persons or property; and In relation to an aircraft: a defect of such a kind that it may affect the safety of the aircraft or cause the aircraft to become a danger to persons or property. Minimum Equipment List Minimum Equipment List (MEL), for an aircraft, means a list of each defect in the aircraft that is approved as a permissible unserviceability under Regulation 37 of CAR. Model Model, for an aircraft, aircraft engine or propeller, means a particular version of a type of aircraft, aircraft engine or propeller that is distinguished from another version of the same type by a change of sufficient effect on the weight, balance, structural strength or operational characteristics that requires a separate entry on a Type Certificate, identifying and approving the particular version as distinct from the identification and approval of other versions. National Aviation Authority National aviation authority, for a foreign country, means: Means the authority that is responsible for regulating civil aviation in the country, and Includes the national airworthiness authority for the country, and If EASA carries out functions on behalf of the country: EASA, and For China, for matters relating to Hong Kong: the Civil Aviation Department of Hong Kong. Operator Operator, of an aircraft, means: If the operation of the aircraft is authorised by an AOC – the holder of the AOC, or If the operation of the aircraft is not authorised by an AOC – the person, organisation or enterprise that makes the aircraft available to the aircraft’s pilot in command for a flight. 2024-10-01 B-10c Aviation Legislation Page 326 of 328 CASA Part 66 - Training Materials Only  Pilot‑Owner Pilot‑owner, of an aircraft, means an individual who: Owns the aircraft, and Is authorised, under Part 61, to fly the aircraft otherwise, chiefly from aerodynamic reactions on surfaces, remaining fixed under given conditions of flight. Registration Holder Registration Holder of an aircraft means the person whose name is entered in the Australian Civil Aircraft Register as that of the aircraft’s owner. Standard Part Standard part means a part that complies with a specification that is established, published and maintained by: An organisation that sets consensus standards for products, or A government agency, and includes: Design, manufacturing, test and acceptance criteria, and Requirements for the uniform identification of the part. State of Registry State of registry, for a foreign registered aircraft, means the foreign country on whose register the aircraft is entered. Time in Service Time in service means: For an aircraft, each period starting when the aircraft takes off for a flight and ending when the aircraft lands at the end of the flight; and For an aircraft engine or propeller that is fitted to an aircraft, each period starting when the aircraft takes off for a flight and ending when the aircraft lands at the end of the flight. Type Type, for an aircraft, aircraft engine or propeller, means a design and make of aircraft, aircraft engine or propeller and, where appropriate, refers to a group of essentially similar aircraft, aircraft engines or propellers which, although possibly existing in different models, stem from a common basic design. 2024-10-01 B-10c Aviation Legislation Page 327 of 328 CASA Part 66 - Training Materials Only  Type-Certificated Type-certificated means issued a Type Certificate or Type Acceptance Certificate. Type Certificate Data Sheet Type Certificate data sheet means a sheet attached to a Type Certificate for an aircraft, aircraft engine or propeller that sets out the limitations prescribed by the applicable airworthiness requirements for the aircraft, aircraft engine or propeller, and any other limitations and information necessary for type certification of the aircraft, aircraft engine or propeller. Type Certification Basis Type certification basis, for an aircraft, aircraft engine or propeller, means the airworthiness standards and any special conditions or other conditions with which the aircraft, aircraft engine or propeller must comply for the issue of a Type Certificate. 2024-10-01 B-10c Aviation Legislation Page 328 of 328 CASA Part 66 - Training Materials Only