AirworthinessBrief N0042123R0002 Industry Day.pdf


Original Source
Contract Opportunity
Dec. 19, 2022



CAS Aircraft Airworthiness
CAS Aircraft Airworthiness

08 September 2022

Presented to:
N00421-23-R-0002 Industry Day

MCAS Cherry Point

Presented by:
Doug Sherline

CAS Class Desk

What is a NAVAIR IFC?

A formal document that provides assurance of

airworthiness & safety of flight and ensures risk
has been identified, mitigated and/or accepted at
the appropriate level, within acceptable bounds
for the intended mission

Flight clearances provide flight / operating
limitations and/or restrictions for specific
configurations and store loadings.
Does not account for every applicable limit or

Does not replace good headwork or common sense


by the pilot / aircrew

Flight Plan

How do I get a Navy Flight Clearance?

PAO Assessment / Determination
Physical Configuration Audit
Interim Flight Clearance

Flight Clearance Data Requirements
Wiring Assessment
EMC SOFT and RADHAZ testing

Continuing Airworthiness

How do I get a NAVY Flight Clearance?

Five primary elements of the USN Flight Clearance

Public Aircraft Operations (PAO) Assessment/Determination and


Physical Configuration Audit (PCA)
Interim Flight Clearance (IFC)
Continuing Airworthiness (AW)


Contains but not limited to the following:

Service being provided
Whos in the binding agreement with the


How Continuing Airworthiness oversight is

being provided
Government Furnished Equipment (GFE) list

PAO Assessment / Determination (1 of 3)

Public aircraft flights or flights of civil aircraft

conducted for a public entity where:
- Flight(s) cannot be conducted fully within 14 CFR
- Public Entity becomes Airworthiness Authority

Examples of PAO missions:

Mission is outside of FAA approved Operating Limits

(e.g. Adversary Fighter or AAR)

Mission is in support of an inherently military

requirement (e.g. Transport of Explosives, Dropping
of Ordnance, Launching Targets, Electronic Attack
(EA) / Electronic Warfare (EW), etc.)

40102(a) Legislative definition of Civil and Public
40125 Legislative qualifications for Public aircraft status

PAO Assessment / Determination (2 of 3)

It is the civil operators responsibility to operate their aircraft in

accordance with 14 CFR

If operations are required outside of 14 CFR, the contractor should
refuse to operate and notify the requesting agency to provide a
PAO declaration



Determination on a flight by flight basis
NAVAIR IFC is required for any DON PAO
Details regarding contracted configuration, mission, usage and pre-
existing FAA certificates can make PAO determinations complicated

PAO Assessment / Determination (3 of 3)

PMA-226, Airworthiness and CYBERSAFE Office (ACO), NAVAIR Aircraft

Controlling Custodian Office (ACCO)

Responsible for PAO Assessment and Determination

Used to determine if the contracted operation with its mission specific equipment is

PAO Assessment

civil or public

Uses U.S. Armed Forces PAO decision tool
Input includes but not limited to the following:

Detailed Mission Description
Contract Data Requirements List (CDRL)
FAA Airworthiness Certificates and Operating Limits
FAA Major Repair and Alteration, Form 337s
FAA Statement of Compliance with AW Standards, Form 8110-3s
Documentation for Unapproved Installations (Installations that do not have FAA approval

documents or are not approved by the FAA)

Carry-on Equipment
Persons on board
Program Letter for Special Experimental or Restricted Certificates
Insurance Documentation

PAO Declaration Letter provided by PMA-226 to Owner/Operator
Owner/Operator provides declaration to FAA, as required by FAA

Physical Configuration Audit (PCA)

Conducted by PMA-226
Establishes existing aircraft pedigree
Conducted on-site
Formal Examination of the as-maintained configuration

(e.g. PAO Airworthiness Checklist) to identify non-
conformances, if any

Examination of aircraft as configured for PAO
Various types of audits: Engineering drawings,
specifications, technical data and tests, Quality
Assurance, processes and procedures and others as
necessary, to determine existing aircraft pedigree for the
intended mission

Continuous Maintenance Record Coverage Critical to Support Pedigree / Airworthiness

Interim Flight Clearance (1 of 3)

Title 14 CFR



Assessment determines

Civil Operation

Civil aircraft with civil certificate

covering all aspects of
intended operation &

Does not meet USC Title 49
for Public Mission aircraft

Operation does not qualify as
Public Operation with PAO tool

Complies with FAA /ACO


Example: Raytheon 727
DoDD 5030.61

Non-Navy Owned


Type 1

Public Operation

Type 2

Public Operation

Based on previous AW certification(s), accepted

aircraft pedigree & review of all aircraft

SMEs apply appropriate AW criteria,

engineering standards, and data requirements
for a Type 1 PAO contracted air services IFC.
Example: FAA Type Certified baseline aircraft

complying with FAA approved maintenance and
operational practices, with modifications for
military purposes which can be fully evaluated
and approved by Navy SMEs

Example: Former military aircraft with current

and clear pedigree with modifications for military
purposes which can be evaluated and approved
by SMEs

Insufficient data available to completely assess Qualitative risk assessments are documented
and accepted.
Generally include operating limitations to ensure
safety to people, property and environment.
Operating restrictions often due to lack of data.
Previous AW certificates, aircraft maintenance
pedigree, intended usage, etc.,
Safe for Flight conducted.
Contract checked for GFR oversight of
maintenance, safety, and ops.
Example: FAA experimentally certified aircraft,
or former foreign military aircraft, with gaps in the
aircraft pedigree, and/or configuration changes
which cannot be fully evaluated due to the lack of
aircraft data.

Navy FC required, effort to likely include:

Contract Language

Enduring audits

SFF Inspection/ GFR

Interim Flight Clearance (2 of 3)

Conduct a Planning Meeting (Class Desk, Contractor, ACO, SMEs)

To occur immediately post contract award
Develop an Airworthiness Qualification Plan (AQP) and Engineering Data

Requirements Agreement Plan (EDRAP)

PCA (Class Desk, Contractor)

Initial PCA to determine aircraft pedigree
Final PCA post modification completion

Communicate early and often (All)

Class Desk: actively coordinate and communicate with SMEs, ACO, Contractor
Program/Contractor: Provide ALL required data, early enough, to allow for timely


Note: If a Safety of Flight hazard is identified, a Systems Safety Risk Acceptance (SSRA) is developed to document the
hazard for formal acceptance.

IFC Process and Sequence of Events (3 of 3)


Determine requirement (Class Desk, SMEs)
Schedule tests (PMA, Class Desk, Contractor, SME)

Typically occur post completion of required aircraft modification (or as required by SMEs)
Electronic equipment (EA/EW Pods) must be available and approved for carriage prior to EMC SOFT


Class Desk submits complete IFC request to the ACO

A complete request means adequate planning & coordination with Stakeholders (Program,

Airworthiness, Customer, Operator, Support Personnel, SMEs/Competencies) is in place and
all data is ready and available

Data includes all flight clearance references and any additional data required per EDRAP for

review and release of an IFC by SMEs and Airworthiness authority

Met all known SME requirements
IFC Review (SMEs, Class Desk)

Provide concurrence

May require additional discussions and documentation

IFC Release (ACO)

Once IFC is released, CAS Class Desk must be notified of any changes that impact:
Aircraft configuration
FAA Certificates Operating Limitations
Operating Procedures

These changes will be assessed to determine if an IFC revision is needed.

Flight Clearance Data Focus (1 of 2)

FAA approved data: Data specifically approved by the FAA or FAA-

delegated representatives

OEM documents

Aircraft Manuals, Procedures, etc.
Model specifications

Military Documentation

Airworthiness Certification
Technical Directives (TCTOs, AFCs, Bulletins, etc.)

Test plans
Test reports
Engineering analyses
Models and Simulations
Engineering Drawings
Any other source data applicable to hardware and software modifications

Flight Clearance Data Focus (2 of 2)

Experimental Certificate: Modifications performed on aircraft with Experimental
Certificate are NOT validated by the FAA. This certificate requires further review of aircraft

Program Letter submitted to FAA for application of Experimental Certificate

Identifies aircraft configuration
States intended purpose

Operating Limitations provided by FAA in conjunction with Experimental Certificate

In the absence of FAA, OEM, or Military approved data, it is good standard
practice to follow the recommended repair and alteration processes and
procedures described in:

AC 43-210A, Standardized Procedures for Obtaining Approval of Data

Used in the Performance of Major Repairs and Major Alterations

Major Repair and Alteration Data Approval Job Aid

Testing & Assessment Requirements Prior to IFC
Release (1 of 2)

Evaluation for