Beyond the Cockpit: Boeing's Flight Test Procedures Unveiled

1. CRM: It’s More Than Just The Cockpit Frank Santoni Chief Pilot, Boeing Brooke Shindler Flight Test Analysis, Boeing Paul Bolds-Moorehead Principle S&C Engineer, Boeing Ralph Mohr Flight Test Safety, Boeing 5/9/07

2. Agenda • Predictive Work Paul • Rehearsal Paul • Test Day Prep Ralph • Execution Frank • Test Conduct Brooke • Video Frank

3. FAR Requirements • Vmcg – Minimum Control Ground Speed • Governed by FAR 25.149 (e) • It must be demonstrated that, when the critical engine is suddenly made inoperative at Vmcg during the takeoff roll, the airplane is safely controllable if the takeoff continued. • During the demonstration, the airplane must not deviate more than 30 ft.

4. Test Preparation/Rehearsal • Extensive prediction of flight characteristics • Begins approx. one year before flight • Multiple variabilities examined for VMCG testing • Key factor: pilot reaction time (PRT) • Other factors: Crosswind, Initial Yaw Rate, Rudder Input Rate, Runway Condition, Hydraulic System Failures

5. Test Preparation/Rehearsal • Factors/Trades:

6. Test Preparation/Rehearsal • Team assigned early • Representatives from all disciplines (pilots, program engineering, test engineering) • Start early discussions on procedures and data metrics • Full team rehearses maneuver in engineering simulator • Fine tune test procedures • Establish abort criteria • Stated requirement that pilots involved in the test must practice in the simulator (part of risk alleviation)

7. Test Preparation/Rehearsal

8. Test Preparation/Rehearsal • Specific benefit example: 777-200LR / GE90-115BL VMCG test • Originally planned for light weight, Flaps 20 (as all previous 777’s had done) • “Conservative” build-up planned: start fast for less deviation, then fuel cuts at slower speeds until >30 ft lateral deviation achieved • Determined that airplane was basically airborne and rolling during simulator rehearsal • Test safety an issue !

9. Test Preparation/Rehearsal • So…… the test plan was adjusted to Flaps 5, mid weight (after analytically showing insignificant effect on resulting VMCG speed) • Rather than traditional build-up, start testing AT predicted VMCG speed, then obtain points on either side to generate required data • Resulted in much safer test, successfully completed

10. Test Director Roles • Test Planning • Coordinates with supporting groups • Flight Crew – Understands any crew comments or concerns • Analysis – Understands the test plan & requirements • Instrumentation – Data monitoring and preflight • Weights – Fuel & Ballast Loading Requirements • Ground Ops & Shop – Configuration, support, release time • Participates in rehearsals / dry-run simulator cab sessions • Develops team working together skills

11. Test Director Roles • Test Sequencing • Risk Assessment • Risk Alleviation • Special Test Requirements • Sequence of Events / Procedures • Before APU Start •  Engine Shutdown

12. Test Director Roles • Test Briefing • Test Crew • Wind Station Operator/Photo • Review Sequence • Discuss Lessons Learned • Discuss Technique • Discuss Monitoring Requirements • Discuss Knock-it-Off Criteria • Cabin Safety & Egress Brief • All participants required to be in attendance

13. Test Director Roles • Test Conduct • Test Director responsible for ensuring team readiness • Comm Check – all the way around • Read & Do – run the procedure like a checklist • Initial Setup Engine Restart

14. Test Director Roles • Test Conduct

15. Test Director Roles • Post Test Debriefing • Discussion of events • Capturing lessons learned • Reporting • Operations Summary

16. Test Conduct – Cockpit Brief • Align the airplane on runway – slight offset for wind • Receive condition card from Analysis • Brief condition • Call 100 kts • Cut speed – put “bug” on speed tape • Ignore engine surge • Pilot apply full rudder – when the nose moves • Knock it off call - review • Normally from back end when A/C cg turns around • If deviation is greater than 50 feet – 2 blocks (25 ft. each) • If data freezes • Pilot decides to • Review recovery procedure • Idle thrust • Control to parallel center line • Speedbrakes up • Max reverse • Brief when to put the nose wheel steering breakers back in • Check that team is ready

17. Test Conduct • Conduct test • Get wind check CP from Windy • Call brake release P on test frequency • Add power slowly P • Track center line P • Feet off pedals prior to cut P • Non flying pilot cut fuel at cut speed CP • React to nose movement P • Full / rapid rudder application P • Condition over at knock it off call or at pilot discretion Analysis/CP/TD/P • Accomplish recovery procedure P • NWS circuit breakers in below 100 knots with pilot call CP/TD • Engine relight per briefed procedure CP/TD • Determine status of tires and brakes for cooling. P/CP/TD

18. Roles and Responsibilities – Engineering • 3 Flight Test Engineers • ADAMS (Data) station • Overall responsibility for running the test in the back • Initial setup of data programs • Run trap • Monitor Lateral Deviation • Knock it off call

19. Roles and Responsibilities – Engineering • Stripchart • Back up on knock it off • Makes quick condition qualities calls (reaction time and max deviation)

20. Roles and Responsibilities – Engineering • Laptop • Works the spreadsheet to make post-condition calls • Takes notes

21. Roles and Responsibilities – Engineering • Program Engineers • Provides intimate knowledge of trade studies and predictive work

22. Decision Time! On test day everyone has a different level of conservatism. Everyone needs to come to next fuel cut decision as a group.

23. Questions?