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AERO LABORATORY DIVISION AIRCRAFT ENGINEERING DIRECTORATE

DIRECTORATE GENERAL OF CIVIL AVIATION

PROCEDURES MANUAL

November, 2012

TABLE OF CONTENTS

SECTION 1 Flight Recorder Laboratory

SECTION 2 Failure Investigation Laboratory

SECTION 3 Material Testing Laboratory

SECTION 4 Physical and Chemical Laboratory (Fuel Lab.)

SECTION 1

FLIGHT RECORDER LABORATORY

FLIGHT RECORDER LABORATORY

Manual

RECORD of REVISIONS

Rev

No.

Issue Date

Remarks Initials

1 15th November, 2012 Issue 2.0

CHAPTER – 1

GENERAL

The Directorate General of Civil Aviation (DGCA) is the regulatory body in the

field of Civil Aviation primarily dealing with safety issues. It is responsible for regulation

of air transport services to/from/within India and for enforcement of civil air regulations,

air safety and airworthiness standards. It also coordinates all regulatory functions with

International Civil Aviation Organisation (ICAO).

The headquarters are located in New Delhi with regional offices in the various

parts of India. DGCA is an attached office to the Ministry of Civil Aviation. There are 14

regional/Sub-regional Airworthiness offices located at Bangalore, Chennai, Delhi,

Kolkatta, Mumbai, Bhopal, Bhubaneshwar, Cochin, Guwahati, Hyderabad, Kanpur,

Lucknow, Patiala and Patna. Apart from the regional Aieworthiness offices, there are 5

Regional Air Safety offices located at Delhi, Mumbai, Chennai, Kolkatta and Hyderabad.

In addition one Regional Aircraft Engineering Directorate office is located at Bangaluru

and the Gliding Centre at Pune.

India is participated in ICAO by the Representative of India.

CHAPTER – 2

Structure of DGCA

DGCA has the following Directorates:

i) Administration Directorate

ii) Directorate of Regulation & Information

iii) Directorate of Air Transport

iv) Directorate of Aerodrome Standards

v) Directorate of Training & Licensing

vi) Directorate of Flying Training

vii) Airspace & Airtransport Management Directorate

viii) Flight Standard Directorate

ix) Directorate of Air Worthiness

x) Directorate of Air Safety

xi) Aircraft Engineering Directorate

Structure for Flight recorder Lab

Director General of Civil Aviation

Joint Director General

Deputy Director General

Deputy Director, Aircraft Engineering

Aeronautical Officer, Aircraft Engineering

CHAPTER – 3

SCOPE OF THE LABORATORY

• To hear & analyze CVR data from the point of view of evaluating recorders airworthiness integrity & crew operational performance.

• To analyze the FDR data printouts from the point of view of evaluating recorders airworthiness integrity, parameters sensors serviceability etc.

• To download and decode various types of Tape & Solid State versions of CVR, which involves use of special equipments to de code the voice, create copies in

digital tape and audio cassettes, making transcriptions. Further the job involves

creating a four-channel audio continuous data tape, with creation of time channel

along with.

• To create transcript of entire data decoded. This involves handling of various dedicated electronic equipment in skillful way. This transcript would give a

tabulated sequence of conversational audio along with elapsed time up to 1/10 sec.

accuracy.

• To perform scientific analysis of various other sound information present in cockpit & linking, sequencing such information with other relevant facts

connected with a fatal accident. This would involve utility of high performance

intelligent signal analyzer and other connected electronics machines.

• To carry out analysis of FDR data creating various aircraft performance graphs & sequencing the events that led to a crash.

• To prepare a comprehensive graphical picture of CVR/FDR data merged together. This involves creating a definition of crash point, a careful time matching of both

the recorders data, aligning all events before & after crash points. Normally this

combined comprehensive graphical timed picture brings out all the facts connected

a crash together. Hence all care is taken in such fact picture creation.

CHAPTER – 4

FUNCTIONS

Routine Monitoring:

1) The lab carries out continuous airworthiness monitoring of the content of CVR/FDR by carrying out regular random study on data recorded. This

monitoring is done as per CAR Section 2 Series I Part V & VI and Airworthiness

Advisory Circulars No. 2 & 3 of 2004.

2) Discrepancies/ shortcomings if any are brought to the notice of Q.C.M. & Flight Safety Manager of concerned airline for corrective action. Also this information is

sent to Director of Air safety and Director of Airworthiness for information and

further action.

3) This lab also assists small operators who don’t have their own downloading and decoding facility in form of downloading the recorders in the laboratory for

routine monitoring.

4) This lab is empowered to download the flight recorder data in-situ for random monitoring.

Accident investigation / Analysis:

1) It is a common practice for Govt. to constitute a court of Inquiry to investigate into the reason for accident/incident. The Flight Recorder Lab provides extensive

assistance to such inquiry commission in the form of downloading/decoding of

CVR and FDR.

2) For CVR, all the four channels are decoded separately in the digital tapes and computer system. Detailed transcription is prepared for all the four channels with

respect to the time for analysis.

3) For FDR, various parameters are decoded into engineering units in a tabulated form. Also various types of graphs are plotted for these parameters for analyzing

the events, carrying out detailed research at the designated spots as required by

committee.

4) Correlation of CVR transcript and FDR readout is carried out which provides a great help in the investigation of the event.

Routine Monitoring of Flight Recorders (CVR/FDR)

Routine Monitoring of Flight Recorders (CVR/FDR)

Applicant Directorate

Non-Satisfactory Satisfactory

STEP 1: Submission

of CVR/FDR data as

per AAC NO. 2 & 3

of 2004 by applicant

Receipt of CVR/FDR data

STEP 2:

Analysis of

CVR/FDR

data data STEP 3: Applicant to take

corrective actions.

Report is released to the

applicant

Analysis of Flight Recorders (CVR/FDR) for investigation.

Analysis of Flight Recorders (CVR/FDR) for investigation

Applicant Directorate

STEP 1: Submission

of CVR/FDR data or

recorder by Dte. of

Air Safety.

Receipt of CVR/FDR data

or recorder

Findings are released to the

Dte. of Air Safety along with

CVR/FDR data in original or

the recorder itself.

STEP 2: Analysis / Investigation of CVR/FDR

data is carried out In accordance with the

‘Manual for Flight Recorder lab’ and as per

requirements of the Dte. of Air Safety.

CHAPTER – 5

EQUIPMENT LIST

1) Multi Channel Digital Audio Recorder (PCM type record/replay)

2) Intelligent Fast Fourier transformer cum Analyser (4 Channel)

3) High Speed Thermal Array Coder (Grey Scale – 3D plot)

4) Graphic Equalizer (30 bands)

5) Professional quality audio amplifier (High frequency response)

6) High performance pre amplifier.

7) Professional; quality of Head sets.

8) Commercial cassettes player deck.

9) 4-Channel spool tape Replayer cum Recorder with variable speed ability.

10) Equipment set up for decoding all versions of L-3 communication recorders & Sundstrand make Voice Recorder.

11) Equipment set up to decode Sundstrand make tape type recorder without echo

appearance.

12) Equipment set up to decode ½ Hr., 2 Hr. L-3 Commu. Solid-state recorders.

13) Equipment set up to decode computerized data from Allied Signal 2 Hrs. duration

SSCVR.

14) A/C power supply unit to assist the lab in powering all the air borne equipments.

15) RPGSE (Recorders Portable Ground Support Equipment): This equipment along

with different connectivity and software is used to download and decode Solid

State CVR and FDR of Honeywell make.

CHAPTER – 6

Brief Description & Calibration Status

1) Multi Channel Digital Audio Recorder (PCM type record/replay)

- An eight channel sophisticated machine with wide frequency response performs writing on DAT cassettes.

- Equipment with built in accurate timer, bar graph display, search facility, programme facility, GPIB interface facility.

The unit has got a built in self test facility. This facility, a software based one,

performs automatically all functions (input, output, read, write) evaluates the

performances of recorders compares with factory set normal level & finally issues out

a statement of OK or with the error details if any. There is no standard calibration

procedure. The unit performs different kinds of advanced A/D conversion, pulse code

modulation wherein there are no provision for user to vary factory set up in the

process of calibration. Calibration as such, only the manufacturing factory can do, that

too would be done only after a major servicing done on the equipment.

2) Intelligent Fast Fourier transformer cum Analyzer (4 Channel ):-

An advanced waveform analyzer that employes fast fourier Transformer (FFT)

computation algorithm. Wide band analysis up to 100 K Hz with real time analysis of

0-20 KHz has built in 128-killo words memory leading to extensive use in audio &

vibration area research. Some of the wide ranging processing functions are; Transient

Wave Observation, Auto Correlation Coefficient, Inverse Fast Fourier,

Transformation Wave form, Arithmetic functions, constant computation,

Differentials, Integrals, Linear frequency spectrum, Power spectrum density, Energy

spectrum density, phase characteristics, 1/1 octave, 1/3 octave, 3 dimensional line /

color scale, wide zoom functions etc.

The unit performs multitask with no provision of calibration. It has a built in

test set up performing self-check and display OK status. In case of any error message

only factory can set unit back to service. In addition as the unit measures and

processes a large no, of parameters, calibration concepts do not hold good. Calibration

of all functions is called for only after the unit undergoing major service, that too at

factory.

3) High Speed Thermal Array Coder ( Grey Scale – 3D plot ) :-

- Serial interfaceable high performance recorder - Ao size 400 dpi continuous single unit thermal print head - Automatic cutting & laying function - Expandable memory upto 10 MB

- Variety of additional interfaces - 16 scales of gray in 3-D plot Again this being a software driven machine there is no requirement of

calibration and there is no set calibration procedure.

4) Graphic Equalizer ( 30 bands ):-

A-30 band (within 0-20 KHz audio range accurate frequency equalizer to

suppress or boost the designed band of frequency present in an audio. This is used to

filter out or boost low-level signals present in a segment of audio signal. By this

process the investigator can get more clarity in the information contest.

Calibration: not applicable, unit is factory sealed, no user adjustable design feature

provided.

5) Professional quality audio amplifier (High frequency response):

A faithful signal level & power amplifier, with excellent frequency response of

0-20 Khz.

Calibration: No set procedure. Factory calibrated & sealed. No user adjustable design

feature provided.

OTHER EQUIPMENTS

Like High performance pre amplifier, Professional quality of Head sets,

Commercial cassettes player deck, 4-Channel spool tape, Replayer cum Recorder with

variable speed ability, High speed strip chart recorder cum analyzer, Equipment set up

for decoding tape version of L-3 communication recorders & Sundstrand make Voice

Recorder, Equipment set up to decode Sundstrand make tape type recorder without

echo appearance, Equipment set up to decode ½ Hr., 1 Hr, 2 Hr. L-3 Commu. Solid

state recorders, Equipment set up to decode computerized data from Allied Signal /

Honeywell SSCVR/ SSFDR, A/C power supply units are various accessories

equipments used in the process of CVR/FDR analysis cum research.

Dedicated equipments like SSCVR/SSFDR replay system are all factories sealed

and there is no set procedure for calibration.

CHAPTER – 7

TEST PROCEDURE

ROUTINE / RANDOME MONITORING:-

Cockpit Voice Recorders

Different types of Cockpit Voice Recorders or the information transferred into a

commercial cassette tapes are brought to this office by various operators. All details like

CVR type, Sl. No., Operator, Aircraft Registration No., Date of Flight; Sector of Flight

etc. are entered in a register maintained and a particular Sl. No. is marked on that case.

1) The decoding is done & the content are heard repeatedly to check

- Integrity of recorder, quality of recording, noise level etc. - Crew adherence to Cockpit procedure, discipline, calling & response to all checklists.

- Presence of any warning sounds.

2) Reports are prepared separately for each case signed by authorized signatory and

sent to operators.

3) Shortcoming/discrepancies if any, are marked in the analyzed reports and are sent

to DAW and DAS for further action.

5) This lab also downloads and decodes the CVR randomly for analyzing the data. The discrepancies like noise, low intensity either by ATC or crew in brought to the

notice of operators for corrective action by implementation of suitable procedure

as per the manual.

Flight Data Recorders

1) DFDR data are received in the form of floppies & printout. Reading is done to check

the following aspects:

- Data continuity, limit of missing frames - Parameter values, engineering meaning - Correctness of altitude, Heading values both at T/O & landing airfields. - Abnormal rise or low in any parameter value. - Rate of change of any parameter

2) After the study a technical report is prepared & sent to the operators for follow up

actions.

3) All these cases are properly numbered & the same is reflected in all related

papers of the case including final reports.

4) In case of major deviation found the reports are referred to Directorate of Air

Worthiness, & Directorate of Air Safety.

5) In case of minor discrepancies, operator is called for consultation, so as to resolve

the issues.

ACCIDENT / INCIDENT INVESTIGATION

The following procedure is adopted during investigation of accidents/incidents:

Cockpit Voice Recorders

• The accident/incident met flight recorders are brought to this lab by Directorate of Air Safety.

• The recorders are identified by its part No., Make & Type.

• The required tools/cables/hardware and software/equipments are identified and kept ready for the task.

• The recorders are photographed as it is in the presence of the Inspector of accident / Court of enquiry as the case may be.

• The recorder is dismantled using unconventional way depending on the type of mechanical, environmental or fire damage, by an authorize person.

• The recording media (tape) is separated from the main unit of recorder.

• Suitable and identified playback equipment are used to reproduce the data. This data is stored in a PC or megnatised DAT Tape to one immediate faithful copy,

which is used for further analysis and research.

• The original tape/copy is sealed and secured well.

• After a no of hearing, timed transcript is prepared. This transcript is validated by Dte. of Air Safety / Flight Standard Dte. / AAIB.

• Further scientific advanced research is undertaken. However, the scope of research work purely depends on the requirement of the expert committee investigating the

case. This kind of research work undertaken again differs from case to case

depending upon various gray areas present in the technical aspects of the event.

Flight Data Recorders

• The accident/incident met flight recorders are brought to this lab by Directorate of Air Safety.

• The recorders are identified by its part No., Make & Type.

• The required tools/cables/hardware and software/equipments are identified and kept ready for the task.

• The recorders are photographed as it is in the presence of the Inspector of accident / Court of enquiry as the case may be.

• The raw data is extracted in the lab from the damaged recorder by software ‘ROSE’ in case of the L-3 Communications recorders and stored in a PC for

decoding it into engineering units.

• Further the data is analysed and researched by making a no. of combinations of different parameters, decoding them into graphs and tabular form. This data is

validated by Dte. of Air Safety / Flight Standard Dte. / AAIB.

Correlation of Data

• For advanced analysis, the data from Cockpit Voice Recorder and Flight Data Recorder is correlated to enable the investigators research the event more

effectively.

-50

-25

0

25

50

75

100

125

150

175

-180 -170 -160 -150 -140 -130 -120 -110 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20

Rel. T ime

CAS Heading Pitch Roll

LOG BOOK OF CALIBRATION STATUS

As none of the equipment needs calibration in true sense, no logbook is

maintained.

STANDARD DOCUMENTS

No specific IS or BS standards are recommended for the kind of jobs being

undertaken by Black Box Lab. Hence no specific folder is maintained on this topic.

CHAPTER – 8

Formats

for

Reports

CHAPTER – 9

TIME LIMIT FOR DISPOSAL OF VARIOUS CASES

S. N. Subject No. of working days/ hours for disposal of

application

1 CVR Routine Monitoring

26 Days

2 FDR Routine Monitoring

26 days

3 CVR Incident /Accident

Analysis

Depending on complexity

of case

4 FDR Incident /Accident

Analysis

Depending on complexity

of case

5 Downloading of L-3 SSCVR

03 hours

6 Downloading of L-3 SSCVR

02 hours

7 Downloading of Tape Version

CVR

01 day

SECTION 2

FAILURE INVESTIGATION LABORATORY

REVISIONS

The revisions are carried out as and when required to accommodate the

amendments made in Aircraft Rules, Civil Aviation Requirements.

The space below is provided to keep a record of such revisions.

RECORD OF REVISIONS

No. Date of Revision Remarks

CHAPTER – 1

GENERAL

The Directorate General of Civil Aviation (DGCA) is the regulatory body in field of Civil Aviation primarily dealing with safety issues. It is responsible for regulation of air transport services to/from/within India and for enforcement of civil air regulations, air safety and airworthiness standards. It also co-ordinates all regulatory functions with International Civil Aviation Organization (ICAO).

The headquarters are located in New Delhi with regional offices in

the various parts of India. Directorate General of Civil Aviation is an attached office of the Ministry of Civil Aviation. There are 14 (fourteen) Regional/Sub-regional Airworthiness Offices located at Bangalore, Chennai, Delhi, Kolkata, Mumbai, Bhopal, Bhubaneswar, Cochin, Guwahati, Hyderabad, Kanpur, Lucknow, Patiala and Patna. Apart from the Regional Airworthiness Offices, there are 5 (five) Regional Air Safety offices located at Delhi, Mumbai, Chennai, Kolkata and Hyderabad. In addition one Regional Research & Development Office is located at Bangalore and the Gliding Centre at Pune.


CHAPTER – 2

Structure of DGCA

DGCA has the following 10 Directorates;

i) Administration Directorate

ii) Aerodrome Standards Directorate

iii) Air Safety Directorate

iv) Air Transport Directorate

v) Airworthiness Directorate

vi) Flight Inspection Directorate

vii) Information & Regulation Directorate

viii) Aircraft Engineering Directorate

ix) Training & Licensing Directorate

x) Flying Training Directorate

Structure for Failure investigation Laboratory





Aeronautical officer, Aircraft Engineering

CHAPTER – 3

Scope of Failure Investigation Laboratory

The objective of Failure Investigation laboratory is to determine primary cause of failed aircraft/helicopter components involved in accident/incident. The primary objective of ‘Failure Analysis Laboratory’ is two fold, firstly to know most probable cause of failure and secondly to provide remedial action to avoid its recurrence. The main objectives of the laboratory are as follows:-

� Design deficiency

� Errors in the selection of materials

� Processing and fabrication faults

� Improper inspection & maintenance

� In-service abnormalities and environmental effects, etc.

CHAPTER – 4

INTRODUCTION OF MACHINES /EQUIPMENTS IN THE LABORATORY 1. SCANNING ELECTRON MICROSCOPE (SEM)(MODEL LEO 1450). 2. STEREOMICROSCOPE (MODEL WILD-M8). 3. OPTICAL MICROSCOPE MODEL (REICHERT-JUNG MEF3A)

DESCRIPTION OF MACHINES /EQUIPMENT

CHAPTER – 5

SAMPLE PREPARATION

CHAPTER – 6

The following steps are adopted by the laboratory for Investigation after

receiving the failed parts after accident /Incident from Air Safety

Directorate/regional Office/ Operator or Airlines :-

Step-1 Collection of background data and selection of samples.

Step-2

Visual examination of failed parts and photographic evidence in-as-is condition

Step-3

Mechanical testing.

Step-4 Cleaning of samples.

Step-5

Macroscopic examination (fracture surface, secondary cracks, surface condition etc)

Step-6

Microscopic examination (failure mechanism) by using the Scanning Electron Microscope

Step-7

Metallographic examination (grain size, cracks, microstructure, etc.)

Step-8 Finalization of the report indicating probable sequence of failure

Step-9 Issuance of report after the approval

CHAPTER – 6

Workflow for Failure Investigation/Examination Laboratory

Collection of background data and selection of Sample

Failed Parts Received From Air

Safety/Operator

Technical Information from Operators with the help of Air Safety.

Laboratory Examination at Macro & Micro Level with

the help of Scanning Electron Microscope

Release of report Fig.1

CHAPTER – 7

FORMAT OF THE REPORT

SECTION 3

MATERIAL TESTING LABORATORY .

TABLE OF CONTENTS

PREFACE REVISIONS

CHAPTER CONTENTS PAGE NO.

1 General 5

2 Structure of DGCA and Material Testing Laboratory

6-7

3 Scope of Material Testing Laboratory

8-9

4 Introduction of Machines /Equipments in the laboratory.

11

5 Sample Preparation 12

6 Testing of samples 13

7 Format of the Report 14-15

REVISIONS

The revisions are carried out as and when required to accommodate the

amendments made in Aircraft Rules, Civil Aviation Requirements.

The space below is provided to keep a record of such revisions.

RECORD OF REVISIONS

No. Date of Revision Remarks

CHAPTER – 1

GENERAL

The Directorate General of Civil Aviation (DGCA) is the regulatory body in field of Civil Aviation primarily dealing with safety issues. It is responsible for regulation of air transport services to/from/within India and for enforcement of civil air regulations, air safety and airworthiness standards. It also co-ordinates all regulatory functions with International Civil Aviation Organization (ICAO).

The headquarters are located in New Delhi with regional offices in

the various parts of India. Directorate General of Civil Aviation is an attached office of the Ministry of Civil Aviation. There are 14 (fourteen) Regional/Sub-regional Airworthiness Offices located at Bangalore, Chennai, Delhi, Kolkata, Mumbai, Bhopal, Bhubaneswar, Cochin, Guwahati, Hyderabad, Kanpur, Lucknow, Patiala and Patna. Apart from the Regional Airworthiness Offices, there are 5 (five) Regional Air Safety offices located at Delhi, Mumbai, Chennai, Kolkata and Hyderabad. In addition one Regional Research & Development Office is located at Bangalore and the Gliding Centre at Pune.


CHAPTER – 2

Structure of DGCA

DGCA has the following 10 Directorates;

xi) Administration Directorate

xii) Aerodrome Standards Directorate

xiii) Air Safety Directorate

xiv) Air Transport Directorate

xv) Airworthiness Directorate

xvi) Flight Inspection Directorate

xvii) Information & Regulation Directorate

xviii) Aircraft Engineering Directorate

xix) Training & Licensing Directorate

xx) Flying Training Directorate

Structure for Material Testing Laboratory





Aeronautical officer, Aircraft Engineering

Support staff, Aircraft Engineering

CHAPTER – 3

Scope of Material Testing Laboratory

The objective of Material Testing laboratory is as follows:

a) Monitor the quality of welding in aviation context and testing welded samples received in the laboratory.

b) Testing of upholstery materials for aircraft cabin.

The details of the tests carried out in the laboratory are as follows:-

� Testing of mechanical properties of welding samples i.e. tensile, Shear &

Bend test etc. and micro testing of weld material.

� Testing of upholstery material for flame time, dripping, burn length, etc.

CHAPTER – 4

INTRODUCTION OF MACHINES /EQUIPMENTS IN THE LABORATORY 1. SHAMADZU AUTOGRAPH UNIVERSAL TESTING MACHINE MODEL AG-25 TG5, 25 TON CAPACITY. 2. ROCKWELL HARDNESS TESTER TYPE 6402 3. 5% COPPER SULPHATE SOLUTION FOR BENT TEST. 4. EQUIPMENT FOR TESTING OF FLAMABILITY TEST.

CHAPTER – 5

SAMPLE PREPARATION

1. TEST SAMPLES AND SPECIMENS FOR WELDING

Standard test samples are received in the laboratory. The samples should be

strictly prepared as per the CAR, Section-2, and Series L Part XIV. Before

testing, it is verified in the laboratory.

2. TEST SAMPLES AND SPECIMENS FOR UPHOLSTERY MATERIAL

TESTED. (FLAMMABILITY TEST)

The samples must meet the requirements mentioned in CAR, Section-2, and

Series X Part IV. Before testing, it is verified in the laboratory.

CHAPTER – 6

TESTING OF WELDING SAMPLES

The following steps are adopted by the laboratory for testing the samples:-

Step-1

After receiving the samples, inspection is carried out for verification of sample’s specific dimensions.

Step-2

Samples are prepared to the specific dimensions if the dimensions are not to the requirements.

Step-3

Mechanical testing with the help of UTM machine and other laboratories tests are carried out.

Step-4

Stress, strain calculations etc. are carried out and compared with the standard Checklist /CAR.

Step-5

Report prepared and released after approval.

Workflow for Material Testing Laboratory for welding samples

CHAPTER – 6

Samples Received

along

with fees from Air

Safety/Operator

Samples are prepared for testing after checking the dimensions.

Laboratory

Examination

Stress, strain calculations etc. are carried out and compared with the standard checklist/CAR

Repot Released Fig.1

TESTING OF SAMPLES FOR UPHOLSTERY MATERIAL

The following steps are adopted by the laboratory for testing the samples:-

Step-1

After receiving the samples, inspection is carried out for verification of sample’s specific dimensions.

Step-2

Samples are prepared to the specific dimensions if the dimensions are not to the requirements.

Step-3

Flammability Test in the laboratory and Record keeping Step-4

Comparison of observations against requirement

Step-5

Report prepared and released after approval.

Workflow for Material Testing Laboratory for upholstery material

Samples are prepared for testing after checking the dimensions.

Laboratory Examination

Observed value compared with the standard checklist/CAR

Repot Released Fig.1

CHAPTER – 7

FORMAT OF THE REPORT

GOVERNMENT OF INDIA

CIVIL AVIATION DEPARTMENT

OFFICE OF THE

DIRECTOR GENERAL OF CIVIL

AVIATION AIRCRAFT ENGINEERING DIRECTORATE OPP. SAFDARJUNG AIRPORT, NEW DELHI – 110 003 TELEPHONE/ FAX : 91-11-24622500

Reference: No.0/ 2012-AED Dated: : 00.00.0000

The ---------------- ------------------------ ------------------------

Subject :- Test report of Welding samples.

Sir, Reference is invited to your letter No. MM/DGCA-WELD/MM. dated. 00 month ,0000 on the above subject. Your request has been examined and the test reports are enclosed.

(MMMMM..) Dy. Director Aircraft Engineering Directorate

For Director General of Civil Aviation

TEST REPORT

TEST REPORT NO.TC/WELD/101/2010-2011 DATED: 00.00.0000

Sample submitted has been tested and the results obtained are given below. This report relates only to the sample tested and does not guarantee the bulk of the materials etc. to be of equal quality.

Sample of : Sheet to Sheet Supplied By : MMMMM.. Reference Nos. : 0/0-/0/0 Dated : 00/00/0000 Received on : 00/00/0000 Specification : CAR series ‘L’ Part xiv Division 2 (Issue I) Description of Test1: Sheet to Sheet (Tensile)

Sample Serial No.: 1 2 3 4 5 6 7 8 9

Identification Mark: ----- ----- ----- ----- ----- ----- ----- ---- ----

Group No. I VII I IV I IV V I I

Specification: 6L-17 AMS-4901

6L-17 SS-321 (AMS 5510P)

6L-17 SS-321 (AMS 5510P)

N-75 6L-17

Thickness of Specification(in mm)

1.65 1.60 1.65 1.58 1.65 1.55 1.62 1.65 1.65

Cross sectional area (in mm²):

----- ----- ----- ----- ----- ----- ----- ---- ----

Ultimate Tensile Stress(in kg/mm²)

----- ----- ----- ----- ----- ----- ----- ---- ----

Location of Fracture (in mm away from weld)

----- ----- ----- ----- ----- ----- ----- ---- ----

Test Remarks Pass/F

Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F

Description of Test 2: Sheet to Sheet (Micro Test)

Micro test remarks:

Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F

Description of Test 3: Sheet to Sheet (Bend Test)

Bend test remarks:

Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F Pass/F

Remarks: - Sample submitted conforms to the specification requirements. TESTED BY CHECKED &

APPROVED BY Aeronautical Officer Dy. Director (AED)

Letter Head

TEST REPORT TEST REPORT NO.TC/FM/00/12-13 DATED:

00.00.0000

Sample submitted has been tested and the results obtained are given below. This report relates only to the sample tested and does not guarantee the bulk of the materials etc. to be of equal quality.

Sample of : Supplied By : Reference No. : Dated 00 Month

0000 Received on : Colour : Specification : F.A.R. Part 25, App.-F,Part I(a)(I)(iv)

Test Description Observed value Requirement

1.Vertical Test (a) Flame applied for 12 Seconds (b) After removal of the flame source, flame continue to burn for: (c) Dripping (d) Burn length

12 Seconds

Flame time after removal of the flame not exceed 15 sec. Dripping should not continue for more than average of 5 sec. After falling. Avg. Burn length not to exceed 203.2 mm

Remarks: - Sample submitted conforms to the specification requirements. TESTED BY CHECKED & APPROVED

BY ( MMMMMMMMMMM..) (MMMMMMMMMMMM)

Aeronautical Officer Dy. Director (AED)

SECTION 4

PHYSICAL AND CHEMICAL LABORATORY

(FUEL LAB)

INTRODUCTION

Physical & Chemical Lab is engaged in the analysis of Aviation Fuels

and Lubricating oil in various connections such as random testing of

Aviation Turbine Fuel drawn from different AFS of the country through

DGCA officials, for approval of commissioning of new Tanks, Refuellers

and Pipelines for accidental/incidental investigations and prior to every

VVIP Flight.

The Physical & Chemical Lab is engaged in the following activities: -

1. Prior to fueling of every VVIP flight, samples of fuel to be used for

such flights are drawn by DGCA officials and sent to this lab for testing.

Test reports are sent before such flights.

2. For commissioning of new Tanks, Pipelines, Refuellers etc fuel

samples are drawn by DGCA officials for testing in the lab for their

approval.

3. Samples of Aviation Turbine Fuel are periodically drawn by DGCA

officials from the storage tanks of the air field station in different parts of the

country for testing in the lab to monitor the quality of fuel used in air-craft.

4. Periodically samples of Aviation Gasoline are tested as per

requirement.

5. For every accidental/incidental investigations, Fuel

samples/Lubricating Oil/Hydraulic Fluid etc., are drawn by DGCA officials

and sent to this lab for testing.

Structure of Physical & Chemical Lab.





Aeronautical Officer

Jr. Aeronautical Officer

Aviation fuel,

oil, aviation

Gasoline,

VVIP flight

fuel sample,

from

Airworthiness

Directorate

Aviation fuel

& oil sample

etc of the

aircraft

involved in

accident/

incident from

Air-Safety

Directorate

Check the particulars/details of the sample

Receipt the aviation fuel samples along

with details / specification requirements

Visual Examination of the sample as per

specification requirement

Physical and Chemical analysis/ testing as

per the specification requirement

Release of Test Report

Workflow for Physical and Chemical Laboratory

TESTING PARAMETER OF AVIATION PRODUCT

1. VVIP Flight Fuel Sample 2. Aviation Turbine Fuel Sample 3. Aviation Gasoline Fuel Sample 4. Lubricating Oil Sample

5. Hydraulic Fluids Sample

1. VVIP flight Fuel Sample

For any cross-country movement of VVIP, it has been made mandatory to

check the quality of aviation turbine fuel. Prior fuelling the aircraft, the

samples are drawn by DGCA officials and tested in the physical & chemical

lab of DGCA refueling of VVIP flight aircraft is carried out only after

satisfactory test results of fuel sample. In this connection following tests are

carried out

Type

Quantity

required

Tests

VVIP Flight

Fuel

Samples

Two Litres

1.Appearance

2.Acidity

3.Doctor test

4. Mercaptan

sulphur

5.Density

6.Aniline Gravity

Product/Specific

Energy

7.Copper strip corrosion

8. Smoke Point

9. Naphthalene Content

10.Water reaction

11.Existent gum

12.Flash point

2 Aviation Turbine Fuel Sample

Samples of aviation turbine fuel are drawn by DGCA officials for

commissioning of storage tanks, commissioning of pipelines,

commissioning of refuller, incident/accident investigation and to monitor the

quality of fuel used in the aircraft. These samples sent to this laboratory for

testing. In this connection following tests are carried out:-

Type Qty. Req. Tests

Commissioning of

Storage Tank,

Pipeline, Refullers,

Incident/Accident

investigation and to

monitor the quality

of fuel used in the

aircraft.

Two Litres 1. Appearance

2. Total Acidity

3. Aromatics

4. Olefins

5.Doctor test

6.Sulphur Mercaptan

7. Total Sulphur

8. Distillation

9. Flash Point

10. Density

11. Freezing Point

12. Viscosity

13. Smoke Point

14. Naphthalene content

15. Specific Energy / AGP

16. Copper Strip Corrosion

17. Existent Gum

18. Water Reaction

3. Aviation Gasoline Sample

Samples of aviation gasoline are drawn by DGCA officials for incident/accident investigation and to monitor the quality of fuel used in the aircraft. These samples sent to this laboratory for testing. In this connection following tests are carried out:-

Type Quantity

required

Tests

Quality Control

Monitoring,

Incident/Accident

Investigation Samples

Two Litres 1. Appearance

2. Colour (visual)

3. Distillation

4. Density

5. Aniline Gravity Product


7. Water Reaction

8. Existent Gum

9.Tetra Ethyl Lead

10. Freezing Point

4. Lubricating oil samples

Samples of lubricating oil are drawn by DGCA officials for incident/accident investigation and sent to this laboratory for testing. In this connection following tests are carried out:-

Type Quantity

required

Tests

Accident/Incident

investigation samples

One litre 1. Appearance

2. Acidity

3. Viscosity

4. Flash Point


6. Pour Point

7. Ash Content

5. Hydraulic Fluid Samples

Samples of hydraulic fluids are drawn by DGCA officials for incident/accident investigation and sent to this laboratory for testing. In this connection following tests are carried out:-

Type Quantity required Tests

Accident / Incident

Investigation Sample

One Litre

1. Appearance 2. Acid Number 3. Viscosity 4. Flash Point 5. Pour Point

Brief Description of Equipment and Calibration Requirements

SL.NO. NAME OF THE

EQUIPMENT

DESCRIPTION CALIBRATION

REQUIREMENT

1. Density

(by Hydrometer)

Hydrometers are

used to determine

the density of

Aviation fuels

Hydrometers &

Thermometer

IP-39 C

2. Distillation

Apparatus

It is used to

determine the

distillation

characteristics of

Aviation fuels

Thermometers

IP-5 C &

IP-6 C

3. Abel Flash Point

Apparatus

It is used to

determine the

flash point of

Aviation Turbine

Fuel having flash

point between

–30°C to 70°C

Thermometer

IP-75 C &

IP-74 C

4.

5.

Pensky Martin

closed Cup Flash

Point Apparatus

Open Flash Point

Apparatus

It is used to

determine the

flash point of

lubricating oil

It is used to

determine the

flash point of

hydraulic fluid

having flash

point ranging

more than 120o C

Thermometer

IP-15 C

Thermometer IP-74 C

6.

Reid Vapour

Pressure

Apparatus

It is used to

determine the

vapour pressure

less than 180 kpa

of volatile non-

viscous Aviation

fuels

Thermometer IP-

23C and Pressure

Gauze

7. Smoke Point

Apparatus

It is used to

determine the

smoke point of

Aviation Turbine

fuel.

Calibration with

standard sample as

per IP-57

8. Copper

Corrosion

Apparatus

It is used to

determine the

corrosion

tendencies

towards copper

of Aviation

fuels

Thermometer

IP-64 C

9. Silver Corrosion

Apparatus

It is used to

determine the

corrosion

tendencies

towards silver of

ATF

Thermometers

IP-64 C

10. Kinematic

Viscosity

Apparatus

It is used to

determine the

kinematic

viscosity of

Aviation fuels

Thermometers

IP-31C/32C

and Viscometers

11. Freezing Point

Apparatus

It is used to

determine the

temperature

below which

solid

hydrocarbon

crystals may

form in Aviation

turbine fuel and

Aviation gasoline

Thermometers

IP-14 C

12. Existent Gum

Apparatus

It is used to

determine the

existent gum

content of

Aviation fuels

Thermometers

IP-73 C/

Pressure Gauge

Electronic

Balance

13. Balance It is used to

weigh the

samples

Electronic Balance

14. Fluorescent

Indicator

Adsorption

Apparatus

It is used to

determine the

hydrocarbon type

i.e., aromatics,

olefins and

saturates in

Aviation fuels

Calibration with

standard samples

as per IP- 156

before doing

analysis.

15. Lamp Sulphur

Method

It is used to

determine the

presence of

sulphur in ATF

Calibration as per

IP-107 before

doing analysis

16. Aniline Point

Apparatus

It is used to

determine the

aniline point of

Aviation fuels

Thermometers

IP-21 C

Aviation Gasoline Test Report Performa

£ÉÉ®iÉ ºÉ®BÉEÉ® GOVERNMENT OF INDIA

xÉÉMÉ® ÉÊ´ÉàÉÉxÉxÉ àÉcÉÉÊxÉnä¶ÉÉãÉªÉ O/O THE DIRECTOR GENERAL OF CIVIL AVITION

ºÉ{ÉEn®VÉÆMÉ AªÉ®{ÉÉä]Ç BÉEä ºÉÉàÉxÉä ,iÉBÉExÉÉÒBÉEÉÒ BÉEäxp xÉ<Ç ÉÊnããÉÉÒ -3 OPP. S.J.AIRORT TECHNICAL CENTRE, N.DELHI-3

{ÉÉÊ®FÉhÉ ÉÊ®{ÉÉä]Ç ºÉÆJªÉÉ ]ÉÒ.ºÉÉÒ./AºÉÉÒºÉÉÒ./A´É.MÉèºÉ/ ÉÊnxÉÉÆBÉE : TEST REPORT NO. TC/ AV.GAS./ DATED : To

ÉÊ]{{ÉhÉÉÒ - |ÉºiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MÉªÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉÆ¤ÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉÉºÉxÉ xÉcÉÒ cè * NOTE : THE SAMPLE SUBMITTED HAS BEEN TESTED AND THE RESULTS OBTAINED ARE

GIVEN BELOW. THIS REPORT RELATES TO THE SAMPLE TESTED AND DOES NOT

GUARANTEE THE BULK OF THE MATERIALS ETC. TO BE OF EQUAL QUALITY.

______________________________________________________________________________________

_____ ÉÊ´ÉÉÊxÉnä¶ÉxÉ ºÉ. - bä{ÉE. º]äxÉ. 91-90( <Ç¶ÉÖ ºÉ.-4 )/ +ÉÉ<Ç.AºÉ.1604-1994 SPECIFICATION NO.- DEF. STAN. 91-90 ( ISSUE NO. 4) / IS 1604-

1994 xÉàÉÚxÉÉ /SAMPLE : ÉÊVÉºÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MÉªÉÉ/SUPPPLIED BY : |Én¶ÉÇBÉE º]ÉBÉEÂÂ REP. STOCK : ºÉÆnÇ£É ºÉÆJªÉÉ REF. NO. : ]èBÉE ºÉÆ. TANK NO. : ¤ÉèSÉ ºÉ. BATCH NO. :

|ÉÉ{iÉ BÉE®xÉä BÉEÉÒ ÉÊiÉÉÊlÉ DATE OF RECEIVING :

ºÉèà{ÉÉËãÉMÉ BÉEÉÒ ÉÊiÉÉÊlÉ DATE OF SAMPLING : VÉÉÆSÉ BÉEÉ BÉEÉ®hÉ REASON FOR TESTING :

µÉEàÉÉÆBÉE Sr.no.

MÉÖhÉtÉàÉÇ Characteristics

{ÉÉÊ®FÉhÉ {ÉÉÊ®hÉÉàÉ Test Result

+ÉÉ´É¶BÉEiÉÉ Requirement

1. ÉÊnJÉÉ´É] Appearance

ºÉÉ{ÉE SÉàÉBÉEÉÒãÉÉ +ÉÉè® ºÉÉàÉÉxªÉ iÉÉ{ÉàÉÉxÉ {É® BÉEÉä<Ç ~ÉäºÉ {ÉnÉlÉÇ +ÉÉè® {ÉÉxÉÉÒ ®ÉÊciÉ Clear bright &

free from solid

matter &

undissolved water

at normal ambient

temp.

2. ®ÆMÉ colour (visual) xÉÉÒãÉÉ / Blue 3. vÉxÉi´É Density At 15oC

Kg/m3

ÉÊ®{ÉÉä]Ç / Report

4. ]äbÅÉ <lÉÉ<ÇãÉ ãÉèb Tetraethyl Lead content g Pb/ l, Max

0.56

5. VÉãÉ |ÉÉÊiÉÉÊµÉEªÉÉ Water Reaction +É.+ÉÆiÉ®{Éß~ ®äÉË]MÉ Interface Rating +ÉÉ. {ÉßlÉBÉEÉ´É ®äÉË]MÉ Separation Rating <. +ÉÉªÉiÉxÉ {ÉÉÊ®´ÉiÉÇxÉ Volume change

2.0 (Max.)

2.0 (Max.)

2.0 (Max.)

6. ®éb ´ÉÉ−{É nÉ¤É Ried Vapour Pressure at 37.8

oC kPa

38.0-49.0

7. ÉÊcàÉÉÆBÉE ÉÊ¤ÉxnÖ Freezing Point OC

-60 (Max.)

8. AÉÊxÉãÉÉÒxÉ MÉÖ°ôi´É =i{ÉÉn ,Aniline Gravity Product Min.

7500

9. iÉÉÆ¤ÉÉ ºÉÆFÉÉ®hÉ ´ÉMÉÉÔBÉE® +ÉÉÊvÉBÉEiÉàÉ Copper Strip corrosion

Classification for 2 hours at

100 oC Max.

1ºÉä LÉ®É¤É xÉcÉÓ

Not worse than

no.1

-------------------------------------------------------------------------------------------- +ÉàªÉÖÉÎBÉDiÉªÉÉÆ /Remarks: -------------------------------------------------------------------------------------------- {ÉÉÊ®ÉÊFÉiÉ /TESTED BY :

VÉÉÆSÉBÉEiÉÉÇ/TESTED BY : +ÉxÉÖàÉÉäÉÊniÉ APPROVED BY :

(Deputy Director)

for DGCA

10. MÉÉån BÉEÉÒ àÉÉèVÉÚnMÉÉÒ,ÉÊàÉ.OÉÉ/100ÉÊàÉ.ãÉÉÒ. Existent Gum mg/100ml

3.0 (Max.) 11. +ÉÉºÉ´ÉxÉ Distillation

i) +ÉÉ®ÆÉÊ£ÉBÉE BÉD´ÉlÉxÉÉÆBÉE Initial Boiling Point

oC

ii) <ÇÆtÉxÉ ´ÉºÉÚãÉÉÒ Recovered 10 % by volume at

oC

40 % by volume at oC



iii) +ÉÆÉÊiÉàÉ BÉD´ÉlÉxÉÉÆBÉE Final Boiling Point

oC

iv) 10% +ÉÉè® 50%´ÉÚºÉãÉÉÒ BÉEÉ iÉÉ{ÉàÉÉxÉ BÉEÉ ªÉÉäMÉ Sum of 10%+50%

evaporated temp.

v) +É´É¶Éä−É Residue % by vol.

vi) cÉÉÊxÉ Loss % by vol.

ÉÊ®{ÉÉä]Ç / Report

75 (Max.)

75 (Min.)

105(Max.)

135(Max.)

170 (Max.)

135 (Min.)

1.5 (Max.)

1.5(Max.)

VVIP Flight Fuel Test Report Performa

£ÉÉ®iÉ ºÉ®BÉEÉ® GOVERNMENT OF INDIA xÉÉMÉ® ÉÊ´ÉàÉÉxÉxÉ àÉcÉÉÊxÉnä¶ÉÉãÉªÉ

O/O THE DIRECTOR GENERAL OF CIVIL AVIATION

ºÉ{ÉEn®VÉÆMÉ AªÉ®{ÉÉä]Ç BÉEä ºÉÉàÉxÉä ,iÉBÉExÉÉÒBÉEÉÒ BÉEäxp xÉ<Ç ÉÊnããÉÉÒ -3 OPP. S.J.AIRPORT TECHNICAL CENTRE, N.DELHI-3

{ÉÉÊ®FÉhÉ ÉÊ®{ÉÉä]Ç ºÉÆJªÉÉ ]ÉÒ.ºÉÉÒ. / A.]ÉÒ.A{ÉE./2012/ ÉÊnxÉÉÆBÉE : TEST REPORT NO. TC/ATF/2012/ DATED :

To

ÉÊ]{{ÉhÉÉÒ - |ÉºiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MÉªÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉÆ¤ÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉ´ÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉÉºÉxÉ xÉcÉÒ cè * NOTE : THE SAMPLE SUBMITTED HAS BEEN TESTED AND THE RESULTS

OBTAINED ARE GIVEN BELOW. THIS REPORT RELATES TO THE SAMPLE

TESTED AND DOES NOT GUARANTEE THE BULK OF THE MATERIALS ETC.

TO BE OF EQUAL QUALITY.

________________________________________________________________ ÉÊ´ÉÉÊxÉnä¶ÉxÉ ºÉ. - bä{ÉE. º]äxÉ. 91-91( <Ç¶ÉÖ ºÉ.-7 )/ +ÉÉ<Ç.AºÉ.1571-2008 SPECIFICATION NO.- DEF. STAN. 91-91 (ISSUE NO.7) / IS 1571-2008

xÉàÉÚxÉÉ SAMPLE : VÉä] A-1 / JET A-1 BÉEà{ÉxÉÉÒ BÉEÉ xÉÉàÉ /COMPANY’S NAME : ÉÊVÉºÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MÉªÉÉ SUPPLIED BY : |Én¶ÉÇBÉE º]ÉBÉEÂ REP. STOCK : ºÉÆn£ÉÇ ºÉÆJªÉÉ REF. NO. : ]èBÉE ºÉÆ. TANK NO. : ¤ÉèSÉ ºÉ. BATCH NO. : |ÉÉ{iÉ BÉE®xÉä BÉEÉÒ ÉÊiÉÉÊlÉ DATE OF RECEIVING: ºÉèà{ÉÉËãÉMÉ BÉEÉÒ ÉÊiÉÉÊlÉ DATE OF SAMPLING :

µÉEàÉÉÆBÉE Sr.no.




1. ÉÊnJÉÉ´É] Appearance

ºÉÉ{ÉE SÉàÉBÉEÉÒãÉÉ +ÉÉè® ºÉÉàÉÉxªÉ iÉÉ{ÉàÉÉxÉ {É® BÉEÉä<Ç ~ÉäºÉ {ÉnÉlÉÇ +ÉÉè® {ÉÉxÉÉÒ ®ÉÊciÉ Clear bright &

free from solid

matter &

undissolved water

at normal ambient

temp.

2.

+ÉàãÉiÉÉ Acidity total mg KOH /g

0.015 (Max.)

3.

MÉÆtÉBÉE àÉ®BÉEä{]xÉ Sulphur Mercaptan% by Mass ,

0.003 (Max.)

4. bÉBÉD]® {ÉÉÊ®FÉhÉ Doctor test xÉBÉEÉ®ÉiàÉBÉE Negative*

5. vÉxÉi´É Density At 15oC Kg/m3 775 - 840

6. AÉÊxÉãÉÉÒxÉ MÉÖ°ôi´É =i{ÉÉn , Aniline Gravity Product

4800 ( Min.)

7.

tÉÚ©É ÉÊ¤ÉxnÖ Smoke Point , mm

19 (Min.)

8. xÉ{ÉlÉãÉÉÒxÉ % +ÉÉªÉiÉxÉ Naphthalenes % Vol.

3.0 (Max.)

9.

ºÉÆFÉÉ®hÉ Corrosion iÉÉÆ¤ÉÉ ºÉÆFÉÉ®hÉ ´ÉMÉÉÔBÉE®hÉ +ÉÉÊvÉBÉEiÉàÉ Copper corrosion Classification

for 2 hours at 100 oC, Max.

1 (Not Worse than

No.1 as per

ASTM Copper

Strip Corrosion

Standards)

10

ºÉÆnÚÉBÉE Contaminants MÉÉån BÉEÉÒ àÉÉèVÉÚnMÉÉÒ,ÉÊàÉ.OÉÉ/100ÉÊàÉ.ãÉÉÒ. Existent Gum mg/100ml

7.0 (Max.)

11. VÉãÉ |ÉÉÊiÉÉÊµÉEªÉÉ Water Reaction +ÉÆiÉ®{Éß~ ®äÉË]MÉ Interface Rating

1(b) (Max.)

12.

º{ÉÖ®ÉÆBÉE , Flash Point oC

38.0 (Min.)

+ÉàªÉÖÉÎBÉDiÉªÉÉÆ : REMARKS :

{ÉÉÊ®ÉÊFÉiÉ/TESTED BY

Checked By +ÉxÉÖàÉÉäÉÊniÉ/Approved By ( Deputy Director )

for DGCA *The alternative requirement Doctor Test is a secondary requirement of Sulfur Mercaptan. In the event of a conflict between Sulfur Mercaptan and Doctor Test results, requirement Sulfur Mercaptan shall prevail.

Aviation Turbine Fuel Test Report Performa

£ÉÉ®iÉ ºÉ®BÉEÉ® GOVERNMENT OF INDIA xÉÉMÉ® ÉÊ´ÉàÉÉxÉxÉ àÉcÉÉÊxÉnä¶ÉÉãÉªÉ

O/O THE DIRECTOR GENERAL OF CIVIL AVIATION

ºÉ{ÉEn®VÉÆMÉ AªÉ®{ÉÉä]Ç BÉEä ºÉÉàÉxÉä ,iÉBÉExÉÉÒBÉEÉÒ BÉEäxp xÉ<Ç ÉÊnããÉÉÒ -3 OPP. S.J.AIRPORT TECHNICAL CENTRE, N.DELHI-3

{ÉÉÊ®FÉhÉ ÉÊ®{ÉÉä]Ç ºÉÆJªÉÉ ]ÉÒ.ºÉÉÒ. / A.]ÉÒ.A{ÉE./2012/ ÉÊnxÉÉÆBÉE : TEST REPORT NO. TC/ATF/2012/ DATED :

To

ÉÊ]{{ÉhÉÉÒ - |ÉºiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MÉªÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉÆ¤ÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉ´ÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉÉºÉxÉ xÉcÉÒ cè * NOTE : THE SAMPLE SUBMITTED HAS BEEN TESTED AND THE RESULTS

OBTAINED ARE GIVEN BELOW. THIS REPORT RELATES TO THE SAMPLE

TESTED AND DOES NOT GUARANTEE THE BULK OF THE MATERIALS ETC.

TO BE OF EQUAL QUALITY.

________________________________________________________________ ÉÊ´ÉÉÊxÉnä¶ÉxÉ ºÉ. - bä{ÉE. º]äxÉ. 91-91( <Ç¶ÉÖ ºÉ.-7 )/ +ÉÉ<Ç.AºÉ.1571-2008 SPECIFICATION NO.- DEF. STAN. 91-91 (ISSUE NO.7) / IS 1571-2008

xÉàÉÚxÉÉ SAMPLE : VÉä] A-1 / JET A-1 BÉEà{ÉxÉÉÒ BÉEÉ xÉÉàÉ /COMPANY’S NAME : ÉÊVÉºÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MÉªÉÉ SUPPLIED BY : |Én¶ÉÇBÉE º]ÉBÉEÂ REP. STOCK : ºÉÆn£ÉÇ ºÉÆJªÉÉ REF. NO. : ]èBÉE ºÉÆ. TANK NO. : ¤ÉèSÉ ºÉ. BATCH NO. : |ÉÉ{iÉ BÉE®xÉä BÉEÉÒ ÉÊiÉÉÊlÉ DATE OF RECEIVING: ºÉèà{ÉÉËãÉMÉ BÉEÉÒ ÉÊiÉÉÊlÉ DATE OF SAMPLING :

TEST REPORT NO. TC/APP/ATF/2012/ DATED /ÉÊnxÉÉÆBÉE : µÉEàÉÉÆBÉE Sr.no.

MÉÖhÉtÉàÉÇ

Characteristics

Method



1

ÉÊnJÉÉ´É] Appearance

Visual

2ºÉÉ{ÉE SÉàÉBÉEÉÒãÉÉ +ÉÉè® ºÉÉàÉÉxªÉ iÉÉ{ÉàÉÉxÉ {É® BÉEÉä<Ç ~ÉäºÉ {ÉnÉlÉÇ +ÉÉè® {ÉÉxÉÉÒ ®ÉÊciÉ Clear bright &

free from solid

matter &

undissolved

water at

normal

ambient temp.

2 ºÉÆªÉÉäVÉxÉ Composition +ÉàãÉiÉÉ Acidity total mg KOH

/g

P:113

0.015 (Max)

3 Aä®ÉäàÉäÉÊ]BÉE Aromatics % by

volume

P:23

25 (Max)

4 MÉÆtÉBÉE àÉ®BÉEä{]xÉ Sulphur Mercaptan%

by Mass

P:109

0.0030 (Max)

5

*bÉBÉD]® {ÉÉÊ®FÉhÉ Doctor test

P: 19

Negative

6 BÉÖEãÉ MÉÆtÉBÉE .à Sulphur total, % by

mass

P:34

0.30 (Max)

7 ´ÉÉ{É¶ÉÉÒãÉiÉÉ Volatality +ÉÉºÉ´ÉxÉ Distillation +ÉÉ®ÆÉÊ£ÉBÉE BÉD´ÉlÉxÉÉÆBÉE Initial Boiling Point

oC

P:18

Report

8 <ÇÆtÉxÉ ´ÉºÉÚãÉÉÒ Fuel Recovered


P:18

205 (Max.)



P:18

Report



P:18

Report

11 +ÉÆÉÊiÉàÉ BÉD´ÉlÉxÉÉÆBÉE Final Boiling Point oC,

P:18

300(Max.)

12 +É´É¶ Residue %by vol.

P:18 1.5 (Max.)

13 cÉÉÊxÉ Loss % by vol.

P:18 1.5 (Max.)

14 º{ÉÖ®ÉÆBÉE , Flash Point oC ,

P:20 38.0 (Min.)

15

tÉxÉi´É Density At 15oC Kg/m

P:16

775-840

16

iÉ®ãÉiÉÉ Fluidity ÉÊcàÉÉÆBÉE ÉÊ¤ÉxnÖ Freezing Point

oC ,

P:11

-47 (Max.)

17

ncxÉ Combustion AÉÊxÉãÉÉÒxÉ MÉÖ°ôi´É =i{ÉÉn , Aniline Gravity Product

P:3

4800 (Min.)

18

tÉÚ©É ÉÊ¤ÉxnÖ Smoke Point , mm

P:31

19 (Min.)

19

xÉ{ÉlÉãÉÉÒxÉ % +ÉÉªÉiÉxÉ Naphthalenes % Vol.

P: 118

3.0 (Max.)

20

ºÉÆFÉÉ®hÉ Corrosion iÉÉÆ¤ÉÉ ºÉÆFÉÉ®hÉ ´ÉMÉÉÔBÉE®hÉ, Copper corrosion

Classification for 2 hours at 100

oC,

P: 15

Not worse

than no.1

(Max.)

21

ºÉÆnÚÉBÉE Contaminants MÉÉån BÉEÉÒ àÉÉèVÉÚnMÉÉÒ, ÉÊàÉ.OÉÉ/100ÉÊàÉ.ãÉÉÒ. Existent Gum

mg/100ml

P: 29

7.0 (Max.)

22 VÉãÉ |ÉÉÊiÉÉÊµÉEªÉÉ Water Reaction +ÉÆiÉ®{Éß~ ®äÉË]MÉ Interface Rating

P:42

1b (Max.)

+ÉàªÉÖÉÎBÉDiÉªÉÉÆ :

REMARKS :

TESTED BY: CHECKED BY +ÉxÉÖàÉÉäÉÊniÉ/APPROVED BY:

(Deputy Director)

For DGCA *The alternative requirement Sulphur Mercaptan is a secondary requirement to Doctor Test. In the event of

a conflict between Sulfur Mercaptan and Doctor Test results, requirement Sulphur Mercaptan shall

prevail.

Lubricating Oil Test Report Performa

£ÉÉ®iÉ ºÉ®BÉEÉ® GOVERNMENT OF INDIA

xÉÉMÉ® ÉÊ´ÉàÉÉxÉxÉ àÉcÉÉÊxÉnä¶ÉÉãÉªÉ O/O THE DIRECTOR GENERAL OF CIVIL AVITION


{ÉÉÊ®FÉhÉ ÉÊ®{ÉÉä]Ç ºÉÆJªÉÉ ]ÉÒ.ºÉÉÒ. /ÉÊàÉºÉÂ / TEST REPORT NO. TC/MISC./ DATED /ÉÊnxÉÉÆBÉE : _____________________________________________________________

To

ÉÊ]{{ÉhÉÉÒ - |ÉºiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MÉªÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉÆ¤ÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉÉºÉxÉ xÉcÉÒ cè * NOTE: THE SAMPLE SUBMITTED HAS BEEN TESTED AND THE RESULTS OBTAINED ARE

GIVEN BELOW. THIS REPORT RELATES TO THE SAMPLE TESTED AND DOES NOT

GUARANTEE THE BULK OF THE MATERIALS ETC. TO BE OF EQUAL QUALITY.

______________________________________________________________________________________

_____

ÉÊ´ÉÉÊxÉnä¶ÉxÉ ºÉ. - ÉÊàÉãÉÂÂ - {ÉÉÒ.+ÉÉ®.A{ÉE.- 7808 AãÉÂ SPECIFICATION NO.- MIL – PRF- 7808 L xÉàÉÚxÉÉ : <ÆVÉxÉ +ÉÉäªÉãÉ OÉäb -3 SAMPLE : Engine oil grade-3

ÉÊVÉºÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MÉªÉÉ : SUPPPLIED BY :

|Én¶ÉÇBÉE º]ÉBÉEÂÂ REP. STOCK : ºÉÆnÇ£É ºÉÆJªÉÉ REF. NO. : ]èBÉE ºÉÆ. TANK NO. : ¤ÉèSÉ ºÉ. BATCH NO. :



TEST REPORT NO. TC/MISC./ DATED /ÉÊnxÉÉÆBÉE :

µÉEàÉÉÆBÉE Sl.no.




1. tÉxÉi´É Density At 15oC Kg/m

3

------

2. BÉE. ¶ÉÖptÉÉÉÊiÉBÉE ºlÉÉxÉ xªÉÚxÉiÉàÉ / Min. a. KinematicViscosity Cst at 40 oC

JÉ. ¶ÉÖptÉÉÉÊiÉBÉE ºlÉÉxÉ xªÉÚxÉiÉàÉ / Min. b. KinematicViscosity Cst at 100 oC

11.5

3.0

3. º{ÉÖ®ÉÆBÉE Flash Point oC xªÉÚxÉiÉàÉ / Min.

210

4. +ÉàãÉiÉÉ +ÉÉÊvÉ Acidity number mg KOH /g

Max.

(As per IP-139)

0.30

--------------------------------------------------------------------------------------------

+ÉàªÉÖÉÎBÉDiÉªÉÉÆ : REMARKS :

--------------------------------------------------------------------------------------------

{ÉÉÊ®ÉÊFÉiÉ / Tested By: VÉÉÆSÉBÉEiÉÉÇ / Checked By: +ÉxÉÖàÉÉäÉÊniÉ Approved By:

(Deputy Director)

For DGCA

Hydraulic Fluids Test Report Performa

£ÉÉ®iÉ ºÉ®BÉEÉ®

GOVERNMENT OF INDIA xÉÉMÉ® ÉÊ´ÉàÉÉxÉxÉ àÉcÉÉÊxÉnä¶ÉÉãÉªÉ

O/O THE DIRECTOR GENERAL OF CIVIL AVITION


{ÉÉÊ®FÉhÉ ÉÊ®{ÉÉä]Ç ºÉÆJªÉÉ ]ÉÒ.ºÉÉÒ. /ÉÊàÉºÉÂ / TEST REPORT NO. TC/MISC./ DATED /ÉÊnxÉÉÆBÉE : To

ÉÊ]{{ÉhÉÉÒ - |ÉºiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MÉªÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉÆ¤ÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉÉºÉxÉ xÉcÉÒ cè * NOTE : THE SAMPLE SUBMITTED HAS BEEN TESTED AND THE RESULTS OBTAINED ARE

GIVEN

BELOW. THIS REPORT RELATES TO THE SAMPLE TESTED AND DOES NOT GUARANTEE THE

BULK OF THE MATERIALS ETC. TO BE OF EQUAL QUALITY.

______________________________________________________________________________________

_____

ÉÊ´ÉÉÊxÉnä¶ÉxÉ ºÉ. - ÉÊàÉãÉÂÂ - 5606 ASÉÂ SPECIFICATION NO.- MIL – 5606 H xÉàÉÚxÉÉ : cÉ<bÅÉäÉÊãÉBÉE {ÉEãÉÚ<b SAMPLE : Hydraulic Fluid

ÉÊVÉºÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MÉªÉÉ : SUPPPLIED BY :

|Én¶ÉÇBÉE º]ÉBÉEÂÂ REP. STOCK : ºÉÆnÇ£É ºÉÆJªÉÉ REF. NO. : ]èBÉE ºÉÆ. TANK NO. : ¤ÉèSÉ ºÉ. BATCH NO. :



TEST REPORT NO. TC/MISC./ DATED /ÉÊnxÉÉÆBÉE :

µÉEàÉÉÆBÉE Sl.no.




1. tÉxÉi´É Density At 15oC Kg/m

3

------

2. BÉE. ¶ÉÖptÉÉÉÊiÉBÉE ºlÉÉxÉ xªÉÚxÉiÉàÉ / Min. a. KinematicViscosity Cst at 40 oC

JÉ. ¶ÉÖptÉÉÉÊiÉBÉE ºlÉÉxÉ xªÉÚxÉiÉàÉ / Min. b. KinematicViscosity Cst at 100 oC

13.2

4.90

3. º{ÉÖ®ÉÆBÉE Flash Point oC xªÉÚxÉiÉàÉ / Min.

82

4. +ÉàãÉiÉÉ +ÉÉÊvÉBÉEiÉàÉ Acidity number mg KOH /g

Max.

(As per IP-139)

0.20

5. |É´ÉÉc ÉÊ¤ÉxnÖ Pour Point oC +ÉÉÊvÉBÉE /Max

-60

--------------------------------------------------------------------------------------------

+ÉàªÉÖÉÎBÉDiÉªÉÉÆ : Remarks :

--------------------------------------------------------------------------------------------

{ÉÉÊ®ÉÊFÉiÉ / Tested By: VÉÉÆSÉBÉEiÉÉÇ / Checked By: +ÉxÉÖàÉÉäÉÊniÉ Approved By:

(Deputy Director)

for DGCA

aero laboratory division aircraft engineering directorate directorate ... laboratory division...

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