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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.
India is participated in ICAO by the Representative of India.
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
Joint Director General
Director General of Civil Aviation
Deputy Director General
Deputy Director, Aircraft Engineering
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.
India is participated in ICAO by the Representative of India.
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
Joint Director General
Director General of Civil Aviation
Deputy Director General
Deputy Director, Aircraft Engineering
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.
Director General of Civil Aviation
Joint Director General
Deputy Director General
Deputy Director, Aircraft Engineering
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
6. Copper Strip Corrosion
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
5. Copper Strip Corrosion
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
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ÉÊ]{{ÉhÉÉÒ - |ɺiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MɪÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉƤÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉɺÉxÉ 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( <ǶÉÖ ºÉ.-4 )/ +ÉÉ<Ç.AºÉ.1604-1994 SPECIFICATION NO.- DEF. STAN. 91-90 ( ISSUE NO. 4) / IS 1604-
1994 xÉàÉÚxÉÉ /SAMPLE : ÉÊVɺÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MɪÉÉ/SUPPPLIED BY : |Én¶ÉÇBÉE º]ÉBÉE 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
+ÉɴɶBÉEiÉÉ 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 |ÉÉÊiÉÉʵÉEªÉÉ Water Reaction +É.+ÉÆiÉ®{Éß~ ®äÉË]MÉ Interface Rating +ÉÉ. {ÉßlÉBÉEÉ´É ®äÉË]MÉ Separation Rating <. +ÉɪÉiÉxÉ {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 ÉʤÉxnÖ Freezing Point OC
-60 (Max.)
8. AÉÊxÉãÉÉÒxÉ MÉÖ°ôi´É =i{ÉÉn ,Aniline Gravity Product Min.
7500
9. iÉÉƤÉÉ 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
-------------------------------------------------------------------------------------------- +ÉàªÉÖÉÎBÉDiɪÉÉÆ /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. +ÉɺɴÉxÉ 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
50 % by volume at oC
90 % 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) +ɴɶÉä−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¶ÉÉãɪÉ
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
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To
ÉÊ]{{ÉhÉÉÒ - |ɺiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MɪÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉƤÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉ´ÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉɺÉxÉ 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( <ǶÉÖ 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 : ÉÊVɺÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MɪÉÉ SUPPLIED BY : |Én¶ÉÇBÉE º]ÉBÉE 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.
MÉÖhÉtÉàÉÇ Characteristics
{ÉÉÊ®FÉhÉ {ÉÉÊ®hÉÉàÉ Test Result
+ÉɴɶBÉEiÉÉ 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.
+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 ÉʤÉxnÖ Smoke Point , mm
19 (Min.)
8. xÉ{ÉlÉãÉÉÒxÉ % +ÉɪÉiÉxÉ Naphthalenes % Vol.
3.0 (Max.)
9.
ºÉÆFÉÉ®hÉ Corrosion iÉÉƤÉÉ 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 |ÉÉÊiÉÉʵÉEªÉÉ Water Reaction +ÉÆiÉ®{Éß~ ®äÉË]MÉ Interface Rating
1(b) (Max.)
12.
º{ÉÖ®ÉÆBÉE , Flash Point oC
38.0 (Min.)
+ÉàªÉÖÉÎBÉDiɪÉÉÆ : 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¶ÉÉãɪÉ
O/O THE DIRECTOR GENERAL OF CIVIL AVIATION
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To
ÉÊ]{{ÉhÉÉÒ - |ɺiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MɪÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉƤÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉ´ÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉɺÉxÉ 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( <ǶÉÖ 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 : ÉÊVɺÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MɪÉÉ SUPPLIED BY : |Én¶ÉÇBÉE º]ÉBÉE 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
{ÉÉÊ®FÉhÉ {ÉÉÊ®hÉÉàÉ Test Result
+ÉɴɶBÉEiÉÉ Requirement
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 ºÉƪÉÉäVÉxÉ 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{ɶÉÉÒãÉiÉÉ Volatality +ÉɺɴÉxÉ Distillation +ÉÉ®ÆÉÊ£ÉBÉE BÉD´ÉlÉxÉÉÆBÉE Initial Boiling Point
oC
P:18
Report
8 <ÇÆtÉxÉ ´ÉºÉÚãÉÉÒ Fuel Recovered
10 % by volume at oC
P:18
205 (Max.)
9 <ÇÆtÉxÉ ´ÉºÉÚãÉÉÒ Fuel Recovered
50 % by volume at oC
P:18
Report
10 <ÇÆtÉxÉ ´ÉºÉÚãÉÉÒ Fuel Recovered
90 % by volume at oC
P:18
Report
11 +ÉÆÉÊiÉàÉ BÉD´ÉlÉxÉÉÆBÉE Final Boiling Point oC,
P:18
300(Max.)
12 +ɴɶ 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 ÉʤÉxnÖ 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 ÉʤÉxnÖ Smoke Point , mm
P:31
19 (Min.)
19
xÉ{ÉlÉãÉÉÒxÉ % +ÉɪÉiÉxÉ Naphthalenes % Vol.
P: 118
3.0 (Max.)
20
ºÉÆFÉÉ®hÉ Corrosion iÉÉƤÉÉ 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 |ÉÉÊiÉÉʵÉEªÉÉ Water Reaction +ÉÆiÉ®{Éß~ ®äÉË]MÉ Interface Rating
P:42
1b (Max.)
+ÉàªÉÖÉÎBÉDiɪÉÉÆ :
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
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. /ÉÊàɺÉ / TEST REPORT NO. TC/MISC./ DATED /ÉÊnxÉÉÆBÉE : _____________________________________________________________
To
ÉÊ]{{ÉhÉÉÒ - |ɺiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MɪÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉƤÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉɺÉxÉ 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. - ÉÊàÉãÉ - {ÉÉÒ.+ÉÉ®.A{ÉE.- 7808 AãÉ SPECIFICATION NO.- MIL – PRF- 7808 L xÉàÉÚxÉÉ : <ÆVÉxÉ +ÉÉäªÉãÉ OÉäb -3 SAMPLE : Engine oil grade-3
ÉÊVɺÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MɪÉÉ : SUPPPLIED BY :
|Én¶ÉÇBÉE º]ÉBÉE 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 :
TEST REPORT NO. TC/MISC./ DATED /ÉÊnxÉÉÆBÉE :
µÉEàÉÉÆBÉE Sl.no.
MÉÖhÉtÉàÉÇ Characteristics
+ÉɴɶBÉEiÉÉ Requirement
{ÉÉÊ®FÉhÉ {ÉÉÊ®hÉÉàÉ Test Result
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
--------------------------------------------------------------------------------------------
+ÉàªÉÖÉÎBÉDiɪÉÉÆ : 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¶ÉÉãɪÉ
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. /ÉÊàɺÉ / TEST REPORT NO. TC/MISC./ DATED /ÉÊnxÉÉÆBÉE : To
ÉÊ]{{ÉhÉÉÒ - |ɺiÉÖiÉ ÉÊBÉEA MÉA xÉàÉÚxÉä BÉEÉ {ÉÉÊ®FÉhÉ ÉÊBÉEªÉÉ MɪÉÉ cè +ÉÉè® |ÉÉ{iÉ {ÉÉÊ®hÉÉàÉ xÉÉÒSÉä ÉÊnªÉä MÉA cè * ªÉc ÉÊ®{ÉÉæ]Ç xÉàÉÚxÉÉ - {ÉÉÊ®FÉhÉ ºÉä ºÉƤÉÆÉÊtÉiÉ cè +ÉÉè® +ÉÉÊvÉBÉE ºÉÉàÉOÉÉÒ <iªÉÉÉÊn BÉEÉÒ ºÉàÉÉxÉ MÉÖhÉiÉÉ cÉäxÉä BÉEÉ +ÉÉgÉ´ÉɺÉxÉ 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. - ÉÊàÉãÉ - 5606 ASÉ SPECIFICATION NO.- MIL – 5606 H xÉàÉÚxÉÉ : cÉ<bÅÉäÉÊãÉBÉE {ÉEãÉÚ<b SAMPLE : Hydraulic Fluid
ÉÊVɺÉBÉEä uÉ®É ºÉ{ãÉÉ<Ç ÉÊBÉEªÉÉ MɪÉÉ : SUPPPLIED BY :
|Én¶ÉÇBÉE º]ÉBÉE 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 :
TEST REPORT NO. TC/MISC./ DATED /ÉÊnxÉÉÆBÉE :
µÉEàÉÉÆBÉE Sl.no.
MÉÖhÉtÉàÉÇ Characteristics
+ÉɴɶBÉEiÉÉ Requirement
{ÉÉÊ®FÉhÉ {ÉÉÊ®hÉÉàÉ Test Result
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 ÉʤÉxnÖ Pour Point oC +ÉÉÊvÉBÉE /Max
-60
--------------------------------------------------------------------------------------------
+ÉàªÉÖÉÎBÉDiɪÉÉÆ : Remarks :
--------------------------------------------------------------------------------------------
{ÉÉÊ®ÉÊFÉiÉ / Tested By: VÉÉÆSÉBÉEiÉÉÇ / Checked By: +ÉxÉÖàÉÉäÉÊniÉ Approved By:
(Deputy Director)
for DGCA