2 DC9-40 AIRPLANES EACH HAD 1 ENG EXCEED OPERATING LIMITATIONS DUE TO INCORRECT PWR PLANT ENGINEERING DIRECTIVES AND TECHNICIANS FAILURE TO PERFORM ENG RUNS PER THE MAINT MANUAL.

Date: 2002-03 · Aircraft: DC-9 40 · Phase: ground

Anomalies: aircraft-equipment-problem-critical|deviation-discrepancy-procedural-far|deviation-discrepancy-procedural-maintenance|deviation-discrepancy-procedural-published-material-policy

Synopsis

2 DC9-40 AIRPLANES EACH HAD 1 ENG EXCEED OPERATING LIMITATIONS DUE TO INCORRECT PWR PLANT ENGINEERING DIRECTIVES AND TECHNICIANS FAILURE TO PERFORM ENG RUNS PER THE MAINT MANUAL.

Narrative

I AM A LINE MAINT REPRESENTATIVE FOR AN ACR IN ZZZ. MY COMPANY; ON MAR/FRI/02 AND MAR/FRI2/02; ISSUED A WORK ORDER TO BE COMPLIED WITH WHICH STATES THAT A MAX TKOF PWR RUN BE ACCOMPLISHED AND RECORD PARAMETERS. THIS RUN WAS REQUESTED FOR ONLY 1 OF THE ENGS ON EACH OF THE ACFT. I WAS IN THE L SEAT OPERATING THE CTLS AND MR A; A COMPANY DESIGNATED ENG RUN AND TAXI TRAINER; WAS IN THE R SEAT ON EACH OF THE RUNS RECORDING THE PARAMETERS. IT WAS APPARENT TO MYSELF; AS WELL AS MR A; IN EVERYTHING WRITTEN; THAT ENGINEERING WAS REQUESTING PARAMETERS TO BE TAKEN AT MAX TKOF PWR AS STATED AND NOT CHARTED EPR FOR THE DAY. ON MAR/THU/02; PWR PLANT ENGINEERING FOUND THAT DUE TO THE EXCESSIVE TEMPS FROM THE ASSESSMENT RUNS THE ENGS IN QUESTION SHOULD BE FURTHER ADDRESSED AND IT WAS AT THIS TIME THAT I WAS ADVISED THAT IT WAS INDEED NOT PWR PLANT ENGINEERING'S INTENTION TO HAVE HAD US RUN THE ENGS AS STATED. ACFT X WAS THE ACFT THAT WAS RUN ON 03/FRI/02. THIS RUN APPEARED TO GO SMOOTHLY AND ALTHOUGH I HAVE BEEN TOLD BY MY COMPANY THAT MR A WRITTEN PARAMETERS SHOW THAT THIS ENG REACHED 640 DEGS C TO MY RECOLLECTION NEVER WENT PAST A RED LINE OF 620 DEGS C. MR A AND I WOULD CERTAINLY RECALL SUCH AN OCCURRENCE. THIS ENG IN QUESTION RECEIVED A BOROSCOPE INSPECTION WHICH FOUND NO FAULTS. ACFT Y WAS RUN ON MAR/FRI2/02. IN ADDITION TO THE EGT ASSESSMENT; I WAS RECEIVING ENG RUN AND TAXI RECURRENT TRAINING. ACFT Y WAS RUN IN THE SAME MANNER AS THE PREVIOUS ACFT. THE #1 ENG THROTTLE WAS BROUGHT UP TO THE STOP AT WHICH TIME THE EGT WENT TO 640 DEGS C. THE EGT; EPR; AND OUTSIDE AIR TEMP WERE RECORDED AND THE THROTTLE WAS REDUCED IN ORDER TO REMAIN BELOW RED LINE. THE OPERATING LIMITATION FOR THIS ENG IS 595 DEGS C FOR 5 MINS. THIS ENG IS BEING REMOVED AT THIS TIME FOR PRECAUTIONARY MEASURES. THE ENGINEERING WRITTEN REQUEST STATES THAT THE ENG SHOULD BE RUN FOR 3 MINS FOR STABILIZATION. THE ENG ON ACFT Y AS PREVIOUSLY STATED; MAY BE RUN AT 595 DEGS FOR 5 MINS. IT IS NOT UNREALISTIC THAT ONE MAY CONCLUDE THAT PWR PLANT ENGINEERING MAY ALLOW A SLIGHTLY HIGHER TEMP INCREASE FOR 3 MINS (MORE TEMP BUT LESS TIME) IN ORDER TO DOCUMENT A PARTICULAR REGIME THAT COULD BE WORSENING. IF PWR PLANT ENGINEERING HAD REFED THAT THIS ASSIGNMENT SHOULD BE CONDUCTED IN ACCORDANCE WITH THE APPLICABLE MAINT MANUAL REF THEIR INTENTIONS WOULD MOST CERTAINLY HAVE BEEN PRODUCTIVE. THE PAPERWORK FROM ENGINEERING INSTRUCTS THE TECHNICIAN TO MAIL A COPY OF THE COMPLETED FORMS. IF PROCS CALLED FOR A MORE TIMELY RECEPTION OF CONCLUSIONS THIS WOULD HAVE INSURED ANY FAULTS BEING FOUND IMMEDIATELY; RATHER THAN 2 WKS AFTER COMPLETION. I HAVE ENCLOSED A COPY OF THE PAPERWORK DESCRIBED.

Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.