A B737-800 CAPTAIN REPORTS OF CONCERNS ABOUT MAINT DEFERRING AS 'INOP' THE DOOR 1-LEFT OVERHEAD ANNUNCIATOR LIGHT THAT WOULD CONTINUE TO ILLUMINATE ON ITS OWN; TRIGGERING THE MASTER CAUTION LIGHT DURING TKOF ROLL AND AT CRUISE.

Date: 2007-10 · Aircraft: B737-800 · Phase: takeoff

Anomalies: aircraft-equipment-problem-less-severe|deviation-discrepancy-procedural-maintenance|deviation-discrepancy-procedural-published-material-policy|other-erratic-door-warnings

Synopsis

A B737-800 CAPTAIN REPORTS OF CONCERNS ABOUT MAINT DEFERRING AS 'INOP' THE DOOR 1-LEFT OVERHEAD ANNUNCIATOR LIGHT THAT WOULD CONTINUE TO ILLUMINATE ON ITS OWN; TRIGGERING THE MASTER CAUTION LIGHT DURING TKOF ROLL AND AT CRUISE.

Narrative

ACFT WAS DISPATCHED WITH THE L-1 DOOR WARNING SYS ON PLACARD. THE PROB WAS A NASTY REPEATING ONE WITH WKS OF WRITE-UPS AND HONEST TROUBLESHOOTING/PARTS REPLACEMENT. AS WE STARTED THE TKOF ROLL; AT APPROX 30 KTS; WE GOT A MASTER CAUTION (YELLOW LIGHT). LOOKING AROUND I SAW THAT IT WAS THE DOOR ANNUNCIATOR FOR THE L-1 DOOR. AS THE FO WAS HESITATING IN THE CONTINUATION OF THE TKOF ROLL; I TOLD HIM 'IT'S JUST THE DOOR; GO; GO; GO.' WE CONTINUED THE TKOF WITH THE DOOR LIGHT CYCLING ON AND OFF AT VARIOUS SPDS FINALLY CEASING OUT OF 7000 FT. I FEEL THAT THE APPLICATION OF THE MEL WAS WELL INTENTIONAL BUT INEXACT. THE WARNING SYS WORKED; IE; IF THE DOOR OPENED; THE LIGHT CAME ON RELIABLY. THE PROB WAS THE WARNING LIGHT WOULD CYCLE ON ITS OWN. SUCH ACTION COULD PROMPT AN ABORT; WHICH IS A HIGH RISK MANEUVER. THIS IS AN UNFORESEEN CONSEQUENCE OF USING THIS MEL ITEM WHEN THE SYS IS MALFUNCTIONING AS THIS ONE WAS. IN MY OPINION; THE MEL WAS WRITTEN FOR A TOTAL FAILURE OF THE WARNING LIGHT. SUCH APPLICATION WOULD BE PROPER AND SAFE. THE APPLICATION OF THIS MEL IN THIS CASE HOWEVER WAS A SET-UP FOR A POTENTIAL DISASTER. WE OPERATED 2 LEGS ON LONG; CLEAN; DRY RWYS; WHICH ALLOWED US THE LUXURY OF TIME DEALING WITH THE FALSE WARNING. ON A POOR; IE; SHORT/CONTAMINATED RWY; THE RESULTS WOULD HAVE PROBABLY BEEN AN ABORT. WHAT WASN'T RECOGNIZED WAS THE LINKAGE OF THE ERRONEOUS WARNING WITH THE MASTER WARNING SYS AND ITS EFFECTS ON PLT ACTIONS. I SUGGEST THE SCOPE OF THIS MEL ITEM BE RESTR TO TOTAL SYS FAILURE; NOT PARTIAL AS WAS THIS CASE. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: REPORTER STATED HIS CONCERNS ABOUT HIS COMPANY'S MEL MAINT PROCEDURE ALLOWING THE DEFERRAL OF A CABIN DOOR WARNING SYSTEM LIGHT AS 'INOP;' WHEN IN FACT; THE DOOR ANNUNCIATOR LIGHT CONTINUED TO FLICKER 'ON' AND 'OFF' DURING TKOF ROLL AND AT CRUISE. THIS HAS ALSO TRIGGERED THE MASTER CAUTION LIGHT EACH TIME. NO PROCEDURES EXIST IN THE MEL FOR MAINT TO OPEN AND COLLAR A C/B TO ACTUALLY DISARM THE ERRATIC ANNUNCIATOR LIGHT. THE CURRENT MEL PROCEDURE CREATES AN ENVIRONMENT OF CONFUSION AND DISTRACTION DURING CRITICAL OPERATIONAL PERIODS. REPORTER ADDS; IF THE SYSTEM IS DEFERRED AS 'INOP;' THEN THAT SYSTEM SHOULD ACTUALLY BE 'INOP;' AND NOT BE ALLOWED TO CONTINUE FLASHING ERRATIC AND UNRELIABLE WARNINGS. DOOR LIGHTS ARE ILLUMINATED ON THE OVERHEAD ANNUNCIATOR PANEL NOT ON HIS EFIS SYSTEM FWD DISPLAY. REPORTER ALSO STATED HIS MAINT CONTROL SAYS THEY HAVE BEEN CHASING THE CAUSE OF THE ERRATIC DOOR INDICATION FOR TWO WEEKS. DOOR PROXIMITY SWITCHES HAVE BEEN CHANGED SEVERAL TIMES. MAINT SUSPECTS WIRE BUNDLE IS THE ISSUE.

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