An Engine Inspector reports that 12 borescope plugs were removed from a PW-2000 engine and the openings were left uncovered; open to FOD for twelve hours; while inspections were accomplished and inspection write-ups were worked by the Engine Test Run Mechanics. The Borescope procedure was not accomplished until twelve hours after the plugs were removed.
Synopsis
An Engine Inspector reports that 12 borescope plugs were removed from a PW-2000 engine and the openings were left uncovered; open to FOD for twelve hours; while inspections were accomplished and inspection write-ups were worked by the Engine Test Run Mechanics. The Borescope procedure was not accomplished until twelve hours after the plugs were removed.
Narrative
12 EA borescope plugs were removed from a PW-2000 engine; June 2009. The borescope plug openings were not covered as required per our engine shop operations manual. During the next 12 hours; an engine inspection was accomplished on this PW-2000 and 28 each; non-routine write-ups were made and worked by engine test run mechanics. During all this maintenance activity; the 12 each; borescope plug openings were uncovered and open to FOD entering the engine. The PW-2000 was not actually boroscoped until 12 hrs after the plugs were removed. This is just one example of the procedures followed by engine test run personnel. Borescope plug openings are left uncovered after every PW-2000 engine run; while maintenance (work) is done on the engine. I have brought up this issue to my Inspection Supervisor; Inspection Manager; Test Cell Manager; FOD Manager; and the Director of Engine Maintenance on several occasions; but the problem remains unsolved. The engine mentioned above was made serviceable June 2009.
NASA callback
Reporter stated that since he filed his report; a Shop Mechanic had worked with one of their Engine Engineers and using regular threaded borescope plugs; welded 'tee' handles of varying lengths; directly to the top of the plugs with an orange streamer attached to each 'tee' handle. Some of the safety plugs also have a universal joint welded to the plug and the 'tee' handle; is then welded to the universal joint.The various 'tee' handle lengths and universal joints are necessary in order to reach down; around and through hydraulic tubing; engine oil tubing; electrical wire bundles; angle brackets and pneumatic ducts to get to the open borescope holes. Reporter stated the new safety plugs and required installations will be added to their engine job cards. His carrier is also looking at designing similar borescope safety plugs for their other engines.
Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.