A Lead and two other Mechanics report about confusion; distractions; and pressures to accomplish wing tank fuel boost pump changes and fuel tank wire harness replacements; that led to the wing tanks not having the required Clearance to Close; RII Inspections accomplished prior to closing-up the wing fuel tanks on an MD-80 aircraft.
Synopsis
A Lead and two other Mechanics report about confusion; distractions; and pressures to accomplish wing tank fuel boost pump changes and fuel tank wire harness replacements; that led to the wing tanks not having the required Clearance to Close; RII Inspections accomplished prior to closing-up the wing fuel tanks on an MD-80 aircraft.
Narrative
I started at XA00 early start; for 4 hours of fuel tank overtime work; and was assigned to an MD-80 aircraft to finish a fuel pump and harness replacement job. I was told the tanks were closed and signed off. I was told of some confusion about a type of tape to use to satisfy the AMM. I was told that an 'Approved Addition' to the AMM was coming from engineering. After the 'Engineering Approval' arrived; I completed the task of installing the tape on the fuel pump wires. I noted that the fuel tank plates were installed. I was told that a leak check was still needed for the plates and the spar wire feed through grommet. The other assigned AMT transferred fuel and I inspected the spar grommet for leaks and the fuel tank plates for leaks. I then installed the Tie Tape and was approved. At this time I was late for the start of my scheduled shift assignment of XE:00 to XO:30. I hurried and signed off my part of the work accomplished so that I could start my regular work assignment. I would recommend a Dedicated Check List for Leadership to ensure all required paperwork is pulled for fuel tank; Maintenance Check Work Cards; AMM and General Procedures Manual (GPM) 13-02. Dedicated checklist for fuel tank work package review. More training on preventing the 'Norms' with fuel tank work. Dedicated Fuel Tank Coordinator assigned to ensure all Coordinator functions are accomplished. Right now the Coordinator is a dual job function usually not assigned; example one AMT is the Coordinator/Attendant. I had assumed all the necessary documentation was pulled and printed; for example the Task Cards and the AMM and the GPM. I assumed all the procedures were followed up to the point of me starting work on the aircraft.
Second reporter narrative
My work shift started at XA:00 for daytime overtime. I was assigned and tasked to a MD-80 aircraft; for a right wing aft fuel boost pump wiring harness change. No turnover was giving to me upon arrival other than the aircraft's location in the hangar; and that everything was documented on the work progression form. I worked with other Mechanics on 4-hour holdover to complete the harness change. Between XE:00-XF:30 the Holdover's signed their portion of the tasks they completed and then departed. Thereafter; I completed the outside portion of the fuel tank harness; which consist of wiring connection points; routing; and security. At this time; it's about XK:00 hours and that's when I noticed the Maintenance Manual reference error; in Step B(9) of AMM 28-20-07-2; 'Removal/Installation of Fuel Pump Electrical Conduit.' That step requires installation of tape on electrical wires from grommet to terminal board. The problem with this is what tape? And why isn't this information located at the beginning of the chapter under equipment and materials list. I brought this to the attention of management for correction and authority from engineering for a line change approval. Now it's about 45 minutes to an 1 hour from the end of my 10 hour shift; and nothing was getting resolved on how they were going to handle this problem. At this time I'm trying to review and complete paperwork; when Management handed me some faxed reference of electrical tape Part Number and manufacturer for the Boeing 717 aircraft fleet type that will be incorporated in the MD80 fleet later in the year. How does this help me now; I asked? And where is the engineering approval? This is where the disagreement took place; and I needed to get my paperwork duties in order; before my shift expires. I allowed this situation to entice me to overlook and rush through procedures listed on the GPM; Maintenance Manual; and Maintenance Check Work Cards; which was my oversight. Prior to departing my shift I briefed our Technical Lead who was on-shift about the engineering approval requirement needed so the aircraft could be completed. Company should require classroom training and Annual Recurrent Training. Have a mandatory checklist to complete prior to each Fuel Tank Entry job. Awareness intervention for fuel tank qualified crewmembers; which could be introduced via training department. Management to allocate a designated member to be the Coordinator to be in charge of each job; separate from crewmembers who are performing the fuel tank job. GPM 13-02 does give a description of assignments; but it's not performed in a organized manner. My error is assuming that the proper paperwork was previously printed; and while trying to review logbook and paperwork I was distracted from my duties to handle Engineering Approval (changes) in Maintenance Manual Procedures. In essence; I performed an oversight of required paperwork.
Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.