2010-04 · NASA ASRS report 885621
B757 Flight Attendants report electrical fumes during preflight which the Flight Crew believes to be exhaust fumes from ground equipment. During taxi the odor becomes stronger alarming some passengers. The flight returns to the gate where Maintenance discovers a faulty chiller fan.
One hour prior to departure flight attendants smelled an electrical odor in the aft cabin between rows 28-34. One flight attendant stated that the odor caused him a headache and his eyes to water. I went aft and smelled an electrical odor. Five minutes later again went aft and noticed the odor had dissipated noticeably. I then started the APU; disconnected ground power and the air-conditioning. The odor subsided to the point that the First Officer; flight attendants; and myself could no longer smell any odor. We boarded; pushed; and started the engines. The aft flight attendant said the odor had returned and was experiencing a headache. We returned to the gate and maintenance summoned. A chiller blower in the aft galley had shorted. We ventilated the cabin with the APU and doors. We departed a second time. Upon engine start the same flight attendant complained of odor and a headache along with two passengers. Note: Upon announcing a return to the gate they felt better. I consulted with my First Officer; Dispatch; Dispatch Manager; Flight Operations Manager; and maintenance. All agreed the aircraft was safe to fly. The flight attendant who had been ill stated he felt better; but in the interest of safety while airborne and trying expeditiously to operate the flight; a jump seating flight attendant replaced the flight attendant who on three occasions complained of headaches. Any passengers wanting to exit were also disembarked. We flew to destination. There; I asked the passengers and flight attendants if they smelled anything. No one had. I subsequently flew the aircraft on another leg and again asked the flight attendants if they had smelled anything. No one had. The primary purpose of this report is to document the extraordinary measures taken to ensure safety for the crew and passengers prior to flight.
We started to do our safety checks before boarding commenced. Flight attendant's #3 and #4 went to the aft galley. They called me at door 1L and reported smelling a strong acrid smell which they described as an 'electrical burning' odor. I notified the First Officer and we both went back to the aft galley to investigate the odor. I concurred with the two flight attendants and the First Officer who thought that the smell was coming from the exhaust from a truck that was loading mail into the aft pit of the aircraft. First Officer stated that the odor was being 'sucked into the air ducts' and would dissipate once we were in the air. The two of us then walked back to the front of the aircraft and I then briefed with the Captain. I told him of the suspect odor and after our briefing he went back to investigate the odor. I completed my safety checks and we began the boarding process. When the Captain came back up to the cockpit he told me that the odor was being sucked into the ducts from a truck that was loading mail. He stated that he had gone outside to check and could smell the odor emanate from the truck. He stated that once the truck had left the odor was gone (from outside of the aircraft). He then reiterated what the First Officer had said regarding the dissipation of the odor once we were airborne. After push back I received another call from Flight Attendant #4 who told me that the odor had gotten stronger and passengers in the last five rows of the aircraft were starting to voice strong concern and that he and Flight Attendant #3 did not feel safe. I called the cockpit relayed this message to the Captain who then returned the aircraft to the gate. I walked back to the last few rows of the cabin after repositioning the Flight Attendants for door coverage and could smell the strong odor. I spoke with a few of the passengers who were verbalizing their concern with the smell and many wanted to get off of the plane. I then relayed this message to the Captain who came back to the aft cabin and spoke with the passengers explaining that he would never 'fly an unsafe aircraft.' When the jet way finally came up to the aircraft customer service stated that if anyone got 'off the plane they would not be allowed back on' and that 'they would need to make alternate travel arrangements' at the ticket counter as staffing was not adequate at the gate. Passengers were told to gather all of their personal belongings if they exited the aircraft. Approximately 25 to 30 passengers exited the aircraft a few of them in tears. A mechanic was dispatched to the aircraft and began a search of the electrical systems. After approximately one hour the mechanic reported that burned out chiller fans in the aft galley was the cause of the odor. I then asked the Captain for permission to open the two aft doors of the aircraft in order to air the cabin and he approved the request. The aft doors were opened for approximately five minutes and it appeared that the odor had dissipated. A few of the passengers were allowed to re-board the aircraft and we pushed back a second time. I then received another phone call from the aft galley from Flight Attendant #3 who told me that the odor was back quite strong and passengers were once again concerned not feeling safe. I called the Captain relaying this message and we returned to the gate again. The jetway was brought back to the aircraft and Flight Attendant #4 called me and said that he had an 'extreme' headache from the acrid smell. I repositioned him to door #2 and Flight Attendant #2 to the aft of the aircraft allowing Flight Attendant #4 to be by an opened door. I asked him if he thought he could continue with the flight and he was unsure saying that the way he currently felt probably not. I took this information to the Captain letting him know that if Flight Attendant #4 got off we would be below FAA minimum. I went back to door two and Flight Attendant #4 told me had had takenmedication (aspirin) and between the fresh air and the medication he thought he would be fine. I went back to the cockpit informing the Captain who then informed me that he had already arranged to re-crew this position and that if Flight Attendant #4 was reporting feeling 'dizzy' he was 'off'. I took this information back to Flight Attendant #4 who I told to then call the crew scheduling. I then told the agent about the possible below minimums. She informed me that the Captain had already told her about the situation and she had asked a commuting Flight Attendant if she would be willing to work the trip which was agreed to. The Captain went back to the cockpit customer service closed the door and we pushed back a third time. I received a call from the back informing me that one of the electrical panels which the mechanic had unscrewed had not been re-attached and was only being held to the wall by one screw with the other two or three 'dangling'. I then called the cockpit and relayed this information to the Captain who asked me if this was something that he could defer until we got to Chicago. I told him that I could only report what was seen and had no idea if the item could be deferred or not as I was not a mechanic. He then asked me if I had a knife in the galley. I said yes and proceeded to open a roll-up from a tray and give him a knife. He also asked for a fork. He then took the fork and knife went back to the aft galley evidently using these utensils to secure the loose panel. Our flight continued and we arrived three hours late.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.
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