2011-02 · NASA ASRS report 936664
A B757-200 Pilot reports a Maintenance Sub-contractor had reinstalled the same malfunctioning Captain's position Oxygen Mask he had written up that had an leak in the inflatable headband. The Contract Mechanic signed-off his Logbook write-up as 'Operational (OPS) checked OK'. Pilot also notes the preflight 'Press to Test' Crew Oxygen Mask Check does not indicate a malfunctioning harness.
February 2011; Flight YY; ZZZ to ZZZ1; a B757-200 aircraft. In cruise; I attempted to don full face oxygen mask. Mask headband would not inflate due to air leak in band. Immediately swapped First Observer's mask into Captain's position. Initiated High Frequency (HF) phone patch to Dispatch in order to give Maintenance as much early warning as possible. Was advised by Dispatcher that a replacement full face oxygen mask was available in ZZZ. Continued to ZZZ1. [Made Log write-up]; see Log page XXX48. This Log page states that the defective mask was REPLACED. 'Ops (Operational) checked good'. February 2011; [one day later]; Flight XXX; ZZZ1 to ZZZ; same B757-200 aircraft; departed at XA:51pm local time. In cruise I attempted to don full face oxygen mask. Mask headband would not inflate due to air leak in band. Immediately swapped First Observer's mask into Captain's position. Tested OK. Checked smoke goggle fit. Continued to ZZZ. When in VHF range sent early alert via ACARS detailing the history and situation. See Logpage XXX54. That mask could not have 'Ops checked good' because ZZZ1 Maintenance had reinstalled the same defective mask back into the Captain's position. At top of descent called ZZZ Maintenance requesting Maintenance Supervisor meet aircraft. From my perspective I see falsification of [Maintenance] records; let alone the fact that my safety and that of my crew; passengers; and aircraft were jeopardized. Through conversation with Maintenance Control; I have learned that early maintenance alerts many times are not even looked at due to the availability of [Contract] Maintenance in ZZZ1. It would appear that our Air Carrier Maintenance Department needs to thoroughly scrutinize the Maintenance subcontractor in ZZZ1. I have been with company for 27-plus years. I have operated our B-757s for 23-plus years. I am now reverting to the tried and true method of completely removing the oxygen mask from the stowage box during my preflight inspection.
Reporter stated the storage box for the Crew Oxygen Mask is too small for the size of the mask. Even though the mask; whether folded correctly or incorrectly; can be reinstalled into the box; the small storage size contributes to the wear of the inflatable headband harness material. As the masks are removed and reinstalled during flights; an air embolism or hole develops in the harness; preventing inflation. The mask harness is suppose to inflate automatically when the mask is removed from the storage box; allowing the pilot to don the mask with one hand.Reporter stated the Boeing pre-flight 'Press to Test' procedure does not indicate a failure of the quick donning inflation harness; only that oxygen is flowing to the mask. As a result; he is now completely removing the crew oxygen mask from the stowage box to verify the serviceability of the mask. Reporter also stated He has worked as an Aircraft Mechanic prior to becoming a Pilot and has flown the B-757's many of his 27 years at his company. From his experience; especially as a Mechanic; the sign-off of his Logbook crew oxygen mask write-up by the Contract Maintenance provider; was a falsification of Maintenance records. The flights involved were ETOPS routes.
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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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