Five mechanics report about removing a damaged Common Nozzle Assembly (CNA) from the right engine of an A330 aircraft for the first time and installing a new serviceable CNA. Lack of a proper lifting dolly called for in the Maintenance Manual (M/M); no tool instructions or print-outs; no training and assumptions contributed to the primary nozzle not being transferred over to the new installed CNA nozzle assembly.
Synopsis
Five mechanics report about removing a damaged Common Nozzle Assembly (CNA) from the right engine of an A330 aircraft for the first time and installing a new serviceable CNA. Lack of a proper lifting dolly called for in the Maintenance Manual (M/M); no tool instructions or print-outs; no training and assumptions contributed to the primary nozzle not being transferred over to the new installed CNA nozzle assembly.
Narrative
I; along with several other mechanics were assigned to an A330 aircraft to replace the Common Nozzle Assembly (CNA) on the right engine. First shift started the removal of the nozzle. We completed the removal at the beginning of our shift. Since this was the first CNA removal here in ZZZ; most of the mechanics in the hangar that day; a Maintenance Supervisor and a Maintenance Manager came over to the aircraft to observe the replacement. We positioned the cradle to the CNA and using a forklift removed the CNA. The proper lifting dolly called for in the Aircraft Maintenance Manual (AMM) was not made available by the company. The fork lift driver placed the removed CNA near the new one. We then installed the lifting fixture to the removed CNA to remove it from the transport dolly. This was done after much discussion since we had never seen or used this tooling before. Several people not working the aircraft came over to watch/comment on the lifting fixture operation. The lifting fixture was then placed on the new CNA to remove it out of the container. At this time the overhead crane being used became entangled in the safety ropes hanging from the ceiling. This diverted our attention from the new CNA for a brief period of time until the ropes were freed. The new CNA was then placed into the transport cradle and was positioned near the right engine using the forklift. Using the forklift to raise the CNA cradle assembly took much attention due to the close proximity of the forklift to the engine C-Duct. While raising the new CNA to align the alignment pins; much input was given by all the people watching the installation as to how best to align the nozzle. This was in addition to the mechanics actually doing the installation. The CNA was installed after some difficulty due to having to position the forklift/transport cradle perfectly to align the pins and took longer than we expected. The aircraft was on a scheduled release and was due to fly a revenue flight that evening.
Second reporter narrative
Second shift. I; along with several other mechanics were tasked with an A330 right engine CNA replacement due to damage. First Shift started the job; they pulled the required paperwork and ordered the tooling required; and started removal. When our [second] shift started; we attached the holding cradle; secured the holding straps and using a forklift removed the [damaged] CNA contained in the holding cradle. I positioned the nozzle to a staging area near the new serviceable CNA and access to the overhead crane. Using the overhead crane and the nozzle rotating fixture tool; we attached the [fixture] to the damaged nozzle and removed it from the holding cradle and rotated 90-degrees and set it in temporary holding on the hangar floor; (nozzle opening facing down). We then removed the rotating fixture and attached it to the new serviceable nozzle in its storage container. Also facing 90-degrees front-end down. We removed the nozzle from the [storage] crate; inspected and installed the [serviceable nozzle] into the empty holding cradle and secured with straps. Using the forklift to lift the holding cradle and nozzle assembly; we installed it to the rear of number 2 engine and torqued per AMM. Reviewing the Remove and Replace (R/R) procedures; there was communication about making sure that the FADEC rating was properly set to match this nozzle assembly. Two mechanics were tasked and accomplished [FADEC rating verification] satisfactorily. We paid a lot of attention to the unique way these tools worked as to not cause any further damage or delay. This job was accomplished by several mechanics and this was the first time these tools were used in ZZZ. All discussions with all mechanics during this task did not bring up transferring the nozzle liner. We inadvertently failed to change over the [nozzle Liner] part. After completing this job as the senior Mechanic involved in the work and talking with my coworkers; we were satisfied the repair was completed satisfactorily and I signed-off the discrepancy in the logbook. Overseas; four days later; [the CNA nozzle liner was reported not installed].
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.