Flight crew of an large transport air carrier aircraft returned to land on 2 different occasions due...

Narrative:

Received call from the captain of flight X at approximately XA00 pm from operation reporting his low pressure filter bypass light came on at takeoff and was still on after engine shutdown. I entered a maintenance alert and called phxoo to get a mechanic. I also faxed the MEL checks and the ipc reference showing the location of both switches. The captain called again and stated his crew was 'uncomfortable' about the oil because it was close to the red line limits. I told the captain we were checking the oil and the filter. I entered another maintenance alert to check the filter and oil. The mechanic stated he replaced the filter and installed a new o-ring. The filter and oil looked good and the captain agreed and was happy. The emc and myself were on the phone with the captain. I asked the crew to run the engine to pressure check the new installation. During engine run the mechanic found a fuel leak. After a couple of calls and a facsimile we located the poppet valve he needed. The mechanic said it was the fuel control filter, but it turned out to be the fuel pump filter poppet. The poppet was replaced and leak checked. The aircraft was dispatched with everyone satisfied. The mechanic was very professional and knowledgeable. During the second takeoff, the light came on again with high oil temperature and pressure. The crew shut down the engine again. I contacted phxoo and informed them of the return. At that time the operation person asked if the old filter should have metal in it. I told him in no way should that filter have metal and why didn't the mechanic tell me. Any type of metal in the main oil filter requires an inspection of the quantity and type of material found before flight. I told the operation person to hold onto the filter. Air carrier maintenance had arrived at this time and accomplished the second check of the filter. The new filter that the FBO had just installed was also full of metal. I told phxmm to mark both filers and send to sfo line maintenance. Needed better communication between mechanic and myself.

Original NASA ASRS Text

Title: FLC OF AN LGT ACR ACFT RETURNED TO LAND ON 2 DIFFERENT OCCASIONS DUE SHUTTING DOWN 1 ENG AFTER TKOF DUE A LOW PRESSURE FILTER BYPASS LIGHT WARNING.

Narrative: RECEIVED CALL FROM THE CAPT OF FLT X AT APPROX XA00 PM FROM OP RPTING HIS LOW PRESSURE FILTER BYPASS LIGHT CAME ON AT TKOF AND WAS STILL ON AFTER ENG SHUTDOWN. I ENTERED A MAINT ALERT AND CALLED PHXOO TO GET A MECH. I ALSO FAXED THE MEL CHKS AND THE IPC REF SHOWING THE LOCATION OF BOTH SWITCHES. THE CAPT CALLED AGAIN AND STATED HIS CREW WAS 'UNCOMFORTABLE' ABOUT THE OIL BECAUSE IT WAS CLOSE TO THE RED LINE LIMITS. I TOLD THE CAPT WE WERE CHKING THE OIL AND THE FILTER. I ENTERED ANOTHER MAINT ALERT TO CHK THE FILTER AND OIL. THE MECH STATED HE REPLACED THE FILTER AND INSTALLED A NEW O-RING. THE FILTER AND OIL LOOKED GOOD AND THE CAPT AGREED AND WAS HAPPY. THE EMC AND MYSELF WERE ON THE PHONE WITH THE CAPT. I ASKED THE CREW TO RUN THE ENG TO PRESSURE CHK THE NEW INSTALLATION. DURING ENG RUN THE MECH FOUND A FUEL LEAK. AFTER A COUPLE OF CALLS AND A FAX WE LOCATED THE POPPET VALVE HE NEEDED. THE MECH SAID IT WAS THE FUEL CTL FILTER, BUT IT TURNED OUT TO BE THE FUEL PUMP FILTER POPPET. THE POPPET WAS REPLACED AND LEAK CHKED. THE ACFT WAS DISPATCHED WITH EVERYONE SATISFIED. THE MECH WAS VERY PROFESSIONAL AND KNOWLEDGEABLE. DURING THE SECOND TKOF, THE LIGHT CAME ON AGAIN WITH HIGH OIL TEMP AND PRESSURE. THE CREW SHUT DOWN THE ENG AGAIN. I CONTACTED PHXOO AND INFORMED THEM OF THE RETURN. AT THAT TIME THE OP PERSON ASKED IF THE OLD FILTER SHOULD HAVE METAL IN IT. I TOLD HIM IN NO WAY SHOULD THAT FILTER HAVE METAL AND WHY DIDN'T THE MECH TELL ME. ANY TYPE OF METAL IN THE MAIN OIL FILTER REQUIRES AN INSPECTION OF THE QUANTITY AND TYPE OF MATERIAL FOUND BEFORE FLT. I TOLD THE OP PERSON TO HOLD ONTO THE FILTER. ACR MAINT HAD ARRIVED AT THIS TIME AND ACCOMPLISHED THE SECOND CHK OF THE FILTER. THE NEW FILTER THAT THE FBO HAD JUST INSTALLED WAS ALSO FULL OF METAL. I TOLD PHXMM TO MARK BOTH FILERS AND SEND TO SFO LINE MAINT. NEEDED BETTER COM BTWN MECH AND MYSELF.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.

Attributes
ACN	248725
Time
Date	199308
Day	Fri
Local Time Of Day	1201 To 1800
Place
Locale Reference	airport : phx
State Reference	AZ
Altitude	agl bound lower : 0 agl bound upper : 0
Environment
Flight Conditions	VMC
Light	Daylight
Aircraft 1
Controlling Facilities	tower : phx
Operator	common carrier : air carrier
Make Model Name	Large Transport, Low Wing, 3 Turbojet Eng
Flight Phase	climbout : takeoff
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	other personnel other
Qualification	other other : other
ASRS Report	248725
Person 2
Affiliation	company : air carrier
Function	other personnel other
Qualification	other other : other
Events
Anomaly	aircraft equipment problem : critical non adherence : published procedure non adherence : far other anomaly other
Independent Detector	aircraft equipment other aircraft equipment : unspecified other flight crewa
Resolutory Action	other
Consequence	Other
Supplementary
Primary Problem	Aircraft
Air Traffic Incident	other

Flight crew of an large transport air carrier aircraft returned to land on 2 different occasions due shutting down 1 engine after takeoff due a low pressure filter bypass light warning.