Aircraft equipment problem. Broken bleed line caused warning of duct leak and subsequent engine shutdown. Flight crew declared emergency and returned for landing. After maintenance found the loose bleed line and reconnected it, the aircraft was dispatched again as a ferry flight. Again, the duct warning came on and the flight crew returned. A broken fitting on the water separator was discovered.

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Attributes
ACN	333726
Time
Date	199604
Day	Mon
Local Time Of Day	1201 To 1800
Place
Locale Reference	airport : mco
State Reference	FL
Altitude	msl bound lower : 1500 msl bound upper : 1500
Environment
Flight Conditions	VMC
Light	Daylight
Aircraft 1
Controlling Facilities	tracon : mco
Operator	common carrier : air carrier
Make Model Name	Brasilia EMB-120 All Series
Operating Under FAR Part	Part 135
Flight Phase	climbout : intermediate altitude
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	flight crew : first officer
Qualification	pilot : cfi pilot : atp
Experience	flight time last 90 days : 270 flight time total : 7000 flight time type : 3000
ASRS Report	333726
Person 2
Affiliation	company : air carrier
Function	flight crew : captain oversight : pic
Qualification	pilot : atp
Events
Anomaly	aircraft equipment problem : critical
Independent Detector	aircraft equipment other aircraft equipment : unspecified other flight crewa
Resolutory Action	flight crew : declared emergency none taken : unable
Consequence	Other
Supplementary
Primary Problem	Aircraft

Narrative:

Climbing through approximately 1500 ft MSL duct leak warning came on. Followed checklist items which led to #1 engine being shut down. Informed flight attendant and passenger prior to shutdown. Declared emergency to ATC and returned to mco. Followed maintenance which discovered a bleed line that came loose. We launched as ferry flight (in same aircraft). At same geographical position and altitude, same warning came on for same engine. Followed same procedure as above except we had no passenger on board. Declared emergency and returned to mco. Maintenance found a broken fitting on water separator for deicing boot bleed. Replaced fitting and resumed trip. CRM worked as advertised. Delayed shutting engine down a little to complete notifications to flight attendants, passenger and company but no harm done this time.

Original NASA ASRS Text

Title: ACFT EQUIP PROB. BROKEN BLEED LINE CAUSED WARNING OF DUCT LEAK AND SUBSEQUENT ENG SHUTDOWN. FLC DECLARED EMER AND RETURNED FOR LNDG. AFTER MAINT FOUND THE LOOSE BLEED LINE AND RECONNECTED IT, THE ACFT WAS DISPATCHED AGAIN AS A FERRY FLT. AGAIN, THE DUCT WARNING CAME ON AND THE FLC RETURNED. A BROKEN FITTING ON THE WATER SEPARATOR WAS DISCOVERED.

Narrative: CLBING THROUGH APPROX 1500 FT MSL DUCT LEAK WARNING CAME ON. FOLLOWED CHKLIST ITEMS WHICH LED TO #1 ENG BEING SHUT DOWN. INFORMED FLT ATTENDANT AND PAX PRIOR TO SHUTDOWN. DECLARED EMER TO ATC AND RETURNED TO MCO. FOLLOWED MAINT WHICH DISCOVERED A BLEED LINE THAT CAME LOOSE. WE LAUNCHED AS FERRY FLT (IN SAME ACFT). AT SAME GEOGRAPHICAL POS AND ALT, SAME WARNING CAME ON FOR SAME ENG. FOLLOWED SAME PROC AS ABOVE EXCEPT WE HAD NO PAX ON BOARD. DECLARED EMER AND RETURNED TO MCO. MAINT FOUND A BROKEN FITTING ON WATER SEPARATOR FOR DEICING BOOT BLEED. REPLACED FITTING AND RESUMED TRIP. CRM WORKED AS ADVERTISED. DELAYED SHUTTING ENG DOWN A LITTLE TO COMPLETE NOTIFICATIONS TO FLT ATTENDANTS, PAX AND COMPANY BUT NO HARM DONE THIS TIME.

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.