Narrative:

I was asked to be the inspector on this job at about XA30 by my lead mechanic. At the time I ask why the pump was to be changed and was told the pump was leaking at the quad ring. I talked to the mechanic on the job after the pump was removed and we both looked at the pump mount and spine shaft which looked good. He said that he retorqued all mount bolts and I watched the check torque on the quad adapter. I was on standby on the ground next to the engine for the most of the rest of the installation. As the pump install was completed I checked for loose fuel lines per manual. As the fuel control was being installed I was again on standby. After all fuel lines on the fuel control were installed I did the wrench check on the fuel lines and went back to standby to wait for the mechanic to lock-wire all fuel lines. At this time, I noted the proper installation and security of the fuel control unit (FCU). All nuts were installed and appeared to be torqued, all lines (PS4 and drain lines) also appeared to be secured. I could not see a safety lockwire on the PS4 line from the top but I know some mechanics will put lockwire on this line from the bottom or the other side before they put the FCU unit on the mount pad. From the bottom side, I could see what I believed to be the PS4 safety. As the last part of the job was working and I was on standby the lead mechanic ask if I would do the wet motor after the job was finished. I said no problem but if the crew were in the flight deck I would run the engine after the wet motor. The so and I ran the engine with no passenger on board and the engine checked out ok at that time. Aircraft left the blocks at XH11 and the engine flamed out as the crew pushed the thrust levers up for takeoff. The called back to maintenance to say they had no oil pressure on #1 engine. The aircraft taxied back to the gate with #1 shut down. We had 2 hung starts at 39 percent N2 and 40 percent N2 oil pressure was coming up but not in the green band. We opened the cowl to check the engine and FCU. I again checked all fuel lines and fittings, all looked good and no leaks. I then checked on top of the FCU. The main fuel line and the PS4 line also looked ok at this time. I touched the PS4 line and gave it a pull and it popped off in my hand. We secured the PS4 line and the crew ran the engine which again checked out ok. Flight departed at XI20 and went to sfo. The crew called back, 'a-ok on #1, thanks for a good job.' I feel I might have found this loose PS4 'B' nut if the maintenance called out to wrench-check all lines on main engine fuel pump and FCU and not just fuel lines. Reference maintenance manual inspector 2) wrench-check fuel lines disturbed. This would require me to touch and torque check, not just inspect per 1) inspect fuel pump and module and all fuel tubes for proper installation and security.

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Original NASA ASRS Text

Title: A B747-100 RETURNED TO THE GATE DUE TO #1 ENG FLAMED OUT WHEN ADVANCING THE THROTTLE TO TKOF PWR. FOUND PS4 LINE LOOSE AT FUEL CTL UNIT.

Narrative: I WAS ASKED TO BE THE INSPECTOR ON THIS JOB AT ABOUT XA30 BY MY LEAD MECH. AT THE TIME I ASK WHY THE PUMP WAS TO BE CHANGED AND WAS TOLD THE PUMP WAS LEAKING AT THE QUAD RING. I TALKED TO THE MECH ON THE JOB AFTER THE PUMP WAS REMOVED AND WE BOTH LOOKED AT THE PUMP MOUNT AND SPINE SHAFT WHICH LOOKED GOOD. HE SAID THAT HE RETORQUED ALL MOUNT BOLTS AND I WATCHED THE CHK TORQUE ON THE QUAD ADAPTER. I WAS ON STANDBY ON THE GND NEXT TO THE ENG FOR THE MOST OF THE REST OF THE INSTALLATION. AS THE PUMP INSTALL WAS COMPLETED I CHKED FOR LOOSE FUEL LINES PER MANUAL. AS THE FUEL CTL WAS BEING INSTALLED I WAS AGAIN ON STANDBY. AFTER ALL FUEL LINES ON THE FUEL CTL WERE INSTALLED I DID THE WRENCH CHK ON THE FUEL LINES AND WENT BACK TO STANDBY TO WAIT FOR THE MECH TO LOCK-WIRE ALL FUEL LINES. AT THIS TIME, I NOTED THE PROPER INSTALLATION AND SECURITY OF THE FUEL CTL UNIT (FCU). ALL NUTS WERE INSTALLED AND APPEARED TO BE TORQUED, ALL LINES (PS4 AND DRAIN LINES) ALSO APPEARED TO BE SECURED. I COULD NOT SEE A SAFETY LOCKWIRE ON THE PS4 LINE FROM THE TOP BUT I KNOW SOME MECHS WILL PUT LOCKWIRE ON THIS LINE FROM THE BOTTOM OR THE OTHER SIDE BEFORE THEY PUT THE FCU UNIT ON THE MOUNT PAD. FROM THE BOTTOM SIDE, I COULD SEE WHAT I BELIEVED TO BE THE PS4 SAFETY. AS THE LAST PART OF THE JOB WAS WORKING AND I WAS ON STANDBY THE LEAD MECH ASK IF I WOULD DO THE WET MOTOR AFTER THE JOB WAS FINISHED. I SAID NO PROB BUT IF THE CREW WERE IN THE FLT DECK I WOULD RUN THE ENG AFTER THE WET MOTOR. THE SO AND I RAN THE ENG WITH NO PAX ON BOARD AND THE ENG CHKED OUT OK AT THAT TIME. ACFT LEFT THE BLOCKS AT XH11 AND THE ENG FLAMED OUT AS THE CREW PUSHED THE THRUST LEVERS UP FOR TKOF. THE CALLED BACK TO MAINT TO SAY THEY HAD NO OIL PRESSURE ON #1 ENG. THE ACFT TAXIED BACK TO THE GATE WITH #1 SHUT DOWN. WE HAD 2 HUNG STARTS AT 39 PERCENT N2 AND 40 PERCENT N2 OIL PRESSURE WAS COMING UP BUT NOT IN THE GREEN BAND. WE OPENED THE COWL TO CHK THE ENG AND FCU. I AGAIN CHKED ALL FUEL LINES AND FITTINGS, ALL LOOKED GOOD AND NO LEAKS. I THEN CHKED ON TOP OF THE FCU. THE MAIN FUEL LINE AND THE PS4 LINE ALSO LOOKED OK AT THIS TIME. I TOUCHED THE PS4 LINE AND GAVE IT A PULL AND IT POPPED OFF IN MY HAND. WE SECURED THE PS4 LINE AND THE CREW RAN THE ENG WHICH AGAIN CHKED OUT OK. FLT DEPARTED AT XI20 AND WENT TO SFO. THE CREW CALLED BACK, 'A-OK ON #1, THANKS FOR A GOOD JOB.' I FEEL I MIGHT HAVE FOUND THIS LOOSE PS4 'B' NUT IF THE MAINT CALLED OUT TO WRENCH-CHK ALL LINES ON MAIN ENG FUEL PUMP AND FCU AND NOT JUST FUEL LINES. REF MAINT MANUAL INSPECTOR 2) WRENCH-CHK FUEL LINES DISTURBED. THIS WOULD REQUIRE ME TO TOUCH AND TORQUE CHK, NOT JUST INSPECT PER 1) INSPECT FUEL PUMP AND MODULE AND ALL FUEL TUBES FOR PROPER INSTALLATION AND SECURITY.

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.