Narrative:

Engineering provided part numbers for all fuel nozzles that were being replaced. I installed the new fuel nozzles by part number as listed on the engineering order. The fuel nozzles were all pre-drawn as a kit from stores. I assisted with some of the following; the new fuel nozzles were laid out on a work table. The packaging was removed; packingsecond officer-rings were installed; the copy of the stores parts tag with the nozzle position number was attached to each new nozzle; the hard copy of the stores part tag along with the position number was attached to the removed fuel nozzles; the new fuel nozzles were re-bagged along with the mounting bolts and brackets (if any) and laid back on the table in numerical sequence. I installed the new fuel nozzles 5 through 9 per the maintenance manual. Supplemental information from acn 748681: reporter stated the shift turnover said that he bought off the nozzles that were installed on previous shift and to just continue with the rest. Previous shift engine mechanics had all of the remaining fuel nozzles installed and ready for torque of the mounting flange bolts when I was called out to the job. We torqued the remaining nozzle mount flanges and safetied; then we torqued the coupling nuts and safetied those and turned over to next shift to accomplish the pressure leak check before installing the shrouds. Since the project had been here for at least an entire shift by the time our shift got the job we thought the validating of the part numbers had already been done. Supplemental information from acn 748683: I arrived on shift to relieve days. The tie in was such that here are all the new fuel nozzles that you are to install. All the new nozzles were in plastic ziploc bags with new o-rings and seals installed and lubed. Additionally all bags were carefully numbered as to which position to be installed. I then proceeded to install fuel nozzles 12 through 15 and signed for my work. Supplemental information from acn 749646: mr X and mr Y informed me that the nozzles were installed and require leak check and safety. Write-up was short sign for nozzles installed. We accomplished leak check and safety per maintenance manual and completed the paperwork. Supplemental information from acn 749647: fuel nozzles had already been installed and brought off for installation. I accomplished a leak check of all the fuel nozzles; their safeties; installation of the shrouds around the fuel nozzles and their safeties. I turned over to next shift the fuel nozzle fire protection shrouds were in need of replacement. Callback conversation with reporter revealed the following information: multiple shifts and mechanics/inspectors involved with the removal and replacements of the fuel nozzles. This particular engine had all 20 fuel nozzles replaced; but only four of the 20 nozzles appear to be affected by the incorrect part number. Aircraft was removed from service down line. Primary mistake by mechanics and inspectors was not cross-referencing the fuel nozzle part numbers on the engineering order with his company's ipc stores catalog for correct position effectivity.

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Original NASA ASRS Text

Title: A B737-700/800 ACFT HAD INCORRECT FUEL NOZZLES INSTALLED DUE TO INCORRECT PART NUMBERS ON ENGINEERING DIRECTIVE.

Narrative: ENGINEERING PROVIDED PART NUMBERS FOR ALL FUEL NOZZLES THAT WERE BEING REPLACED. I INSTALLED THE NEW FUEL NOZZLES BY PART NUMBER AS LISTED ON THE ENGINEERING ORDER. THE FUEL NOZZLES WERE ALL PRE-DRAWN AS A KIT FROM STORES. I ASSISTED WITH SOME OF THE FOLLOWING; THE NEW FUEL NOZZLES WERE LAID OUT ON A WORK TABLE. THE PACKAGING WAS REMOVED; PACKINGS/O-RINGS WERE INSTALLED; THE COPY OF THE STORES PARTS TAG WITH THE NOZZLE POS NUMBER WAS ATTACHED TO EACH NEW NOZZLE; THE HARD COPY OF THE STORES PART TAG ALONG WITH THE POS NUMBER WAS ATTACHED TO THE REMOVED FUEL NOZZLES; THE NEW FUEL NOZZLES WERE RE-BAGGED ALONG WITH THE MOUNTING BOLTS AND BRACKETS (IF ANY) AND LAID BACK ON THE TABLE IN NUMERICAL SEQUENCE. I INSTALLED THE NEW FUEL NOZZLES 5 THROUGH 9 PER THE MAINT MANUAL. SUPPLEMENTAL INFO FROM ACN 748681: RPTR STATED THE SHIFT TURNOVER SAID THAT HE BOUGHT OFF THE NOZZLES THAT WERE INSTALLED ON PREVIOUS SHIFT AND TO JUST CONTINUE WITH THE REST. PREVIOUS SHIFT ENG MECHS HAD ALL OF THE REMAINING FUEL NOZZLES INSTALLED AND READY FOR TORQUE OF THE MOUNTING FLANGE BOLTS WHEN I WAS CALLED OUT TO THE JOB. WE TORQUED THE REMAINING NOZZLE MOUNT FLANGES AND SAFETIED; THEN WE TORQUED THE COUPLING NUTS AND SAFETIED THOSE AND TURNED OVER TO NEXT SHIFT TO ACCOMPLISH THE PRESSURE LEAK CHK BEFORE INSTALLING THE SHROUDS. SINCE THE PROJECT HAD BEEN HERE FOR AT LEAST AN ENTIRE SHIFT BY THE TIME OUR SHIFT GOT THE JOB WE THOUGHT THE VALIDATING OF THE PART NUMBERS HAD ALREADY BEEN DONE. SUPPLEMENTAL INFO FROM ACN 748683: I ARRIVED ON SHIFT TO RELIEVE DAYS. THE TIE IN WAS SUCH THAT HERE ARE ALL THE NEW FUEL NOZZLES THAT YOU ARE TO INSTALL. ALL THE NEW NOZZLES WERE IN PLASTIC ZIPLOC BAGS WITH NEW O-RINGS AND SEALS INSTALLED AND LUBED. ADDITIONALLY ALL BAGS WERE CAREFULLY NUMBERED AS TO WHICH POS TO BE INSTALLED. I THEN PROCEEDED TO INSTALL FUEL NOZZLES 12 THROUGH 15 AND SIGNED FOR MY WORK. SUPPLEMENTAL INFO FROM ACN 749646: MR X AND MR Y INFORMED ME THAT THE NOZZLES WERE INSTALLED AND REQUIRE LEAK CHK AND SAFETY. WRITE-UP WAS SHORT SIGN FOR NOZZLES INSTALLED. WE ACCOMPLISHED LEAK CHK AND SAFETY PER MAINT MANUAL AND COMPLETED THE PAPERWORK. SUPPLEMENTAL INFO FROM ACN 749647: FUEL NOZZLES HAD ALREADY BEEN INSTALLED AND BROUGHT OFF FOR INSTALLATION. I ACCOMPLISHED A LEAK CHK OF ALL THE FUEL NOZZLES; THEIR SAFETIES; INSTALLATION OF THE SHROUDS AROUND THE FUEL NOZZLES AND THEIR SAFETIES. I TURNED OVER TO NEXT SHIFT THE FUEL NOZZLE FIRE PROTECTION SHROUDS WERE IN NEED OF REPLACEMENT. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: MULTIPLE SHIFTS AND MECHANICS/INSPECTORS INVOLVED WITH THE REMOVAL AND REPLACEMENTS OF THE FUEL NOZZLES. THIS PARTICULAR ENGINE HAD ALL 20 FUEL NOZZLES REPLACED; BUT ONLY FOUR OF THE 20 NOZZLES APPEAR TO BE AFFECTED BY THE INCORRECT PART NUMBER. ACFT WAS REMOVED FROM SERVICE DOWN LINE. PRIMARY MISTAKE BY MECHANICS AND INSPECTORS WAS NOT CROSS-REFERENCING THE FUEL NOZZLE PART NUMBERS ON THE ENGINEERING ORDER WITH HIS COMPANY'S IPC STORES CATALOG FOR CORRECT POSITION EFFECTIVITY.

Data retrieved from NASA's ASRS site as of January 2009 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.