Narrative:

Installed post mod '90 degree ignitors' into aircraft X and two previous post mod aircraft over the last 30 days using pre-mod task card. Discussion with other mechanics confirmed post mod aircraft receiving pre mod instructions improperly applied to post mod pw-150 turbines. Pre mod aircraft have or should have original straight ignitors. Post mod aircraft have '90 degree' ignitors installed; which are not consistent with this task's written direction and chemicals. An engineering change request form was initiated and forwarded on the morning of september xa. The engineering change request form submitted was rejected by staff; with three scenarios offered and received on september xb. In-depth discussion with leads and supervisors led to a recommendation to submit a second engineering change request form; which was submitted with the original engineering change request form documentation on september xc by interoffice mail -- for reconsideration. Engineering and records sends down a task card; which addresses pre mod ignitors to be removed and replaced at 1000 hours of operation on post mod serial numbered PW150 turbines. Aircraft X was one of those aircraft. The second engineering change request form suggests mechanics review at the commencement of work; whether the aircraft being worked is pre or post. If the aircraft is post and engineering and records has send down a pre mod task card; cease all further work. The lead and supervisor will then delete the task card from the work order. The pre mod task card does not identify the correct torques to be applied to the ms nuts attaching the ignitors to the turbine case. The lubricant listed is a traffic-50 for connection of the exciter attachment threads for the leads. The post mod task card has a separate compound listed.callback conversation with reporter revealed the following information: reporter stated even though the task cards are incorrect; they are trying to satisfy the intent of the job card for replacing the straight ignitors and 90-degree exciter ignitor wires on their 'pre-mod' dhc-400 aircraft with 90-degree ignitors and straight ignitors for 'post-mod' aircraft. The three ms nuts referred to in the job card secure the post-mod ignitor plug in place on the engine case; instead of the screw-in type ignitor found on the pre-mod engines. The post-mod ignitors also have a crush ring washer that must be installed with the ignitor; whereas the pre-mod engine ignitors do not have one. Reporter stated the teflon lubricant traffic-50 is to be used on the post-mod exciter leads to the ignitor. On the pre-mod engines the lubricant is for the threads of the ignitor plug. Reporter also stated his carrier's engineering has not responded to their second request for document corrections.

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Original NASA ASRS Text

Title: MECHANIC REPORTS THAT POST-MOD DEHAVILLAND DHC-400 ACFT ARE RECEIVING PRE-MOD INSTRUCTIONS FOR ENG IGNITOR CHANGES THAT ARE BEING IMPROPERLY APPLIED TO THEIR PW-150 ENGINES.

Narrative: INSTALLED POST MOD '90 DEGREE IGNITORS' INTO ACFT X AND TWO PREVIOUS POST MOD AIRCRAFT OVER THE LAST 30 DAYS USING PRE-MOD TASK CARD. DISCUSSION WITH OTHER MECHANICS CONFIRMED POST MOD AIRCRAFT RECEIVING PRE MOD INSTRUCTIONS IMPROPERLY APPLIED TO POST MOD PW-150 TURBINES. PRE MOD AIRCRAFT HAVE OR SHOULD HAVE ORIGINAL STRAIGHT IGNITORS. POST MOD AIRCRAFT HAVE '90 DEGREE' IGNITORS INSTALLED; WHICH ARE NOT CONSISTENT WITH THIS TASK'S WRITTEN DIRECTION AND CHEMICALS. AN ENGINEERING CHANGE REQUEST FORM WAS INITIATED AND FORWARDED ON THE MORNING OF SEPTEMBER XA. THE ENGINEERING CHANGE REQUEST FORM SUBMITTED WAS REJECTED BY STAFF; WITH THREE SCENARIOS OFFERED AND RECEIVED ON SEPTEMBER XB. IN-DEPTH DISCUSSION WITH LEADS AND SUPERVISORS LED TO A RECOMMENDATION TO SUBMIT A SECOND ENGINEERING CHANGE REQUEST FORM; WHICH WAS SUBMITTED WITH THE ORIGINAL ENGINEERING CHANGE REQUEST FORM DOCUMENTATION ON SEPTEMBER XC BY INTEROFFICE MAIL -- FOR RECONSIDERATION. ENGINEERING AND RECORDS SENDS DOWN A TASK CARD; WHICH ADDRESSES PRE MOD IGNITORS TO BE REMOVED AND REPLACED AT 1000 HOURS OF OPERATION ON POST MOD SERIAL NUMBERED PW150 TURBINES. ACFT X WAS ONE OF THOSE AIRCRAFT. THE SECOND ENGINEERING CHANGE REQUEST FORM SUGGESTS MECHANICS REVIEW AT THE COMMENCEMENT OF WORK; WHETHER THE AIRCRAFT BEING WORKED IS PRE OR POST. IF THE AIRCRAFT IS POST AND ENGINEERING AND RECORDS HAS SEND DOWN A PRE MOD TASK CARD; CEASE ALL FURTHER WORK. THE LEAD AND SUPERVISOR WILL THEN DELETE THE TASK CARD FROM THE WORK ORDER. THE PRE MOD TASK CARD DOES NOT IDENTIFY THE CORRECT TORQUES TO BE APPLIED TO THE MS NUTS ATTACHING THE IGNITORS TO THE TURBINE CASE. THE LUBRICANT LISTED IS A TFC-50 FOR CONNECTION OF THE EXCITER ATTACHMENT THREADS FOR THE LEADS. THE POST MOD TASK CARD HAS A SEPARATE COMPOUND LISTED.CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: REPORTER STATED EVEN THOUGH THE TASK CARDS ARE INCORRECT; THEY ARE TRYING TO SATISFY THE INTENT OF THE JOB CARD FOR REPLACING THE STRAIGHT IGNITORS AND 90-DEGREE EXCITER IGNITOR WIRES ON THEIR 'PRE-MOD' DHC-400 ACFT WITH 90-DEGREE IGNITORS AND STRAIGHT IGNITORS FOR 'POST-MOD' ACFT. THE THREE MS NUTS REFERRED TO IN THE JOB CARD SECURE THE POST-MOD IGNITOR PLUG IN PLACE ON THE ENGINE CASE; INSTEAD OF THE SCREW-IN TYPE IGNITOR FOUND ON THE PRE-MOD ENGINES. THE POST-MOD IGNITORS ALSO HAVE A CRUSH RING WASHER THAT MUST BE INSTALLED WITH THE IGNITOR; WHEREAS THE PRE-MOD ENGINE IGNITORS DO NOT HAVE ONE. REPORTER STATED THE TEFLON LUBRICANT TFC-50 IS TO BE USED ON THE POST-MOD EXCITER LEADS TO THE IGNITOR. ON THE PRE-MOD ENGINES THE LUBRICANT IS FOR THE THREADS OF THE IGNITOR PLUG. REPORTER ALSO STATED HIS CARRIER'S ENGINEERING HAS NOT RESPONDED TO THEIR SECOND REQUEST FOR DOCUMENT CORRECTIONS.

Data retrieved from NASA's ASRS site as of May 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.