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A line mechanic reports about the difficulties installing a replacement wing fuel boost pump on a B767-300 aircraft that resulted in 10;000 lbs (pounds) of fuel spilling onto the ramp. Mechanic suggests his air carrier make defueling associated fuel tank for boost pump replacement a policy; to prevent the recurring fuel spills they have experienced.
| Attributes | |
| ACN | 965765 |
| Time | |
| Date | 201108 |
| Local Time Of Day | 1201-1800 |
| Place | |
| Locale Reference | ZZZ.Airport |
| State Reference | US |
| Environment | |
| Light | Daylight |
| Aircraft 1 | |
| Make Model Name | B767-300 and 300 ER |
| Operating Under FAR Part | Part 121 |
| Flight Phase | Parked |
| Component | |
| Aircraft Component | Fuel Booster Pump |
| Person 1 | |
| Function | Technician |
| Qualification | Maintenance Airframe Maintenance Powerplant |
| Events | |
| Anomaly | Aircraft Equipment Problem Critical Deviation - Procedural Hazardous Material Violation Deviation - Procedural Published Material / Policy |
Narrative:
While replacing fuel boost pump on a B767-300 aircraft at terminal gate; [I] removed pump per aircraft maintenance manual (amm) with no problems or fuel leakage. While installing replacement pump; had difficulty installing new pump due to alignment of [boost pump] index pin. Tried reinstalling original pump to investigate; but its index pin was bent at an angle and the new pump index pin was straight. While reinstalling original pump; fuel began leaking out of tank. Reason for fuel leakage was due to fuel pump index pin being bent. After fuel started pouring out of tank; notified maintenance control to contact fire department; maintenance supervisor and all concerned of fuel spillage. ZZZ personnel used absorbent material to contain fuel spillage. Base manager was told to stop the leak. He then put on rain gear; gloves and face shield to install original pump which had its guide pins removed to facilitate installation to stop leak. It took the base manager 10-15 minutes to install pump and prevent further leakage. Approximately 10;000 lbs of fuel spilled onto ramp. Suggest defueling associated fuel tank prior to fuel boost pump replacement. Company should make this a policy [to defuel tank first]. This is not the first time a fuel spill has occurred during boost pump replacement.
Original NASA ASRS Text
Title: A Line Mechanic reports about the difficulties installing a replacement wing Fuel Boost Pump on a B767-300 aircraft that resulted in 10;000 lbs (pounds) of fuel spilling onto the Ramp. Mechanic suggests his Air Carrier make defueling associated fuel tank for Boost Pump replacement a Policy; to prevent the recurring fuel spills they have experienced.
Narrative: While replacing Fuel Boost Pump on a B767-300 aircraft at Terminal Gate; [I] removed pump per Aircraft Maintenance Manual (AMM) with no problems or fuel leakage. While installing replacement pump; had difficulty installing new pump due to alignment of [Boost Pump] Index pin. Tried reinstalling original pump to investigate; but its Index pin was bent at an angle and the new pump Index pin was straight. While reinstalling original pump; fuel began leaking out of tank. Reason for fuel leakage was due to fuel pump Index pin being bent. After fuel started pouring out of tank; notified Maintenance Control to contact Fire Department; Maintenance Supervisor and all concerned of fuel spillage. ZZZ personnel used absorbent material to contain fuel spillage. Base Manager was told to stop the leak. He then put on rain gear; gloves and face shield to install original pump which had its guide pins removed to facilitate installation to stop leak. It took the Base Manager 10-15 minutes to install pump and prevent further leakage. Approximately 10;000 lbs of fuel spilled onto Ramp. Suggest defueling associated fuel tank prior to Fuel Boost Pump replacement. Company should make this a Policy [to defuel tank first]. This is not the first time a fuel spill has occurred during boost pump replacement.
Data retrieved from NASA's ASRS site as of April 2012 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.