B757-200
Maintenance Powerplant; Maintenance Airframe
Maintenance Lead Technician 25
Situational Awareness; Troubleshooting; Time Pressure; Confusion; Communication Breakdown
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Published Material / Policy
General Maintenance Action
Aircraft; Company Policy; Environment - Non Weather Related; Human Factors; Logbook Entry; Manuals; Procedure
Condition: Questionable airworthiness of a B757-200 aircraft fuel system with 23;500 LBS onboard. Due to an unknown potential fuel contamination (example: cloudy film / streak in fuel sample). A fuel sample was sent to an outside contract vendor; Company X; for testing. Preliminary results from company X's lab report indicated samples taken in January 2012; showed all test pass except for biological contaminants as [that] test [was] pending results. I was notified by local management that results would not be available for 72-hours; thus questioning the airworthiness of the fuel onboard. I was also notified that the lab report was sufficient and to return the aircraft to service per B757 Aircraft Maintenance Manual (AMM) 28-10-00-2. Also; preliminary lab reports were not certified by officials at the lab; or by anyone from our Company quality assurance. I later received an additional lab report from Management and it was officially signed by the lab; but not by anyone in our Company; and the lab report was missing the micro-biological test. It seemed it was eliminated from the report. I was then directed that the report was sufficient to clear the discrepancy per the AMM and the report itself. Problem: [Either our] company engineering; or our company; does not have any definitive procedures or overview to address a fuel contamination issue; or any procedures for a certified company representative to concur with any lab results that it receives; there are no checks or balances. Also it appears the company had the micro-biological test removed; 'which is specific in the AMM' to certify the initial test results. Instead; [they] just had an Engineering Order (EO) created for 72-hours; pending final results and to sump the system prior to every flight. Fix: The Company needs to create an official procedure to address fuel contamination; a Liaison to certify test results from outside vendors. Note: I was directed to clear the discrepancy or fear disciplinary actions; or losing a job; clarification was very cloudy. I later asked if the test results had passed and was told not to worry about it; that it wasn't an issue. Later that week I was handed a simple e-mail posting that claimed micro-biological test was OK.
Reporter stated when he raised his initial concern about a possible fuel or fuel tank contamination due to the cloudy film streak in the fuel sample; his Manager was OK with the plan to change both engine fuel filters and releasing the aircraft. When he informed his Manager that an additional 6;000 LBS of fuel would have to be loaded and a full High Power Engine Run on both engines accomplished; his Manager decided not to change the engine fuel filters.Reporter stated he was originally instructed to take fuel samples on the B757 aircraft; but when the airworthiness of the fuel became an issue because of the cloud streak in the fuel sample; which many times indicates micro-biological contamination; Management's attitude became intimidating. Especially since the testing lab's results for micro-biological contamination would not be available for at least 72-hours.Reporter stated the intimidating behavior from his Manager and Supervisor was very upsetting. He was told him he must sign-off the fuel contamination write-up; or be terminated; even though everyone knew the required lab report for the Micro-Biological Test would not be available to determine a Maintenance plan for dealing with that type of possible contamination. He doesn't know what mechanics are suppose to do; when faced with job termination for refusing to sign-off a write-up; or whether the FAA would help protect a Mechanic's job for refusal to violate an FAR.
A Line Mechanic reports about the intimidating behavior and job termination threats by his Manager if he did not sign-off a write-up for a cloudy film streak in a fuel sample from a B757-200 aircraft. Mechanic noted a required micro-biological test had not been completed that would certify the airworthiness of the aircraft's fuel.