Date: 201603
Local time of day: 1801-2400
Location: ZZZ.Airport, US
Flight conditions: VMC
Light: Night
Aircraft: MD-11
Operator: Air Carrier
Operating under: Part 121
Flight plan: IFR
Mission: Cargo / Freight / Delivery
Flight phase: Takeoff / Launch
ATC / advisory: Tower ZZZ
Aircraft component: Pneumatic System - Indicating and Warning
Component problem: Failed
Reporter organization: Air Carrier
Reporter function: Pilot Flying; Captain
Reporter qualification: Flight Crew Air Transport Pilot (ATP)
Human factors: Other / Unknown; Confusion
Second reporter function: Pilot Not Flying; First Officer
Anomaly: Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural MEL / CDL
Detector: Automation Aircraft Other Automation; Person Flight Crew
When detected: In-flight
Result: Flight Crew Returned To Gate; Flight Crew Rejected Takeoff; General Maintenance Action
Contributing factors: Human Factors; MEL; Procedure; Aircraft
Primary problem: Ambiguous

Narrative: After pushback had air system malfunction. Completed maintenance procedures and added MEL 36-23 (Manf Fail Det Loop). On takeoff roll got Master Caution and BLEEDS NOT OFF alert. Rejected TO < 80 kts. Consulted Maintenance Control by phone and was advised to return to gate. Attempted second takeoff under MEL 21-08 (ESC Auto Mode). RTO <80 kts for same alert. Returned to gate for further trouble shooting. After extensive review of MEL; Aircraft Systems Manual; FMS manual; and Pilot Handbook I discovered I had missed a step in the MEL operations procedures and that this oversight was the probable cause for the alert on the second takeoff attempt. Advised MX; consulted with Dispatch and Maintenance Control; then performed a normal; Air System Manual preflight and takeoff.The Predeparture Maintenance process should have driven us to return to gate rather than attempt troubleshoot over the phone. Change verbiage in MEL 21-08. Under Ops notes (O); 3.A and B should read 3.A On the Performance Computer - Takeoff Input Screen select 'AIR CONDITIONING...PACKS ON.' 3.B On the FMS 'Takeoff' Page select 'PACKS-ON.'Note: The default value is 'PACKS-OFF' which will cause a 'BLEEDS NOT OFF' alert when Takeoff power is set and any bleed is not manually turned to OFF. Ultimately; the second RTO could have been prevented by closer scrutiny and confirmation that all MEL procedures were complied with. In addition; MEL 36-23 (Manf Fail Det Loop) Should state plainly that this MEL only applies when MEL 28-08 is also applied.


Second narrative: Confusion about proper MEL; MEL verbiage; infrequent use of this particular MEL. First MEL provided by Maintenance Control in accordance with post departure maintenance process was incorrect. That caused the first Rejected Takeoff. After returning to the gate and consulting with maintenance a different MEL was applied. At that point we were already several hours into our communication with both Maintenance Control and local maintenance. We missed one of the notes directing us to select 'packs on' in the FMS on the second MEL which caused the master caution alert when the throttles were pushed up for takeoff. Post departure maintenance process should have driven us to return to gate rather than attempt trouble shooting over phone. Closer attention to detail when using a rarely seen MEL. Add a Note or caution to MEL 36-23 that this MEL assumes the Aircraft is already on MEL for ESC Auto Mode inoperative and procedures for that MEL are complied with.


Synopsis: MD11 flight crew experienced an air system malfunction after pushback. Added the appropriate MEL according to Maintenance Control and received a master caution for bleeds not off when during takeoff followed by RTO.  After returning to the gate and consulting with Maintenance; a different MEL was applied; but the crew did not properly configure the performance computer and FMS for operation under this MEL resulting in another RTO for the same master caution. After careful scrutiny; the correct MEL and procedures were performed with no master cautions generated during takeoff.