Narrative:

Shortly after takeoff with bleed air off, the captain began to reconfigure the aircraft for normal bleed air operation. A strong rush of air was noted in cockpit and flight attendants noted similar problem in cabin. Captain began to troubleshoot by redoing the after takeoff portion of the bleeds off takeoff checklist and confirming proper position of bleed, pack, and isolation valve switches. Passing through 10000 ft, a jump seating B737 first officer, seated in the cabin, came forward and informed us of smoke in the cabin. We all donned oxygen masks, requested an immediate return to boston, and began the smoke/fume elimination checklist. I continued to fly the aircraft while captain and jump seater accomplished checklist procedures and set appropriate navigation/communication frequencys. We declared an emergency and were cleared for a straight-in visual approach for runway 33L at boston. Configured aircraft for a flaps 30 degree, maximum autobrake landing. Touchdown and rollout were normal. Configured aircraft for possible evacuate/evacuation prior to shutdown. Flight attendants were instructed to disarm and open left forward and right aft doors for ventilation. Crash crew reported no visible smoke, flames, or hot spots. Captain elected to not evacuate/evacuation and have aircraft towed back to gate. Supplemental information from acn 497623: I was a jump seater on my company's plane going from bos to mco to start a trip. I am an first officer on this aircraft and have flown this ship many times. I was seated at row X seat a for the takeoff. It was a bleeds off, flaps 1 degree takeoff on runway 9 at bos. Everything was normal during the takeoff up through about 1500 ft MSL. At that point the crew was reconfiguring the bleeds when I noticed that the packs did not sound right. They were extremely loud. Passing 10000 ft MSL, I got up and went to the lead flight attendant seated at door 1L and told her to call the cockpit and tell them the packs were not working correctly. At that point, I noticed the back half of the aircraft was filling up with smoke. I then went into the cockpit and told the captain what was happening and we all started to run checklist and turn the aircraft back around for an emergency landing on runway 33L in bos. Time from smoke discovery to landing was approximately 10 mins. We ran all the checklists and were able to stop the smoke by turning off all engine bleeds. We landed and stopped on the runway, shut down, and had the fire crewas check the aircraft. They said it was ok. After they cleared the aircraft, we towed it back to the gate and had the people deplane there.

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Original NASA ASRS Text

Title: B737-200 CREW HAD SMOKE AND FUMES IN CABIN ON CLBOUT OF BOS.

Narrative: SHORTLY AFTER TKOF WITH BLEED AIR OFF, THE CAPT BEGAN TO RECONFIGURE THE ACFT FOR NORMAL BLEED AIR OP. A STRONG RUSH OF AIR WAS NOTED IN COCKPIT AND FLT ATTENDANTS NOTED SIMILAR PROB IN CABIN. CAPT BEGAN TO TROUBLESHOOT BY REDOING THE AFTER TKOF PORTION OF THE BLEEDS OFF TKOF CHKLIST AND CONFIRMING PROPER POS OF BLEED, PACK, AND ISOLATION VALVE SWITCHES. PASSING THROUGH 10000 FT, A JUMP SEATING B737 FO, SEATED IN THE CABIN, CAME FORWARD AND INFORMED US OF SMOKE IN THE CABIN. WE ALL DONNED OXYGEN MASKS, REQUESTED AN IMMEDIATE RETURN TO BOSTON, AND BEGAN THE SMOKE/FUME ELIMINATION CHKLIST. I CONTINUED TO FLY THE ACFT WHILE CAPT AND JUMP SEATER ACCOMPLISHED CHKLIST PROCS AND SET APPROPRIATE NAV/COM FREQS. WE DECLARED AN EMER AND WERE CLRED FOR A STRAIGHT-IN VISUAL APCH FOR RWY 33L AT BOSTON. CONFIGURED ACFT FOR A FLAPS 30 DEG, MAX AUTOBRAKE LNDG. TOUCHDOWN AND ROLLOUT WERE NORMAL. CONFIGURED ACFT FOR POSSIBLE EVAC PRIOR TO SHUTDOWN. FLT ATTENDANTS WERE INSTRUCTED TO DISARM AND OPEN L FORWARD AND R AFT DOORS FOR VENTILATION. CRASH CREW RPTED NO VISIBLE SMOKE, FLAMES, OR HOT SPOTS. CAPT ELECTED TO NOT EVAC AND HAVE ACFT TOWED BACK TO GATE. SUPPLEMENTAL INFO FROM ACN 497623: I WAS A JUMP SEATER ON MY COMPANY'S PLANE GOING FROM BOS TO MCO TO START A TRIP. I AM AN FO ON THIS ACFT AND HAVE FLOWN THIS SHIP MANY TIMES. I WAS SEATED AT ROW X SEAT A FOR THE TKOF. IT WAS A BLEEDS OFF, FLAPS 1 DEG TKOF ON RWY 9 AT BOS. EVERYTHING WAS NORMAL DURING THE TKOF UP THROUGH ABOUT 1500 FT MSL. AT THAT POINT THE CREW WAS RECONFIGURING THE BLEEDS WHEN I NOTICED THAT THE PACKS DID NOT SOUND RIGHT. THEY WERE EXTREMELY LOUD. PASSING 10000 FT MSL, I GOT UP AND WENT TO THE LEAD FLT ATTENDANT SEATED AT DOOR 1L AND TOLD HER TO CALL THE COCKPIT AND TELL THEM THE PACKS WERE NOT WORKING CORRECTLY. AT THAT POINT, I NOTICED THE BACK HALF OF THE ACFT WAS FILLING UP WITH SMOKE. I THEN WENT INTO THE COCKPIT AND TOLD THE CAPT WHAT WAS HAPPENING AND WE ALL STARTED TO RUN CHKLIST AND TURN THE ACFT BACK AROUND FOR AN EMER LNDG ON RWY 33L IN BOS. TIME FROM SMOKE DISCOVERY TO LNDG WAS APPROX 10 MINS. WE RAN ALL THE CHKLISTS AND WERE ABLE TO STOP THE SMOKE BY TURNING OFF ALL ENG BLEEDS. WE LANDED AND STOPPED ON THE RWY, SHUT DOWN, AND HAD THE FIRE CREWAS CHK THE ACFT. THEY SAID IT WAS OK. AFTER THEY CLRED THE ACFT, WE TOWED IT BACK TO THE GATE AND HAD THE PEOPLE DEPLANE THERE.

Data retrieved from NASA's ASRS site as of July 2007 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.