A B737-700 after takeoff crew advised by cabin attendant of loud air leak at forward entrance door. ...

Attributes
ACN	724001
Time
Date	200701
Local Time Of Day	1801 To 2400
Place
Locale Reference	airport : zzz.airport
State Reference	US
Altitude	agl single value : 200
Environment
Flight Conditions	VMC
Light	Night
Aircraft 1
Controlling Facilities	tower : zzz.tower
Operator	common carrier : air carrier
Make Model Name	B737-700
Operating Under FAR Part	Part 121
Flight Phase	climbout : takeoff
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	flight crew : captain oversight : pic
Qualification	pilot : atp
ASRS Report	724001
Person 2
Affiliation	company : air carrier
Function	flight crew : first officer
Events
Anomaly	aircraft equipment problem : critical
Independent Detector	aircraft equipment other aircraft equipment : cabin alt indicator other other : 3
Resolutory Action	other
Consequence	other
Supplementary
Problem Areas	Aircraft Maintenance Human Performance
Primary Problem	Aircraft

Narrative:

On takeoff from ZZZ to ZZZ1 at 200 ft the flight attendants called the flight deck to say there was a loud air leak coming from the top left corner of the forward entry door. In the cockpit there was no indication from the master caution light or the overhead door light. However; looking at the pressurization panel the aircraft was not being pressurized. We followed the QRH; advised ATC of our problem and asked to return to ZZZ. When taxiing into the gate the mechanics noticed that the top right side of the forward entry door was not sealed properly. After we shut down the air carrier at the gate I went back to the cabin so the flight attendant could show me the area where the air leak was coming from before we opened the door. The door handle was indeed locked down in the proper position but you could notice that the top left corner of the door did not look right. It is easy to miss as the closet blocks the view of this area. As to no master caution lights in the cockpit I found that the only micro switch for the forward entry door is located at the mid position on the r-hand side of the door where the cams and the door was closed and locked properly.

Original NASA ASRS Text

Title: A B737-700 AFTER TKOF CREW ADVISED BY CABIN ATTENDANT OF LOUD AIR LEAK AT FORWARD ENTRANCE DOOR. RETURNED TO DEP ARPT. DOOR FOUND FALSE LATCHED.

Narrative: ON TKOF FROM ZZZ TO ZZZ1 AT 200 FT THE FLT ATTENDANTS CALLED THE FLT DECK TO SAY THERE WAS A LOUD AIR LEAK COMING FROM THE TOP L CORNER OF THE FORWARD ENTRY DOOR. IN THE COCKPIT THERE WAS NO INDICATION FROM THE MASTER CAUTION LIGHT OR THE OVERHEAD DOOR LIGHT. HOWEVER; LOOKING AT THE PRESSURIZATION PANEL THE ACFT WAS NOT BEING PRESSURIZED. WE FOLLOWED THE QRH; ADVISED ATC OF OUR PROB AND ASKED TO RETURN TO ZZZ. WHEN TAXIING INTO THE GATE THE MECHS NOTICED THAT THE TOP R SIDE OF THE FORWARD ENTRY DOOR WAS NOT SEALED PROPERLY. AFTER WE SHUT DOWN THE ACR AT THE GATE I WENT BACK TO THE CABIN SO THE FLT ATTENDANT COULD SHOW ME THE AREA WHERE THE AIR LEAK WAS COMING FROM BEFORE WE OPENED THE DOOR. THE DOOR HANDLE WAS INDEED LOCKED DOWN IN THE PROPER POS BUT YOU COULD NOTICE THAT THE TOP L CORNER OF THE DOOR DID NOT LOOK RIGHT. IT IS EASY TO MISS AS THE CLOSET BLOCKS THE VIEW OF THIS AREA. AS TO NO MASTER CAUTION LIGHTS IN THE COCKPIT I FOUND THAT THE ONLY MICRO SWITCH FOR THE FORWARD ENTRY DOOR IS LOCATED AT THE MID POS ON THE R-HAND SIDE OF THE DOOR WHERE THE CAMS AND THE DOOR WAS CLOSED AND LOCKED PROPERLY.

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

A B737-700 after takeoff crew advised by cabin attendant of loud air leak at forward entrance door. Returned to departure airport. Door found false latched.