A B757 flight crew had to deal with excessive noise from the first officer's window when it partiall...

Attributes
ACN	789236
Time
Date	200806
Local Time Of Day	0601 To 1200
Place
Locale Reference	airport : zzz.airport
State Reference	US
Altitude	agl single value : 0
Environment
Flight Conditions	Marginal
Aircraft 1
Operator	common carrier : air carrier
Make Model Name	B757-200
Operating Under FAR Part	Part 121
Flight Phase	ground : takeoff roll
Flight Plan	IFR
Person 1
Affiliation	company : air carrier
Function	flight crew : captain oversight : pic
Experience	flight time last 90 days : 250 flight time total : 15000 flight time type : 400
ASRS Report	789236
Person 2
Affiliation	company : air carrier
Function	flight crew : first officer
Experience	flight time last 90 days : 70 flight time total : 10000 flight time type : 360
ASRS Report	789238
Events
Anomaly	aircraft equipment problem : less severe
Independent Detector	other flight crewa other flight crewb
Consequence	other
Supplementary
Problem Areas	Aircraft Flight Crew Human Performance
Primary Problem	Aircraft

Narrative:

On takeoff roll at approximately 80-100 KIAS noise level in cockpit noticeably higher than normal from back of first officer's seat. Continued the takeoff; noise continued to increase. On initial leveloff at 3000 ft decibel level reached a point where verbal communication impossible. First officer attempted to reseat window where noise/air leak was emanating and was unable. I signaled for return to ZZZ and first officer wearing a noise reduction headset communicated with approach and received vectors to localizer at ZZZ. Notified flight attendants and passenger of situation. Flight attendants could hear the noise as well as the first few rows of first class and could barely hear interphone. PA announcement was recalled as 'loud' and clear. Normal approach and overweight landing at approximately 202000 pounds. After taxi in first officer noticed door lock arm about 20 degrees rear of normal perpendicular locked condition. Window was checked in the normal locked status during checklist and taxi out. Maintenance checked operation at gate and window closed locked normally. However; they did find a small bolt in the window channel. They could not determine if this caused the window to become partially unlocked. Overweight inspection showed no abnormal indications and after notifying dispatch and maintenance we reconfigured the aircraft and departed approximately 45 mins later for ZZZ. No recurrence and routine flight. Supplemental information from acn 789238: by rotation it was deafening loud and air was blowing through a gap where the aft portion of the window was partially open; the arm which is supposed to be at 90 degrees was off by about 15 degrees. The window had been properly ratcheted closed and indicated locked with the arm 90 degrees prior to takeoff. Checklists were communicated via hand signals and screaming. Upon inspection after landing the sheared head of an old rusty bolt or nut was found in the track and removed; and the window operated normally.

Original NASA ASRS Text

Title: A B757 FLT CREW HAD TO DEAL WITH EXCESSIVE NOISE FROM THE FO'S WINDOW WHEN IT PARTIALLY OPENED IN FLT. THEY RETURNED TO DEP ARPT AND FOUND A DISCARDED PIECE OF A BOLT IN THE WINDOW CHANNEL.

Narrative: ON TKOF ROLL AT APPROX 80-100 KIAS NOISE LEVEL IN COCKPIT NOTICEABLY HIGHER THAN NORMAL FROM BACK OF FO'S SEAT. CONTINUED THE TKOF; NOISE CONTINUED TO INCREASE. ON INITIAL LEVELOFF AT 3000 FT DECIBEL LEVEL REACHED A POINT WHERE VERBAL COM IMPOSSIBLE. FO ATTEMPTED TO RESEAT WINDOW WHERE NOISE/AIR LEAK WAS EMANATING AND WAS UNABLE. I SIGNALED FOR RETURN TO ZZZ AND FO WEARING A NOISE REDUCTION HEADSET COMMUNICATED WITH APCH AND RECEIVED VECTORS TO LOC AT ZZZ. NOTIFIED FLT ATTENDANTS AND PAX OF SIT. FLT ATTENDANTS COULD HEAR THE NOISE AS WELL AS THE FIRST FEW ROWS OF FIRST CLASS AND COULD BARELY HEAR INTERPHONE. PA ANNOUNCEMENT WAS RECALLED AS 'LOUD' AND CLR. NORMAL APCH AND OVERWT LNDG AT APPROX 202000 LBS. AFTER TAXI IN FO NOTICED DOOR LOCK ARM ABOUT 20 DEGS REAR OF NORMAL PERPENDICULAR LOCKED CONDITION. WINDOW WAS CHKED IN THE NORMAL LOCKED STATUS DURING CHKLIST AND TAXI OUT. MAINT CHKED OP AT GATE AND WINDOW CLOSED LOCKED NORMALLY. HOWEVER; THEY DID FIND A SMALL BOLT IN THE WINDOW CHANNEL. THEY COULD NOT DETERMINE IF THIS CAUSED THE WINDOW TO BECOME PARTIALLY UNLOCKED. OVERWT INSPECTION SHOWED NO ABNORMAL INDICATIONS AND AFTER NOTIFYING DISPATCH AND MAINT WE RECONFIGURED THE ACFT AND DEPARTED APPROX 45 MINS LATER FOR ZZZ. NO RECURRENCE AND ROUTINE FLT. SUPPLEMENTAL INFO FROM ACN 789238: BY ROTATION IT WAS DEAFENING LOUD AND AIR WAS BLOWING THROUGH A GAP WHERE THE AFT PORTION OF THE WINDOW WAS PARTIALLY OPEN; THE ARM WHICH IS SUPPOSED TO BE AT 90 DEGS WAS OFF BY ABOUT 15 DEGS. THE WINDOW HAD BEEN PROPERLY RATCHETED CLOSED AND INDICATED LOCKED WITH THE ARM 90 DEGS PRIOR TO TKOF. CHKLISTS WERE COMMUNICATED VIA HAND SIGNALS AND SCREAMING. UPON INSPECTION AFTER LNDG THE SHEARED HEAD OF AN OLD RUSTY BOLT OR NUT WAS FOUND IN THE TRACK AND REMOVED; AND THE WINDOW OPERATED NORMALLY.

Data retrieved from NASA's ASRS site as of May 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 B757 flight crew had to deal with excessive noise from the first officer's window when it partially opened in flight. They returned to departure airport and found a discarded piece of a bolt in the window channel.