A Captain reports about a continuing problem with excessive flight deck airflow noise levels in the B757-200 aircraft from the air conditioning system that interferes with ATC communications during all phases of flight.
Synopsis
A Captain reports about a continuing problem with excessive flight deck airflow noise levels in the B757-200 aircraft from the air conditioning system that interferes with ATC communications during all phases of flight.
Narrative
This aircraft had previous write-ups regarding noise in cockpit. We once again wrote this up as unacceptable in flight. We briefed Maintenance at ZZZ that we flew entire trip with Right (Rh) Recirculation (Recirc) fan in the 'Off' position and noise level was at a dangerous level; missing numerous Radio calls. I write these reports knowing that our air carrier has no intention of fixing these problems. My purpose now is to attempt to convince the FAA Representative that unless something is done to correct this dangerous situation; it is only a matter of time before we have an accident; due to a mis-communication with ATC; during all phases of flight.Numerous Pilots have taken it upon themselves to purchase expensive headsets to remedy this problem. The next day I checked our computer's Maintenance history for the B757-200; only to find the Rh Recirc fan deferred; and the aircraft sent back out to the Line in the exact same condition we left it in ZZZ. This is unacceptable and in my opinion; dangerous. If assigned this aircraft in the future with nothing else done to correct this problem; I will refuse this aircraft as unsafe.
NASA callback
Reporter stated the airflow noise level gets so bad in flight that many times he and a majority of other B757 flight crew members will shut the right recirculation fan off in flight; including the left pack for the cockpit; to reduce the noise level so they can hear ATC communications. That seems to be the best combination. Many pilots have given up on making write-ups because their carrier has done very little to correct the problem.Reporter stated their own Engineering department acknowledges that flight deck airflow noise is a problem and has issued an Engineering Order to perform specific tests at the gate; but generally they just defer the right recirculation fan for being louder and later just sign-off the write-up as 'works OK'. Flight crews can't shut-off the left recirculation fan because that would also shut-off the equipment cooling fan in flight; which can only be reset on the ground. So they shut-off the left pack instead; which makes the cockpit much quieter; even though that is not a normal procedure.Reporter stated he knows that Federal OSHA has decibel level limits in the workplace; but questions if the FAA has maximum upper limit noise levels in the flight deck. Many crew members have expressed concern for potential hearing loss due to the excessive noise and have bought their own noise-canceling headsets. The noise level interference with ATC communications creates a dangerous environment and is fatiguing because pilots are always cringing to hear what ATC is saying. Reporter stated he knows of one carrier who has purchased noise canceling headsets for their crew members due to the excessive noise levels in the cockpit of that carrier's Boeing aircraft.
More incidents for this aircraft family →
Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.