Unusual sounds and vibrations in flight caused the flight crew of a B757-200 to return to their departure airport where it was determined maintenance had not secured the loose ends of the hinges for the potable water door as required by the CDL procedure for operation with the door removed.
Synopsis
Unusual sounds and vibrations in flight caused the flight crew of a B757-200 to return to their departure airport where it was determined maintenance had not secured the loose ends of the hinges for the potable water door as required by the CDL procedure for operation with the door removed.
Narrative
During climb out; the Lead Flight Attendant informed me of excessive floor vibration and loud noise in the forward galley area. I asked her to have another Flight Attendant to verify and advise me of what she heard. After their reports; I went to the forward galley and heard/felt the noise/vibration. Upon return to the cockpit and after discussion with the First Officer; I believed that the noise/vibration was increasing with the aircraft's increasing speed. I had the First Officer slow to 250 KTS and obtained ATC clearance to return to the departure airport. Our arrival gross weight exceeded the maximum landing weight; so I briefed the crew of our need to declare an emergency; briefed the flight attendants and informed the passengers. We ran the QRH Over-Weight Landing checklist and notified Dispatch. ATC was informed of our emergency status and told us CFR was standing by. I transitioned to pilot flying; landed the aircraft and; after being told the aircraft appeared normal; taxied to the gate. After gate arrival; Maintenance informed me that the potable water service door had been removed; placed in the cockpit; and entered in the CDL on a previous flight leg. The CDL has a requirement to secure the opened compartment's hinges and any other loose items before flight. He said that the door hinges were left unsecured and suggested they might have caused the vibration/noise.
Second reporter narrative
A panel was removed on the right forward fuselage of our B-757 and the hinges were not properly secured at a previous station.
Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.