Narrative:

At 8000 ft an aircraft air duct exploded in cockpit. This caused extreme noise and also blew aircraft yellow insulation throughout the cockpit. This disrupted cockpit and ATC communications. An emergency was declared and a return to pit was accomplished. Oxygen masks were not put to use because both flight crew members were coughing due to the insulation in the cockpit environment. A quick return to point of departure was the only solution. Callback conversation with reporter revealed the following information: the reporter stated the aircraft was a B737-300. The reporter said the air conditioning duct separation occurred under the cockpit floor and behind the lower left instrument panel showering fiberglas insulation throughout the cockpit. The reporter said the oxygen masks were useless as the fiberglas was in the masks. The reporter said maintenance advised the cause was overpressure of the left pack bleed air by the engine mounted pressure regulator and shutoff valve.

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Original NASA ASRS Text

Title: A B737-300 IN INTERMEDIATE CLB AT 8000 FT DECLARED AN EMER AND DIVERTED DUE TO THE COCKPIT FILLED WITH FIBERGLAS INSULATION AND HIGH NOISE LEVEL.

Narrative: AT 8000 FT AN ACFT AIR DUCT EXPLODED IN COCKPIT. THIS CAUSED EXTREME NOISE AND ALSO BLEW ACFT YELLOW INSULATION THROUGHOUT THE COCKPIT. THIS DISRUPTED COCKPIT AND ATC COMS. AN EMER WAS DECLARED AND A RETURN TO PIT WAS ACCOMPLISHED. OXYGEN MASKS WERE NOT PUT TO USE BECAUSE BOTH FLC MEMBERS WERE COUGHING DUE TO THE INSULATION IN THE COCKPIT ENVIRONMENT. A QUICK RETURN TO POINT OF DEP WAS THE ONLY SOLUTION. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATED THE ACFT WAS A B737-300. THE RPTR SAID THE AIR CONDITIONING DUCT SEPARATION OCCURRED UNDER THE COCKPIT FLOOR AND BEHIND THE LOWER L INST PANEL SHOWERING FIBERGLAS INSULATION THROUGHOUT THE COCKPIT. THE RPTR SAID THE OXYGEN MASKS WERE USELESS AS THE FIBERGLAS WAS IN THE MASKS. THE RPTR SAID MAINT ADVISED THE CAUSE WAS OVERPRESSURE OF THE L PACK BLEED AIR BY THE ENG MOUNTED PRESSURE REGULATOR AND SHUTOFF VALVE.

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.