Narrative:

When departing ZZZ jun/mon/00, XA00 am, using a bleeds off takeoff, we started to run the after takeoff checklist at 9200 ft MSL (3000 ft AGL). The right side bleed would not come on and also the cabin would not pressurize. We leveled off at 10000 ft MSL, and completed the automatic fail unscheduled pressurize change checklist via the QRH. ZZZ departure control was told and we requested to come back to land at ZZZ. Our cabin was now pressurized, but the cabin altitude was at 9600 ft. The outflow valve was closed, but we could not get the cabin altitude to come down with single pack operating. Return landing was uneventful. Air carrier maintenance control called out contract maintenance. They worked on aircraft for 2 hours under maintenance control instructions, via the telephone. They ran a pressurization check on the mode control panel and door seals. Also they disabled the right bleed valve through our MEL system. We then departed ZZZ at XC45 am local again and the very same thing happened as first departure and return. 4 hours later 2 of our mechanics arrived from XXX. They installed a new pressurization automatic controller and a right side bleed air valve. They test ran aircraft and it operations checked normal. We then ferried aircraft to XXX arriving at XH15 local.

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Original NASA ASRS Text

Title: A B737-200 MADE 2 TKOFS AND DIVERTED BOTH TIMES DUE TO UNABLE TO PRESSURIZE THE CABIN CAUSED BY A FAILED AUTO PRESSURE CTLR.

Narrative: WHEN DEPARTING ZZZ JUN/MON/00, XA00 AM, USING A BLEEDS OFF TKOF, WE STARTED TO RUN THE AFTER TKOF CHKLIST AT 9200 FT MSL (3000 FT AGL). THE R SIDE BLEED WOULD NOT COME ON AND ALSO THE CABIN WOULD NOT PRESSURIZE. WE LEVELED OFF AT 10000 FT MSL, AND COMPLETED THE AUTO FAIL UNSCHEDULED PRESSURIZE CHANGE CHKLIST VIA THE QRH. ZZZ DEP CTL WAS TOLD AND WE REQUESTED TO COME BACK TO LAND AT ZZZ. OUR CABIN WAS NOW PRESSURIZED, BUT THE CABIN ALT WAS AT 9600 FT. THE OUTFLOW VALVE WAS CLOSED, BUT WE COULD NOT GET THE CABIN ALT TO COME DOWN WITH SINGLE PACK OPERATING. RETURN LNDG WAS UNEVENTFUL. ACR MAINT CTL CALLED OUT CONTRACT MAINT. THEY WORKED ON ACFT FOR 2 HRS UNDER MAINT CTL INSTRUCTIONS, VIA THE TELEPHONE. THEY RAN A PRESSURIZATION CHK ON THE MODE CTL PANEL AND DOOR SEALS. ALSO THEY DISABLED THE R BLEED VALVE THROUGH OUR MEL SYS. WE THEN DEPARTED ZZZ AT XC45 AM LCL AGAIN AND THE VERY SAME THING HAPPENED AS FIRST DEP AND RETURN. 4 HRS LATER 2 OF OUR MECHS ARRIVED FROM XXX. THEY INSTALLED A NEW PRESSURIZATION AUTO CTLR AND A R SIDE BLEED AIR VALVE. THEY TEST RAN ACFT AND IT OPS CHKED NORMAL. WE THEN FERRIED ACFT TO XXX ARRIVING AT XH15 LCL.

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.