Date: 201512
Local time of day: 1201-1800
Location: ZZZ.Airport, US
Flight conditions: IMC
Light: Daylight
Aircraft: Small Aircraft
Operator: Personal
Operating under: Part 91
Flight plan: IFR
Mission: Personal
Flight phase: Initial Climb
Airspace: Class D ZZZ
ATC / advisory: Tower ZZZ
Second aircraft: Light Transport
Reporter organization: Government
Reporter function: Local
Reporter qualification: Air Traffic Control Fully Certified
Second reporter function: Local
Anomaly: ATC Issue All Types; Conflict Airborne Conflict; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural Clearance
Detector: Person Air Traffic Control
Result: Air Traffic Control Provided Assistance; Air Traffic Control Issued New Clearance; Flight Crew Landed in Emergency Condition; Flight Crew Returned To Departure Airport; Flight Crew Requested ATC Assistance / Clarification; Flight Crew Executed Go Around / Missed Approach; Flight Crew Overcame Equipment Problem
Contributing factors: Aircraft; Airspace Structure; Human Factors; Procedure; Weather
Primary problem: Procedure

Narrative: I was working Local Control and launched Aircraft X. I was getting relieved from Local Control and finishing the briefing when Aircraft X said they needed to come back to land because their door was open. The new Local Controller said turn left join the left downwind. I reminded the Local Control that the field was IFR and the last base report we had was OVC008. His response was 'I have to do something with him'. He called to coordinate with TRACON asking them to keep his flight plan open and that he needs to come back to land. The Local Control then decided to launch an aircraft that was holding short for immediate take off. TRACON calls back and says they want to talk to Aircraft X and to put him on a heading of 360. Aircraft X says he can't change frequencies and that he needs to land. I told the Local Controller that the Aircraft X looked like he was extending waiting for instructions. Aircraft Y was on final for the runway. Local Control and TRACON decided to send Aircraft Y around but now you could barely see Aircraft X as they were turning downwind to base low beneath the cloud layer. The Aircraft Y was at 1000 feet but not in sight. They looked very close on the radar but I only ever had Aircraft X in sight. The Local Controller seemed annoyed that I was trying to help. I would coordinated with TRACON immediately and let them know we had an emergency and to take Aircraft Y off the final and sequence. I would not have launched the Aircraft Z because it created a lot of confusion. TRACON and the pilots were both calling at the same time so the Local Control couldn't hear what was being said and had to go back to both parties to repeat.


Second narrative: Cleared Aircraft X for takeoff. Once airborne he advised me he had to return; his door was open. I instructed him to turn left keep it in as close as feasible cleared to land. Aircraft Y was on a 7 mile final. I called TRACON and advised them of the situation. They asked me what I was going to do; that I had to do something. I told him Aircraft X had a door open; I was bringing back to land. He said I can't because it's IFR. I asked him if he wanted me to turn him north to maintain 2000 feet and he said yes. I instructed Aircraft X to turn right heading 360 maintain 2000 feet. He responded he couldn't do that; his door was open. I advised TRACON the pilot says he couldn't do it. Aircraft Y is now on a 5 mile final. Aircraft X is turning a 1 mile left base. I have him in sight. I asked TRACON if they wanted me to turn Aircraft Y left heading 360 maintain 2000 feet. I couldn't understand what he said. I tried to get in contact with to verify; he wouldn't answer so I turned Aircraft Y left heading 360 maintain 2000 feet. I had both aircraft in sight at that time. A better relationship between tower and TRACON. I feel the major problem was a break in communication between the two.


Synopsis: An aircraft departed an airport that was in IFR weather. The aircraft notified tower they had an open door; declared an emergency and needed to return to land. Due to the airport being IFR; TRACON assigned a heading and altitude and requested communication with the aircraft for re-sequencing. There was an arriving aircraft on a 7-10 mile final. The emergency aircraft refused the TRACON instructions and advised tower they needed to land immediately. The tower controller could not establish communication with the TRACON controller so they turned the arrival to a heading and assigned an altitude to maintain.