To touch on some of the things mentioned above. It does it on all projects, and it does it all the time whether SONAR is open or not. It only happens when his computer is plugged into his interface. We've tried different interfaces and that is not the problem.
His machine is a desk top tower...mine is the laptop. It was built by a friend who has built his own computers for his home DAW's which have always worked fine, but he's not a dealer. However, he would be the one to do any serious checking inside the cover.
I don't know if any ports are USB 3, but it makes the noise with all of the USB ports.
I don't know about the graphics card.
When we did the experiment last night everything was the same....monitor, speakers, Interface, location, etc. To do the experiment we had a USB coming from his computer and a separate USB cable coming from my laptop. We'd plug his computer into the Focusrite interface and get the noise. When we unplugged it the noise stops. Then we'd plug my laptop into the same interface and there is no noise. Then, plug his back to the interface and the noise starts again immediately. We were using two separate USB cables, but he's tried other cables the past few days and that doesn't seem to matter. No matter what USB cable, the noise starts as soon as his computer is hooked to the interface.
That's a good point about whether it just started or has it always done it. I'm pretty sure it was fine in the beginning and this noise started later. That would indicate that maybe it is a connection that's come loose. My friend with the computer noise will probably be in later today to answer some of the details that I don't know the answer to. After the experiments last night we're practically sure that the trouble is with his computer, but we don't know where.
Thanks again for all the input. Looks like several others here have had the same, or similar, trouble, so I hope this thread helps others correct the trouble.
DS