HONG KONG– A mid-flight scare aboard an Air India (AI) Boeing 787 from Delhi (DEL) to Hong Kong (HKG) alarmed passengers when unusual door noises disrupted the journey. The incident occurred on June 1, 2025, prompting quick action from the cabin crew.
Passengers on the Delhi-Hong Kong route reported “shaking and hissing” sounds from one of the aircraft’s doors, raising safety concerns. Despite the noise, the flight continued without incident and landed safely at Hong Kong International Airport (HKG).
Photo: Photo: avgeekwithlens/ Harsh TekriwalAir India 787 Door Noise
About an hour after takeoff at 11:45 PM local time from Indira Gandhi International Airport (DEL), passengers began hearing unsettling sounds from a door on the Boeing 787-8.
According to one passenger’s social media post, “The door started shaking and making noises. It seemed the door seal came off due to air pressure.”
Flight attendants swiftly assessed the situation. They placed paper napkins in a visible gap near the door seal and manually applied pressure to reduce the noise. The cabin crew reassured passengers that there was no risk, and the aircraft completed its journey without diversion.
The Air India incident is not isolated. In 2019, a Japan Airlines (JL) Boeing 787 returned to Tokyo (HND) due to similar growling door sounds. Likewise, TUI Airways (BY) and American Airlines (AA) faced comparable events in 2022, both resulting in precautionary returns to origin airports.
The Boeing 787 has been under heightened scrutiny, especially following a recent accident in Ahmedabad that claimed 275 lives.
However, aviation safety experts have clarified that door noise due to pressure leaks does not compromise flight integrity. Aircraft doors are pressurized shut and physically cannot open during flight.
Photo: Utkarsh Thakkar (Vimanspotter)Air India’s Official Response
Air India (AI) issued a statement confirming that all safety protocols were followed. The airline emphasized that the flight crew acted swiftly after determining there was no danger to passengers.
Upon arrival at Hong Kong International Airport (HKG), Air India’s engineering team conducted a thorough inspection. The airline confirmed that the aircraft met all airworthiness parameters. The return flight to Delhi proceeded normally and without incident.
Photo: By Kambui – Air India Boeing 787-8 Dreamliner VT-ANM, CC BY 2.0, https://commons.wikimedia.org/w/index.php?curid=58290529Why Do Boeing 787 Doors Make Noise?
The noises stem from a minor pressure leak at the door seal. At cruising altitude (typically 35,000–40,000 feet), the cabin is pressurized to simulate 6,000–8,000 feet. If a door seal is misaligned or worn, pressurized air may escape through a narrow gap, creating a hissing or growling sound.
The Boeing 787 uses electronically sealed plug-type doors, which differ from manually operated doors found in older aircraft like the Boeing 777.
These doors are tightly locked into the fuselage. However, small maintenance inconsistencies or seal degradation can create noise, though not structural risk.
Investigations Confirm No Structural Danger
Investigations into similar Boeing 787 incidents have consistently shown no risk of decompression or structural failure. In the American Airlines 2022 case, a Paris-bound flight returned after suspected fumes linked to a door seal.
TUI Airways experienced similar noise due to a damaged seal. In each case, safety inspections revealed no critical faults.
Aviation analysts cited by the Times of India stated that such noise typically results from minor door seal misplacement or wear. While alarming, these occurrences are not safety threats and often do not require immediate diversion.
Stay tuned with us. Further, follow us on social media for the latest updates.
Join us on Telegram Group for the Latest Aviation Updates. Subsequently, follow us on Google News
Air India Black Box Recovered, DGCA Calls for 787 Fleet Inspection
The post Air India Boeing 787 Door Noise Causes Mid-Flight Alarm appeared first on Aviation A2Z.
