Shocking Mid-Flight Alert Sparks Immediate Action
Imagine cruising at 35,000 feet when suddenly, an emergency turbine whirs to life without warning. That’s the nightmare scenario that unfolded on an Air India Boeing 787, prompting India’s aviation watchdog to act fast. The Directorate General of Civil Aviation (DGCA) has issued a urgent order for DGCA Air India Boeing 787s RAT reinspection, focusing on the Ram Air Turbine (RAT) emergency power system.
This directive comes hot on the heels of a startling incident where the RAT deployed uncommanded during descent. With Air India’s Dreamliner fleet under scrutiny, safety takes center stage in India’s bustling aviation sector. Here’s a quick rundown of the essentials:
- The Trigger Incident: On October 4, 2025, Air India Flight AI-117 from Amritsar to Birmingham saw the RAT unlock and deploy automatically at around 400 feet, despite no engine or power failure. 20
- Core Issue: Recent replacement of the Power Conditioning Module (PCM) in several aircraft is suspected to have caused improper RAT stowage, leading to the glitch.
- DGCA’s Response: Mandatory reinspection across all affected 787s, plus a demand for Boeing’s global incident report to prevent repeats.
As passengers book flights amid these headlines, questions swirl: Is this a one-off glitch, or a sign of deeper troubles in modern airliners?
Unpacking the RAT System: Your Aircraft’s Last Line of Defense
To grasp the gravity of this DGCA Air India Boeing 787 RAT reinspection, let’s break down what the Ram Air Turbine really does. Tucked away in the belly of the plane, the RAT is no ordinary gadget—it’s a lifesaver.
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What Exactly is a Ram Air Turbine?
The RAT, short for Ram Air Turbine, is a compact wind turbine that springs into action during catastrophes. 9 It uses the rush of oncoming air—think ram pressure from the jet’s speed—to spin blades connected to a generator or hydraulic pump. This provides backup electrical or hydraulic power if the main engines or systems conk out.
On the Boeing 787 Dreamliner, the RAT is engineered for seamless integration with the aircraft’s advanced electrical architecture. Unlike older planes relying on mechanical backups, the 787’s “more electric” design makes the RAT crucial for everything from flight controls to cabin pressurization. But when it deploys without cause? That’s a red flag for false alarms that could rattle pilots and passengers alike.
Experts liken it to a car’s spare tire: essential, but you don’t want it popping out on the highway. In this case, the recent PCM swap—part of routine maintenance to boost electrical efficiency—may have jostled the RAT’s locking mechanism, causing it to “unlock” prematurely.
Why the PCM Change Matters
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The Power Conditioning Module (PCM) is the brain of the 787’s power distribution, converting and regulating electricity for critical systems. Air India, like many operators, routinely replaces these modules during heavy checks to ensure reliability. However, the DGCA Air India Boeing 787 RAT reinspection stems from a potential oversight: Did the swap affect RAT stowage?
A senior DGCA official emphasized, “Air India has been advised to reinspect the RAT for stowage for all aircraft whose PCM module was replaced recently.” 20 This isn’t just busywork—it’s a proactive hunt for stowage discrepancies that could lead to unwanted deployments mid-flight.
For context, Boeing’s Fleet Team Digest has flagged similar quirks globally, though none as dramatic as this uncommanded pop-out. The DGCA isn’t stopping there; they’ve looped in Boeing for a full dossier on worldwide service difficulties post-PCM changes.
Air India’s Dreamliner Journey: From Glory to Grounded Worries
Air India has been synonymous with the Boeing 787 since 2012, when it became one of the first carriers to welcome the fuel-sipping Dreamliner. 21 Today, the airline boasts a fleet of 27 Boeing 787-8s, with more on order as part of its Tata Group revival. 23 These jets have ferried millions across continents, cutting emissions by 20% compared to older models and offering that signature window-side glow from electrochromic glass.
But glory has its glitches. The 787’s history isn’t spotless. Back in 2013, the entire global fleet was grounded for three months over lithium-ion battery fires that scorched two Japanese airliners. 17 Fast-forward to 2025, and shadows linger. A June crash of an Air India 787 shortly after takeoff in India saw investigators pinpointing an active emergency power system as a possible factor. 19
Recent RAT Scares in the Spotlight
This isn’t isolated. Just days before the DGCA’s order, pilots from the Federation of Indian Pilots (FIP) urged grounding the entire 787 fleet, citing electrical gremlins on a Vienna-Delhi flight that forced a Dubai diversion. 15 No fire, no crash—but autopilot failures and cascading malfunctions raised hackles.
The Amritsar-Birmingham episode? Pilots stayed cool, landing safely after the RAT alert. Boeing’s post-incident checks found no faults, and the plane flew back to Delhi the next day. Yet, the FIP’s letter to Aviation Minister Ram Mohan Naidu decried “a series of technical malfunctions,” demanding a special audit.
Air India pushed back, denying any electrical failure on the Vienna leg. Still, with passenger trust on the line, the airline’s complying swiftly. “Safety remains our top priority,” a spokesperson noted, committing to the reinspections without disrupting schedules.
Broader Implications: A Wake-Up Call for Global Aviation?
This DGCA Air India Boeing 787 RAT reinspection ripples beyond India’s borders. Boeing, already under the microscope post-737 MAX woes, faces fresh scrutiny on its 787 lineup. The DGCA’s request for global data could unearth patterns, potentially leading to fleet-wide advisories.
Lessons from History
Aviation safety evolves through such scares. Remember the 2013 grounding? It birthed tougher battery safeguards, saving lives indirectly. Today, with over 1,000 Dreamliners airborne worldwide, even minor tweaks matter.
For airlines, it’s a reminder: Maintenance isn’t optional. PCM swaps, while routine, demand precision to avoid RAT mishaps. Passengers, meanwhile, can rest easier knowing regulators like the DGCA act decisively—inspections are underway, and Boeing’s report is due soon.
External voices echo this. A Reuters analysis on the June crash highlighted RAT’s role in emergencies, urging better diagnostics. Similarly, BBC coverage of a recent RAT trigger landing dissected how these systems prevent disasters, even if they spook crews.
And for a deep dive into RAT tech, check SKYbrary’s guide, which details its hydraulic and electrical backups—vital reading for aviation buffs.
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The Road Ahead: Ensuring Skies Stay Safe
As Air India crews pore over checklists and Boeing crunches data, this episode underscores aviation’s razor-thin margin for error. From PCM tweaks to RAT readiness, every bolt counts in keeping 400 souls aloft.
The reinspections, expected to wrap in days, could greenlight smoother flights—or spark wider fixes. Either way, it’s a testament to vigilance: India’s skies, busier than ever, demand nothing less.
What do you think—should airlines pause 787 ops during such probes? Share your take in the comments below.
Source: Bloomberg Article
Credit: Bloomberg (10:35 AM IST, October 12, 2025)