Operational History of Air India’s AI-171 Dreamliner Before the Tragedy

The Air India aircraft involved in the tragic crash of Flight AI-171 was registered as VT-ANB, bearing Manufacturer Serial Number (MSN) 36279 and Line Number 26. It was a Boeing 787-8 Dreamliner, first flown on December 14, 2013, and delivered to Air India on January 31, 2014. Powered by two GEnx-1B engines, the aircraft had reliably served the airline for over a decade and had accumulated over 41,000 flight hours, which is considered average for its type.

This crash marked the first-ever hull loss of a Boeing 787-8 Dreamliner worldwide. The aircraft was nearly 11 years old at the time of the incident and had maintained a consistent operational record until the tragedy. The crash is a significant moment in civil aviation history, given the model’s previously unblemished safety record.

Investigation and Recovery

Following the accident, the Aircraft Accident Investigation Bureau (AAIB) of India initiated a detailed investigation, with support from the UK Air Accidents Investigation Branch (UK AIB). One of the aircraft’s black boxes—specifically, the Digital Flight Data Recorder (DFDR)—has been recovered from the wreckage by the Anti-Terrorism Squad (ATS). This crucial data is expected to shed light on the aircraft’s final moments and help investigators determine the root cause of the crash.

Although there were no documented safety lapses specifically related to this aircraft, a former Civil Aviation official indicated that the Directorate General of Civil Aviation (DGCA) had previously raised concerns about maintenance practices within the airline.

Fleet History and Prior Incidents

Air India introduced the Boeing 787-8 Dreamliner into its fleet in 2011, and by 2025, it was operating 27 of these aircraft. Between 2015 and 2024, the 787-8 fleet had reported 32 operational incidents, including:

• Engine shutdowns
• Flight control glitches
• Non-retracting landing gear
• Smoke in the cabin
• Loss of communication
• Cracked windshields
• Cabin pressure issues
• Sudden altitude deviations
• Tyre bursts

A notable recent case occurred on December 13, 2024, when Flight AI-113 from Delhi to Birmingham reported a hydraulic leak in the nose landing gear during landing, which grounded the aircraft for 28 hours.

Broader Concerns and Manufacturer’s Advisory

Boeing had previously advised Air India and other operators to avoid flying the 787 in or near high-altitude thunderstorms due to the risk of engine icing. This led to operational changes, including the withdrawal of 787 services from the Delhi–Tokyo route.

Global Safety Record

Despite these scattered incidents, the Boeing 787-8 Dreamliner had maintained a remarkable safety record before the AI-171 tragedy. In over 15 years of service, with more than 1,100 aircraft operating globally, the 787 had no prior fatal accidents or hull losses. The model has been widely praised for its fuel efficiency, structural innovations, and long-haul capabilities, continuing to serve airlines efficiently around the world.