A US-based aviation watchdog has claimed that the Boeing 787 Dreamliner operated by Air India, which crashed in Ahmedabad on June 12 last year, had suffered from multiple technical problems throughout its operational life. The group has warned that such safety concerns linked to the aircraft type may be underestimated globally.

According to a report by Hindustan Times, the Foundation for Aviation Safety (FAS) submitted a detailed presentation to the United States Senate on January 12. The submission reportedly included documents suggesting long-standing system failures in the crashed aircraft. However, the newspaper noted that it could not independently verify the authenticity of these records.

Alleged problems from the first day of service

FAS claims that the aircraft, registered as VT-ANB, experienced technical issues from the very first day it entered service with Air India. According to the group, the problems arose due to a complex mix of engineering, manufacturing, quality control, and maintenance shortcomings.

The alleged issues include electronic and software malfunctions, repeated circuit-breaker trips, damaged wiring, short circuits, power outages, overheating of electrical components, and failures within the power distribution system.

Silence from authorities and airline

When asked to respond to the allegations, a Boeing spokesperson said the company would wait for the decision of India’s Aircraft Accident Investigation Bureau (AAIB) on whether to follow the International Civil Aviation Organization (ICAO) Annex 13 protocol governing aircraft accident investigations.

The Ministry of Civil Aviation declined to comment on the claims, while Air India also did not issue any official response.

Dispute over investigation findings

Commenting on the AAIB’s preliminary report, the Foundation for Aviation Safety alleged that the investigation appeared to focus on pilot error, particularly the handling of the fuel control switch. FAS compared this approach to early investigations into the Boeing 737 MAX crashes, claiming there was a familiar tendency to shift blame toward pilots rather than aircraft systems.

Review of over 2,000 Dreamliners

The foundation said it analysed system-failure reports from more than 2,000 Boeing 787 aircraft, which it claims represent around 18% of the global Dreamliner fleet. According to FAS, Boeing’s 787 programme has faced years of delays and cost overruns running into billions of dollars.

The aircraft involved in the Ahmedabad crash reportedly rolled out of Boeing’s factory in late 2011, completed its first flight in December 2013, was delivered to Air India on January 28, 2014, and began commercial operations on February 8, 2014.

Claims of recurring electrical failures

FAS alleged that system malfunctions began as soon as the aircraft arrived in India in February 2014 and continued throughout its 11 years of service. The reported issues include electrical failures, smoke and gas emissions, electrical shocks, and overheating of power distribution units.

The group cited incidents such as a January 2022 fire in the P100 primary power panel, which allegedly damaged critical safety components and required the replacement of the entire panel. Another incident in April 2022 reportedly led to the aircraft being grounded due to a landing gear indication failure, necessitating multiple component replacements. While photographs were included in the report, FAS did not provide supporting official maintenance documents.

Wider safety concerns raised

According to the foundation, similar electrical problems have been observed in other Air India Dreamliners, as well as Boeing 787 aircraft registered in the United States, Canada, and Australia. The group warned that passengers and crew may be flying on these aircraft without awareness of what it described as “ongoing public safety issues.”

FAS has further alleged that Boeing, Air India, and Indian authorities are withholding safety-related information and has called for a criminal investigation by US authorities into the matter.