- Grounded since 2020, a Boeing 777 returns after years of intensive restoration work
- Air India completes revival of all long‑grounded aircraft inherited post‑privatisation
- Thousands of parts replaced as engineers rebuild a widebody aircraft from the inside out
For years, it sat quietly on the tarmac, grounded and largely forgotten. As Air India went through one of the most turbulent phases in its history, several aircraft in its fleet slipped into limbo - unused, ageing, and written off as too expensive or too complex to fix. When the airline returned to the Tata Group in 2022, rebuilding trust, capability and reliability became urgent priorities. Among the biggest challenges was what to do with dozens of long‑grounded aircraft. The return of one Boeing 777, VT‑ALL, now tells a larger story of revival, patience and a comeback few expected.
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A Boeing 777 That Spent Years Grounded
Photo: Air India
VT‑ALL, a Boeing 777‑300ER, had been grounded since February 2020. Over time, multiple systems became unserviceable and key components aged beyond routine repair. Like many aircraft parked during that period, it slowly slipped out of active planning. By the time Air India took stock of its inherited fleet post‑privatisation, VT‑ALL was one of 30 aircraft that had remained untouched for years. Bringing such an aircraft back to operational life is rare, complex and often avoided altogether. Yet, Air India chose to attempt exactly that.
Why Air India Decided To Bring It Back
Photo: Air India
Post‑2022, Air India committed to rebuilding its fleet and restoring world‑class operational capability. While new aircraft orders drew attention, dealing with the legacy fleet was equally critical. Reviving long‑grounded aircraft is neither quick nor simple. It requires time, investment, manpower and close regulatory oversight. Still, in April 2025, Air India initiated efforts to restore VT‑ALL to support long‑haul expansion, opting for a difficult but necessary path rather than writing the aircraft off.
Inside The Massive Restoration Effort
Photo: Air India
The aircraft entered the AI Engineering Services Limited (AIESL) Nagpur MRO facility in May 2025 for an intensive nose‑to‑tail restoration programme. The scale of work was exceptional. More than 3,000 new key components were installed - a level of replacement rarely seen outside deep structural overhauls. Over 4,000 maintenance tasks were completed, including 80 mandated modifications such as the complex Longeron Modification, a crucial structural reinforcement.
Major assemblies were replaced, including engines, the auxiliary power unit, inlet and fan cowls, and thrust reverser cowls. Nearly every critical system was rebuilt - air‑conditioning, landing gear, hydraulics, oxygen, avionics and engine systems - effectively reconstructing the aircraft's functional backbone.
How Engineers Brought The Aircraft Back To Life
Photo: Air India
Each replacement, system restoration and structural repair underwent stringent testing, documentation and regulatory oversight by the Directorate General of Civil Aviation (DGCA), with technical guidance from Boeing. Skilled engineering teams worked nearly round the clock at the Nagpur facility, carefully restoring the aircraft one system at a time. This was not routine maintenance but a coordinated engineering effort involving Air India's base maintenance, planning, technical services, procurement and supply chain teams, along with the Project Management Office, powerplant division, Continuing Airworthiness Management Organisation (CAMO) and quality assurance teams.
Why This Aircraft's Return Matters
Photo: Air India
With VT‑ALL returning to service, Air India has now completed the revival of all 30 previously grounded aircraft inherited after privatisation. Beyond adding capacity, the aircraft's comeback reflects a broader shift in approach - prioritising safety, reliability and long‑term operational strength. For an airline rebuilding its long‑haul network and global presence, restoring widebody aircraft plays a critical role in stabilising operations and supporting expansion.
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The Journey Ahead
The revival of VT‑ALL is not the end of its transformation. The aircraft, along with other Boeing 777s in Air India's fleet, is scheduled to undergo a full retrofit starting in 2027. Once upgraded, it will feature the new Air India experience, with modern seats, updated amenities and the airline's new livery. For an aircraft grounded for five years and nearly written off, the change is significant.
In many ways, VT‑ALL's journey mirrors Air India's own - a slow, complex revival that required rebuilding from the inside out. What once looked like a wreck on the ground is now ready for the skies again, marking one of the airline's most ambitious and quietly remarkable comebacks.
