Air India has successfully brought a previously grounded Boeing 777-300 ER back into operational status, concluding a significant restoration project. The aircraft, bearing the registration VT-ALL, resumed commercial flights in March 2026 after being out of commission since February 2020. This milestone marks the completion of the revival initiative for all aircraft that were non-operational at the time Air India was privatized.

Details of the Restoration Process

The journey to restore VT-ALL commenced in April 2025, leading the aircraft to the AIESL maintenance, repair, and overhaul facility located in Nagpur by the following month. The refurbishment project involved an extensive overhaul, with visuals from the process illustrating the aircraft stripped down to its essential framework. During this time, the interior cabin fittings and various panels were removed to facilitate access to crucial systems.

In total, the restoration required approximately 3,500 man-hours, involving the execution of over 4,000 maintenance tasks. Key components such as engines, auxiliary power units, and thrust reversers were replaced or installed anew. Additionally, around 80 mandated modifications were executed, including essential structural reinforcements. Major systems, including air conditioning, landing gear, hydraulics, oxygen systems, avionics, and engine systems, were comprehensively overhauled or replaced as part of a complete systems rebuild.

Regulatory Compliance and Testing

Throughout the restoration, each phase—including the replacement of components and system evaluations—was conducted under strict regulatory supervision. The completed aircraft subsequently underwent detailed testing before being granted the necessary approvals to return to commercial service. Following its regulatory test flight, the aircraft received the Airworthiness Review Certificate, a required document that confirms its fitness for operations.

The refurbishment also extended to the aircraft’s cabin interiors, which included upgrades to seats and in-flight entertainment systems. The new configuration comprises 306 seats in economy class, 35 in business class, and four in first class, enhancing overall passenger experience.

Coordination and Future Plans

Air India emphasized that the successful revival of VT-ALL necessitated collaboration among various teams, including those responsible for maintenance, planning, technical services, and quality assurance. With the restoration of this aircraft, Air India announced that all previously grounded planes identified during the privatization phase have now returned to active service.

Looking ahead, Air India revealed plans for a comprehensive retrofit of the Boeing 777 fleet, including VT-ALL, scheduled to begin in 2027. This initiative will incorporate the introduction of new cabin products and updated interior designs, reflecting the airline’s commitment to enhancing passenger services and operational efficiency.

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