GE Expands Boeing 787 Engine Inspections Following Air India Shutdown Incident

General Electric expanded its global engine inspection program following an in-flight engine shutdown on an Air India Boeing 787 aircraft. The Directorate General of Civil Aviation disclosed the technical details of the safety investigation to the Central Information Commission. The safety probe revealed that an High-Pressure Compressor Stage-10 blade broke free during flight. This mechanical failure caused a severe engine surge, forcing the flight crew to shut down the affected engine immediately.

The mechanical failure occurred because the locking lugs on the compressor blade were improperly installed during assembly. This assembly error led to structural fatigue, allowing the heavy titanium blade to detach while operating at high speeds. General Electric quickly updated its worldwide maintenance manuals and service bulletins to prevent similar failures in other GEnx engines. The company mandated stricter tolerance checks and ultrasonic inspections of the compressor assemblies during routine maintenance intervals.

The incident highlights the strict regulatory oversight maintained by India's DGCA in ensuring passenger safety across domestic airlines. Aviation experts note that sharing these critical safety reports openly helps maintain high operational standards. Air India has been upgrading its maintenance facilities to carry out these precision inspections locally. This domestic capability reduces aircraft downtime and guarantees that its widebody Boeing fleet complies with international airworthiness standards.