A Vietnam Airlines Boeing 787-9 suffered substantial damage during take-off from Munich Airport on August 15 after its speed dropped twice during the take-off roll, forcing the pilots to continue the departure despite limited runway remaining. The aircraft later returned safely to Munich after dumping fuel, with all 271 passengers and 16 crew members reported safe.

The incident involved Vietnam Airlines flight VN34, which was operating from Munich to Hanoi. The aircraft, registered as VN-A867, took off at around 1:45 pm local time but encountered technical problems shortly after becoming airborne.

Speed Drops During Take-Off

A preliminary report from Vietnam's Civil Aviation Authority (CAAV), cited by Vietnamese media, has provided details of the incident.

According to the report, the aircraft's speed stopped increasing for around two seconds when it was approximately halfway along runway 26L. The aircraft then accelerated again and reached V1, the speed at which pilots must decide whether to continue or reject a take-off.

The aircraft's speed subsequently dropped for a second time. By then, the pilots determined that there was insufficient runway remaining to safely abort the take-off.

Boeing 787 Takes Off Near Runway End

With the aircraft already committed to the departure, the crew increased engine thrust to maximum. The report said the aircraft had only about 91 metres of runway remaining when the pilot raised the nose and the Boeing 787 became airborne.

Videos circulating online appeared to show the aircraft continuing along the runway for an unusually long distance before lifting off, with dust visible behind the aircraft.

The incident has prompted investigators to examine the cause of the two speed reductions and the aircraft's take-off performance.

Tail Strike Warning Triggered

Shortly after becoming airborne, the aircraft generated warnings indicating a possible tail strike and low tyre pressure.

The crew informed air traffic control and decided to return to Munich Airport. The aircraft climbed to approximately 9,000 feet before beginning to dump fuel to reduce its weight and prepare for landing.

The plane then remained in the vicinity of Munich for more than an hour. It also made low-altitude circuits that allowed air traffic controllers to visually assess its landing gear before the aircraft returned to the airport.

Passengers Brace for Landing

Passengers quoted in local media described a tense situation inside the cabin after the captain informed them that the aircraft had developed a technical problem.

Cabin crew later instructed passengers to adopt the brace position as the aircraft prepared to land.

The Boeing 787-9 eventually landed safely on runway 26R at around 3:57 pm local time, roughly two hours after departing Munich.

Four Main Gear Tyres Burst

A preliminary inspection found that four of the aircraft's eight main landing-gear tyres had burst during the incident. Three damaged tyres were located on the left side, while one was on the right.

Investigators also discovered scrape marks on the underside of the rear fuselage and damage to the aircraft's outer skin, indicating that the tail had struck the runway during take-off.

Despite the extent of the damage, there were no reports of injuries or fire among passengers or crew.

The aircraft was unable to taxi away from the runway under its own power, temporarily affecting airport operations. It remains grounded at Munich Airport while further technical inspections are carried out.

Germany Leads Investigation

Germany's Federal Bureau of Aircraft Accident Investigation (BFU) is leading the investigation into the incident.

Investigators have recovered the aircraft's flight data recorder and cockpit voice recorder. Both have been taken to the BFU headquarters in Braunschweig for examination.

Authorities are expected to investigate why the aircraft's speed dropped twice during the take-off roll and whether the issue was related to the aircraft's engines, systems, runway conditions or other operational factors.

Vietnam's CAAV is assisting German investigators. Vietnam Airlines is also cooperating with the investigation along with Boeing and the aircraft's engine manufacturer.

The investigation is expected to establish the precise sequence of events and determine what caused the aircraft to lose speed during the critical stages of its departure.

Several Lufthansa employees were injured after the nose landing gear of a Boeing 787 Dreamliner collapsed while the aircraft was stationed at a gate at Frankfurt Airport on Thursday, prompting an internal investigation into the incident. No passengers were on board at the time, according to the airline.

The incident occurred before the scheduled departure of the aircraft, when only crew members and ground personnel were present. Lufthansa confirmed that multiple staff members sustained injuries, though the company has not disclosed the severity of those injuries.

The airline said the aircraft had not yet begun passenger boarding procedures when the nose gear failure occurred, preventing what could have been a more serious safety situation.

Investigation Underway

Lufthansa has launched an internal investigation in coordination with aviation authorities to determine the exact cause of the landing gear collapse.

In a statement, the airline said it is working closely with the relevant agencies to examine the circumstances surrounding the incident and assess whether any technical, maintenance, or operational factors contributed to the failure.

The affected aircraft has been removed from service pending the outcome of the investigation.

Boeing 787 in Focus

The aircraft involved is a Boeing 787 Dreamliner, one of the newest long-haul aircraft in Lufthansa’s fleet. The airline operates the 787-9 variant as part of its fleet modernization strategy aimed at replacing older, less fuel-efficient aircraft.

Introduced into commercial service in 2011, the Boeing 787 is a wide-body twin-engine jet designed primarily for international long-haul operations. Depending on cabin configuration, the 787-9 can accommodate nearly 300 passengers.

The aircraft has become a key component of many airlines’ long-haul networks due to its fuel efficiency and extended range capabilities.

Similar Incident in London

The Frankfurt occurrence has drawn comparisons with a similar event involving a Boeing 787 at London’s Heathrow Airport in 2021.

According to findings published by the UK Air Accidents Investigation Branch, a Boeing 787-8 undergoing maintenance experienced a nose landing gear collapse after the gear retracted unexpectedly during testing. Investigators later determined that a safety locking pin had been inserted incorrectly, allowing the gear to fold despite existing safeguards.

While there is currently no indication that the Frankfurt incident resulted from a similar cause, investigators are expected to examine maintenance procedures and technical records as part of the inquiry.

Boeing’s Recent Challenges

The incident comes as Boeing continues to face scrutiny over manufacturing quality and safety oversight across several aircraft programmes.

The Boeing 787 programme has encountered multiple challenges since 2020, including concerns related to production quality, fuselage assembly tolerances, and documentation processes. Regulatory reviews led to temporary pauses in aircraft deliveries while authorities examined compliance and manufacturing standards.

Industry analysts note that while isolated technical incidents do not necessarily indicate a broader design problem, each occurrence involving a modern commercial aircraft attracts significant attention due to the aviation industry's strict safety requirements.

Impact on Operations

Airport operations at Frankfurt were not significantly disrupted, although the affected aircraft was grounded immediately after the incident.

Lufthansa has not announced whether the event will affect its wider Boeing 787 operations. The airline is expected to provide further updates once preliminary findings become available.

Air India Launches Fleet-Wide Checks on Boeing 787s After Fuel Switch Malfunction Reported Mid-Flight

In a swift response to a concerning in-flight report, Air India has initiated immediate inspections of the fuel control switches across its fleet of Boeing 787 Dreamliners. The action comes after a pilot operating a flight from London Heathrow to Bengaluru on February 2 reported a malfunction with the critical switch, which had become locked in position.

The Tata Group-owned carrier, which operates approximately 33 Boeing 787 aircraft, has confirmed that inspections on half of the fleet have already been completed without finding further issues. However, checks on the remaining planes are ongoing as a precautionary measure. The airline has also escalated the matter to Boeing for a priority technical evaluation.

Precautionary Measures and Pilot Alert

The directive for inspections was communicated to pilots via an email from Senior Vice President Manish Uppal. The internal memo stated that a "fleet-wide re-inspection of the fuel control switch latch is being carried out as a precaution." An engineering team has been dispatched to collaborate with Boeing, and until a formal response is received, the additional inspections will continue.

Air India has reiterated its standard safety protocol, instructing all crew members to promptly report any defects observed during operations and to ensure all mandatory pre-flight procedures are thoroughly completed before accepting an aircraft.

The Triggering Incident: London to Bengaluru

The urgent review was triggered by an event on Monday. A pilot reported a problem with a fuel control switch on a Boeing 787, specifically noting that the switch had locked. The aircraft involved had departed London on Sunday and arrived in Bengaluru on Monday morning. Following the pilot’s report, the specific aircraft has been grounded for a detailed engineering examination.

Heightened Vigilance After the Ahmedabad Tragedy

The focus on the fuel control switch is particularly acute due to its connection to a past tragedy. A preliminary investigation into the fatal crash of a Boeing 787-8 in Ahmedabad last June, which claimed 260 lives, indicated the aircraft's fuel supply was cut off shortly after takeoff. While the final investigation is still underway, the link to the fuel system prompted Air India to conduct inspections of these switches last year as well. The latest incident has renewed vigilance around this specific component.

Understanding the Critical Fuel Control Switch

For passengers wondering about the significance, here’s a simple breakdown:

Function: The fuel control switches are located in the cockpit and manage the fuel supply to the engines. They are vital for starting (Run position) or stopping (Cutoff position) engine fuel flow.

Operation: Each engine has its own switch. A Boeing 787, with two engines, has two switches. They are designed with a detent lock mechanism and require a deliberate three-step action to operate—making them difficult to trigger accidentally.

Safety Role: They are a fundamental part of engine control and shutdown procedures, directly linked to aircraft thrust and safety.

While initial inspections have not revealed a widespread fault, Air India’s proactive stance highlights the ever-present emphasis on safety in aviation. The combination of a recent in-flight report and the shadow of the Ahmedabad investigation has created a compelling need for thorough verification. As the checks continue and Boeing assesses the findings, travelers can be assured that the issue is being treated with utmost seriousness, underscoring the industry's layered safety protocols designed to catch and rectify potential concerns before they escalate.