Air India Crash: Fuel Cut-Off & Systemic Failures

Relevance

GS Paper 3 – Disaster Management & Science/Tech:

GS Paper 2 – Governance / Institutions:

Context:

On June 13, 2025, an Air India Boeing 787-8 aircraft crashed near Ahmedabad shortly after take-off, killing at least 260 people, including 19 on the ground.
Preliminary investigation by the Aircraft Accident Investigation Bureau (AAIB) reveals the fuel switches of both engines transitioned to ‘CUTOFF’ just 3 seconds after take-off, leading to engine thrust loss and eventual crash.

Key Findings from AAIB Preliminary Report:

Fuel Switch Malfunction or Manual Error?

DGCA-registered cockpit recording captures:
- One pilot asking, “Why did you cut-off [fuel]?”
- The other denying having done so.
Both fuel control switches moved from RUN to CUTOFF — 1 second apart — then switched back to RUN after 10–12 seconds.

Engine Failure Timeline:

1:38:42 PM – Aircraft becomes airborne
3 seconds later – Fuel switches transition to CUTOFF
Mayday call sent ~30 seconds later
1:39:00 PM – Aircraft crashes near airport boundary

Prior FAA Advisory Ignored:

FAA Advisory (2018) warned of potential disengagement of fuel switch locking feature on Boeing 787-8.
Air India didn’t act, citing non-mandatory nature of the advisory.

Black Box Recovery Delays:

Black boxes (Enhanced Airborne Flight Recorders, EAFRs) recovered:
- Tail section unit: Substantially damaged
- Front unit: Covered in soot, but intact
Data retrieved only after US NTSB kit arrived on June 23 – 10+ days delay
Raises concerns on India’s readiness for crash forensics despite having a black box analysis lab

Technical Insights:

DGAT2 enzyme or technical fault not involved here (unlike Alzheimer’s research in previous note).
Likely human error or mechanical disengagement of fuel lock switches
Report doesn’t recommend changes to Boeing 787-8 aircraft or GE GEnx-1B engines as of now

Critical Issues Highlighted:

1. Pilot Communication & CRM Failure?

Miscommunication or malfunction?
Raises questions on Crew Resource Management (CRM) practices and training

2. Regulatory Oversight Gaps:

Advisory bulletins (FAA) not treated seriously
Maintenance logs show no recent defect — but critical part was last replaced in 2023

3. Crash Forensics Delays:

Despite India having a black box lab, it wasn’t equipped to handle the damage
Dependence on U.S. equipment (Golden Chassis, cables) delayed analysis

Conclusion:

This tragic crash underscores systemic vulnerabilities in aviation safety, regulatory response, and crash investigation infrastructure. While technical malfunction or human error is yet to be conclusively established, the event highlights the urgent need for better compliance with international advisories, faster post-crash data analysis, and crew training in crisis management.

With India expanding its aviation footprint, strengthening civil aviation safety governance, enhancing indigenous black box forensics capacity, and improving aircrew protocols must become national priorities.