July 12, 2025
4 mins read

Fuel switch mystery in Air India horror crash

Cockpit voice recordings, fuel switch anomalies and a possible overlooked advisory emerge in early findings

The preliminary investigation into the crash of Air India flight AI171, which went down shortly after take-off from Ahmedabad airport on June 12, has revealed critical insights, including an unexplained and near-simultaneous shutdown of both engines, cockpit confusion between the pilots, and previously issued safety advisories that went unheeded.

The Aircraft Accident Investigation Bureau (AAIB), which released the preliminary report on July 12, noted that a final report may take up to a year to be completed. However, early findings point to a sudden and catastrophic failure within seconds of the Dreamliner taking off, leading to the deaths of all 230 people on board.

Flight AI171, a Boeing 787-8 Dreamliner (registration VT-ANB), had arrived earlier that morning in Ahmedabad from Delhi as AI423. Upon arrival, a defect report was logged citing a status message “STAB POS XDCR”, which was troubleshot by the airline’s maintenance engineer, and the aircraft was cleared for its onward journey to London-Gatwick at 6:40 UTC.

The report confirmed that the aircraft was airworthy and within operational limits. The crew comprised a Mumbai-based captain with an Airline Transport Pilot License and a co-pilot holding a Commercial Pilot License. Both had reportedly received adequate rest. The flight had 230 passengers on board, including 15 in business class and two infants, supported by 10 cabin crew members.

Ahmedabad: A truck transports the wreckage of the Air India plane that crashed into a medical hostel and canteen complex, in Ahmedabad. (Photo: IANS)

According to the report, take-off commenced at 13:38 IST and the aircraft achieved its maximum recorded airspeed of 180 knots within seconds. At precisely 08:08:42 UTC, both engines shut down almost simultaneously — first Engine 1, followed one second later by Engine 2 — as the fuel cutoff switches transitioned from RUN to CUTOFF mode.

“Engine N1 and N2 began to decrease from their take-off values as fuel supply was interrupted,” the AAIB report stated. More startlingly, cockpit voice recordings captured one of the pilots asking the other: “Why did you cut off?” The other pilot responded in confusion, “I did not.”

The sequence of events was rapid and devastating. CCTV footage confirmed that the aircraft’s Ram Air Turbine (RAT) — a backup power mechanism — deployed during initial climb, suggesting a loss of main electrical power. The plane began losing altitude before it could even cross the airport’s perimeter wall.

An emergency “Mayday” was transmitted at 13:39 IST. Though Engine 1 briefly showed signs of restarting, Engine 2 never regained power despite repeated attempts. The aircraft crashed moments later, killing everyone on board.

The AAIB ruled out bird strikes, hazardous cargo or explosive materials as possible causes. No birds were seen in airport surveillance footage, and the aircraft carried no dangerous goods. The engines, both General Electric GEnx-1B models, had been recently installed — one in March and the other in May 2025 — and the plane’s airworthiness certificate was valid until May 2026.

Of particular concern is a 2018 advisory from the US Federal Aviation Administration (FAA), which warned about the potential disengagement of the fuel control switch lock on certain Boeing aircraft. The advisory, however, was non-mandatory. The AAIB report noted that Air India had not implemented the advisory, raising questions about whether a known risk might have played a role in the crash.

Air India, responding to the AAIB’s findings, expressed condolences to the victims’ families and reiterated its cooperation with investigators. “We continue to mourn the loss and are fully committed to providing support during this difficult time,” the airline said in a statement posted on social media platform X. “We acknowledge receipt of the preliminary report and continue to fully cooperate with the AAIB and other authorities.”

Boeing also issued a statement saying, “Our thoughts remain with the loved ones of the passengers and crew on board Air India Flight 171, as well as everyone affected on the ground in Ahmedabad. We will defer to the AAIB for all details related to the investigation, in adherence with the UN ICAO protocol.”

At this stage, the AAIB has not recommended specific actions for other Boeing 787-8 operators or for GE engine users, but stressed that the investigation remains ongoing. The wreckage and both engines have been moved to a secure location for further analysis.

“The investigation team will review and examine additional evidence, records and information that is being sought from the stakeholders,” the bureau said.

While the cause of the tragic crash remains officially undetermined, the early findings raise unsettling questions about in-flight systems, cockpit procedures, and the efficacy of voluntary compliance with safety advisories.

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