In a tragic aviation disaster that shook the nation, Air India Flight AI171 — a Boeing 787-8 Dreamliner registered as VT-ANB — crashed moments after takeoff from Ahmedabad’s Sardar Vallabhbhai Patel International Airport on June 12, 2025. Aboard were 230 passengers and 12 crew members. Only one passenger survived.
Now, the Aircraft Accident Investigation Bureau (AAIB) has released a Preliminary Report detailing chilling insights into what went wrong during the brief 90 seconds of flight. The key finding: both engine fuel control switches were inexplicably moved to “CUTOFF” shortly after takeoff, leading to total engine shutdown and a failed recovery attempt.
This article provides a comprehensive breakdown of the incident, critical system gaps, flight crew profiles, aircraft history, technical insights, and early-stage accountability concerns — all crafted to inform, analyze, and caution.
Flight AI171: A Routine Takeoff That Ended in Catastrophe
On the morning of June 12, 2025, Air India Flight AI171 departed from Ahmedabad to London Gatwick under clear skies and stable weather. Operating with a relatively young aircraft — the Boeing 787-8 manufactured in 2013 — everything about the pre-departure routine appeared normal.
The aircraft had landed earlier that day from Delhi, and although a minor “STAB POS XDCR” warning was logged, the on-duty engineers reportedly resolved it in line with the Fault Isolation Manual.
With fuel onboard at 54,200 kg and total takeoff weight of 213,401 kg (well within limits), the aircraft started its takeoff roll from Runway 23 at 08:07:37 UTC. Within 6 seconds of lifting off, at a maximum speed of 180 knots IAS, the unthinkable happened.
Fuel Cutoff Mystery: Both Engines Shutdown in Air
According to the downloaded Air India flight data from the Enhanced Airborne Flight Recorder (EAFR), the aircraft transitioned to “airborne mode” at 08:08:39 UTC.
Shockingly, both Engine 1 and Engine 2 fuel control switches moved from RUN to CUTOFF — with just a 1-second interval — causing a complete loss of thrust.
Cockpit Voice Recorder (CVR) data paints a haunting picture. One pilot urgently asked the other, “Why did you cutoff?” to which the other responded, “I didn’t do it.”
This brief exchange suggests possible inadvertent activation, a mechanical fault, or perhaps something more complex — but at this stage, it remains an unresolved mystery.
The Aircraft Struggled to Relight — But It Was Too Late
The aircraft’s automated systems kicked in quickly:
- Ram Air Turbine (RAT) deployed within 4 seconds, providing emergency hydraulic power.
- Fuel switches were toggled back to RUN by 08:08:56 UTC.
- Engine 1 began partial relight, but Engine 2 couldn’t recover.
Despite this attempt, the aircraft lost altitude rapidly and crashed into BJ Medical College Hostel, just 0.9 NM from runway end. The EAFR stopped recording at 08:09:11 UTC, marking the final moment of a catastrophic 94-second flight.
260 Lives Lost, One Survivor: A Grim Human Toll
The human cost was staggering:
- All 10 cabin crew, 2 flight crew, and 229 passengers perished which are on this Air India flight.
- 19 people on the ground, including students and staff at the hostel, were also killed.
- One economy-class passenger, seated near the aft section, survived with critical injuries.
The scale of the tragedy places it among India’s deadliest aviation accidents in recent history, reigniting concerns over crew training, cockpit ergonomics, and adherence to safety advisories.
Aircraft History: VT-ANB Had Passed All Mandatory Checks
The aircraft, registered as VT-ANB, was well within its operational parameters:
- Total flying hours: 41,868
- Engines installed recently: LH engine in May 2025, RH engine in March 2025
- D-Check (major maintenance) was not yet due
- Airworthiness Certificate and all MELs (Minimum Equipment List) were within valid dates
However, a critical element was ignored — a 2018 FAA Special Airworthiness Information Bulletin (SAIB NM-18-33) that warned about fuel control switches disengaging their locking feature on Boeing aircraft. Although not mandatory, the advisory recommended thorough inspections.
Air India did not carry out this inspection, deeming the advisory non-compulsory.
Mechanical, Human, or Design Fault? Early Theories Emerge
1. Mechanical or Systemic Malfunction
Could the fuel switches have disengaged on their own? The bulletin did highlight such cases on Boeing 737s. The B787 shares the same switch model (P/N 4TL837-3D).
Given the lack of recorded defects since 2023, the report leaves the possibility open but inconclusive.
2. Human Error or Inadvertent Activation
Given the co-pilot (Pilot Flying) was relatively young (32 years, 3,403 total hours) versus the PIC’s 15,638 hours, some aviation experts believe accidental activation by brushing against switches cannot be ruled out — especially in high workload takeoff phases.
3. Cognitive or Situational Breakdown
The brief CVR exchange suggests confusion, not intentionality. The absence of clear corrective communication raises flags about CRM (Crew Resource Management) and cockpit dynamics.
Impact and Wreckage Analysis: Fragmentation and Fire
The aircraft broke apart over a 1000 ft x 400 ft debris field, destroying five buildings:
- Tail section embedded in Building A
- Right engine detached, hit water tank
- Left engine struck Building D at ground level
- Cockpit wreckage found 650 ft from initial impact
- Severe thermal damage rendered several components, including thrust levers, unreadable
Yet, both fuel switches were recovered in “RUN” position — suggesting an intentional or auto-initiated relight attempt before impact.
Investigative Response: International Collaboration Mobilized
The response was swift and extensive:
- AAIB formed a team led by Sanjay Kumar Singh (IIC) with 5 investigators
- NTSB (USA) sent representatives, as did FAA, Boeing, and GE
- UK, Canada, and Portugal (whose nationals died onboard) were notified as per ICAO Annex 13
- Flight data was downloaded using a “Golden Chassis” sourced by the NTSB for data extraction
The forward EAFR successfully yielded 49 hours of Air India flight data and 2 hours of CVR.
Flight Crew Profile: A Mixed Experience Crew
Captain
- 56-year-old ATPL holder
- 8,596 hours on B787
- Cleared Class I Medical on Sept 2024
- Had no flight hours in last 24 hours (indicating rest)
First Officer (Co-pilot)
- 32-year-old CPL holder
- 1,128 hours on B787
- Class I Medical cleared in Feb 2025
Both pilots had flown recently and were not fatigued, as per records. The co-pilot was Pilot Flying during the event — an important detail under focus.
Air India’s Accountability and Systemic Reflection
Although the Preliminary Report does not assign blame, the emerging facts reveal possible systemic oversights by Air India:
- Failure to act on advisory SAIB warnings
- Lack of extra checks on recently replaced throttle modules
- Ergonomic vulnerabilities in switch placement
- Potential for CRM training improvements
For Air India, this adds to scrutiny at a time when the airline is undergoing modernization under the Tata Group.
No Recommended Actions Yet — But Pressure Builds
The AAIB has not yet recommended airworthiness directives or operator alerts. However, under the surface, pressure is building internationally.
Experts believe Boeing must:
- Reevaluate the locking mechanism of fuel switches
- Provide clarity on cockpit switch placements and fail-safes
- Work with operators on inadvertent cutoff protection
What Happens Next: The Road Ahead for Indian Aviation
As investigators continue analyzing:
- Postmortem and toxicology reports
- Witness accounts
- In-depth FADEC and electrical bus data
- Final CVR interpretations
The Indian aviation ecosystem — from DGCA to airline operators — faces a crucial moment of introspection.
This crash isn’t just a tragedy. It’s a stress test for systemic resilience, policy enforcement, and how far safety is proactively pursued — not just reactively responded to.
Final Thoughts: Could This Have Been Prevented?
While the investigation is still ongoing, one fact is clear: at least three layers of defense failed — mechanical safeguards, procedural response, and possibly human coordination.
Whether or not Air India will face regulatory consequences, the industry owes it to the victims to not dismiss a non-mandatory advisory as inconsequential.
The tragedy of VT-ANB should become a landmark case — not for blame, but for redesigning how modern aviation learns, reacts, and improves.
