Fuel Cut-Off Led to Air India Express Crash: Probe

Post by : Amit

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A Tragedy Rooted in Human Error

In a devastating revelation following months of forensic investigation, Indian aviation authorities have concluded that a fatal crash involving an Air India Express ATR 72-600 in May 2024 was caused by a manual error involving the fuel control levers in the cockpit. The aircraft, operating a domestic flight in Kerala, suffered a dual engine shutdown mid-air before crash-landing in a rubber plantation near Kozhikode. The crash claimed three lives, including two crew members, and injured over 30 passengers.

The aircraft, which had been performing normally during its initial cruise phase, began losing altitude rapidly after both engines unexpectedly lost power—an extremely rare occurrence in commercial aviation. The final accident investigation report, released this week by India’s Aircraft Accident Investigation Bureau (AAIB), points directly to cockpit mismanagement as the initiating factor.

Fuel Control Levers Were Pulled to ‘Fuel Shutoff’ Position

According to the AAIB report, the key failure occurred when both of the aircraft's engine fuel control levers (FCLs) were manually moved to the "fuel shutoff" position. This action caused an immediate loss of fuel supply to the engines, effectively shutting them down in-flight.

The FCLs are located on the central pedestal between the captain and first officer. They are designed to control the fuel flow to the Pratt & Whitney turboprop engines and are protected with safety latches to prevent accidental movement. However, during an abnormal checklist procedure, both levers were incorrectly and simultaneously pulled to shutoff—causing both engines to flame out.

The report highlights that the cockpit crew appeared to be responding to an unrelated sensor alert at the time and may have misidentified the controls. There was no indication of mechanical failure in the engines or fuel systems, ruling out sabotage or fuel contamination as potential causes.

100 Seconds of Descent Without Power

After the unintentional dual engine shutdown, the aircraft began gliding unpowered at approximately 7,000 feet. The crew made desperate attempts to restart the engines, but because the levers remained in the shutoff position, fuel did not resume flowing even as multiple restart attempts were made.

Investigators estimate that the aircraft remained airborne for less than two minutes following the engine cutoff. The pilots attempted an emergency landing in an open area near the Kozhikode airport but were unable to align with any suitable runway or road. The aircraft crash-landed in a rubber plantation, skidding across wet terrain and partially breaking apart on impact.

The cockpit voice recorder (CVR) and flight data recorder (FDR) captured the entire event, including the moment the fuel levers were pulled, the crew’s growing confusion, and the ultimately unsuccessful restart attempts. The cabin crew and passengers received little warning before the impact, though flight attendants had initiated emergency landing protocols in the final 20 seconds.

A Catalog of Training and SOP Gaps

The AAIB’s report not only points to the fuel control lever error but also identifies critical gaps in crew training, especially regarding emergency and abnormal checklist procedures. The crew, it appears, were following an outdated memory item checklist that didn’t fully match the aircraft’s current software configuration.

Moreover, the co-pilot was still under training for ATR operations and lacked sufficient experience with powerplant-related abnormal scenarios. The captain, although experienced on type, had not received a recent simulator session involving dual-engine failures or manual fuel control lever procedures.

The investigation stresses that standard operating procedures (SOPs) were not strictly followed. Instead of verifying each action with a challenge-response protocol, both crew members moved controls independently—a breakdown in CRM (Crew Resource Management) that proved fatal.

Manufacturer and Operator Response

In response to the findings, ATR, the aircraft manufacturer, and Air India Express have jointly issued updated guidance to all ATR operators. ATR has clarified the design logic behind the fuel control levers and reiterated that they are not part of any memory item checklist unless performing an engine shutdown on the ground.

ATR will now work with operators to enhance cockpit labeling and improve tactile differentiation between engine controls. Meanwhile, Air India Express has committed to retraining all ATR crews on dual-engine failure procedures and revalidating abnormal checklist workflows across its training program.

The airline also issued a statement expressing condolences to the victims’ families and vowing full compliance with all AAIB recommendations.

Aviation Community Reacts with Concern

The crash has stirred serious concern across the global aviation community, not just because of the dual engine failure but because of how easily it might have been avoided. Safety experts stress that the error underscores the need for strict checklist discipline, especially under high-pressure conditions involving ambiguous cockpit warnings.

Multiple pilot unions have called for a reevaluation of memory item training and the increasing complexity of cockpit systems on turboprop aircraft. Analysts point out that while dual engine flameouts are exceedingly rare, inadvertent fuel starvation due to crew action has occurred before, most notably in cases like the 2008 Spanair MD-82 crash and a 2011 TransAsia ATR incident.

Regulatory Changes on the Horizon

India’s Directorate General of Civil Aviation (DGCA) is expected to issue new mandates in light of the AAIB’s findings. These may include mandatory simulator training for fuel control emergencies, stricter adherence to challenge-response protocols in all phases of flight, and a review of cockpit ergonomics across India’s ATR fleets.

Furthermore, the incident may lead to design reconsiderations around how critical fuel controls are positioned and secured within the cockpit. Safety advocates are calling for clearer visual and tactile warnings around shutoff positions, especially in dim light or high-stress environments.

Survivors' Accounts and Impact on the Airline

Survivors of the crash described a sudden loss of engine sound, a steep nose-down pitch, and a terrifying descent with no warning from the cockpit. Several reported that oxygen masks were not deployed due to the low altitude of the descent, and that the landing was so abrupt it “felt like a vertical drop.”

Despite the aircraft breaking apart on impact, the relatively controlled descent meant that most passengers survived, thanks in part to the crew’s emergency preparations in the final moments. However, two pilots and one senior cabin crew member lost their lives.

Air India Express, which was in the process of integrating more ATR turboprops into its regional network, has now paused all future ATR deliveries pending internal reviews. The crash is the airline’s second major incident in four years following the 2020 Calicut runway overrun.

A Preventable Loss

This tragic event is a chilling reminder that even a well-maintained aircraft, flown in clear weather, can become vulnerable to simple human error. The shutdown of both engines was not due to a mechanical defect or sabotage—but a misstep in the cockpit at a critical moment.

Aviation, despite being the safest mode of transport, still demands relentless attention to detail, discipline, and human-machine harmony. As the industry absorbs the lessons from this incident, one clear truth stands out: safety isn’t just about systems—it’s about how those systems are used.

Air India, Aviation, India