Fuel Cutoff Catastrophe: What Went Wrong in the Air India AI-171 Crash?

The Air India Flight AI-171 crash was triggered by manual fuel shutdown during takeoff. Investigators suspect cockpit error as families seek justice.

Jul 13, 2025 - 09:35
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Fuel Cutoff Catastrophe: What Went Wrong in the Air India AI-171 Crash?

When Air India Flight AI-171 tragically crashed shortly after takeoff on June 12, 2025, killing all 260 on board, few imagined that the cause would be something as avoidable—and shocking—as the manual shutdown of fuel supply during takeoff. In the weeks since, a preliminary investigation has revealed a chilling chain of cockpit decisions that turned a routine flight into one of the deadliest aviation disasters in recent years.

The controversy now centers on the fuel switches—controls that manage engine fuel flow—being turned off moments before the aircraft lost power. What has followed is a series of high-stakes questions involving pilot error, system design, and the limits of human judgment under pressure.


A Routine Takeoff Turns Fatal

Flight AI-171, a Boeing 787-8 Dreamliner, departed from Ahmedabad Airport, bound for London Gatwick. Weather conditions were normal. The aircraft reached takeoff speed and began its climb before both engines lost power, just minutes after becoming airborne. The aircraft attempted to return but crashed in a field beyond the runway perimeter, bursting into flames.

All 260 passengers and crew perished. As the black box was recovered, early speculation ranged from engine failure to bird strikes. But what investigators found was even more troubling—the engine fuel switches had been manually turned off.


The Pilots in Command

The flight was being commanded by two experienced professionals:

  • Captain Sumeet Sabharwal, 56, a senior Air India pilot with over 15,600 hours of flight time, and also a certified flight instructor.

  • First Officer Clive Kunder, 32, a relatively young pilot with approximately 3,400 hours of experience.

Both pilots were reportedly well-rested before the flight, and toxicology reports ruled out alcohol or substance use. According to internal documents obtained by investigative outlets, neither pilot had any known disqualifying medical conditions. Previous rumors about medical impairments have not been substantiated by official findings or verified health records.


The Fuel Button Controversy: Deliberate or Accidental?

According to the Aircraft Accident Investigation Bureau (AAIB), cockpit voice recordings and flight data confirm that the engine fuel control switches were manually turned to “cutoff” mode shortly after takeoff. This action directly caused both Rolls-Royce Trent 1000 engines to flame out, leaving the aircraft powerless.

What’s still unclear is why the switches were moved.

  • The CVR (Cockpit Voice Recorder) reveals that Captain Sabharwal expressed confusion seconds before the engines lost thrust.

  • First Officer Kunder can be heard asking if engine power was dropping, followed by rapid checklist references and calls for a return to the airport.

No voice from the cockpit has yet claimed responsibility for the switch movement, but the AAIB confirmed that there is no known mechanical or software failure that could have flipped the switches without human input.

This leads investigators to strongly suspect that one of the pilots manually moved the switches, either due to a misinterpretation of controls or possibly under pressure during what they thought was a technical anomaly.

A senior investigator, speaking under anonymity, said:

“This wasn’t a case of a system failure—it was a manual override. Whether deliberate or the result of cockpit confusion is still being investigated. But it’s clear: human hands were on those switches.”


Medical History Rumors Dismissed

In the days following the crash, speculation swirled that one of the pilots—rumored to be Captain Sabharwal—might have had an undisclosed health condition that contributed to the accident. These reports gained traction on social media but were never backed by any medical or regulatory authority.

The Directorate General of Civil Aviation (DGCA) has since released a statement confirming that both pilots held valid medical certificates, and neither had any recent medical deferments or psychological evaluations that would have disqualified them from flying. The agency emphasized that health-related impairment has been ruled out as a factor in the crash.


Aviation Experts React

The aviation community has responded with alarm and concern. Veteran pilot and aviation safety analyst Ajay Bansal noted:

“Fuel control switches are not something you toggle mid-flight unless there's a very specific failure checklist being followed. If someone touched those switches in the wrong sequence or misidentified them under stress, that’s a serious training failure.”

He added that dual-verification protocols for critical in-flight adjustments—like fuel flow—may need to be implemented across airlines in response.

Another concern is the ergonomics of the Dreamliner cockpit, where the placement of switches and knobs is designed for maximum clarity. However, in high-stress scenarios, even well-trained professionals can misidentify controls, especially when alarms are going off or power readings suddenly dip.


Families Demand Accountability

In the aftermath, grieving families have begun to organize legal efforts against Air India and Boeing. Many are demanding answers about how something so basic—fuel flow—could be mishandled on one of the most advanced aircraft in the sky.

A family member of a victim told reporters:

“We can’t believe that the cause was someone flicking the wrong switch. It makes the loss even more painful—knowing this might have been prevented.”

Several international aviation lawyers are now exploring whether system design, pilot training, or procedural lapses may hold Air India or Boeing partially liable.


Regulatory Shakeup Coming?

Industry insiders say the DGCA and India’s Civil Aviation Ministry are already drafting new policies in response to the AI-171 disaster. Proposed changes may include:

  • Reinforced cockpit training for emergency situations involving engine anomalies

  • Mandatory two-step confirmation for fuel shutoff procedures

  • Real-time cockpit telemetry monitoring for flagging abnormal switch activity

There’s also talk of launching a nationwide audit of cockpit compliance protocols across Indian airlines to ensure no other aircraft is at risk due to procedural ambiguity or human factors.


Conclusion: A Wake-Up Call for the Industry

The Air India Flight AI-171 tragedy will likely go down in history not just for the loss of life, but for its hauntingly avoidable cause. While fuel cutoff systems are intended for emergencies—not casual adjustment—the human element of aviation remains the most unpredictable variable.

Whether caused by stress, misidentification, or an unexplained decision, the action that led to the death of 260 people now serves as a grave reminder: cockpit actions, even the smallest switch, can have fatal consequences.

As the final AAIB report nears completion, families, regulators, and the global aviation community await a complete picture—but already, the lessons from this catastrophe are pushing aviation policy and procedure toward greater accountability and safety.

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