What Went Wrong? Six Possible Errors in the Air India AI-171 Boeing 787 Accident

The tragic crash of Air India Flight AI171, a Boeing 787 Dreamliner operating from Ahmedabad to London Gateway, has raised several questions about what may have caused this devastating accident.

The aircraft, an 11-year-old jet delivered to Air India on January 31, 2014, had accumulated nearly 41,000 flight hours and was powered by GENx-1B engines. It was primarily used for long-haul international routes and was part of Air India’s fleet of 34 Dreamliners.

On June 12, 2025, the flight was carrying around 242 passengers and a substantial amount of fuel for its 9.5-hour journey—estimated to be between 66,000 and 100,000 kilograms. Such a heavy fuel load, combined with a full passenger load, meant the aircraft was operating near its maximum takeoff weight.

Maintenance Background

The maintenance of Air India’s Boeing 787 fleet is handled by Air India Engineering Services Ltd. (AIESL), a government-owned MRO (Maintenance, Repair, and Overhaul) provider with facilities in Mumbai, Delhi, and other locations.

Despite Air India’s privatization by the Tata Group in 2022, AIESL remains a separate state-owned entity. Air India has also partnered with SIA Engineering Company to build a new maintenance hub at Kempegowda International Airport in Bengaluru, set to enhance widebody MRO capabilities from 2026.

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Theories and Technical Observations

Several possible causes have been speculated based on available information, though none are confirmed. These include:

1. Engine Thrust Failure

During takeoff, engine thrust is vital to generate the lift required for departure. In this case, eyewitness reports and video evidence suggest a lack of sufficient thrust, possibly leading to failure to gain altitude.

A dual engine failure during takeoff is highly unusual and suggests a critical issue such as fuel supply disruption or systemic malfunction.

2. Flap Malfunction

Flaps are crucial during takeoff to increase lift at lower speeds. If the flaps failed to deploy or operate correctly, the aircraft might not have been able to lift off safely.

Malfunctioning control surfaces, possibly caused by electrical or hydraulic failure, could have played a role in the failed takeoff.

3. Fuel Supply or Electrical System Failure

In modern jets like the 787, each engine draws fuel from its respective wing tank. Fuel delivery depends on electrically powered pumps. If electrical power is lost, fuel may not reach the engines, leading to a complete loss of thrust.

The 787 also relies on engine-driven electrical generators, with an auxiliary power unit (APU) as backup. A failure in both engines would result in a major electrical failure, which could explain the inability to pump fuel or control hydraulic systems.

4. Hydraulic and Avionics System Disruption

Electrical power also supports the aircraft’s hydraulic systems, which control key components like landing gear and flaps. If electrical supply is disrupted, hydraulics can fail, preventing retraction of the landing gear and proper deployment of flight control surfaces—critical during takeoff and climb.

5. Landing Gear Observation

Videos shared on social media suggest the landing gear remained extended, even after takeoff. This may indicate the aircraft was attempting an emergency landing shortly after liftoff. The failure to retract the gear could point to electrical or hydraulic issues, further supporting the theory of systemic failure.

6. Load Imbalance

Another potential factor is improper weight distribution. If cargo or baggage was not loaded correctly, or if the center of gravity was outside acceptable limits, the aircraft’s balance could be affected.

This would not typically be noticed while taxiing but could severely impact flight stability after takeoff, especially under high weight conditions. Improper load balancing may also limit the effectiveness of engine thrust and control surfaces.

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Ongoing Investigation

These are currently unconfirmed theories. The actual cause will only be determined after a detailed investigation by the DGCA (Directorate General of Civil Aviation), NTSB (National Transportation Safety Board), and Boeing.

The aircraft’s black box has already been recovered, including the cockpit voice recorder and flight data recorder. These tools will provide vital information on engine performance, fuel system behavior, sensor data, and crew actions in the moments leading up to the crash.

This investigation will reveal how the aircraft transitioned from ground to air and what exactly went wrong during this critical phase. While we have presented potential causes—such as flap or thrust failure, electrical malfunction, or load imbalance—these remain speculative until verified by the authorities.