Air India A320 Declared 'Mayday Fuel' After Critical Fuel Drop in 2023 Probe.

An official government investigation found that an Air India Mayday fuel emergency in May 2023 was caused by a series of operational failures, not a technical problem. The incident involved Air India flight AI-850, an Airbus A320 carrying 149 passengers from Pune to Delhi. The aircraft was forced to make an emergency landing with critically low fuel reserves.

Anatomy of a Near Miss

The incident occurred on May 25, 2023. The flight departed Pune (PNQ) despite bad weather forecasts for its destination, Delhi (DEL). Aviation rules require two alternate airports for such conditions. However, Air India cleared the flight with only one alternate, Jaipur, weakening aviation safety margins from the start.

As the Air India flight AI-850 approached Delhi, severe weather suspended all landings. Air Traffic Control (ATC) instructed the aircraft to hold. The jet remained in a prolonged holding pattern for over an hour and eight minutes. During this time, the aircraft burned nearly 2.8 tonnes of fuel.

Delayed Diversion and Worsening Conditions

Despite the extended delay, the crew's decision to divert was delayed. When they finally diverted, fuel levels were barely enough to reach the single alternate airport, Jaipur. The situation quickly worsened. The crew diverted to Jaipur without checking the latest weather update. This oversight meant they missed a crucial report showing a sudden deterioration in conditions. Thunderstorms and wind shear made landing at Jaipur unsafe. The aircraft was forced to discontinue its landing attempt there.

With fuel reserves falling to about 1,600 kg, Jaipur was no longer a viable option. Delhi remained closed. The pilots had no planned safe landing airport left. At this point, they declared a full Airbus A320 fuel emergency, issuing a "Mayday fuel" call.

Critical Fuel Levels and Regulatory Response

The aircraft diverted again, this time to Gwalior (GWL), an airport not included in the original flight plan. The jet performed a visual landing. When the Airbus A320 touched down, it had just 464 kg of fuel remaining. By the time the engines were shut down, the fuel had dropped to a razor-thin 348 kg. This left virtually no margin for any further delay or technical trouble.

The investigation concluded that the emergency was a result of delayed decision-making and operational errors. It was not caused by any technical failure. The report flagged multiple shortcomings on the airline's part. These included inadequate alternate airport planning and a failure by the airline’s operations control centre to intervene decisively. Internal fuel management guidance was also found to be insufficient.

Industry-Wide Implications

Following the release of the DGCA investigation findings, the Directorate General of Civil Aviation (DGCA) issued a directive. The regulator advised Air India to immediately tighten its flight release procedures. The airline was directed to strictly comply with alternate airport planning rules. The DGCA stressed the importance of protecting aviation safety margins at all times. They also warned that fuel emergencies leave no room for further contingencies. Conservative decision-making must override commercial or scheduling pressures. This incident highlights a recurring challenge in Indian aviation, where previous investigations have also found deficiencies in fuel planning and pilot decision-making during adverse weather. The DGCA’s action underscores the need for robust ground-cockpit coordination across the industry. Read more commercial aviation news at https://flying.flights.

Key Takeaways for Aviation Stakeholders

• 464 kg: The critically low amount of fuel remaining on the Airbus A320 upon touchdown at Gwalior.
• One Hour: The duration of the prolonged holding pattern near Delhi, which burned 2.8 tonnes of fuel.
• DGCA investigation findings cited inadequate alternate airport planning and delayed crew action as the root cause.
• The regulator stressed that delayed decision-making must be avoided to protect safety margins and prevent future Air India Mayday fuel incidents.