Key Highlights
- Air India flight AI-191 forced to return to Mumbai three hours after takeoff due to technical malfunction
- Both Mumbai-Newark (AI-191) and Newark-Mumbai (AI-144) flights cancelled following incident
- Third major Air India technical issue in recent days, raising safety concerns
- Same Boeing 787-8 aircraft experienced emergency landing 18 days ago with ram air turbine activation
- Separate Air India flight struck by bird in Chennai, causing engine damage on Tuesday
- Airline arranging hotels and alternative flights for stranded passengers in Mumbai and Newark
Mumbai: Air India faced another operational setback on Wednesday evening when flight AI-191, bound for Newark, New Jersey, from Mumbai, was forced to turn back mid-journey due to a suspected technical malfunction. The Boeing aircraft had been airborne for approximately three hours when the flight crew detected anomalies, prompting an immediate decision to return to Mumbai’s Chhatrapati Shivaji Maharaj International Airport as a precautionary measure. The incident marks the third significant technical problem involving Air India aircraft within a matter of days, intensifying scrutiny over the airline’s maintenance protocols and fleet reliability.
The Mumbai-Newark Incident: Timeline and Response
Flight AI-191 departed Mumbai airport at 1:15 AM on Wednesday, carrying passengers on what should have been a routine long-haul journey to Newark Liberty International Airport in the United States. The trans-Atlantic route typically takes approximately 16 hours, making it one of Air India’s longest non-stop services connecting India with North America.
However, roughly three hours into the flight, when the aircraft would have been cruising over the Arabian Sea or approaching Middle Eastern airspace, the pilot and crew members identified potential technical irregularities. Following standard aviation safety protocols, the captain made the decision to abort the journey and execute a safe return to the departure airport rather than continue toward the destination or attempt a diversion to an alternate airport.
The aircraft landed safely back in Mumbai, where it was immediately removed from active service and sent for a comprehensive technical inspection by Air India’s engineering team. Aviation authorities have not yet disclosed the specific nature of the technical fault that triggered the return, though investigations are ongoing to determine the root cause and ensure similar issues don’t recur.
Cascading Operational Impact
The technical diversion had immediate ripple effects on Air India’s trans-Atlantic operations. Following the incident, the airline was forced to cancel not only the affected Mumbai-Newark flight (AI-191) but also its reciprocal service, the Newark-Mumbai flight (AI-144). This decision left passengers stranded at both ends of the route, creating significant logistical challenges for the airline.
Air India responded with a formal statement acknowledging the disruption and outlining passenger assistance measures. An airline spokesperson confirmed: “Arrangements for hotels and alternative flights have been made for passengers stranded in Mumbai. Passengers in Newark have been informed of the situation, and necessary arrangements are being made for them.”
The airline is working to accommodate affected travelers on alternate flights, though the limited number of direct India-US services means some passengers may face extended delays or need to accept connecting flights through European or Middle Eastern hubs.
Pattern of Recent Technical Issues
Wednesday’s incident represents the third significant technical problem involving Air India aircraft in recent days, raising questions about fleet maintenance standards and operational oversight. The frequency of these incidents has drawn attention from aviation safety regulators and prompted concerns among passengers and industry observers.
Hong Kong-Delhi Flight Incident: Just days earlier, on Thursday morning, Air India flight AI-315 operating from Hong Kong to Delhi experienced technical difficulties before takeoff. The Boeing 787-8 Dreamliner was scheduled for departure at 8:50 AM Hong Kong time but required a component reset before it could safely operate. The technical intervention delayed the flight by nearly three hours, with the aircraft eventually departing around 11:30 AM after engineers completed necessary procedures and safety checks.
Previous Emergency Landing: Remarkably, the same Boeing 787-8 Dreamliner involved in the Hong Kong incident had experienced a serious technical malfunction just 18 days prior. During that earlier flight from Amritsar to Birmingham, England, the aircraft’s ram air turbine (RAT) unexpectedly deployed—a backup power system that only activates during major electrical or hydraulic failures. The RAT is essentially an emergency generator that deploys from the aircraft fuselage during critical situations, providing essential power to vital flight systems when primary power sources fail.
The deployment of the RAT is considered a serious incident in aviation, as it indicates a significant system malfunction. The pilot of that flight exercised exemplary judgment and caution by declaring an emergency and executing a precautionary landing. The fact that the same aircraft experienced another technical issue less than three weeks later raises questions about whether the initial problem was fully resolved or whether underlying systemic issues remain.
Bird Strike in Chennai: Adding to Air India’s challenging week, a separate incident occurred on Tuesday when an Air India aircraft operating from Colombo, Sri Lanka, to Chennai encountered a bird strike during its landing approach. The bird collided with one of the aircraft’s engines, causing visible damage and producing unusual sounds that were immediately noticed by the flight crew.
According to Chennai airport officials, the bird strike occurred during the critical landing phase. Despite the engine damage, the experienced pilot maintained control and completed a safe landing at Chennai International Airport. Following standard protocols for bird strike incidents, Air India’s engineering team conducted a thorough inspection of the damaged engine. As a precautionary measure and pending completion of repairs, the airline cancelled the aircraft’s scheduled return flight from Chennai to Colombo.
Safety Implications and Industry Context
Bird strikes are relatively common in aviation, with thousands occurring globally each year. However, they can pose serious risks, particularly during takeoff and landing when aircraft are at lower altitudes where birds typically fly. Modern jet engines are designed and tested to withstand bird ingestion to a certain degree, but significant strikes can cause substantial damage requiring extensive repairs.
The convergence of multiple technical incidents within such a short timeframe is unusual even for a large carrier operating hundreds of daily flights. While individual mechanical issues are inevitable in any complex transportation system, the pattern raises legitimate questions about:
- Maintenance inspection frequencies and thoroughness
- Parts replacement schedules and quality control
- Fleet age and modernization plans
- Engineering oversight and follow-up procedures after incidents
- Crew training for handling technical irregularities
Regulatory Oversight and Investigation
India’s Directorate General of Civil Aviation (DGCA), the country’s aviation regulatory body, closely monitors all significant technical incidents involving Indian carriers. While the agency has not issued public statements about these specific Air India incidents, standard procedures require airlines to submit detailed incident reports for every operational irregularity, particularly those involving diversions, emergency landings, or safety system deployments like the RAT activation.
The DGCA typically conducts thorough investigations when patterns of technical issues emerge with specific aircraft or across an airline’s fleet. Such investigations can result in mandatory safety directives, enhanced inspection requirements, or, in serious cases, temporary groundings until concerns are adequately addressed.
Air India’s Fleet and Modernization Efforts
Air India has been undergoing a significant transformation since its privatization and acquisition by the Tata Group in January 2022. The airline inherited an aging fleet with deferred maintenance issues accumulated during years of government ownership and financial constraints. The new management has announced ambitious plans to modernize the fleet, including orders for hundreds of new aircraft from both Boeing and Airbus.
However, fleet renewal takes years to complete, meaning Air India continues operating many older aircraft that require more intensive maintenance and are statistically more prone to technical issues. The Boeing 787 Dreamliner, involved in multiple recent incidents, while considered a modern aircraft type, may have accumulated significant flight hours requiring careful monitoring and proactive component replacement.
Passenger Confidence and Industry Reputation
For Air India, these incidents come at a particularly sensitive time as the airline works to rebuild its reputation and compete more effectively with Gulf carriers and other international airlines serving the India-international market. Technical reliability is fundamental to passenger confidence, and a series of publicized incidents, regardless of their ultimate causes or severity, can influence booking decisions and market perception.
The airline’s handling of passenger care during disruptions, including hotel accommodations and rebooking assistance, represents an important aspect of damage control. However, the ultimate solution requires demonstrating consistent operational reliability through robust maintenance practices and transparent communication about safety measures.
