Date: 17th December 2024
Location: Kochi International Airport (VOCI), India
Aircraft: Boeing 737-800, registration VT-GHD
Operator: Air India Express
Flight Number: IX-471
Route: Kochi (India) to Bahrain (Bahrain)
Occupants: 104 passengers and 8 crew
Injuries: None reported
Summary of Events
On 17th December 2024, Air India Express Flight IX-471, a Boeing 737-800 en route from Kochi to Bahrain, encountered a tyre failure during its departure from Runway 09 at Kochi International Airport. The aircraft continued its climb and levelled off at cruise altitude FL340 over the Arabian Sea.
Approximately 240 nautical miles northwest of Kochi, the crew was informed by Air Traffic Control (ATC) that tyre debris had been discovered on the departure runway. As a precautionary measure, the crew decided to return to Kochi for further inspection.
The aircraft performed a low approach to Runway 09 to allow ground personnel to visually inspect the landing gear, followed by a full stop landing. The aircraft landed without further incident approximately 1 hour and 45 minutes after departure.
A replacement aircraft, VT-GHE, was dispatched, completing the flight to Bahrain with a delay of approximately 5 hours and 20 minutes.
Sequence of Events
1. Departure from Kochi:
• The Boeing 737-800 departed Runway 09 at Kochi International Airport without immediate signs of abnormality.
2. Discovery of Tyre Debris:
• ATC notified the crew of tyre debris found on the runway shortly after takeoff. The crew continued the climb to FL340 while assessing the situation.
3. Decision to Return:
• Given the risk of damaged landing gear, the crew made the decision to return to Kochi for inspection.
4. Low Approach and Landing:
• A low pass was conducted over Runway 09 to enable ground personnel to visually inspect the landing gear for signs of damage.
• After confirming the landing gear could support a landing, the crew safely landed on Runway 09.
5. Post-Landing Assessment:
• Upon landing, the aircraft was inspected, confirming tyre damage as the cause of the debris.
Aircraft Details
• Type: Boeing 737-800
• Registration: VT-GHD
• Configuration: Passenger aircraft
• Engines: 2x CFM56
The Boeing 737-800 is a workhorse in medium-haul operations, equipped with redundant safety systems to handle landing gear or tyre-related malfunctions.
Initial Findings
1. Tyre Failure on Departure:
• A portion of one or more tyres detached during the takeoff roll, leaving debris on the runway.
• Tyre damage in early phases of flight poses potential risks to landing performance, wheel assemblies, and hydraulic systems.
2. Crew Response:
• The crew followed standard operating procedures (SOPs), including notifying ATC, conducting a low approach for inspection, and safely landing back at Kochi.
3. Risk Mitigation:
• A precautionary return ensured passenger and aircraft safety, avoiding any potential escalation during landing at Bahrain.
Safety Risks
1. Landing Gear Integrity:
• A damaged tyre can affect braking efficiency, increase stopping distances, and stress wheel assemblies during landing.
2. Debris Hazard:
• Runway debris can pose risks to other aircraft, necessitating immediate identification and removal to prevent Foreign Object Damage (FOD).
3. Operational Delays:
• Unplanned returns disrupt schedules and necessitate replacement aircraft, impacting airline operations and passenger connectivity.
Recommendations
1. Tyre Inspection Protocols:
• Conduct thorough pre-departure tyre inspections to identify potential anomalies, especially for aircraft operating on high-frequency short-to-medium haul routes.
2. Runway Monitoring:
• Enhance runway inspection systems, including the use of automated FOD detection tools, to identify tyre debris quickly and minimise risks to other aircraft.
3. Crew Training:
• Reinforce crew training for inflight tyre-related emergencies, including low approaches, diversion planning, and safe return protocols.
4. Maintenance Review:
• Conduct a detailed inspection of the landing gear and wheel assemblies to determine the root cause of the tyre failure.
Safety Lessons
This incident highlights the importance of effective communication between flight crews and ATC, along with adherence to established emergency protocols. The successful outcome underscores the critical role of precautionary measures in managing tyre-related issues, ensuring passenger safety and aircraft integrity.
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