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Caspian Airlines Flight 7908 Incident Report: Crash in Northern Iran

Date: 15th July 2009

Location: Near Qazvin, Northern Iran

Aircraft: Tupolev Tu-154M, registration EP-CPG

Flight Number: 7908

Operator: Caspian Airlines

Flight Route: Tehran (Iran) to Yerevan (Armenia)

Passengers: 153

Crew: 15

Summary of Events

On 15th July 2009, Caspian Airlines Flight 7908, a Tupolev Tu-154M, crashed in a rural area near the city of Qazvin in northern Iran, killing all 168 people on board. The flight had departed from Tehran’s Imam Khomeini International Airport and was bound for Yerevan, Armenia, when it experienced a catastrophic failure at an altitude of approximately 34,000 feet, just 16 minutes after take-off. The aircraft plunged to the ground at high speed and exploded upon impact, leaving no survivors.

The crash scattered wreckage across a wide area of farmland, with eyewitnesses reporting seeing the plane on fire before it struck the ground. The cause of the crash was later determined to be a failure in one of the aircraft’s engines, leading to a loss of control. This disaster marked one of the deadliest aviation accidents in Iranian history and underscored the risks associated with operating aging aircraft in commercial fleets.

Aircraft and Crew Information

The aircraft involved in the crash was a Tupolev Tu-154M, a Soviet-designed, narrow-body, three-engine airliner widely used across Eastern Europe and parts of Asia. The Tu-154 was first introduced in the 1970s and became the backbone of many airlines’ fleets in the region. However, by 2009, the Tu-154 was considered outdated, and many of its operators faced challenges maintaining the aircraft due to parts scarcity and the increasing age of the airframes.

The aircraft, registration EP-CPG, had been in service for nearly two decades at the time of the crash, having been built in 1987. It had accumulated several thousand flight hours and had undergone multiple maintenance cycles, though questions were raised about the quality of maintenance given the sanctions imposed on Iran, limiting access to spare parts and technical support for older Soviet-era aircraft.

The flight crew consisted of an experienced captain with over 14,000 flight hours, a first officer with extensive experience on the Tupolev Tu-154, and a competent cabin crew. Despite their experience, the crew faced insurmountable challenges once the aircraft suffered the catastrophic engine failure, leaving them with little time to react before the aircraft became uncontrollable.

Sequence of Events

Flight 7908 took off from Tehran at approximately 11:33 local time, destined for Yerevan’s Zvartnots International Airport in Armenia. The flight initially proceeded as expected, with the aircraft climbing steadily toward its cruising altitude. At around 11:50, while the aircraft was at an altitude of approximately 34,000 feet, one of its three engines suffered a severe mechanical failure.

Eyewitness reports, along with data recovered from the aircraft’s black boxes, indicated that the engine failure caused an intense fire, which spread rapidly through the airframe. The flight crew attempted to manage the emergency, but the damage to the aircraft was too extensive. The fire compromised critical control systems, and the aircraft entered a steep, uncontrolled descent.

The aircraft crashed into farmland near the village of Jannatabad, approximately 75 miles northwest of Tehran. The impact created a large crater, and much of the wreckage was destroyed by the post-crash fire. Local residents described hearing a loud explosion and seeing the aircraft in flames before it impacted the ground. Rescue teams arrived at the crash site, but it quickly became apparent that there were no survivors. The bodies of all 168 passengers and crew members were recovered in the aftermath of the disaster.

Weather and Conditions

The weather at the time of the crash was reported to be clear, with no significant meteorological factors that would have contributed to the accident. Visibility was good, and there were no reported issues with turbulence or wind shear that could have affected the flight. The clear conditions made it easier for investigators to focus on mechanical or technical causes as the primary factors behind the crash.

Investigation and Analysis

The investigation into the crash of Caspian Airlines Flight 7908 was conducted by Iranian aviation authorities with assistance from international experts. Given the aircraft’s age and the known challenges associated with maintaining Soviet-era aircraft, the investigation quickly focused on potential mechanical failures and the state of the aircraft’s engines.

Engine Failure: The investigation revealed that the primary cause of the crash was a catastrophic failure in one of the aircraft’s three engines, specifically the rear-mounted Kuznetsov NK-8 engine. The failure led to an intense fire, which quickly spread through the aircraft’s structure. The engine, which was several decades old, had experienced significant wear and tear over its years of operation. Investigators found evidence of metal fatigue in the engine’s turbine blades, which may have contributed to the failure.

Fire and Loss of Control: Once the engine failure occurred, the fire that followed rapidly damaged critical control systems, making it impossible for the crew to maintain control of the aircraft. The intense heat compromised the aircraft’s hydraulic systems, which are essential for controlling the aircraft’s ailerons, elevators, and rudder. The loss of these systems resulted in the aircraft’s steep, uncontrolled descent. The speed and angle of the descent left the crew with no opportunity to recover.

Maintenance and Sanctions: The investigation also raised concerns about the maintenance practices used on the aging Tupolev Tu-154 fleet. Due to international sanctions imposed on Iran, access to spare parts and technical support for Soviet-era aircraft was limited. This meant that many airlines, including Caspian Airlines, had to rely on outdated parts or improvised repairs to keep their aircraft operational. The investigation noted that while the engine had undergone routine inspections, the wear and tear identified in the post-crash analysis may not have been detected or addressed during previous maintenance checks.

Conclusions

The crash of Caspian Airlines Flight 7908 was the result of a catastrophic engine failure, which led to an uncontrollable fire and the loss of critical control systems. The age of the aircraft, combined with the challenges of maintaining Soviet-era airframes under international sanctions, was a contributing factor to the accident. The engine failure, exacerbated by metal fatigue and insufficient maintenance, left the crew with no time to respond before the aircraft became uncontrollable.

The crash was a tragic reminder of the risks associated with operating older aircraft, particularly those with limited access to spare parts and technical support. The disaster claimed the lives of all 168 people on board, making it one of the deadliest aviation accidents in Iran’s history.

Recommendations

Following the investigation, several key recommendations were made to improve aviation safety and prevent similar incidents in the future:

1. Phasing Out Aging Aircraft: Airlines should prioritise the replacement of aging aircraft, particularly those with known reliability issues and limited access to spare parts. Governments should consider offering financial support to airlines operating older aircraft to assist with fleet modernisation.

2. Enhanced Maintenance and Inspections: More rigorous maintenance and inspection protocols should be implemented for older aircraft, particularly focusing on engine wear and tear. Advanced diagnostic tools, such as metal fatigue analysis, should be employed to detect potential issues before they lead to catastrophic failures.

3. International Collaboration: Countries affected by sanctions that limit access to aviation parts and technology should collaborate with international bodies to find solutions for maintaining safe air operations. This may include negotiated agreements to allow access to critical aviation technology for safety purposes.

Safety Lessons and Industry Impact

The crash of Caspian Airlines Flight 7908 highlighted the challenges faced by airlines operating aging aircraft, particularly in regions where sanctions or economic limitations restrict access to the parts and technology needed to maintain safe operations. The disaster underscored the importance of rigorous maintenance practices and the need for early retirement of aging airframes with known reliability issues.

The aviation industry has since taken steps to enhance the safety of older aircraft, including more stringent inspection protocols and increased support for fleet modernisation. The lessons learned from this tragedy continue to shape the policies surrounding aircraft maintenance and the safe operation of older fleets worldwide.

Disclaimer

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Our investigation reports are based on all the evidence and facts we have at the time of writing and posting. We apologise if any details are missed or are not fully accurate.

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