Overview
• Operator: TUI Airways
• Aircraft Model: Boeing 787-8 Dreamliner
• Registration: G-TUIB
• Flight Number: BY-173
• Route: Cancun (Mexico) → Manchester (UK)
• Date: 21 December 2023
• Occupants: 291 passengers, 10 crew
• Declared Emergency: Fuel Mayday
• Final Fuel on Landing: 1250 kg (Minimum Required: 1911 kg)
Incident Summary
TUI Airways flight BY-173 from Cancun to Manchester was forced to enter a holding pattern due to adverse weather conditions at Manchester, specifically strong crosswinds and windshear on final approach. The crew initially planned to divert to East Midlands (EMA) but was denied clearance due to capacity constraints, leaving Birmingham (BHX) as the only viable option.
Upon final approach to Birmingham’s runway 33, the aircraft encountered windshear, requiring a go-around. Following the missed approach, the crew declared a Mayday due to low fuel and positioned for another approach. The aircraft landed safely but with 1250 kg of remaining fuel, which was below the regulatory minimum of 1911 kg, classifying the incident as a serious safety event.
Sequence of Events
Holding Over Manchester
• Strong crosswinds (50° off runway 23’s centerline) caused multiple aircraft to abort landings.
• The crew entered a holding pattern but was unable to obtain an Expected Approach Time (EAT) due to congestion.
• Another aircraft reported windshear, prompting the crew to seek an alternate landing option.
Attempted Diversion to East Midlands (EMA)
• EMA was the planned alternate, but ATC refused the diversion due to a miscommunication between airport operations and ATC.
• EMA’s ATC incorrectly assessed the airport as unable to accommodate the Boeing 787, despite available capacity.
Diversion to Birmingham (BHX)
• The aircraft diverted to Birmingham runway 33, which had a 40° crosswind component and similar weather to Manchester.
• While within crosswind limits, windshear remained a known risk.
Missed Approach & Fuel Emergency
• On final approach to BHX, the aircraft received a windshear warning and executed a go-around, further reducing fuel reserves.
• The crew declared a Mayday due to low fuel, but did not use the “Mayday” callsign prefix when communicating with Birmingham ATC.
Extended Track Before Landing
• Following the missed approach, Birmingham Radar advised a 25nm track before reattempting landing.
• ATC missed an opportunity to prioritize G-TUIB over another aircraft (HA-LZY), leading to additional fuel consumption.
• The aircraft landed safely with only 1250 kg of fuel remaining, below the regulatory minimum.
Key Findings from the AAIB Investigation
Fuel Management & Planning
• The aircraft departed Cancun with only 15 minutes of additional fuel, despite ample capacity to take more.
• The crew incorrectly assumed that high winds at Manchester would subside by 0600 UTC, leading to insufficient contingency planning.
• Had the crew loaded more fuel, they could have held longer or diverted earlier without reaching emergency levels.
Decision-Making & ATC Coordination
• EMA diversion refusal was based on incorrect internal communication, leading to a missed opportunity for a safer landing.
• The missed opportunity to prioritize G-TUIB at BHX resulted in an extended flight path and increased fuel burn during a critical phase.
Emergency Handling & Communication
• The crew declared a fuel emergency following the missed approach but did not use the “Mayday” prefix consistently.
• This reduced situational awareness for other aircraft on the frequency, though Birmingham ATC was already aware of the emergency.
• The lack of explicit prioritization from ATC prolonged the emergency situation unnecessarily.
Analysis & Safety Implications
1. Fuel Planning & Risk Assessment
• The crew underestimated the need for extra contingency fuel, despite clear warnings of adverse weather.
• Regulatory fuel minimums were met, but conservative fuel planning would have mitigated the emergency.
2. ATC Communication & Diversion Handling
• EMA’s refusal was based on incorrect internal communication, highlighting the need for better ATC-ground coordination.
• ATC’s failure to prioritize the emergency aircraft led to unnecessary fuel burn.
3. Operational Decision-Making
• The missed approach was unavoidable due to windshear, but an earlier diversion could have prevented the emergency.
• The aircraft landed safely, but dangerously close to fuel exhaustion, increasing risk in case of another missed approach.
Recommendations & Preventative Measures
1. Stronger Fuel Planning Procedures
• Airlines should factor in additional contingency fuel for known weather risks, even beyond minimum regulatory requirements.
2. Improved ATC Diversion Protocols
• Airports must ensure clear communication between ATC and ground operations to avoid unnecessary diversion refusals.
• Expedited diversion approvals should be enforced for aircraft nearing fuel limits.
3. ATC Emergency Prioritization
• When an aircraft declares Mayday for fuel, ATC must immediately prioritize its landing over all other traffic.
• Controllers should verify fuel status and minimize extended flight paths.
4. Standardized Crew Communication
• Flight crews should be explicit and consistent in emergency declarations, using “Mayday” prefixes across all ATC handovers.
Conclusion
The TUI Airways Boeing 787-8 incident at Birmingham was a serious safety event caused by misjudged fuel planning, diversion mismanagement, and a delayed emergency response.
Had extra fuel been loaded, or EMA accepted the diversion, or ATC prioritized the aircraft correctly, the emergency could have been prevented.
This case highlights the critical importance of conservative fuel planning, robust ATC procedures, and effective emergency handling to ensure flight safety in adverse conditions.
Disclaimer
This report is based on available information as of 13 February 2025. While every effort has been made to ensure accuracy, the completeness of the details cannot be guaranteed. If you are the rightful owner of any referenced materials and wish them removed, please email takedown@cockpitking.com.
