On June 17, 2025, Air India Flight AI180, operating on a route from San Francisco (SFO) to Mumbai (BOM), was forced to make an unexpected and precautionary stop at Kolkata’s Netaji Subhash Chandra Bose International Airport (CCU) due to a technical issue involving its left engine.
The Boeing 777‑200LR aircraft had taken off from SFO late in the evening prior, landed as scheduled in Kolkata, but could not continue to Mumbai. No injuries were reported.
Passengers were safely deplaned after several hours on the tarmac, and the airline initiated re‑booking on alternate flights.
Sequence of Events
- 12:45 a.m. IST: Flight AI180 lands in Kolkata after an approximate 17‑hour journey from San Francisco .
- 2:00 a.m. IST: The flight was scheduled to depart for Mumbai, but inspection revealed an issue with the left engine and the flight was delayed .
- 5:20 a.m. IST: The captain, citing passenger safety, ordered everyone to deplane. Passengers disembarked and waited in the terminal while mechanics assessed the situation.
- Ground Response: Crews inspected the engine thoroughly. The flight was effectively cancelled at that moment, with Air India arranging hotel accommodations and rebooking for the ~211 affected passengers
Technical Perspective & Maintenance Oversight
Though Air India has not officially disclosed the specific fault, most sources suggest a technical snag with the left engine. While it’s unclear whether routine landing‑checks or in‑flight alarms first triggered the issue, standard operational protocols required crew intervention and precautionary action .
Experts in flight safety noted that Air India’s recent track record has become a point of concern. For instance:
- A Boeing 787 Dreamliner (AI315) earlier returned mid‑air from Hong Kong to Delhi due to a suspected in‑flight technical issue.
- Just days prior, a devastating crash of another Dreamliner near Ahmedabad killed over 270 people, prompting Indian aviation regulators to order comprehensive fleet inspections.
In response, Air India and the DGCA (Directorate General of Civil Aviation) have mandated extra safety checks on all Boeing aircraft, especially monitoring fuel systems, engine electronics, and take-off thrust mechanics.
Impact of Regional Airspace Restrictions
In mid‑June, intensified tensions between India and Pakistan resulted in Pakistani airspace being closed to Indian carriers. This forced flights from North America—such as SFO–Mumbai—to follow alternate routes via the Atlantic, Europe,
Middle East, and then into eastern Indian airports like Kolkata for fuel and transit.
Such rerouting increases flight duration and operational complexity, raising the likelihood of unscheduled technical halts due to elevated engine wear and logistical challenges.
Passenger Experience: Delay, Frustration, and Resolution
Passengers aboard AI180 reported an uneasy wait of over five hours before disembarkation:
- Many had already missed connecting flights from Mumbai and were left scrambling with their itinerary.
- Ground staff arranged food and hotel accommodations as seats on onward flights were limited.
- Despite frustration, some passengers acknowledged preferring the delay over a potential safety risk, especially in light of recent tragedies .
Air India lacked a public explanatory statement but reportedly organized “special arrangements” to assist stranded passengers to reach Mumbai.
Safety First Amid Aviation Scrutiny
India’s aviation industry has seen growing scrutiny:
- Air India’s performance at SFO has been deemed the worst among carriers flying from San Francisco, with 41.5% of flights delayed and 8.5% delayed beyond two hours between 2020–2024.
- Average delays have improved recently, but routes via delayed transit hubs such as Kolkata and rerouting due to geopolitical factors remain bottlenecks .
Still, aviation analysts emphasize that delays caused by technical issues are preferable to risking passenger safety. The handling of AI180 indicates a methodical approach—deplaning only after exhaustive checks—suggesting a cautious yet competent response.
What Happens Next?
- Engine Fault Diagnosis
Air India’s technical team will repair the engine before the aircraft can fly again. Type 777 parts and qualified technicians must be on site. Given current procedures, the aircraft may remain grounded for 24–48 hours. - Passenger Re‑Accommodation
Affected travelers are to be rebooked, likely on flights departing Mumbai later that day or the next. Those with tight onward connections may face further rescheduling. - Fleet-Wide Inspections
Following the Ahmedabad crash, the DGCA has intensified inspections of all Boeing aircraft. Any findings here may influence inspection schedules across the fleet.
- Operational Adjustments
With Pakistani airspace still off-limits and route delays ongoing, Air India may revise schedules, allocate backup aircraft, or stagger layovers at Kolkata or Delhi to improve resilience.
The AI180 incident underscores a challenging phase for Air India’s long-haul operations:
- Prolonged airtime due to rerouting
- Increased strain on systems
- Growing public and regulatory scrutiny
Yet, the handling of the technical issue—prioritizing flight safety and orderly passenger deplaning—demonstrates a responsible response in line with aviation best practices.
While grounded aircraft and delayed travelers are inconvenient, the alternative—an in‑flight engine failure—is far graver.
The incident also emphasizes the need for airlines to build redundancy into long-haul routes, ensuring that mechanical issues can be addressed without jeopardizing schedules or safety.
For Travelers: Key Takeaways
- If you’re flying SFO–Mumbai: Check your flight status specifically for AI180 and expect possible delays.
- Stay alert to changing transit routes (especially via Kolkata) and allow extra buffer time for onward travel.
- Always monitor notifications via Air India’s app, email alerts, or airport boards—especially for technical or rerouting updates.
Although the incident caused inconvenience for over 200 passengers, its transparent handling, absence of injuries, and prompt response should reassure flyers.
As aviation regulators continue their investigation and fleet-wide inspections, passenger safety remains firmly in the cockpit.
