Pilot aborts flight after critical maintenance oversight by TUI engineers
- An investigation revealed that TUI did not activate the engine bleed air system after maintenance, leading to a pressurization failure.
- Both pilots failed to notice the oversight or follow emergency protocols, resulting in a cabin altitude warning that persisted for 43 minutes.
- The flight returned safely to Manchester without injuries, underscoring significant safety lapses in cockpit and maintenance protocols.
On October 17, 2023, a Boeing 737-8K5 operated by TUI Airlines took off from Manchester Airport in the United Kingdom, bound for Kos, Greece. The aircraft had 193 individuals on board, including 187 passengers and six crew members, when the flight was aborted shortly after takeoff due to a critical failure in the aircraft's pressurization system. Investigators from the Air Accidents Investigation Branch noted that the engine bleed air system, necessary for pressurizing the cabin, was not activated because maintenance engineers failed to turn the switches back on after conducting their work the night before. This oversight presented a potential hypoxia risk to those onboard, as the cabin was not pressurized during initial climb. Although the pilots were alerted by a cabin altitude warning, they did not adhere to proper emergency protocols, allowing the warning light to remain illuminated for over 40 minutes before the decision to return to Manchester was made. Fortunately, the aircraft landed safely, and there were no reported injuries among passengers or crew. The investigation highlighted a systematic failure in communication and protocol adherence among the engineering and flight crews. Just three days later, on October 20, 2023, the same aircraft experienced another incident at Leeds Bradford Airport, where it veered off the runway during poor weather conditions caused by Storm Babet. This sequence of events raised serious concerns about TUI's maintenance procedures and the potential for similar oversights in the future, stressing the importance of compliance with safety checks and protocols.