We're Not Responsible For 3 Of 4 Recent Dhruv Chopper Crashes: HAL Chief To NDTV

We're Not Responsible For 3 Of 4 Recent Dhruv Chopper Crashes: HAL Chief To NDTV

Dhruv helicopters have faced several fleet-wide groundings following investigations into recent crashes

Bengaluru:

According to Dr. DK Sunil, Chairman and Managing Director of Hindustan Aeronautics Limited (HAL), three of the four Dhruv helicopter crashes involving the Indian Navy and Coast Guard since 2023 were not caused by manufacturing or design defects attributable to HAL.

The HAL Dhruv helicopter, which serves as a crucial workhorse across India's armed forces, has experienced multiple crashes leading to repeated fleet-wide groundings pending investigations. The Dhruv fleet was grounded for the third time since 2023 this January. Currently, approximately 338 Dhruv helicopters remain in service, with Army and Air Force units having since received clearance to resume flying operations.

"Regarding the four crashes that have occurred—three in the Coast Guard and one in the Navy—three were caused by factors unrelated to manufacturing or design. The issues were connected to either maintenance practices or operational procedures," Dr. Sunil explained during an exclusive interview with NDTV.

However, the most recent Coast Guard Dhruv crash on January 5, 2025, revealed a fracture in a critical component—the Non-Rotating Swashplate Bearing (NRSB). "For the latest Coast Guard incident, we discovered an NRSB fracture that prompted a defect investigation committee to conduct a thorough analysis. We observed a clear distinction—Army and Air Force helicopters did not exhibit this defect, allowing us to clear them for flight operations. They are currently flying."

The Non-Rotating Swashplate Bearing is an essential component in a helicopter's rotor system. Located within the swashplate assembly, this mechanical element controls rotor blade pitch to manage lift, direction, and helicopter stability.

"We collected all gearboxes for comprehensive crack inspections and found no issues in Army and Air Force variants. For the Naval variant, we investigated potential causes including corrosion and stress factors. We also conducted deck landing tests since their usage pattern differs significantly from Air Force and Army operations. We performed tests in Vizag under rough sea conditions," the HAL Chairman stated. "That data has now been collected. The defect investigation committee will meet shortly to determine the root cause and necessary actions. We expect to conclude the investigation this month and immediately implement any required modifications or one-time inspection procedures."

However, the complete return to service for all Navy and Coast Guard choppers remains several months away, as each helicopter's gearbox must undergo inspection and receive clearance.

"I anticipate it will take several months before the entire fleet returns to operational status. This specific variant operated by the Navy and Coast Guard comprises approximately 29 helicopters. The Coast Guard has lost 3, and the Navy has lost 1. Processing 4-5 gearboxes monthly, we should complete the necessary work within six to seven months."

The Advanced Light Helicopter (ALH) Dhruv, an indigenous multi-role platform developed by Hindustan Aeronautics Limited, has experienced a series of accidents throughout 2024-2025, particularly affecting maritime operators—the Navy and Coast Guard.

Three crashes involving the Coast Guard Dhruv Mk III variant, which had been delivered as recently as 2022-2023, have highlighted what were previously considered persistent reliability issues.

On March 8, 2023, a Navy Dhruv MK III naval variant executed an emergency water landing off Mumbai's coast, prompting the navy to ground the aircraft pending investigation. All three crew members were rescued. Prior to the incident, the crew reported experiencing a "sudden loss of power and rapid loss of height."

On March 26, 2023, a Coast Guard ALH Dhruv Mk III crashed near Kochi International Airport during a training flight. All crew members survived this incident.

On September 2, 2024, a helicopter from Coast Guard Squadron 835 was forced to make an emergency landing in the Arabian Sea off Gujarat's Porbandar coast while conducting a medical evacuation mission for an injured crew member from a ship. The helicopter encountered technical difficulties before ditching at sea. Both pilots tragically lost their lives, and a third crew member initially went missing. The bodies of all three Coast Guard personnel were eventually recovered, with no survivors. This particular Coast Guard Dhruv had been operational for barely two years.

On January 5, 2025, another Mk III helicopter from the same Coast Guard squadron crashed during a training flight at the Porbandar Air Enclave. Two pilots and an aircrew diver perished when the helicopter burst into flames on the runway. Reports indicate the pilots encountered unresponsive controls, raising questions about potential actuator or transmission failure.

These accidents, which claimed at least six lives, prompted immediate action, with the January 2025 Porbandar crash triggering a complete suspension of the ALH fleet across all branches—Army, Navy, Air Force, and Coast Guard. This marked the third major grounding of Dhruv helicopters since 2023.