Air India Dreamliner fuel switch issue caused by incorrect handling, not mechanical fault: DGCA report

Air India Grounds Dreamliner After Pilot's Alert

A Boeing 787-8 Dreamliner operated by Air India was grounded earlier this month following a pilot's report of a potential issue with the fuel control switch during a flight from London to Bengaluru.

The incident unfolded on February 1 when, during engine start in London, the crew noticed the switch failing to stay latched in the "RUN" position under light vertical pressure on two occasions. On the third try, it latched properly, and the flight proceeded without further problems, with the crew monitoring engine parameters closely and avoiding unnecessary contact with the switch.

Upon landing in Bengaluru, the pilot logged the defect, prompting Air India to immediately pull the aircraft, registered as VT-ANX, from service as a safety precaution. The airline notified the Directorate General of Civil Aviation (DGCA) and engaged Boeing, the original equipment manufacturer, for urgent checks.

DGCA Findings Point to Handling Error

The DGCA's detailed investigation, released recently, concluded that no mechanical fault existed in the fuel control switch.

Air India's engineering team, following Boeing-recommended procedures, inspected both left and right switches on the grounded aircraft. They found the switches satisfactory, with the locking mechanism fully seated and secure when force was applied correctly—parallel to the base plate.

However, when improper force was applied at an angle, such as pressing with a finger or thumb in the wrong direction, the switch could easily slip from "RUN" to "CUTOFF" due to the design of the angular base plate.

"Both left and right switches were checked and found satisfactory, with the locking tooth/pawl fully seated and not slipping from RUN to CUTOFF. When full force was applied parallel to the base plate, the switch remained secure. However, applying external force in an incorrect direction caused the switch to move easily," the DGCA noted from Air India's observations.

These checks were conducted in the presence of DGCA officers, confirming the pull-to-unlock force was within limits across tested components. No abnormal engine parameters were observed at any stage.

Echoes of Past Tragedy Spark Renewed Scrutiny

This episode has reignited concerns over the fuel control switch, especially in light of the tragic June crash of an Air India Boeing 787-8 from Ahmedabad that claimed 260 lives.

Preliminary findings from that disaster indicated the fuel switches moved to "CUTOFF" shortly after takeoff, cutting engine thrust and leading to the crash just 30 seconds into the flight.

an Air India spokesperson emphasized.

One of our pilots has reported a possible defect on the fuel control switch of a Boeing 787-8 aircraft. After receiving this initial information, we have grounded the said aircraft and are involving the OEM to get the pilot’s concerns checked on priority. The safety of our passengers and crew remains top priority,

In response to the recent event, the DGCA has directed Air India to disseminate Boeing's precise operating procedure for the fuel cutoff switch to all crew members. A video released by the regulator highlighted common incorrect handling methods, underscoring the need for proper training.

Air India had previously inspected fuel switches across its entire Boeing 787 fleet per DGCA instructions and found no issues, but this incident prompted fresh vigilance. Boeing has been supportive throughout, aiding the reviews.

Aviation experts note that while the switches are designed to be fail-safe, precise handling is critical to prevent inadvertent activation. Pilots' groups have called for fleet-wide reinspections, viewing this as a vital safety reminder.

The DGCA report brings relief by ruling out hardware defects, focusing instead on procedural adherence to avert risks. With the aircraft now cleared after checks, Air India continues emphasizing crew training amid the shadow of past incidents, prioritizing passenger safety above all.