Air India Pilot Reports Possible Defect in Fuel Control Switch of Boeing 787-8 Aircraft

An Air India pilot recently identified a potential issue with the fuel control switch on a Boeing 787-8 aircraft. This plane, which flew from London to Bengaluru, has been grounded for inspection. The incident occurs amid an ongoing investigation into a previous Dreamliner crash last June. More than 200 passengers were on board when the aircraft landed in Bengaluru.

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Air India has acknowledged the pilot's report regarding the possible defect in the fuel control switch. The airline has grounded the aircraft and is collaborating with the Original Equipment Manufacturer (OEM) to address the pilot's concerns promptly. The Directorate General of Civil Aviation (DGCA) has been informed about this matter.

Fuel Control Switch Concerns

The fuel control switch is crucial as it manages engine start and shutdown, using RUN and CUT OFF positions respectively. A source mentioned that the switch failed to stay in the RUN position, moving towards CUT OFF instead. It remains unclear when during the flight this issue was noticed by the pilot.

Following a directive from DGCA, Air India inspected all Boeing 787 aircraft in its fleet for similar issues but found none. The airline operates 33 Boeing 787s, including 26 legacy Boeing 787-8s and seven Boeing 787-9s, with six from Vistara.

Ongoing Investigations

The focus on fuel control switches intensified after a tragic crash involving Air India's Boeing 787-8 last June. The Aircraft Accident Investigation Bureau (AAIB) is examining this crash, which resulted in 260 fatalities, including 241 passengers. Preliminary findings indicated that fuel supply was cut off shortly after take-off.

The AAIB's initial report, released on July 12 last year, highlighted that both engines' fuel supply was interrupted within one second of each other. This caused confusion among pilots, as cockpit voice recordings revealed one pilot questioning why the engines were cut off.

Boeing's Involvement

Boeing has confirmed its communication with Air India and is assisting in reviewing the situation. However, there has been no immediate response from DGCA regarding this incident.

The Safety Matters Foundation, a not-for-profit group, reported that during engine start-up, the left engine's fuel control switch exhibited abnormal behaviour. It failed to lock in the RUN position twice, moving towards CUT OFF instead. This malfunction could potentially lead to an unintended engine shutdown during flight under certain conditions.

In 2025, Boeing delivered 14 Boeing 787s to various airlines worldwide, including 12 Boeing 787-9s. The ongoing investigations and inspections aim to ensure passenger safety and prevent future incidents related to fuel control switches.

With inputs from PTI