Air India to Reinspect Boeing 787 Fuel Switches After Pilot Flags Defect, Regulator Informed
Air India has ordered a fresh inspection of fuel control switches across its Boeing 787 Dreamliner fleet, a day after one of its pilots reported a possible defect during a London–Bengaluru flight. The airline has grounded the aircraft involved and informed aviation regulator Directorate General of Civil Aviation (DGCA) about the incident.
The development comes amid heightened scrutiny of fuel control systems following last year’s fatal Dreamliner crash in Ahmedabad.
What We Know So Far
According to sources, Air India will now reinspect the fuel control switches (FCS) of its entire Boeing 787 fleet as a precautionary measure.
The move follows a report by a pilot operating Flight AI132 from London Heathrow to Bengaluru on Monday. After landing, the pilot logged a defect, stating that the left engine fuel switch had slipped from “RUN” to “CUT OFF” and was not locking properly.
Key confirmed details so far:
- The incident involved a Boeing 787-8 aircraft.
- The aircraft has been grounded for technical inspection.
- More than 200 passengers were on board the flight.
- The airline has informed the DGCA.
- The original equipment manufacturer is being consulted.
Fuel control switches regulate fuel flow to the engines and are critical for safe flight operations. Any malfunction in this system is treated as a serious technical concern.
Official Statements
Air India confirmed the development in a statement issued earlier.
“We are aware that one of our pilots has reported a possible defect on the fuel control switch of a Boeing 787-8 aircraft. After receiving this information, we have grounded the said aircraft and are involving the OEM to get the pilot’s concerns checked on a priority basis,” the airline said.
Sources in the aviation regulator said the DGCA is monitoring the situation closely and has sought a detailed technical report from the airline.
A senior official, speaking on condition of anonymity, said, “All safety-related incidents are reviewed in detail. The airline has been asked to ensure compliance with maintenance protocols.”
The manufacturer, Boeing, is expected to assist in the technical evaluation of the component.
Timeline of Events
- June 12, 2025: A Boeing 787-8 operated by Air India crashes shortly after take-off from Ahmedabad, killing 241 passengers.
- July 2025: Aircraft Accident Investigation Bureau (AAIB) releases a preliminary report noting fuel switches were in “cutoff” position.
January 27, 2026 (Monday): Air India Flight AI132 lands in Bengaluru from London.
- After Landing: Pilot records defect in logbook regarding fuel switch.
- Same Day: Aircraft is grounded and regulator informed.
- January 28, 2026 (Tuesday): Air India decides to reinspect its Dreamliner fleet.
Details of the Fuel Switch Issue
Sources said that after landing in Bengaluru, the pilot noted that the left engine fuel switch had moved from “RUN” to “CUT OFF” without being securely locked.
In aircraft systems:
- “RUN” is used to keep engines operational.
- “CUT OFF” shuts down fuel supply.
On the Boeing 787 Dreamliner, fuel switches are guarded toggles located on the centre pedestal between the pilots. They are fitted with a spring-loaded locking mechanism designed to prevent accidental movement. Pilots must lift the switch before changing its position.
The reported inability of the switch to remain locked has raised safety concerns, especially given past incidents involving similar systems.
Link to the Ahmedabad Crash Investigation
The latest development has drawn attention due to its similarity to findings in last year’s Ahmedabad crash.
In its preliminary report, the AAIB stated that both fuel control switches were found in the “cutoff” position after the accident. Cockpit voice recordings reportedly captured one pilot questioning the other about switching off fuel supply, which the second pilot denied.
The final investigation report into Flight AI171 is still awaited.
Aviation experts say the latest incident increases pressure on authorities to complete the probe.
An aviation safety analyst said, “Any recurring issue involving fuel control systems must be exa
mined thoroughly. It is too early to draw conclusions, but consistency in such reports requires attention.”
Regulatory and Industry Response
The DGCA has not issued a formal directive yet but is understood to be reviewing inspection reports.
Industry sources said:
- The regulator may order special audits if further anomalies are detected.
- Additional safety checks could be mandated.
- Airlines operating similar aircraft may be advised to conduct inspections.
A senior airline official said, “Preventive checks are standard practice in such cases. It does not mean there is a systemic fault, but safety protocols demand caution.”
International aviation bodies are also monitoring the situation, given the global use of the Boeing 787 platform.
Impact on Operations
At present, Air India has not announced large-scale cancellations linked to the inspections.
However:
The grounded aircraft may remain out of service until cleared.
Maintenance schedules may be revised.
Backup aircraft may be deployed on affected routes.
Passengers on upcoming long-haul routes have been advised to check flight status with the airline.
An Air India spokesperson said operations continue “as scheduled with necessary adjustments”.
What Happens Next
Several developments are expected in the coming days:
- Technical inspection report submission to DGCA
- Possible regulator directives
- Manufacturer assessment of the fuel switch system
- Review of maintenance records
- Potential fleet-wide safety advisories
Authorities are also awaiting the final AAIB report on the Ahmedabad crash, which may influence future regulatory action.
For now, officials stress that the situation is being handled under established safety frameworks and there is no immediate cause for alarm.
Our Final Thoughts
The latest fuel switch incident places renewed focus on aircraft safety at a time when India’s aviation sector is expanding rapidly. Air India’s decision to ground the affected aircraft and conduct fleet-wide inspections reflects adherence to precautionary standards, which is essential for maintaining public trust.
While no operational failure occurred during the London–Bengaluru flight, the reported malfunction cannot be treated lightly, particularly in the context of last year’s Ahmedabad tragedy. Recurrent concerns around similar components demand transparent investigation and timely regulatory oversight.
At the same time, it is important to distinguish between confirmed technical faults and developing assessments. At present, there is no official finding of a systemic defect. The airline, regulator, and manufacturer are still evaluating the issue.
For India’s aviation ecosystem, the episode underlines the importance of strong safety institutions, independent investigations, and clear communication with passengers. As airlines modernise fleets and expand networks, sustained investment in maintenance and training will remain critical.
The coming weeks, especially the release of the final crash report, will be crucial in shaping future policy and operational practices. Until then, measured responses rather than speculation will best serve passenger confidence and industry stability.