DGCA flags potential fuel control switch risk on Air India Boeing 787, advises crew training after inspections confirm no mechanical fault; improper handling could move switch from RUN to CUTOFF, regulators say.
The commander of the aircraft flagged the issue in the log book
New Delhi: The Directorate General of Civil Aviation (DGCA) on Tuesday advised Air India to educate its flight crew on the correct procedures for operating fuel control switches after an inspection found no mechanical fault but flagged the risk of unintended movement if handled improperly.
The alert comes after an Air India Boeing 787-8 aircraft, VT-ANX, operating flight AI 132 from London to Bangalore, reported abnormal fuel control switch behaviour during engine start.
According to the DGCA, the flight crew observed on two occasions that the fuel control switch did not remain positively latched in the “RUN” position when light vertical pressure was applied. On a third attempt, the switch latched correctly and remained stable for the remainder of the flight.
Both the left and right switches were checked and found to be mechanically sound. The locking tooth and pawl were fully seated, and the switch remained secure when proper force was applied. However, the DGCA noted that applying external force in an incorrect direction could cause the switch to slip from RUN to CUTOFF due to the angular design of the base plate.
The regulator observed that a video circulating on social media demonstrated an incorrect procedure for operating the fuel cut-off switch. DGCA advised Air India to circulate Boeing’s recommended procedures to ensure all crew members follow the correct method and avoid accidental movement of the switch.
Following the report, Air India referred the matter to Boeing for guidance. Inspections were conducted on the affected aircraft’s fuel control unit as well as a similar unit on another aircraft. In all cases, the pull-to-unlock force was found to be within operational limits. The checks were conducted in the presence of DGCA officers, confirming that the switches were serviceable.
The flight proceeded without incident. Crew members performed physical verification to ensure the switch was fully latched in the RUN position before continuing the engine start procedure. No abnormal engine parameters, warnings, or alerts were reported during the flight.
The DGCA emphasized that proper training and adherence to recommended procedures are crucial to avoid unintended movement of fuel control switches and maintain operational safety across Air India’s fleet.
