DGCA Reviews Fuel Control Switch Observation on Air India B787 Flight; No Safety Compromise Found

Before proceeding further, the crew conducted a physical verification to ensure the switch was fully and positively latched in the “RUN” position.

 

An Air India Boeing 787-8 aircraft (registration VT-ANX) operating Flight AI-132 from London to Bengaluru on February 1, 2026, experienced an operational observation related to the fuel control switch during engine start at London. The matter has since been examined by Air India Engineering in coordination with Boeing, under the oversight of the Directorate General of Civil Aviation (DGCA).

Incident Description

During engine start procedures at London, 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 the third attempt, the switch latched correctly and remained stable thereafter.

Before proceeding further, the crew conducted a physical verification to ensure the switch was fully and positively latched in the “RUN” position. No abnormal engine parameters, cautions, warnings, or system alerts were observed during engine start or at any point during the flight.

The operating crew member was appropriately briefed, unnecessary contact with the switch was avoided, and engine indications and alerting systems were closely monitored throughout the flight. The flight was completed without incident.

Post-Flight Reporting and Technical Inspection

After landing at Bengaluru, the crew reported the observation in the Pilot Defect Report (PDR). Air India subsequently referred the matter to M/s Boeing for technical guidance.

Based on Boeing-recommended inspection procedures, Air India Engineering conducted detailed checks on the fuel control switches. The findings were as follows:

• Both left and right fuel control switches were found satisfactory

• The locking tooth/pawl was fully seated and did not slip from “RUN” to “CUTOFF”

• When full force was applied parallel to the base plate, the switch remained securely latched

• However, when external force was applied in an incorrect direction, the switch could move from “RUN” to “CUTOFF” due to the angular design of the base plate, which allows slippage if pressed improperly with a finger or thumb

Verification of Pull-to-Unlock Force

In addition, following Boeing’s communication, the pull-to-unlock force of the fuel control switch was tested using the recommended procedure on:

• The involved aircraft’s fuel cutoff switch

• The fuel control unit intended for installation

• The fuel cutoff switch of another aircraft

In all cases, the pull-to-unlock force was found to be within prescribed limits. These inspections were carried out in the presence of DGCA officers.

Social Media Video Found Technically Incorrect

A video currently circulating on social media showing operation of the fuel control switch was also analysed. Based on Boeing-recommended procedures, it was concluded that the procedure demonstrated in the video is incorrect and does not reflect the approved method for operating the fuel cutoff switch.

Advisory to Crew

In light of the findings, Air India has been advised to circulate Boeing’s recommended operating procedure for the Fuel CUT OFF switch to all flight crew members to prevent incorrect handling and misinterpretation.

Conclusion

The examination confirmed that:

• The fuel control switches were serviceable and compliant

• No system malfunction or safety risk was identified

• Crew actions were procedurally sound and precautionary

• The flight was operated safely with no operational impact

The matter has been addressed through technical verification and crew advisory, with no further action required at this stage.