The Air India Boeing 787 fleet has once again come under scrutiny after a pilot reported abnormal behaviour in a fuel control switch during engine start on flight AI132 from London to Bengaluru.
The incident, which initially appeared to echo earlier concerns surrounding the Dreamliner’s fuel control system, prompted a precautionary fleet-wide inspection and a wave of public attention.
Yet, as regulators and engineers complete their evaluations, a clearer picture is emerging—one that suggests the issue may not stem from a mechanical defect at all.
The Incident on VT-ANX, The Air India Boeing 787…
The aircraft at the centre of the latest report, Boeing 787-8 VT-ANX, was grounded upon arrival in Bengaluru after the operating crew observed that one of the engine fuel control switches slipped from RUN toward CUTOFF when light vertical pressure was applied.
The switch latched correctly on the third attempt, and the flight continued without any abnormal engine indications or system warnings.
This prompted Air India to initiate a precautionary re-inspection of fuel control switches across its entire Dreamliner fleet.
The airline, which operates 33 Boeing 787s, emphasised that the move was taken out of an abundance of caution, and no aircraft were grounded beyond VT-ANX.
DGCA Findings: A Matter of Handling, Not Hardware
As the Directorate General of Civil Aviation (DGCA) began its investigation, early speculation centred on whether the issue reflected a deeper mechanical flaw—particularly given the historical context of the Ahmedabad crash in 2025, where investigators examined the possibility of uncommanded fuel switch movement.
However, the regulator’s findings have been unequivocal. After detailed inspections conducted by Air India’s engineering team in the presence of DGCA officials, both fuel control switches on VT-ANX were found to be fully serviceable.
The locking tooth and pawl were properly seated, and the switch did not slip from RUN to CUTOFF when force was applied correctly—parallel to the base plate.
Crucially, the DGCA concluded that the reported behaviour was not caused by a mechanical defect but by incorrect handling.
The angled base plate of the switch assembly means that if force is applied in the wrong direction, the switch can move more easily than intended. This is a handling sensitivity rather than a design flaw.
Revisiting Our Previous Coverage
In our earlier reporting at The Aviation Hub, we highlighted the seriousness of the initial observation made at Heathrow, where the crew of AI132 encountered what appeared to be a malfunction in the left engine’s fuel control switch during pre-departure procedures.
At the time, the anomaly raised legitimate concerns, particularly given the historical context and the sensitivity of fuel control systems on the 787.
However, the latest regulatory findings reshape the narrative. What was initially described as a “defective” switch may not have been defective at all. Instead, the switch’s behaviour appears consistent with the design characteristics outlined by Boeing and confirmed during DGCA-supervised inspections.
This distinction matters. A mechanical defect implies a systemic risk across the fleet, whereas a handling-related issue points to procedural reinforcement rather than hardware replacement.
The DGCA has already recommended additional pilot training to ensure correct operation of the fuel control switches, underscoring that the solution lies in technique rather than engineering.
A Wider Context of Heightened Sensitivity at Air India…
The scrutiny surrounding this incident is amplified by the industry’s heightened awareness following the 2025 Ahmedabad crash, where fuel control switch behaviour formed part of the investigative focus.
While the circumstances differ significantly, any anomaly involving the 787’s fuel system understandably triggers concern.
Air India’s decision to conduct a fleet-wide inspection—its second in two years—reflects this environment of caution.
Yet the outcome of these inspections reinforces confidence in the aircraft’s systems.
No abnormalities were found across the fleet, and all switches tested were deemed satisfactory.
A Reminder of the Importance of Precision
The Air India 787 fuel switch incident serves as a reminder of the fine margins that define modern aviation.
A slight deviation in handling technique can mimic the symptoms of a mechanical fault, triggering extensive inspections and public concern. But as the DGCA’s findings make clear, not every suspected defect is a defect in reality.
For Air India, the episode underscores the importance of procedural rigour. For regulators, it highlights the value of swift, transparent investigation.
And for the industry, it reinforces a broader truth: in aviation, perception and reality can diverge—but only evidence can bridge the gap.
Continue to follow The Aviation Hub for more analysis and insight!
