DGCA orders airlines to inspect fuel switch of their Boeing 787 fleet after Air India crash preliminary report

AAIB as part of its preliminary report into the Air India flight 171 crash, revealed that the two switches supplying fuel to the twin-engine Boeing 787 Dreamliner (VT-ANB) were both found in the 'Cutoff' position. Per the data, moments after lift-off the switches were turned to cutoff mode within a second of each other.

The US Federal Aviation Administration (FAA) had in 2018 issued a Special Airworthiness Information Bulletin (SAIB) to various Boeing models, including the 787, to prevent accidental use of the switches.

The AAIB report adds that Air India did not carry out the inspection recommended in the bulletin as it was not mandatory.

"This SAIB was issued based on reports from operators of Model 737 airplanes that the fuel control switches were installed with the locking feature disengaged. The airworthiness concern was not considered an unsafe condition that would warrant an airworthiness directive (AD) by the FAA," the AAIB report added.

The report mentions that the fuel control switch design, including the locking feature, is similar on various Boeing airplane models.

The particular plane involved in the Ahmedabad crash, VT-ANB, had a clean maintenance record since 2023, details in the preliminary report revealed on Saturday. All required inspections were current, and the aircraft had valid airworthiness certificates, the report said.

Major airlines across the world have started checking the locking mechanism in the fuel switches of Boeing 787 aircraft following AAIB's initial findings.

According to engineering work instructions, Etihad Airways has asked their engineers to inspect the locking mechanism of the fuel control switches in the B787 aircraft. People aware of the development said that Singapore Airlines have also started the process.

This is despite the Federal Aviation Administration and Boeing telling operators of the plane that the fuel switch locks on Boeing planes are safe.

Fuel control switches for the engines of an Air India flight that crashed last month were moved from the “run” to the “cutoff” position moments before impact, starving both engines of fuel, a preliminary investigation report said early Saturday.

The movement of the fuel control switches allows and cuts fuel flow to the plane’s engines. The report, issued by India’s Aircraft Accident Investigation Bureau, also indicated that both pilots were confused over the change to the switch setting, which caused a loss of engine thrust shortly after takeoff.