Air India Completes Fuel Switch Inspections on Boeing 787 Fleet with No Issues Found

Air India has concluded that there are no issues with the fuel control switch locking mechanisms on its Boeing 787 Dreamliner fleet, following recent inspections. Air India issued an official statement stating, "Over the weekend, our Engineering team initiated precautionary inspections on the locking mechanism of Fuel Control Switch (FCS) on all our Boeing 787 aircraft. The inspections have been completed and no issues were found."

The Directorate General of Civil Aviation (DGCA) instructed Indian airlines to inspect the fuel switch locks on Boeing 787 and 737 aircraft by 21 July, after an initial report from the Aircraft Accident Investigation Bureau (AAIB) linked fuel switch disengagement to the crash of Air India flight AI 171. The Boeing 787-8 disaster, which resulted in 270 fatalities shortly after takeoff from Ahmedabad, has heightened scrutiny on aircraft safety systems. The preliminary investigation revealed unusual activity with the aircraft’s fuel switches moments before the crash, although no definitive cause has yet been established.

Data from the flight revealed the aircraft, carrying 54,200 kg of fuel with a total takeoff weight of 213,401 kg, was within operational limits when it lifted off at 13:08:39 IST. Moments after, both engine fuel control switches were manually turned off and reactivated within a second, an unusual sequence that has drawn scrutiny. A distress call was made shortly after, but no further communication was received before the aircraft crashed.

In response, airlines including Air India, Air India Express, Akasa Air, and SpiceJet, as well as international carriers such as Singapore Airlines and Etihad Airways, have conducted precautionary checks. Meanwhile, the US Federal Aviation Administration (FAA) and Boeing maintain that the fuel lock mechanisms remain safe, with the FAA citing no issues on the 787 to date.

All Boeing 787-8 aircraft operated by Air India have also undergone replacement of their Throttle Control Modules, in line with Boeing’s maintenance schedule. The Aviation Authority reassures that the fuel switch locks remain safe, despite ongoing precautionary measures by airlines worldwide.

The investigation into the Ahmedabad crash continues, with authorities examining the aircraft’s final moments, including abnormal fuel switch activity shortly after takeoff.