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The Directorate General of Civil Aviation said on Tuesday that the fuel control switch issue reported on an Air India Boeing 787-8 aircraft was not due to a mechanical fault but linked to incorrect handling of the switch.
The regulator’s comments came after Air India grounded a Boeing 787-8 Dreamliner earlier this month as a precaution, following a pilot report about the fuel control switch during a flight from London to Bengaluru.
Also Read | Air India grounds Boeing 787-8 over possible fuel control switch defect
On a subsequent attempt, the switch latched correctly and remained stable for the rest of the flight, which was completed without incident.
After landing in Bengaluru, the crew reported the observation in the post-flight defect report, following which Air India referred the matter to Boeing for technical guidance.
Based on checks recommended by Boeing, Air India’s engineering team examined both left and right fuel control switches.
The DGCA said the switches were found to be serviceable, with the locking mechanism properly seated and functioning as designed. When force was applied in the correct direction, the switch remained secure in the “RUN” position.
Also Read | Air India working on revised plan for profitability
However, the regulator noted that when external force was applied in an incorrect direction, the switch could move from “RUN” to “CUTOFF” more easily. This, the DGCA said, was due to the angular design of the switch base plate and did not indicate a defect.
"Both left and right switches were checked and found satisfactory, with the locking tooth/pawl fully seated and not slipping from RUN to CUTOFF. When full force was applied parallel to the base plate, the switch remained secure. However, applying external force in an incorrect direction caused the switch to move easily from RUN to CUTOFF, due to the angular base plate allowing slip when pressed improperly with finger or thumb," observed Air India engineering upon inspection of the issue, the DGCA statement noted.
Pull-to-unlock force checks were carried out on the affected aircraft, on the fuel control unit scheduled to be installed, and on a similar aircraft. In all cases, the force required to unlock the switch was found to be within prescribed limits. These checks were conducted in the presence of DGCA officials.
Air India, meanwhile, said the aircraft was grounded purely as a precautionary step and that the aircraft manufacturer has been involved to examine the issue on a priority basis.
The DGCA said it will continue to monitor the matter, but stressed that there was no safety incident during the flight and no evidence of a technical failure in the fuel control switch.
The regulator’s comments came after Air India grounded a Boeing 787-8 Dreamliner earlier this month as a precaution, following a pilot report about the fuel control switch during a flight from London to Bengaluru.
Also Read | Air India grounds Boeing 787-8 over possible fuel control switch defect
What the DGCA found
According to the DGCA, the issue was first noticed during engine start in London, when the crew observed that the fuel control switch did not remain firmly latched in the “RUN” position when light vertical pressure was applied.On a subsequent attempt, the switch latched correctly and remained stable for the rest of the flight, which was completed without incident.
After landing in Bengaluru, the crew reported the observation in the post-flight defect report, following which Air India referred the matter to Boeing for technical guidance.
Based on checks recommended by Boeing, Air India’s engineering team examined both left and right fuel control switches.
The DGCA said the switches were found to be serviceable, with the locking mechanism properly seated and functioning as designed. When force was applied in the correct direction, the switch remained secure in the “RUN” position.
Also Read | Air India working on revised plan for profitability
However, the regulator noted that when external force was applied in an incorrect direction, the switch could move from “RUN” to “CUTOFF” more easily. This, the DGCA said, was due to the angular design of the switch base plate and did not indicate a defect.
"Both left and right switches were checked and found satisfactory, with the locking tooth/pawl fully seated and not slipping from RUN to CUTOFF. When full force was applied parallel to the base plate, the switch remained secure. However, applying external force in an incorrect direction caused the switch to move easily from RUN to CUTOFF, due to the angular base plate allowing slip when pressed improperly with finger or thumb," observed Air India engineering upon inspection of the issue, the DGCA statement noted.
Social media video misleading: DGCA
The DGCA also addressed a video circulating on social media that appeared to show the fuel switch moving easily. After analysing the clip, the regulator said the procedure shown in the video did not follow Boeing’s recommended method and was therefore incorrect.Pull-to-unlock force checks were carried out on the affected aircraft, on the fuel control unit scheduled to be installed, and on a similar aircraft. In all cases, the force required to unlock the switch was found to be within prescribed limits. These checks were conducted in the presence of DGCA officials.
Advisory to crews
The regulator said Air India has been advised to circulate Boeing’s recommended procedure for operating the fuel cut-off switch among its flight crews to avoid improper handling.Air India, meanwhile, said the aircraft was grounded purely as a precautionary step and that the aircraft manufacturer has been involved to examine the issue on a priority basis.
The DGCA said it will continue to monitor the matter, but stressed that there was no safety incident during the flight and no evidence of a technical failure in the fuel control switch.
