Air India finds no issues with the fuel control switch locking mechanism in its Boeing 787
1. The Crash That Sparked Global Concern
Fuel Switch Safety – On June 12, 2025, an Air India Boeing 787-8 aircraft tragically crashed shortly after takeoff from Ahmedabad, killing 260 people. The Aircraft Accident Investigation Bureau (AAIB) released a preliminary report revealing that fuel control switches for both engines had moved from “RUN” to “CUTOFF” within one second of each other.
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Key findings from the AAIB report:
- Sudden fuel cutoff led to dual engine failure
- Cockpit voice recordings captured confusion: “Why did you cut off?” “I didn’t”
- No mechanical fault confirmed, but switch movement remains unexplained
The incident raised urgent questions about the locking mechanism of the fuel control switches, prompting a wave of inspections across airlines operating Boeing 787 and 737 aircraft.
2. Air India’s Inspection: No Faults Found
In response to the AAIB report, the Directorate General of Civil Aviation (DGCA) directed all Indian carriers to inspect the locking mechanism of fuel control switches on Boeing aircraft. Air India swiftly complied, initiating precautionary inspections across its entire 787 fleet.
Inspection highlights:
- Engineering teams checked the Fuel Control Switch (FCS) locking system
- All Boeing 787-8 aircraft underwent Throttle Control Module (TCM) replacements as per Boeing’s maintenance schedule
- No issues were found with the locking mechanism
The FCS is a critical component that regulates fuel flow to the engines. Its locking feature is designed to prevent accidental movement, requiring pilots to lift the switch before transitioning between modes.
Air India also instructed pilots to remain vigilant and report any anomalies in the technical log, reinforcing a culture of safety and accountability.
3. Global Ripple Effect: Airlines & Regulators Respond
The crash and subsequent findings have triggered a global response. Airlines and regulators worldwide are reassessing the safety of Boeing’s fuel control systems.
Notable developments:
- Etihad Airways issued an engineering work order to inspect its Boeing 787 fleet after a flight diversion
- South Korea’s transport ministry is preparing mandatory inspections for all Boeing jets in the country
- The FAA’s 2018 advisory on potential locking mechanism failures has resurfaced, though it was not mandatory
The FAA’s bulletin warned that improper installation could disable the locking feature, allowing switches to move without pilot input. While Boeing maintains that the design is safe, the renewed scrutiny underscores the importance of proactive safety checks.
4. Engineering Integrity vs Human Error: What Comes Next?
The AAIB report did not assign blame, but the mystery surrounding the switch movement has sparked debate over mechanical failure vs human error. Experts suggest several possibilities:
- Disengaged locking mechanism due to component fatigue
- Electrical or software malfunction misinterpreting switch position
- Pilot error, though cockpit recordings suggest otherwise
Air India’s clean inspection report adds complexity to the investigation. If no mechanical fault exists, the focus may shift to training protocols, cockpit ergonomics, and system redundancies.
Meanwhile, aviation authorities are expected to:
- Reevaluate maintenance advisories and make them mandatory
- Enhance cockpit design reviews for critical switches
- Promote cross-airline data sharing to identify systemic risks
Final Thoughts
Air India’s confirmation of no faults in its Boeing 787 fuel control switches offers temporary reassurance, but the broader implications remain unresolved. As investigations continue, the aviation industry faces a pivotal moment, balancing engineering precision, human factors, and regulatory oversight.
The tragedy has reignited calls for transparency, accountability, and global cooperation in aviation safety. Because in the skies, even a one-second lapse can change everything.
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