Airlines around the world have started checking the fuel switch locking mechanism in Boeing 787 aircraft following initial investigation findings into a recent Air India crash. Engineering instructions reviewed by a source show that Etihad Airways has asked its engineers to inspect the fuel control switch locking systems in its Boeing 787 fleet. Singapore Airlines has also reportedly started similar inspections.
This action comes even though Boeing and the US Federal Aviation Administration (FAA) have told airlines that the fuel switch locks in Boeing 787s are safe. Since Boeing 787 is manufactured in the US, many countries adopt FAA standards to maintain safety and compatibility. However, individual airlines and regulators may take independent action if they see a risk.
Sources said that India’s Directorate General of Civil Aviation (DGCA) and Air India are still examining the issue and have not issued any similar safety directive.
According to a preliminary investigation by India’s Aircraft Accident Investigation Bureau (AAIB), the fuel control switches of the Air India aircraft involved in the crash were moved from the “run” to the “cutoff” position just before the crash. This action stopped fuel flow to both engines, leading to a loss of thrust shortly after takeoff. The report also noted confusion among the pilots regarding the switch position at the time of the accident.
Modern aircraft like the Boeing 787 have protective features such as metal locks and guards around the fuel control switches to prevent accidental shutdowns. These safety features were introduced after older aircraft experienced similar issues.
The FAA had earlier issued an advisory bulletin in 2018 warning about the possible disengagement of the locking feature in fuel control switches. Air India told investigators it did not carry out those inspections, as the FAA bulletin was advisory and not mandatory. The FAA’s notice had addressed concerns seen in the Boeing 737 model and not the 787.
The report also revealed that Air India had replaced the throttle control module, which includes fuel switches, twice in 2019 and 2023. Engineers said the thrust and fuel control systems are part of the same integrated unit in the Boeing 787. AAIB further noted that no defects in the fuel switch system were reported since 2023.
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