Air India has grounded one of its Boeing 787-8 Dreamliner aircraft after a pilot reported a potential defect in the fuel control switch following a flight from London to Bengaluru. The aircraft, operating as flight AI132, landed in Bengaluru on Monday morning.
According to sources, the pilot noticed the potential issue with the fuel control switch after the aircraft landed and immediately reported it. The airline has since taken the aircraft out of service to conduct a thorough inspection.
In a statement released on Monday, Air India acknowledged the incident, stating, "We are aware that one of our pilots has reported a possible defect on the fuel control switch of a Boeing 787-8 aircraft". The airline added that it is involving the aircraft's original equipment manufacturer (OEM) to examine the concerns raised by the pilot on a priority basis. The matter has also been reported to the Directorate General of Civil Aviation (DGCA), the aviation regulatory body in India. Air India emphasized that the safety of passengers and crew remains their top priority.
The incident has raised concerns, especially in light of a tragic accident involving an Air India Dreamliner in June 2025. In that incident, flight AI171, en route from Ahmedabad to London Gatwick, crashed shortly after takeoff, resulting in the deaths of all 260 people on board, including 241 passengers. The preliminary report by the Aircraft Accident Investigation Bureau (AAIB) investigating the crash indicated that the fuel supply to both engines was cut off within one second, causing confusion in the cockpit. The report also noted that one of the pilots was heard asking the other why he cut off the fuel supply, to which the other pilot responded that he did not.
Following the preliminary findings of the June 2025 crash, the DGCA issued a directive on July 14, 2025, mandating all airlines operating Boeing 787 and Boeing 737 aircraft to inspect the locking mechanisms of their fuel control switches. Air India stated that it had already conducted these checks on all Boeing 787 aircraft in its fleet following the DGCA directive and found no issues.
According to Safety Matters Foundation, during the engine start of flight AI132, the switch failed to remain locked in the RUN position on two attempts, moving towards CUTOFF. This malfunction could lead to an inadvertent engine shutdown in flight under specific conditions.
The current incident involving the possible fuel control switch defect is particularly significant given the ongoing investigation into the Ahmedabad crash and the concerns surrounding the fuel control system. It remains unclear whether the fuel switch cutoff in the previous crash was due to mechanical failure or another cause. The investigation is still underway.