Air India has launched an investigation to determine whether standard operating procedures were followed by the crew of a Boeing 787-8 Dreamliner after a fuel control switch issue was reported on a flight from London Heathrow (LHR) to Bengaluru (BLR) on February 1st. The incident has prompted scrutiny from both Indian and UK aviation regulators.
Following the flight, the pilot reported a potential defect in one of the fuel control switches, which are essential components for managing fuel flow to the engines. These switches are located on the cockpit control panel, positioned behind the throttle levers, and are used to start or shut down engines, and in emergencies, to manually shut down or restart engines.
According to the Directorate General of Civil Aviation (DGCA), India's aviation regulator, during engine start at Heathrow, the crew observed on two occasions that one of the fuel control switches "did not remain positively latched" in the 'run' position when light pressure was applied. Pilots are required to lift each switch slightly to override a locking mechanism that is designed to prevent accidental movement between the 'run' and 'cut-off' positions. The crew was eventually able to latch the switch on the third attempt, and a physical verification confirmed it was stable in the 'run' position. Throughout the engine start and the remainder of the flight, no abnormal engine parameters or warnings were observed.
As a precaution, Air India grounded the aircraft and initiated inspections of the fuel control switches across its Boeing 787 fleet. The airline also involved the Original Equipment Manufacturers (OEMs) to examine the pilot's concerns. The DGCA has advised Air India to reinforce the recommended Boeing procedures for operating the fuel cut-off switches on the 787 with all crew members.
Following the incident, Air India completed precautionary checks on its Boeing 787 fuel control switches and found no issues. The DGCA also stated that the fuel control switch issue was not due to a mechanical fault but was instead linked to incorrect handling of the switch.
The UK aviation regulator has requested an explanation from Air India regarding how the Boeing 787 Dreamliner was permitted to fly from London despite the possible fuel switch issue.
This incident occurs amidst an ongoing investigation into a fatal Air India 787-8 crash in Ahmedabad last June, where preliminary findings indicated that both fuel-control switches transitioned from the 'run' to the 'cut-off' position just before the aircraft lost height and crashed. The switches on Boeing 787 operate through a two-step mechanism and must be lifted before being moved between “run” and “cutoff”. The incident has raised concerns about pilot adherence to safety protocols and the potential for human error.