The Directorate General of Civil Aviation (DGCA) has ordered a fresh inspection of the fuel control switch system on an Air India Boeing 787 aircraft after a reported technical anomaly during operations earlier this year.
According to reports, the decision follows concerns raised after pilots on a London–Bengaluru flight observed unusual behaviour in the fuel control switch mechanism during engine start procedures. The switch is a critical component that regulates fuel flow to aircraft engines.
As part of the new safety review, DGCA officials will travel to Boeing’s facility in Seattle, United States, to oversee testing of the removed fuel control switch panel. The regulator has termed the matter “sensitive” and has insisted that the inspection be conducted in the presence of its officers to ensure a thorough evaluation.
The move comes after earlier precautionary inspections across Air India’s Boeing 787 fleet, which had not found any systemic defects in the fuel switch locking mechanism. However, the latest incident has prompted renewed scrutiny of the component, which has been under observation in global aviation safety discussions.
Fuel control switches on the Boeing 787 have been closely monitored by regulators worldwide following past safety concerns and investigations into rare incidents involving engine shutdowns. While previous checks did not confirm a design fault, authorities continue to review isolated reports of abnormal behaviour.
Air India has supported the latest inspection process, stating that the component has already been sent to the original equipment manufacturer (OEM) for detailed examination. The airline has reiterated that safety remains its top priority and has cooperated fully with DGCA directives.
The broader investigation is also linked to ongoing reviews of earlier incidents involving Boeing 787 aircraft, including a fatal crash in 2025 in which fuel supply interruption was identified as a critical factor under investigation.
A final report on the overall safety review is expected once the OEM testing and DGCA-supervised analysis are completed.
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