DGCA: Wrong Force Caused Air India 787 Fuel Switch Issue, Not Defect

India's aviation regulator, the DGCA, clarified that the movement of a fuel cut-off switch on an Air India Boeing 787-8 was caused by an external force being applied in the wrong direction, not a mechanical defect. The switches were tested and found to be secure when force was applied correctly. The incident led to the aircraft being grounded as the airline involved the manufacturer for checks. The Federation of Indian Pilots has urged an investigation, noting this is the third known incident of uncommanded fuel switch movement on a Boeing 787.

Key Points: DGCA: Air India 787 Fuel Switch Moved Due to Incorrect Force

  • DGCA says switch moved due to wrong force application
  • Switches tested and found mechanically sound
  • Aircraft was grounded after pilot report
  • FIP President cites history of similar 787 incidents
3 min read

"incorrect application" of force caused fuel switch to move from RUN to CUTOFF on Air India Boeing 787-8: DGCA

DGCA clarifies an Air India Boeing 787-8 fuel switch moved due to incorrectly applied external force, not a mechanical defect, after pilot report grounded aircraft.

"applying external force in an incorrect direction caused the switch to move easily from RUN to CUTOFF - DGCA Rejoinder"

New Delhi, February 4

The Directorate General of Civil Aviation released a rejoinder on Tuesday regarding the purported malfunction of the fuel cut-off switch on Air India Boeing B787-8 aircraft VT-ANX, which was identified by the crew on two occasions on January 1.

They clarified that an external force was applied in the wrong direction, resulting in the switch from "RUN to CUTOFF".

"Both left and right switches were checked and found satisfactory, with the locking tooth/pawl fully seated and not slipping from RUN to CUTOFF. When full force was applied parallel to the base plate, the switch remained secure. However, applying external force in an incorrect direction caused the switch to move easily from RUN to CUTOFF, due to the angular base plate allowing slip when pressed improperly with finger or thumb," the rejoinder said.

It comes after an Air India Boeing 787-8 aircraft was grounded after a pilot reported a possible defect in the fuel control switch.

An Air India spokesperson said that one of its pilots has reported a possible defect on the fuel control switch of a Boeing 787-8 aircraft, and the matter has been communicated to DGCA, the country's aviation regulator.

The spokesperson said the airline is engaging the Original Equipment Manufacturer (OEM) to get the pilot's concerns checked on priority.

"We are aware that one of our pilots has reported a possible defect on the fuel control switch of a Boeing 787-8 aircraft. After receiving this initial information, we have grounded the said aircraft and are involving the OEM to get the pilot's concerns checked on a priority basis. The matter has been communicated to the aviation regulator, DGCA. Air India had checked the fuel control switches on all Boeing 787 aircraft in its fleet after a directive from the DGCA, and had found no issues. At Air India, the safety of our passengers and crew remains a top priority," the spokesperson said.

On Monday, following the incident, Federation of Indian Pilots (FIP) President Captain CS Randhawa urged the Directorate General of Civil Aviation (DGCA) and the Aircraft Accident Investigation Bureau (AAIB) to immediately investigate possible electrical faults in Boeing 787 aircraft, citing repeated incidents involving uncommanded movement of fuel control switches.

Captain Randhawa noted this was the third known incident in which uncommanded movement of fuel control switches had been recorded on a Boeing 787 aircraft.

Speaking to ANI, Captain CS Randhawa said, "The first incident on the Boeing 787-800 aircraft took place on 17 February 2019 at Osaka on an ANA flight, which was landing at Osaka, where both fuel control switches on touchdown, when the throttles were brought to idle position, both these switches went to cutoff position automatically due to an electrical malfunction of the TCMA. We have been relating the same theory for the Air India 171 crash on 12th June at Ahmedabad. This is the third incident where there has been an uncommanded movement of the fuel control switches on the Boeing 787 aircraft."

- ANI

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Reader Comments

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Priya S
Thank God the pilot reported it and the aircraft was grounded immediately. Safety first! 🙏 Kudos to the crew for being vigilant. This is why reporting even a "possible" defect is so crucial. Better safe than sorry.
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Captain CS Randhawa
This is the third such incident globally on the 787. The DGCA rejoinder is focusing on a single instance of "force", but we must investigate the underlying electrical system, the TCMA. The pattern suggests a systemic issue Boeing must address. Passenger safety is non-negotiable.
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Aditya G
As an aviation enthusiast, this is concerning. The switch should have a positive lock. If it can slip due to "angular base plate", that's an engineering problem. Hope the OEM issues a proper fix and not just a clarification. Our skies must be safe.
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Sarah B
I fly Air India frequently between Delhi and London. While I appreciate the transparency, this is a bit scary. They checked all 787s and found no issues, but the pilot still found a problem. Shows the checks might need to be more rigorous. Will be watching this space.
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Karthik V
The DGCA's detailed rejoinder is actually a good sign – it shows they did a proper inspection. The explanation makes technical sense. Sometimes switches can be actuated wrongly. The key is proper training for crew on the specific force required. Chalta hai attitude won't work here.

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