The incident occurred on February 1, when Flight AI132 experienced a fuel control switch issue during engine start in London. The flight crew observed on two occasions that the switch did not remain positively latched in the “RUN” position when light vertical pressure was applied. On the third attempt, the switch engaged correctly and remained stable. The crew then performed a physical verification to ensure the switch was fully latched before continuing the flight.
“No abnormality was observed during engine start or anytime thereafter. The crew was briefed on the observation, avoided unnecessary contact with the switch, and closely monitored engine indications and alerting systems. The flight was completed without incident,” the DGCA stated.
Following the flight, Air India grounded the aircraft and initiated a fleet-wide inspection of fuel control switches on its Boeing 787-8 fleet. The DGCA, in coordination with Boeing, checked both left and right switches. While the switches were secure under full force applied parallel to the base plate, they could move from “RUN” to “CUTOFF” if external force was applied in an indirect direction due to the angular design of the base plate. Boeing confirmed that the pull-to-unlock force of the switches remained within recommended limits.
Sources further indicated that a specific component of the fuel control switch module will be replaced. The component has a total lifespan of 20,000 hours but had only been used for 3,440 hours—less than 20% of its total life. The impacted module will be sent to the original equipment manufacturer (OEM) for further inspection.
The DGCA noted that all inspections were carried out in the presence of its officers and in consultation with Boeing.
This development comes less than a year after a tragic accident involving an Air India Boeing 787-8. In June 2024, Flight AI171 crashed shortly after taking off from Ahmedabad for London, killing 230 passengers and 12 crew members on board, along with 19 people on the ground. Only one passenger survived the crash, marking India’s worst aviation accident in three decades.
