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Air India Ahmedabad plane crash: DGCA asks airlines to check fuel switch locking system in Boeing 737, 787 jets

Air India Ahmedabad plane crash: DGCA asks airlines to check fuel switch locking system in Boeing 737, 787 jets

The Hindua day ago
Aviation regulator DGCA on Monday (July 15, 2025) ordered airlines to inspect the lock on the fuel control switches on Boeing 787 and Boeing 737 planes by July 21, a move that comes days after the preliminary probe report into the Air India's Boeing 787 crash found that the switches were cut off before the accident last month.
The Federal Aviation Administration (FAA), back in 2018, had flagged the potential disengagement of the fuel control switch locking feature on certain models of Boeing aircraft, including 787s and 737s. It was mentioned in a Special Airworthiness Information Bulletin (SAIB) but there was no airworthiness directive, indicating that the issue was not a safety concern.
'It has come to the notice of DGCA, that several operators- internationally as well as domestic have initiated inspection on their aircraft fleet as per the SAIB NM-18-33 dated 17th December 2018. In the view of above all airline operators of the affected aircraft are hereby advised to complete the inspection required,' the DGCA said in an order.
Fuel control switches regulate the flow of fuel into aircraft engines.
A senior official didn't immediately confirm which operators would be impacted. Air India operates Boeing 787 aircraft, and Air India Express and SpiceJet operate Boeing 737 aircraft.
Though IndiGo too has Boeing 787 aircraft, but since these are leased from a foreign airline they won't be subjected to this order, one senior DGCA official explained.
In its preliminary report on the Boeing 787-8 crash released on Saturday, the Aircraft Accident Investigation Bureau (AAIB) said the fuel supply to both engines of the plane was cut off within a gap of one second, causing confusion in the cockpit soon after take off.
'In the cockpit voice recording, one of the pilots is heard asking the other why did he cut off. The other pilot responded that he did not do the same,' the report said.
However, AAIB did not mention any recommended action.
Air India flight AI 171, operated with the Boeing 787-8, enroute to London Gatwick crashed soon after takeoff from Ahmedabad on June 12, killing 260 people.
(with PTI inputs)
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Air India crash: Are Boeing's fuel switches faulty? Could it have caused the tragedy?
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Air India crash: Are Boeing's fuel switches faulty? Could it have caused the tragedy?

After the Air India crash in Ahmedabad, the Indian aviation regulator and other airlines across the world have ordered checks of the fuel control switches in their Boeing planes. This comes after the fuel switches have come under scrutiny following the initial investigation into the accident. An old advisory that flagged issues with the mechanism of these cogs has also resurfaced read more Remains of the Air India plane that crashed moments after taking off from the Ahmedabad airport, Thursday in June. File image/PTI Days after the preliminary report on Air India Flight AI-171, which crashed in Ahmedabad in June, highlighted the role of fuel switches, many airlines within India as well as abroad are now investigating this mechanism. India's aviation regulator, the Directorate General of Civil Aviation (DGCA), has ordered all airlines, which operate the Boeing's 787 and 737, to check fuel control switch locking mechanisms on them by July 21. Moreover, Etihad Airlines and other major airlines across the world have also started checking the locking mechanism in the fuel switches. STORY CONTINUES BELOW THIS AD But why? What's going on? We get you the answers. Checks ordered for fuel switches in India and abroad On Monday (July 14), the DGCA ordered all airlines to check fuel switch locking system in Boeing 787, 737 planes in the aftermath of the deadly Air India plane crash that killed 241 passengers on board. The Indian aviation regulator has asked airlines to complete these checks by July 21, next Monday. Currently, only two Indian airlines operate these variants of the plane — Air India and IndiGo. An NDTV report states that Air India has completed checks on 50 per cent of the fleet in question with no malfunctions being found as of yet in the fuel switch's locking mechanism. Notably, Etihad Airlines and airline operators in South Korea have also been asked to carry out checks on fuel control switches. Korean Air Lines, in fact, on Tuesday, announced that it had begun inspecting fuel control switches and would implement any additional requirements the transport ministry may have. Additionally, even Singapore Airlines have started the process. Bloomberg also reported that Oman Air has also completed checks on fuel switches, while Saudi is checking its jets. The investigation underway at the site of the Air India plane crash, in Ahmedabad. PTI Reasons for the checks The DGCA's order and the other checks being carried out comes after the Aircraft Accident Investigation Bureau's preliminary report, released last Saturday (July 12), stated that both of the Boeing 787 Dreamliner's fuel-control switches moved to the 'cutoff' position. This led to the airplane's engines being starved of fuel and lose power. Moreover, the cockpit voice recorder captured one pilot asking the other why he had cut off the fuel in the final moments before the crash. The other pilot responded that he had not done so, the report revealed, raising questions about the position of the critical engine fuel cutoff switches. The report doesn't clarify who or how the fuel switches jumped from 'run' to 'cutoff' just after takeoff. Fuel control switches, located on the critical cockpit control panel, are used to start or shut down engines on the ground. What is very important to note here is that these switches cannot be accidentally or gently moved by pilots operating a flight. The fuel cutoff switches are spring-loaded to remain firmly in place. A pilot must first pull the switch up before moving it from the 'run' to the 'cutoff' position, or vice versa. STORY CONTINUES BELOW THIS AD However, the US Federal Aviation Administration (FAA) had flagged a potential issue with fuel control switches on Boeing airplanes in 2018. In a Special Airworthiness Information Bulletin (SAIB), NM-18-33, indicated that there was a potential equipment malfunction with the fuel switches. The bulletin had flagged the potential disengagement of the fuel control switch locking feature on certain models of Boeing aircraft, including 787s and 737s. In a recommendation, the FAA wrote, 'Inspect the locking feature of the fuel control switch to ensure its engagement. While the airplane is on the ground, check whether the fuel control switch can be moved between the two positions without lifting up the switch. If the switch can be moved without lifting it up, the locking feature has been disengaged and the switch should be replaced at the earliest opportunity.' The wreckage of the Air India plane that crashed moments after taking off from the Ahmedabad airport, lies on a building, in Ahmedabad. Both switches feeding fuel to the two engines of Air India flight 171 were cut off followed before the plane crashed in Ahmedabad, seconds after taking off, the first investigation report into the crash has revealed. PTI What is notable is that at the time, the FAA did not consider it to be an unsafe condition. Moreover, the AAIB noted that the 'airworthiness concern was not considered an unsafe condition' and Air India did not carry out the inspections as the 'as the SAIB was advisory and not mandatory'. STORY CONTINUES BELOW THIS AD The AAIB noted that the throttle control module was replaced on VT-ANB in 2019 and 2023. However, the reason for the replacement was not linked to the fuel control switch. There has been no defect reported pertaining to the fuel control switch since 2023 on VT-ANB,' the AAIB report says. Notably, this is not the first time that airlines and regulators worldwide have stepped away from FAA directives to independently take decisions impacting flight safety. In 2019, various governments and regulators ignored the FAA after an Ethiopian Airlines Boeing 737 MAX aircraft crashed. But it wasn't just the US FAA that had issued a bulletin on the fuel switches in Boeing aircraft. It has now emerged that the UK Civil Aviation Authority warned about a similar fuel system flaw. On May 15, 2024, the UK regulator issued a directive to operators of five Boeing aircraft variants urging them to review and address a US Federal Aviation Administration Airworthiness Directive. The FAA directive had flagged fuel shutoff valve actuators, critical to preventing fuel leaks and engine shutdowns, as a potential safety concern. STORY CONTINUES BELOW THIS AD The CAA notice explicitly listed the Boeing 737, 757, 767, 777, and 787 models and directed airlines to take mandatory action by either testing, inspecting, or replacing fuel shutoff valve actuators on affected planes as a precaution. 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