Air India Grounds 787; DGCA Cites Crew Procedure in Fuel Switch Incident

Air India has grounded one of its Boeing 787 Dreamliner aircraft, registration VT-ANX, following a reported issue with a fuel control switch (FCS). The incident occurred on flight AI132 from London Heathrow to Bengaluru. The aircraft was immediately taken out of service upon landing for inspection.

Incident Details and Immediate Response

The issue was flagged by the flight crew during engine start at London Heathrow Airport. Pilots observed that the left engine's fuel control switch failed to remain positively latched in the 'RUN' position twice. This occurred when only "light vertical pressure" was applied to the switch. The switch finally latched correctly on the third attempt. The flight proceeded to Bengaluru without further incident or abnormal engine warnings.

Following the pilot's log entry, Air India grounded the aircraft. The airline stated it immediately involved the Original Equipment Manufacturer (OEM) for priority inspection. The matter was also escalated to the Directorate General of Civil Aviation (DGCA).

DGCA Findings and Fleet Inspection

The DGCA quickly launched a DGCA safety investigation into the fuel control switch issue. On Tuesday, the regulator issued a statement regarding its initial findings. The DGCA concluded that a mechanical fault was not the cause of the switch movement. Instead, the regulator suggested the issue stemmed from the risk of unintended movement. This movement occurs if external force is applied in an incorrect direction.

Consequently, the DGCA advised Air India to reinforce crew training. This training must focus on the correct, Boeing recommended procedures for operating the fuel cut-off switches.

Out of an abundance of caution, Air India initiated a precautionary, fleet-wide re-inspection. This inspection covers the fuel control switch latch on all 33 of its Boeing 787 Dreamliner aircraft. The airline confirmed it is in contact with Boeing and the switch manufacturer, Honeywell.

Broader Safety Context

This latest VT-ANX technical snag has drawn significant industry attention. The incident is being viewed in the context of the fatal Flight 171 Ahmedabad crash in June 2025.

Preliminary reports for that accident indicated that both engine fuel control switches transitioned to the 'CUTOFF' position shortly after takeoff. Fuel control switches are a critical safety component. They require a two-step action—lifting before moving—to prevent an inadvertent engine shutdown in flight. The London incident raises questions about the switch's locking mechanism. It also highlights the importance of adherence to proper operational procedures.

Air India emphasized that passenger and crew safety remains its highest priority. The DGCA safety investigation remains ongoing. The regulator continues its oversight of the airline's fleet inspection process. The outcome will be critical for future operational guidelines. The findings will also inform the ongoing investigation into the Ahmedabad crash.

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