Air India Dreamliner fuel switches to undergo inspection at US facility

India has directed that the fuel control switches from an Air India Boeing 787-8 Dreamliner be sent to the original equipment manufacturer's facility in the United States for further inspection in the presence of Directorate General of Civil Aviation (DGCA) officials.

The move is part of continued airworthiness monitoring of the switches installed on the aircraft, which was grounded on February 2 after operating flight AI 132 from London Heathrow to Bengaluru.

While starting the engine before departure from London, the crew observed twice that the left fuel control switch did not remain positively latched in the "RUN" position when light vertical pressure was applied.

The switch remained stable on the third attempt and the crew monitored the aircraft closely during the flight, which was completed without incident.

After the aircraft landed in Bengaluru, the pilot recorded the issue in the defect report, noting that the switch appeared to slip from "RUN" to "CUTOFF" when pushed slightly and did not lock positively in the selected position.

The aircraft, registered as VT-ANX, was subsequently grounded.

Air India then carried out inspection and functional testing of the fuel control switches in accordance with procedures prescribed by the original equipment manufacturer (OEM), in the presence of DGCA officials.

The regulator said the switches were found to be satisfactory when operated using Boeing's recommended procedure, remaining in the "RUN" position instead of moving to "CUTOFF", which can stop the supply of fuel to the engines.

However, DGCA noted that if the switch was handled incorrectly, it could move easily from "RUN" to "CUTOFF".

Based on the inspection findings and evidence submitted, the OEM concluded that the switch was mechanically functioning as designed and considered the unit serviceable.

But the DGCA decided that the fuel control switches involved be inspected at the OEM's facility in the US in the presence of its officers.

"The DGCA India, as part of continued airworthiness of the involved Fuel Control Switch, has directed for their inspection at OEM facility in presence of DGCA officers," civial aviation ministry said in a statement.

The regulator also asked Air India to circulate Boeing's recommended procedure for operating the switch to its flight crew.

The issue drew significant attention as it surfaced amid an ongoing investigation into the crash of an Air India Boeing 787-8 Dreamliner near Ahmedabad last June that killed 260 people.

In a preliminary report released in July, India's Aircraft Accident Investigation Bureau (AAIB) said the aircraft's engines shut down shortly after take-off after both fuel control switches moved from "RUN" to "CUTOFF", but it did not determine how that occurred.

A final report is expected in the coming months.