Detailed DGCA probe reveals human error caused fuel switch glitch

Safety regulators recently cleared a Boeing 787-8 Dreamliner operated by Air India after a technical scare during a flight from London to Bengaluru. The incident, involving flight AI-132, initially sparked concerns when the crew noticed a potential malfunction in the left engine fuel control switch. Because these switches regulate fuel flow to the engines, any movement toward the "cutoff" position could lead to an engine shutdown while in the air.

The Director General of Civil Aviation (DGCA) conducted a thorough inspection after the aircraft landed safely in Bengaluru. While the flight crew reported that the switch failed to lock properly in the "run" position twice during pre-flight checks, investigators found no mechanical defects. The DGCA noted that the fuel control switches on both the left and right sides were functioning within standard safety limits.

The investigation revealed that the issue was likely caused by how the switch was handled. According to the official statement, applying force in the wrong direction can cause the switch to slip due to its angular base plate. However, when the "pull-to-unlock" safety mechanism—which requires lifting the switch before moving it—was used correctly, the system remained secure.

This specific safety concern has been under intense scrutiny since the tragic Air India crash in Ahmedabad in June 2025. Following that event, aviation experts have been hyper-vigilant about Boeing 787 fuel systems. In this case, the DGCA briefed the crew on proper handling techniques to avoid accidental contact or improper force.

Air India’s engineering team, alongside DGCA officials, confirmed that all engine parameters remained stable throughout the journey. The flight was completed without further issues. For now, the regulator has advised pilots to avoid unnecessary contact with the switch housing to prevent similar scares in the future.

​​​​​​​Image Source: The Federal