Air India on Wednesday confirmed that it has successfully completed precautionary inspections of the Fuel Control Switch (FCS) across its entire operational Boeing 787 Dreamliner fleet, with no technical defects detected. The move comes amid heightened regulatory scrutiny following a pilot’s observation of unusual switch behaviour on an international flight earlier this week.
The airline said the checks were conducted purely as a safety precaution and reaffirmed that all Dreamliner aircraft remain airworthy and compliant with regulatory standards.
Precautionary Checks Triggered by Pilot Report
The inspections were initiated after a pilot operating the London–Bengaluru AI132 flight reported what was described as abnormal behaviour of the fuel control switch during engine start. Although the flight was completed safely without any incident, the report prompted Air India to act swiftly.
According to the airline, the inspections were carried out “in an abundance of caution” to rule out any potential risk and ensure the highest safety margins.
DGCA Oversight and Independent Verification
The Directorate General of Civil Aviation (DGCA) closely monitored the process and conducted independent inspections alongside Air India’s engineering teams.
The regulator earlier clarified that:
- No abnormal engine parameters were recorded during the AI132 flight
- No cockpit warnings were triggered
- The fuel control switches were found to be within prescribed operational limits
An Air India spokesperson acknowledged the regulator’s proactive role, stating that the fleet was cleared only after DGCA’s independent verification.
Context of Wider Investigation Raises Attention
The development comes at a sensitive time for the aviation sector, as investigators continue to examine the AI171 crash, where a possible fuel switch cut-off is among the factors under review. While there is no direct link between the two cases, the broader investigation has intensified regulatory vigilance across fleets.
This heightened scrutiny likely contributed to the airline’s decision to conduct fleet-wide re-inspections rather than limit checks to a single aircraft.
Fuel Switch Module to Be Sent to Boeing
Despite the inspections yielding no faults, Air India confirmed that the specific fuel control switch module involved in the AI132 observation will be replaced and sent to Boeing for detailed technical evaluation.
Notably, the component had completed less than 20 per cent of its certified service life, indicating no immediate wear-and-tear concerns. The step is being taken purely as a preventive measure.
Incorrect Procedure Video Addressed
The DGCA also flagged a video circulating on social media, stating that it demonstrated an incorrect method of operating the fuel cut-off switch. The regulator clarified that the video did not reflect approved procedures and could lead to misinterpretation.
In response, Air India said it will fully comply with regulatory guidance to circulate OEM-recommended operating procedures to all flight crew members. The airline also plans to reinforce reporting protocols and handling procedures to avoid confusion.
Air India Reaffirms Safety Commitment
Air India reiterated that safety remains its top priority and emphasized that all actions taken were preventive rather than corrective.
“No issues were identified during the inspections,” the airline said, adding that it continues to work closely with regulators and manufacturers to maintain global safety standards.