Air India inspects Boeing 787 fuel control switches after pilot flags defect on VT-ANX

Air India Ltd. has initiated a precautionary fleet-wide inspection of fuel control switches on its Boeing 787 Dreamliner aircraft after a pilot reported a potential defect on one aircraft following a long-haul flight from London Heathrow Airport (LHR), UK to Kempegowda International Airport (BLR), Bengaluru, India on February 1, 2026. The affected airplane, a Boeing 787-8 Dreamliner registered VT-ANX, was promptly grounded upon landing and removed from service pending detailed evaluation.

The move follows heightened industry attention on Boeing 787 fuel system components since a fatal Air India accident near Sardar Vallabhbhai Patel International Airport (AMD), Ahmedabad, on June 12, 2025, in which both engines lost thrust as fuel control switches transitioned from RUN to CUTOFF, resulting in 260 fatalities. That crash threaded fuel switch functionality into the forefront of global aviation safety concerns.

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Fuel control switch reported defect on Air India Boeing 787

Air India’s senior vice president for flight operations, Manish Uppal, communicated internally to Boeing 787 pilots that the airline’s engineering team escalated the fuel control switch concern to Boeing for priority assessment, and began a precautionary fleet-wide re-inspection “out of an abundance of caution”:

“Following the reported defect involving a Fuel Control Switch on one of our B787 aircraft…our engineers…have initiated precautionary fleet-wide re-inspection of the Fuel Control Switch (FCS) latch to verify normal operations…. To date, no adverse findings have been reported on the aircraft for which this re-inspection is completed…..We would also like to remind all crew to promptly report any defects observed during operations and to ensure that all required actions are completed prior to accepting the aircraft”

What the defect report entailed

• The issue was documented after engine start during post-flight inspection; the left engine fuel control switch reportedly failed to remain latched in ‘RUN’ and moved toward ‘CUTOFF’ on two separate attempts.

• Pilots ensured the switch was positively latched before completing the flight to Bengaluru without abnormal engine indications.

• The airline informed India’s Directorate General of Civil Aviation (DGCA) and Boeing.

Fuel control switches regulate fuel flow to aircraft engines and have two principal positions: RUN (normal fuel flow for engine operation) and CUTOFF (fuel supply ceased to engine). These switches are spring-loaded and require a deliberate, lift-then-move action to minimise inadvertent activation.

Regulatory Response: DGCA Evaluations and Comments

The DGCA has reviewed the grounded airplane’s switches and reported that both fuel control switches were found to be “within safety norms,” with locking mechanisms aligning with Boeing’s prescribed standards when tested correctly.

In the cockpit voice recording, one of the pilots is heard asking the other why did he cutoff (the fuel control switch). The other pilot responded that he did not do so.

The regulator also clarified that no abnormal engine parameters or warnings were recorded during engine start or flight operations and urged crews to observe manufacturer-recommended handling procedures.

The Directorate General of Civil Aviation (DGCA) said the anomaly was first observed during engine start procedures at London, reported The Financial Express.

“During engine start in London, on two occasions crew observed that the fuel control switch did not remain positively latched in the ‘RUN’ position when light vertical pressure was applied. On the third attempt, the switch latched correctly in ‘RUN’ and subsequently remained stable,” the DGCA said in its formal rejoinder.

The regulator added that flight crew followed prescribed verification procedures before continuing the operation and reported no associated system abnormalities during or after the event.

“Before continuing with the rest of procedure, a physical verification was performed by the crew to confirm that the switch was fully and positively latched in the ‘RUN’ position. No abnormal engine parameters, cautions, warnings, or related system messages were observed during engine start or at any time thereafter,” the DGCA stated.

DGCA also the observation was formally communicated within the cockpit, after which:

• flight crew maintained heightened surveillance of engine parameters
• associated alerting systems for the duration of the sector

As a precaution, further handling of the fuel control switch was deliberately minimized.

The anomaly was documented by the crew upon arrival in Bengaluru, prompting Air India to escalate the matter to Boeing for technical direction. The DGCA added that the carrier has been advised to disseminate Boeing’s recommended procedures for fuel cut-off switch operation across its pilot workforce.

What did Air India say about the matter?

Air India said the issue was first identified after a pilot reported a potential irregularity involving a fuel control switch on a Boeing 787-8, prompting the airline to take the aircraft out of service as a precaution and notify both the manufacturer and the regulator, a spokesperson said:

“After receiving this initial information, we have grounded the said aircraft and are involving the OEM to get the pilot’s concerns checked on a priority basis,”

The airline also pointed to earlier compliance actions taken across its Dreamliner fleet following regulatory instructions and reiterated its safety position.

“Air India had checked the fuel control switches on all Boeing 787 aircraft in its fleet after a directive from the DGCA, and had found no issues. At Air India, the safety of our passengers and crew remains top priority,”

Final considerations

While the recent inspection by Air India and regulator findings point to no immediate mechanical failure, the significance of fuel control switch functionality cannot be overstated given the catastrophic consequences of inadvertent fuel cutoff events in high-altitude, high-energy flight phases.

Ongoing analysis by Boeing and aviation authorities is expected to clarify whether procedural, mechanical, or ergonomic factors contributed to the anomaly on VT-ANX, and whether broader operational advisories are necessary.