Air India has taken the significant step of grounding a Boeing 787 Dreamliner after one of its pilots identified a concerning issue with a critical fuel control switch during operations at London Heathrow Airport. This development has reignited scrutiny over the aircraft's systems, coming less than a year after the tragic Ahmedabad crash that claimed 260 lives.
Heathrow Incident Revives Safety Concerns
The incident occurred during engine start procedures at Heathrow, where the pilot discovered that a fuel control switch moved from the "run" to "cutoff" position without the required safety action being followed. According to sources quoted by The Times of India, the pilot conducted multiple tests and found the switch's locking mechanism was not functioning correctly on two separate attempts.
Detailed Sequence of Events
During pre-flight checks, the pilot lightly pushed the left fuel control switch to verify its locking feature was operational. To their concern, the switch moved despite not being lifted first – a clear violation of the designed two-step safety mechanism. A second check produced the same result, with the switch failing to lock properly. Only on the third attempt did the mechanism function as intended, remaining locked until deliberately lifted.
"We are aware that one of our pilots has reported a possible defect on the fuel control switch of a Boeing 787-8 aircraft," Air India confirmed in an official statement. "After receiving this initial information, we have grounded the said aircraft and are involving the Original Equipment Manufacturers to get the pilot's concerns checked on a priority basis."
Fleet-Wide Inspection Launched
In response to the incident, Air India has initiated a comprehensive inspection of fuel control switches across its entire Boeing 787 fleet. The airline currently operates 33 of these advanced aircraft, making this a substantial safety undertaking.
Manish Uppal, Air India's senior vice president for flight operations, communicated directly with Boeing 787 pilots about the precautionary measures. "While we await Boeing's response, our engineers – out of an abundance of caution – have initiated precautionary fleet-wide re-inspection of the fuel control switch latch to verify normal operations," he stated in an email circulated on Tuesday.
Connection to Ahmedabad Tragedy
This latest incident casts new light on the ongoing investigation into the June 2025 Ahmedabad crash. Preliminary reports from the Aircraft Accident Investigation Bureau had indicated cockpit confusion about fuel switches shortly before the Dreamliner came down, with one pilot questioning why the other had moved the switches to "cutoff" – a claim the second pilot denied.
While initial findings suggested no technical or design fault, implying possible pilot error, the Heathrow incident raises serious questions about this conclusion. The crash, involving a London-bound flight, resulted in the loss of 260 lives with only one survivor.
Regulatory and Industry Response
Air India has formally communicated the matter to India's aviation regulator, the Directorate General of Civil Aviation (DGCA). Boeing has acknowledged the situation, stating they are "in contact with Air India and supporting their review of this matter."
The aircraft involved was operating as Air India flight AI 132 from London to Bengaluru, originally scheduled to depart at 9.05pm local time but eventually taking off at 9.40pm following the safety checks.
Expert Analysis and Industry Calls
Air safety expert Amit Singh highlighted the particular significance of this incident, noting that the US aviation regulator had cautioned as far back as 2018 about potential malfunctions in Boeing 787 fuel control switches that could lead to inadvertent engine shutdowns.
"Occurring after Air India said its fleet's fuel control switches have been checked and amid the ongoing June 12 B787 crash investigation, it raises serious questions about inspection adequacy and demands the highest level of regulatory scrutiny," Singh told The Times of India.
The Federation of Indian Pilots has renewed its call for Boeing 787 aircraft to be grounded pending thorough inspections of their electrical systems. This development comes despite Air India's previous assurance that checks conducted after the Ahmedabad crash had "found no issues" with the switches across their fleet.
The incident underscores the ongoing challenges in aviation safety and the critical importance of robust inspection protocols, particularly for components as vital as fuel control systems in modern aircraft.
