Boeing Fuel-Switch Locks Under Emergency Inspection by India Following Air India Flight 171 Crash Incident
The Directorate General of Civil Aviation (DGCA) in India has issued a directive for comprehensive inspections of fuel control switch locking mechanisms on Boeing 787 Dreamliners and certain 737 variants. This mandate comes in response to the June crash of Air India Flight 171 near Ahmedabad, which claimed 260 lives.
The preliminary report from the Aircraft Accident Investigation Bureau (AAIB) found that both engine fuel-control switches on the Boeing 787 involved in Flight AI171 had unexpectedly transitioned from RUN to CUTOFF shortly after takeoff, causing dual engine failure and the subsequent crash.
The DGCA's directive is grounded in a 2018 advisory by the US Federal Aviation Administration (FAA) that highlighted potential malfunctions in fuel control switches on some Boeing 737 and 787 models. The FAA did not classify this as an "unsafe condition" nor make inspections compulsory then, but the Air India accident has raised urgency on this issue.
Affected Indian operators include Air India, IndiGo, SpiceJet, and Air India Express, totaling nearly 150 Boeing aircraft in active fleets. All affected airlines in India must submit inspection outcomes by the deadline of July 21.
International carriers such as Etihad Airways, Singapore Airlines, and several Asian airlines have also initiated reviews and inspections of fuel switch lock mechanisms, emphasizing global concerns over the issue and the need for mandatory checks.
The inspections affect models including Boeing 737-700/800/900ER, 767, 787-8/9/10, and several older 747/757 variants. The order applies only to Indian airlines operating Boeing 787 and 737 aircraft equipped with fuel control switches made by Honeywell International but excludes Boeing 777 models with different switch types.
Air India has already inspected approximately half its 787 fleet and most of its 737 aircraft with no defects found. The DGCA's directive also asks airlines to submit their inspection plans and reports post-inspection.
The final crash report is due in 12 months and will probe mechanical integrity, cockpit procedures, and regulatory compliance involving Boeing and FAA advisories. The AAIB's report has raised suspicion of potential pilot error or mechanical anomaly, but no definitive cause has been attributed yet.
The safety checks come after a risk was highlighted in the 2018 FAA Special Airworthiness Information Bulletin, where fuel control switch locks could complacently disengage, allowing unintended movements. The DGCA's approach emphasizes a deadline of July 21 to ensure airworthiness and passenger safety.
Regulators in Korea, UAE, Japan, and others may adopt enhanced safety measures in response to the global concern. The cockpit voice recorder captured a tense exchange: "Why did he cut off? I did not do so." The ongoing inspections aim to restore confidence in safety protocols and prevent a repeat of the tragedy.
The inspections on fuel control switch locking mechanisms, following the DGCA's directive, have been initiated by international airlines such as Etihad Airways, Singapore Airlines, and several Asian airlines, highlighting a global recognition of the potential malfunctions and the necessity for mandatory checks.
Notably, these inspections affect various Boeing models including the 737-700/800/900ER, 767, 787-8/9/10, and certain 747/757 variants. Regulators in Korea, UAE, Japan, and others may adopt enhanced safety measures in response to the noted risks.
The aviation industry and financial markets around the world are monitoring industry giants like Boeing and Honeywell International for their response to the identified issues in the fuel control switches, which could impact the entire transportation sector if notaddressed adequately.
