Safety regulators have cleared an Air India Boeing 787-8 Dreamliner after a technical scare during flight AI-132 from London to Bengaluru, when crew noticed a potential malfunction in the left engine fuel control switch.

The Director General of Civil Aviation conducted a thorough inspection after the aircraft landed safely, finding no mechanical defects in the fuel control systems.

Incident Details

The flight crew reported that the fuel control switch failed to lock properly in the "run" position twice during pre-flight checks. These switches regulate fuel flow to engines, and any movement toward the "cutoff" position could potentially cause an in-flight engine shutdown.

Despite the initial concerns, investigators found both left and right fuel control switches were functioning within standard safety limits.

Handling Technique Identified as Cause

The DGCA investigation revealed the issue was likely caused by improper switch handling rather than mechanical failure. According to the official statement, applying force in the wrong direction can cause the switch to slip due to its angular base plate.

When the "pull-to-unlock" safety mechanism—requiring the switch to be lifted before moving—was used correctly, the system remained secure. The regulator briefed the crew on proper handling techniques to prevent accidental contact or improper force application.

Heightened Scrutiny Post-Ahmedabad Crash

This safety concern has been under intense examination since the tragic Air India crash in Ahmedabad in June 2025. Aviation experts have maintained heightened vigilance regarding Boeing 787 fuel systems following that incident.

Flight Completed Safely

Air India's engineering team and DGCA officials confirmed all engine parameters remained stable throughout the journey, with the flight completed without further issues.

The regulator has advised pilots to avoid unnecessary contact with switch housings to prevent similar scares.