DGCA directs all airlines to inspect Boeing fuel switches by July 21

Order applies to B737 and 787, which have fuel-control switches made by Honeywell

Two days after the release of the preliminary report on the Dreamliner AI-171 fatal crash, the Directorate General of Civil Aviation (DGCA) has directed all airlines to inspect the locking mechanism of fuel-control switches on their Boeing aircraft. The airlines have to submit the inspection reports by July 21, DGCA said on Monday.

 

The DGCA directive is significant against the backdrop of the recent Aircraft Accident Investigation Bureau (AAIB) report, which stated that both engine fuel-control switches on the Boeing 787 aircraft on flight AI171 had “transitioned” from RUN to CUTOFF just seconds after takeoff, resulting in a dual engine failure.  

   

The aviation safety regulator’s order will apply to Boeing 737 and 787, which are equipped with fuel-control switches manufactured by American conglomerate Honeywell International. Boeing 777 aircraft, which features a different type of fuel-control switches, is not covered under the DGCA directive.   

 

AAIB’s preliminary report, made public on Saturday, has been widely criticised for omission of key technical details related to the crash, which killed 241 on board and 19 on the ground on June 12.    

 

Among Indian carriers, the inspection applies to Boeing aircraft in the fleets of five airlines. Air India operates 191 aircraft in total, of which 57 are Boeing jets, including 787s and 777s. Air India Express has 75 Boeing 737s in its 114-aircraft fleet. IndiGo, with a total fleet of 414 aircraft, has 10 Boeing 777, 787s and 737s acquired on lease. SpiceJet operates 29 Boeing aircraft out of 55 in its fleet, while Akasa Air’s entire fleet of 30 aircraft comprises Boeing 737 MAX planes, according to planespotters.net.

 

Only Air India and IndiGo have Boeing 777s, which are not covered under the DGCA’s inspection directive. 

 

While the cause of the fuel-control switch transitioning to the cutoff position remains undetermined, international airlines such as Singapore Airlines and Etihad Airways have taken early action. In the last couple of days, the airlines started inspecting the fuel-control switches on their Boeing 787 fleet. When asked about these inspections, the Etihad Airways spokesperson said: “Etihad always ensures its maintenance is fully compliant.” The Singapore Airlines spokesperson did not respond to Business Standard’s queries.

 

South Korea, meanwhile, was also preparing to mandate inspections of fuel-control switches on all Boeing aircraft in the country.

 

A spokesperson for the South Korean transport ministry on Monday said the upcoming checks would follow the guidance of the 2018 advisory issued by the US Federal Aviation Administration (FAA), though no specific timeline for completion was provided.

 

The AAIB report had on Saturday revealed that the Boeing 787 involved in the crash was equipped with the same fuel control switches flagged in the FAA’s 2018 bulletin. Air India told investigators it had not carried out the recommended inspections at the time, citing the advisory nature of the bulletin. The aircraft’s throttle control module had been replaced in 2019 and 2023, though not due to any issue related to the fuel switches.

 

 

In its Monday order, the DGCA noted that the FAA had in December 2018 issued a special airworthiness information bulletin (SAIB) -- number NM-18-33 -- regarding the potential for disengagement of the fuel control switch locking feature on multiple Boeing models, including the 737, 747, 757, 767, 787, and others.

 

The FAA had in 2018 received reports that in some cases, the fuel control switches were installed in a way that bypassed or disabled the locking mechanism, which is meant to prevent accidental movement of the switch from the “RUN” to “CUTOFF” position. Without the lock engaged, the switches could potentially be moved more easily, raising the risk of unintentional engine shutdown during flight.

 

Though the FAA had determined that the issue did not constitute an “unsafe condition” requiring a mandatory airworthiness directive, it had recommended that operators inspect the switches and replace any with disengaged locking features. It specifically advised a part upgrade for certain 737 models with switches built by Honeywell. The SAIB was advisory and not mandatory.

 

The DGCA on Monday noted that several domestic and international airlines have now initiated such inspections. Therefore, it instructed all Indian operators of affected aircraft to “complete the inspection required under SAIB Number: NM-18-33...no later than July 21, 2025”. Operators must also submit an inspection plan and post-inspection report to the DGCA and the concerned regional office.

 

“Strict adherence to the timeline is essential to ensure continued airworthiness and safety of operations,” the DGCA added in its order.

 

According to flight data cited in the AAIB report, the switches on both engines of AI171 moved from “RUN” to “CUTOFF” just three seconds after the aircraft lifted off from runway 23 of Ahmedabad airport on June 12. The two movements occurred one second apart.

 

The cockpit voice recorder captured one pilot asking the other why the fuel was cut off, to which the other replied that he had not done it. A Mayday call was made seconds later before the aircraft crashed into the BJ Medical College hostel compound.