Why is Dreamliner’s fuel system under watch? | Explained

The story so far: On February 1, 2026, an Air India flight (AI 132) scheduled from London Heathrow to Bengaluru was preparing for departure when the crew reported that one of the two fuel control switches on the Boeing 787-8 had moved to ‘Cutoff’. The incident came under intense scrutiny, as the fuel switches and their functioning are a key part of the ongoing investigation into the June 12, 2025 crash of Air India flight 171 (Ahmedabad-London Gatwick), also a Boeing 787-8.

What happened next?

As the left fuel control switch “slipped from Run to Cutoff”, the crew is said to have checked the switches by touching them. It was only in the third attempt that the switch remained in the ‘Run’ position.

Also read: Air India starts inspection of fuel control switches in its Boeing 787 planes

The crew decided to continue with the flight — a distance of about 8,000-plus kilometres — with no further incident.

How was the incident reported?

The Safety Matters Foundation, a non-profit and independent aviation safety think tank in India, put out a note that called for a “transparent investigation after this new fuel system incident”. It said that the incident was “alarming as it mirrors a known risk previously identified by the U.S. Federal Aviation Administration”. It highlighted how, “in 2018, the FAA had issued a Safety Alert For Operators SAIB NM-18-33, warning that certain fuel control switches, including those on Boeing 787s, could malfunction in this exact manner, increasing the risk of accidental engine shutdown.” The Foundation said that “the incident was troubling, as the airline had said that it had conducted precautionary checks across its 787 fleet and found no issues.”

India’s regulator, the Directorate General of Civil Aviation (DGCA), came into the picture after the incident was reported. In a note titled “Rejoinder on News Item relating to purported malfunction of Fuel Cut Off Switch on M/s Air India Boeing B787-8 aircraft”, the DGCA gave a detailed, technical account of the incident: “...the switch did not remain positively latched in the ‘Run’ position when light vertical pressure was applied but latched correctly in ‘Run’ and was stable during the third attempt.”

The note also said that the crew had “physically verified that the switch was fully and positively latched in the ‘Run’ position”, adding that “no abnormal engine parameters, cautions, warnings, or related system messages were observed during engine start or at any time thereafter”. The note went on to say that “the operating crew member was briefed on the observation, unnecessary contact with the switch was avoided, and engine indications and alerting systems were closely monitored during the full flight.”

The crew reported the incident in the pilot defect report, after which the airline reached out to the manufacturer, Boeing, for guidance. The DGCA note also said that Boeing had recommended checks on the switches. The airline’s engineering department found both switches to be functioning satisfactorily. The DGCA said that the inspections were done in the presence of DGCA officers, and Air India was advised to “circulate the Boeing recommended procedure for the operation of Fuel Cut Off switch to its crew members”.

The aircraft was initially grounded in Bengaluru but was cleared for operations later. It left for Delhi on February 5.

What have the other responses been?

In response to a query by The Hindu, a statement by an Air India spokesperson said, “Following the DGCA closure on the matter, Air India will be following its safety investigation protocol and take appropriate action. We will fully adhere to the regulator’s guidance to circulate OEM [original equipment manufacturer]-recommended operating procedures for the operation of the FCS [fuel control switch] to all crew members.”

Also read: Air India plane flown after physical checks, no abnormal parameters noticed: DGCA

The airline is said to have inspected its Boeing 787 fleet once again. It operates 26 Boeing 787-8s and seven 787-9s (the newest jet was inducted in January 2026). IndiGo too has six leased Boeing 787-9s (from Norse Atlantic Airways). Boeing, in a statement to The Hindu, said, “We are in contact with Air India and are supporting their review of this matter.” 

In response to an e-mail/telephonic call by The Hindu, a spokesperson for the Air Accidents Investigation Branch-U.K., said, “We are aware of reports in the media about an event on a flight between London Heathrow and Bangalore on 2 February. We are engaged with the U.K. Regulatory Authority, who we understand is working to establish the facts.”

In a comment to The Hindu on fuel switches, Professor David Cirulli, UAS Department of Flight, Embry-Riddle Aeronautical University, Asia Academics, Worldwide Campus, said that “aircraft flight decks have evolved over many years of operational experiences with a focus on safety. The industry thrives on creating the best and safest means of transportation.” He pointed out that one item of focus is the human factor.

“This study and area of expertise covers a broad range of items, but one in particular is the human-to-machine interface. Fuel flow to the engines is a safety-critical issue. Inadvertent engagement or disengagement are both drastically important for numerous reasons. Over time, the industry — both regulatory and operational safety — recognised the necessity to ensure that inadvertent operations do not occur. It is for this reason that these switches require multiple movements (pull/twist) with a locking mechanism to reach the engaged or disengaged states. The fundamental designs of these switches remain the same over most aircraft and fleets, with solid operational performance. The reliability of the system, for this reason, is very high,” he said.