DGCA Orders Fuel Switch Inspections on Boeing Aircraft After Deadly Air India Crash
The Directorate General of Civil Aviation (DGCA) has issued a mandatory directive to inspect engine fuel switches on all affected aircraft registered in India, following the preliminary findings of the Aircraft Accident Investigation Bureau (AAIB) into the tragic Air India crash in Ahmedabad on June 12, which claimed 260 lives. The regulator has instructed all airline operators to complete the inspection of engine fuel switches by July 21, 2025. In addition to this, the DGCA has mandated modifications for aircraft, engines, and components in accordance with airworthiness directives issued by the country of design or manufacture.
The directive specifically targets Boeing aircraft models, including the 737 series and the 787 Dreamliner series (787-8/9/10). The order cites concerns about a potential disengagement of the fuel control switch locking feature, which could lead to unintended engine shutdowns mid-flight. This action is based on an earlier Special Airworthiness Information Bulletin (SAIB No. NM-18-33) issued by the U.S. Federal Aviation Administration (FAA) on December 17, 2018, which had flagged the risk of unintentional movement of the fuel switches.
The move by DGCA comes in the wake of the 15-page preliminary AAIB report into the June 12 crash of an Air India Boeing 787-8 Dreamliner. The report revealed that both engines shut down seconds after take-off, resulting in a fatal crash into the BJ Medical College hostel building in Ahmedabad. A total of 241 passengers and crew on board, along with 19 people on the ground, were killed.
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According to the AAIB, both Engine 1 and Engine 2 fuel cutoff switches moved from RUN to CUTOFF within one second of each other. This sudden transition caused the engines to lose thrust, and although there was a brief moment of recovery, they ultimately failed to stabilise. At 08:08:42 UTC, just before the failure, the aircraft had reached a speed of 180 knots indicated airspeed (IAS).
The investigation also highlighted that the Extended Airframe Flight Recorder (EAFR) sustained significant damage and could not be accessed through standard procedures. However, drone photography and videography at the wreckage site have been completed, and the wreckage has since been moved to a secure location near the airport. Both engines have been retrieved and quarantined for further analysis, and key components are currently under examination.
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Fuel Switch Component Replaced Twice Before Crash
According to sources cited by PTI, Air India had replaced a critical cockpit component housing the fuel control switches, known as the Throttle Control Module (TCM), on its 787-8 Dreamliner twice—once in 2019 and again in 2023. These replacements were carried out in compliance with Boeing’s Maintenance Planning Document (MPD), which mandates a change every 24,000 flight hours. The TCM contains the fuel cutoff switches that, according to investigators, unexpectedly shifted to "CUTOFF" shortly after takeoff—disabling both engines and leading to the fatal crash. However, the AAIB report clarified that the replacements were not due to any known defect in the fuel switches themselves.
The accident has placed renewed scrutiny on the design of the aircraft’s fuel control system. While both Boeing and the FAA maintain the system’s safety, the incident has prompted serious questions. Boeing recently sent out a Multi-Operator Message to all 787 operators globally, reiterating that no immediate action is needed.
Notably, the AAIB also referenced a 2018 FAA advisory that had recommended inspections of the fuel switch locking mechanism to prevent accidental movement. However, since the advisory was non-binding, Air India did not carry out the suggested inspection. As investigations continue, the DGCA's directive seeks to ensure all affected aircraft are thoroughly inspected and made compliant with international airworthiness standards to prevent any recurrence of such a catastrophic failure.
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