DGCA Rejoinder on Air India Fuel Switch Scare Points to ‘Incorrect Direction’ Handling

India’s aviation regulator has issued a fresh clarification in the controversy surrounding an Air India flight after a reported fuel switch anomaly triggered safety concerns and revived memories of a past aviation tragedy. The Directorate General of Civil Aviation (DGCA) said there was no technical malfunction in the aircraft’s fuel control switches and suggested that external force applied in an incorrect direction may have caused the switch movement that led to the scare.

The incident took place on flight Air India AI-132, operated by a Boeing 787-8 Dreamliner, before departure from Heathrow Airport to Bengaluru on February 1. During pre-flight checks, pilots reportedly observed abnormal behaviour of the left engine’s fuel control switch, which allegedly failed to remain locked in the “run” position and appeared to shift toward “cutoff.” Since the switch regulates fuel flow to the engine, any unintended movement can raise fears of an engine shutdown during flight.

Following the report, the aircraft was later grounded in Bengaluru for detailed inspection. The issue quickly drew attention because it came months after the fatal Air India Flight AI 171 crash, which had intensified scrutiny of fuel control mechanisms on Boeing 787 aircraft.

In its rejoinder, the DGCA said that engineering teams found both the left and right fuel control switches functioning normally. Inspections confirmed that the locking mechanism was intact and did not slip from “run” to “cutoff” under standard conditions. According to the regulator, when force was applied correctly—parallel to the switch’s base plate—the control remained secure.

However, investigators observed that pressing the switch with force in a different direction could allow it to move more easily due to the angular design of the base plate. The DGCA suggested that such incorrect handling might explain the anomaly reported by the crew, introducing a new dimension to the debate around whether the issue stemmed from equipment or human interaction.

The regulator also highlighted that engine parameters remained normal during start-up and throughout the journey, and that cockpit monitoring systems did not show any abnormal alerts. After the incident, Air India’s engineering department carried out checks in the presence of DGCA officials, including tests of the “pull-to-unlock” feature—a safety mechanism requiring pilots to lift the switch before moving it between positions to prevent accidental shutdowns.

Officials said the required pull-to-unlock force was found to be within Boeing’s recommended limits in all tests. Crew members were briefed on the findings and advised to avoid unnecessary contact with the switches during operations.

The episode has sparked debate within aviation circles about cockpit ergonomics, pilot training, and the role of procedural handling in preventing safety scares. While the DGCA has ruled out a mechanical fault, the reference to “incorrect direction” handling has added a fresh twist to the ongoing discussion about aircraft safety protocols.

As investigations into aviation incidents remain under intense public scrutiny, regulators and airlines alike are emphasising the need for precise procedures and careful cockpit interaction to ensure that isolated anomalies do not escalate into larger safety risks.