Aviation Safety – Air India Begins Fleet-Wide Checks on Boeing 787 Fuel Switches
Aviation Safety – Air India has launched a comprehensive inspection of fuel control switches across its entire Boeing 787 fleet after a technical irregularity was reported on one of its long-haul aircraft earlier this week.
The decision follows a report from a pilot who noticed an issue with the fuel control switch while operating a Boeing 787-8 flight from London Heathrow to Bengaluru. The aircraft landed safely on Monday morning and was immediately withdrawn from service for detailed technical checks, according to people familiar with the matter.
Airline Orders Preventive Inspections Across All Dreamliners
In an internal communication to Boeing 787 flight crew, Air India’s Senior Vice President of Flight Operations, Manish Uppal, confirmed that the airline has begun a precautionary, fleet-wide re-inspection of the fuel control switch latch system. The move applies to all 33 Dreamliner aircraft currently operated by the airline.
The inspections are being carried out as a preventive step while the airline awaits technical feedback from Boeing. Uppal stated that the airline’s engineering division has already escalated the matter to the aircraft manufacturer for urgent review and technical assessment.
No Irregularities Found in Completed Checks So Far
According to the internal note, engineers have completed re-inspections on several aircraft and have not identified any abnormal findings to date. The airline emphasized that the checks are being conducted out of an abundance of caution rather than due to evidence of a systemic issue.
Uppal reassured pilots that normal operations would continue only after all mandatory inspections and procedures are fully completed, underlining the airline’s focus on safety and regulatory compliance.
Crews Asked to Report Even Minor Technical Concerns
Alongside the technical review, Air India has instructed its cockpit and cabin crews to remain vigilant and report any technical irregularities observed during operations without delay. The airline has also reiterated that no aircraft should be accepted for flight unless all reported issues are resolved in line with approved maintenance procedures.
This approach, sources said, reflects a renewed emphasis on early detection and reporting of potential faults, even when they appear minor or isolated.
Context Linked to Earlier Safety Reviews
Fuel control switch systems have been under heightened scrutiny since last year, when Air India conducted similar inspections following a fatal crash involving a Boeing 787-8 aircraft near Ahmedabad. That accident, which claimed 260 lives, prompted industry-wide attention after a preliminary investigation suggested that fuel supply to the engines may have been interrupted shortly after take-off.
While there is no indication that the current technical report is connected to that incident, the earlier findings have made airlines more cautious when addressing any fuel-related anomalies.
Details of the Recent London–Bengaluru Flight
The aircraft involved in the latest report departed London Heathrow on Sunday and arrived in Bengaluru early Monday. After the pilot flagged the issue, the aircraft was grounded as a standard safety measure. Engineers began examining the fuel control switch soon after landing, and the plane remains out of service pending clearance.
Overview of Air India’s Boeing 787 Fleet
Air India currently operates 33 Boeing 787 aircraft, comprising 26 Boeing 787-8 planes and seven Boeing 787-9 variants. The fleet includes aircraft inherited from Vistara following the merger, as well as a specially configured wide-body jet inducted earlier this year.
The airline has stated that it will continue working closely with Boeing and aviation regulators to ensure that all findings are reviewed thoroughly and that any necessary corrective actions are implemented promptly.