DGCA Orders Boeing Fuel-Switch Inspections Nationwide After Air India Tragedy

New Delhi, July 16, 2025 – In a decisive safety enforcement, India’s civil aviation regulator, the Directorate General of Civil Aviation (DGCA), has issued a directive requiring intensive inspections of the fuel-control switch locking systems on Boeing aircraft—specifically the 787 Dreamliner and select 737 variants. This move comes in response to the preliminary findings of the Aircraft Accident Investigation Bureau (AAIB) concerning the June 12 crash of Air India Flight AI171, which tragically took the lives of 260 people. The DGCA has asked airlines to complete these inspections and report results by July 21, 2025.

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1. Ghosts from the Cockpit: What the AI171 Report Revealed

The AAIB’s early investigation uncovered a startling detail: both engine fuel-control switches transitioned to the “cutoff” position almost instantly after takeoff—silent interrupts on both engines within a single second. The cockpit voice recorder captured a pilot asking, “Why did you cut off the fuel?” to which the colleague replied, “I did not do so.” This abrupt transition indicates a potentially human-triggered action—though motive and intent remain unknown. Reuters+15AP News+15AIRLIVE+15New York Post+7Reuters+7Wikipedia+7

2. FAA’s 2018 Warning Goes Unheeded

Curiously, a 2018 Special Airworthiness Information Bulletin (SAIB NM‑18‑33) from the U.S. Federal Aviation Administration had already urged airlines to inspect the locking tabs on these fuel-control switches across Boeing’s 717, 737, 747, 757, 767, and 787 models—highlighting the risk that lights may be unlocked or disengaged. However, this advisory was non-mandatory, leading many operators, including Air India, to skip the recommended checks. Relevant maintenance records showed throttle control module replacements in 2019 and 2023 for the crashed aircraft, but no link was established to the fuel switch. The Times of India+5Wikipedia+5The Times of India+5

3. DGCA Directive: Comprehensive Inspections by July 21

On July 14, the DGCA formally instructed airlines including Air India, IndiGo, SpiceJet, Akasa Air, and Air India Express to inspect every Boeing 787 and relevant 737 aircraft in their fleets. The mandate demands the full check of spring-loaded locking tabs and brackets guarding the switches. Each affected carrier must submit inspection plans immediately, followed by a detailed report by July 21—rigorously reviewing switch behaviour to ensure they cannot accidentally move.

4. International Response: A Global Safety Chain

DGCA’s directive aligns India with other aviation regulators—such as those in the UAE, South Korea, the UK, and the US—who have similarly initiated inspections. Airlines including Etihad, Singapore Airlines, Qantas, ANA, Lufthansa, and Korean Air have voluntarily conducted assessments since the AI171 revelations, with no reported deficiencies. The Economic Times+4The Indian Express+4New York Post+4

5. Inside the Lock Mechanism: One Lift, One Vote

These fuel-control switches have a unique safety feature: a top-lift mechanism that must be manually lifted before toggling between RUN and CUTOFF. The bracketed guard and spring-loaded lock make accidental operation very unlikely. Mechanics confirm that both switches shutting off simultaneously is highly improbable—even on the ground. Still, the DGCA’s blanket inspections seek to leave no stone unturned. New York Post+6The Indian Express+6Leeham News and Analysis+6

6. Air India’s Post-Crash Action

Air India has already inspected over half of its 33 Dreamliners and nearly all affected 737s. The carrier, led by CEO Campbell Wilson, reported that no mechanical faults were discovered relating to switch positions or fuel quality. Essential maintenance checks—fuel valves, engine fuel actuators, and corresponding systems—were completed after the crash. While precautionary, these proactive steps underscore the airline's commitment to safety. Financial Times+5AP News+5Bloomberg.com+5

7. Beyond Mechanics: Human Factors and Speculation

The AI171 report has sparked public conjecture—some leaning toward human error, others speculating intentional action. Pilot associations have expressed deep concern at premature insinuations, urging restraint until all data is analysed. AAIB’s report contains no definitive conclusions on intent or technical failure, only factual observations. Meanwhile, DGCA’s inspections focus strictly on mechanical safeguards. The Times+15Financial Times+15AP News+15

8. Systemwide Safety Context in Indian Aviation

DGCA data via RTI requests reveals that India recorded 65 engine shutdown incidents and 11 mayday alerts in the five years preceding AI171. Although those incidents did not involve fuel control systems, the cumulative trend highlights vulnerabilities in aircraft systems. The regulator’s directive now aims to power a shift from reactive responses to systemic anticipation. Reuters+7Wikipedia+7The Economic Times+7

9. What Happens After July 21?

Airlines must submit full reports to DGCA headquarters and regional offices. Any failing locks or disengaged tabs will require immediate replacement. Following this, DGCA may assess whether a mandatory Airworthiness Directive (AD) is needed—transforming the advisory from SAIB into enforceable regulation. These inspections may also become standard protocol in maintenance schedules. The Times of India+2AIRLIVE+2The Times of India+2

10. Wider Implications for Stakeholders

• Passengers find reassurance in improved safety standards and transparent action.

• Airlines gain clarity on risk mitigation but face routine maintenance adjustments.

• Pilots, as professional stakeholders, appreciate objective procedures over speculation.

• Insurers, financiers, and regulators benefit from reinforced risk control and trust.

Final Thoughts

By mandating comprehensive inspections, DGCA is sending a clear message: safety, not speculation, must guide aviation policy. Even if earlier advisories were non-mandatory, regulators are now prioritizing preventive oversight as part of a broader safety culture. As inspection outcomes become public, India’s aviation sector has an opportunity to strengthen its global reputation—ensuring every check and switch safeguards lives in the air.