DGCA officials to witness testing of Air India 787 fuel-control switch module

India’s aviation regulator is preparing to send officials to Seattle to observe testing of a fuel-control switch module removed from an Air India Boeing 787 following a reported technical concern during a flight earlier this year.

According to Reuters, officials from the Directorate General of Civil Aviation (DGCA) plan to witness Boeing’s examination of the component at the aircraft manufacturer’s facility in Seattle as part of what Indian authorities have described internally as a “sensitive” matter.

The testing relates to a Boeing 787 flight operating between London and Bengaluru in February, during which pilots reportedly identified irregular behaviour involving fuel-control switches during engine start procedures.

The development has renewed attention on fuel-control switch systems aboard Boeing Dreamliner aircraft at a time when investigators are preparing a final report into last year’s fatal Air India 787 crash in Gujarat.

Fuel switches came under scrutiny after pilot observations

According to previously disclosed DGCA findings referenced by Reuters, pilots on the February Air India flight observed that the fuel-control switches did not remain fixed in the “run” position during the first two attempts when light vertical pressure was applied.

The switches reportedly stabilised on a third attempt before take-off proceeded normally.

Fuel-control switches on Boeing 787 aircraft regulate the flow of fuel into aircraft engines and are designed to remain locked in position unless deliberately moved through specific pilot actions.

The switches have drawn heightened scrutiny since preliminary findings linked to last year’s Air India crash indicated the fuel supply had been cut off to both engines almost simultaneously.

According to Reuters, the crash killed 260 people and became the world’s deadliest aviation accident in a decade.

Module sent to Seattle despite initial checks

The switch module involved in the February London-Bengaluru incident was initially examined and reportedly found “serviceable” by both Boeing and the DGCA.

Air India also stated that the component had been confirmed as “fully functional”.

Despite those findings, the module was later sent to Boeing’s Seattle facility for further technical examination.

Reuters reported that confidential internal emails showed the DGCA instructed Air India to ensure a regulator representative was present during testing.

According to the report, DGCA Deputy Director of Airworthiness Manish Kumar wrote in a March 9 email that the “strip/test examination” at Boeing’s premises should take place in the presence of a DGCA officer because “the matter is sensitive in nature”.

The regulator has not publicly elaborated on why the matter is considered sensitive.

Indian officials want closer review of locking mechanism

According to Reuters, Indian authorities now want to more closely examine the switch locking mechanism itself.

Officials reportedly plan to study whether external pressure applied at a particular angle could potentially move the switches while locked.

The additional testing is expected to take place in June.

Key details linked to the planned Seattle examination include:

• Component removed from an Air India Boeing 787 after a February London-Bengaluru flight
• DGCA officials expected to travel to Seattle for testing observation
• Examination to focus on fuel-control switch locking mechanism
• Testing scheduled around the anniversary of last year’s fatal Air India crash
• Air India reportedly covering travel costs for two DGCA officials

According to Reuters, Indian government officials described the move as part of efforts to conduct a “thorough” examination.

Boeing and regulators maintain no confirmed mechanical finding

The incident has also highlighted the distinction between precautionary examination and confirmed mechanical failure.

The U.S. Federal Aviation Administration has previously stated that last year’s Air India crash does not currently appear to have resulted from a mechanical issue.

Reuters earlier reported that recorded cockpit dialogue suggested one pilot may have cut fuel flow to the engines while the other pilot was flying the aircraft.

Those claims were strongly rejected by an Indian pilots’ union and by the captain’s father, both of whom called for broader independent investigation into possible causes.

Meanwhile, Air India stated that the Seattle testing is intended to ensure a “thorough and conclusive evaluation” of the component “as a measure of abundant caution”.

The airline added that the examination would involve controlled laboratory testing to definitively confirm the module’s performance and integrity.

Neither Boeing nor the DGCA publicly responded to Reuters’ requests for additional comment.

UK regulators had also reviewed the February incident

The February London incident had also drawn attention from the UK Civil Aviation Authority.

According to Reuters, UK authorities questioned why the flight proceeded despite the reported irregularity and why the issue was formally reported only after landing.

At the time, Air India reportedly informed UK authorities that the switch module had been checked and found serviceable.

Boeing later issued a service bulletin to Boeing 787 operators reminding airlines of existing operational procedures related to the switches, although the company did not issue new technical guidance.