Airlines Worldwide Alert Pilots to Fuel Control Switch Risks on Boeing 787s

After the tragic crash of Air India Flight AI171 on June 12, global airlines are taking no chances. The preliminary investigation pointed to a possible malfunction or mishandling of the fuel control switches on the Boeing 787-8 aircraft.

In response, airlines worldwide—including Abu Dhabi-based Etihad Airways and Singapore Airlines—have issued new directives urging pilots to exercise extreme caution with fuel control switches and have launched fleet-wide inspections of the locking mechanisms involved.

Etihad’s Precautionary Measures

Etihad Airways has taken the lead by issuing a formal bulletin to its pilots and engineering teams. The directive emphasizes caution during operation of fuel control switches on the Boeing 787 and highlights that these actions are being taken “out of an abundance of caution” as the official investigation into the Air India crash is still underway with no conclusive findings yet.

In a separate technical bulletin, Etihad has also instructed its maintenance crew to inspect the locking mechanism of the fuel switches installed on the 787 Dreamliner fleet. This inspection is focused on ensuring that the locking feature—which prevents accidental movement of the switch—is fully functional.

Detailed Inspection Protocol

The Etihad engineering bulletin outlines a step-by-step procedure to assess the integrity of the locking mechanism:

• Attempt to gently move the Left (L) fuel control switch from “CUTOFF” to “RUN” without lifting the switch.
• If the switch cannot be moved without lifting, the locking mechanism is confirmed functional.
• If the switch moves freely without lifting, it indicates a failed or disengaged locking feature, prompting an immediate replacement of the Throttle Control Module (TCM).

This directive is based on guidance previously shared by Boeing and the FAA’s 2018 Special Airworthiness Information Bulletin (SAIB), which first raised concerns about improperly engaged fuel switch locks in certain Boeing aircraft models.

Fuel Switches Under Global Scrutiny

The AI171 crash report suggested that both fuel control switches were moved to ‘CUTOFF’ just seconds after takeoff, leading to a total engine failure. While it is still unclear whether this occurred due to mechanical failure or human error, the Etihad directive brings renewed focus to the possibility of a design or mechanical issue with the fuel switch locking system.

Following Etihad’s lead, Singapore Airlines and other international carriers have also initiated checks across their Boeing 787 fleets to prevent any similar occurrences.

Conclusion

While the final report on the Air India tragedy is still awaited, Etihad’s proactive move highlights how one accident can trigger a global reassessment of safety protocols. As airlines ramp up inspections and brief their pilots, the aviation industry is once again reminded that in air safety, every switch, every lock—and every precaution—matters.

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