FAA Says Boeing 787 Fuel Cutoff Switches Are Safe

A couple of days ago, India’s Aircraft Accident Investigation Bureau (AAIB) released its preliminary report into the tragedy of Air India flight AI171, the Boeing 787-8 that crashed seconds after taking off from Ahmedabad, killing 260 people.

The preliminary report simply shares the facts as they’re known, and doesn’t draw any conclusions. That being said, the United States’ Federal Aviation Administration (FAA) has just released a memo about the Boeing 787 fuel control switches, which is pretty telling…

FAA suggests fuel control switches were moved manually

As a reminder, the investigation into the crash of AI171 is centered around the aircraft’s fuel control switches. Investigators know that these were moved from the “RUN” to “CUTOFF” position just moments after takeoff, one second apart.

Ordinarily, these switches are only moved on the ground when starting or stopping engines, or in the air during an emergency. However, you’d never use them just seconds after takeoff, when there are no signs of engine issues, since there’s no chance to recover at such a low altitude.

In the cockpit voice recorder, one of the pilots was “heard asking the other why did he cutoff,” and “the other pilot responded that he did not do so.”

So anyway, one big question has been whether a human actually manually moved these switches, or whether there was some horrible technical or mechanical failure that somehow caused the switches to move positions.

While the AAIB has been leading the investigation, the FAA has been providing technical support, so is always aware of the details of the investigation. When there was talk of something involving the fuel control switches, some people pointed out a December 2018 Special Airworthiness Information Bulletin (SAIB), regarding potential disengagement of the fuel control switch locking feature on Boeing 737s, based on reports that the fuel control switches were installed with the locking feature disengaged.

However, that doesn’t appear to be the case here. Per the document:

Although the fuel control switch design, including the locking feature, is similar on various Boeing airplane models, the FAA does not consider this issue to be an unsafe condition that would warrant an Airworthiness Directive on any Boeing airplane models, including the Boeing 787.

In other words, the FAA seems confident that the fuel control switches as such are safe. I don’t think that’s terribly surprising, though it really only leaves one other explanation…

Why did a human move the fuel control switches?

With the FAA essentially confirming that there’s nothing wrong with the Boeing 787’s fuel control switches, that makes it pretty clear that investigators believe this accident happened because a human moved the switches. The question is, why would a human move the switches to “CUTOFF,” when that was guaranteed to send the plane straight into the ground?

It’s hard to envision a scenario where this was done accidentally, especially just a few seconds after takeoff, during the most critical phase of the flight. I would imagine the information that hasn’t been released yet is probably pretty telling.

As of now, the only thing we know about the conversation between the two pilots is how “in the cockpit voice recording, one of the pilots is heard asking the other why did he cutoff,” and “the other pilot responded that he did not do so.” I think the next interesting details will be:

  • What was the conversation before and after that happened?
  • Was it the captain or first officer asking that question?

With the first officer being the pilot flying and the captain being the pilot monitoring, the captain would’ve been the one more likely in a position to move these switches without it being super obvious (since the pilot flying is using both hands, initially for the yoke and thrust, and then just for the yoke). That assumes there was no one else in the flight deck (and there’s no mention of anyone else in the flight deck in the preliminary report).

It’s hard to imagine any situation in which this could happen by accident, especially if the (much more experienced) captain was the one who moved the switches…

Bottom line

The FAA has released a memo reassuring airline operators that there are no issues with the Boeing 787 fuel control switches, since those switches are the center of the investigation into Air India’s 787-8 crash. I don’t think this is terribly surprising, but it’s also a good clue that the investigation is likely centered around the human factors here, rather than some horrible design flaw that could impact other flights.

What do you make of this FAA memo, and its implications?

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H8TE2SAITOLDUSO Guest

I called this from Day 1. Terrorism or sabotage!

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Gesot Guest

It’s become absolutely ridiculous — they’re treating us like lobotomized fools. The worst part is that they are tarnishing the reputation of professionals who cannot defend themselves. I can’t understand why the scenario in which the pilot monitoring performed the first step of the memory item — “Fuel control switches… CUTOFF THEN RUN” — has been completely ruled out. That is the first action a pilot is supposed to take after losing both engines. In the entire history of aviation, no one in the final seconds of their life has ever lied or pretended. How can anyone believe such a scenario?Isn’t it far more plausible that both FADECs failed? Especially considering the FAA itself issued a bulletin warning that if full FADEC resets are not performed after a certain number of hours, they could spontaneously reboot at any phase of flight? Soon they’ll probably “find” a suicide note too — just like they dragged the name of the Malaysian captain through the mud with the claim that he supposedly rehearsed the route in his home simulator. And yet, the theory goes that he wanted his family to collect insurance — but somehow kept the “evidence” on his own personal computer? Even in the case of the 787 incident, the supposed suicidal pilot allegedly said, “Let me shut down both engines during takeoff and see what happens,” and handed control to the co-pilot. Wouldn’t it have been easier to just crash the plane himself? Have we forgotten that in the Hudson incident, they initially tried to blame Sully too? Yet video footage — an irrefutable witness — shows a stable attitude, controlled flight, and the crew clearly doing their best under impossible circumstances. There was no sign of erratic inputs or panic. And let’s be honest — no one expects Boeing to be shut down. That would trigger chaos in the global economy. But let’s not insult the intelligence of professionals and the public just to protect the image of a corporation.

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Watson Diamond

Even if a deliberate act by a pilot, that doesn't mean there aren't things that can be improved. Humans are always the weakest link in any system, and any good engineer knows that the system's design must mitigate that to the extent possible. For example, make the left engine fuel switch reachable only by the captain, and the right engine fuel switch reachable only by the copilot. That way a pilot cannot unilaterally cut fuel to both engines. Or lock the switches entirely for the first 2 minutes of flight time.

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Mark Guest

@echino No, it cant be done. If you get a major engine problem, such as an engine fire or a big bird strike causing massive vibration, it must be put to CUTOFF. But moving any of them require both pilots agree its the right one. Inhibit pilots of cutting off the fuel cant be done.

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John Guest

Isn't the most telling remark from the interim report that (among other experts) they will be taking advice from an "aviation psychologist"? A loose switch doesn't need a psychologist but a pilot's actions / state of mind does

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