I’ll not go any further than the investigation report that’s in the public domain. The Air India AI171 Boeing 787-800 Preliminary Report is published for all to read. The aircraft’s Enhanced Airborne Flight Recorder (EAFR) has been replayed. Sadly, this report raised questions as much as it closes down erroneous theories.
It warrants saying again, and again. My thoughts are with the friends and families of those affected. They deserve to know exactly what happened and as far as is possible, why. Not only that but the global travelling public need to be confident that any necessary corrective action is being taken to prevent a recurrence of such a rare fatal accident.
What requires a one or two words is one of the commonest ways we interact with electrical and electronic systems. The humble switch. In fact, they are far from humble and come in lots of shapes and sizes. The general idea is that a mechanical device, that can be manipulated with a purpose in mind, is used to control the flow of electrical current. There are non-mechanical switches, but I’ll not go there for the moment.
I remember conversations with my aircraft electrical engineering colleagues. It goes like this – you deal with the small currents (avionic systems), and we will deal with the big ones (power systems). Also, a mantra was that all electrical systems are, in part, mechanical systems. Switches, cables, generators, control valves, relays, bonding, you name it, they are in part, mechanical systems. In the past traditional electrical engineers got a but jittery when faced with “solid state” controls (semiconductors).
Switches. I’ve seen the words “cognitive engagement” used. In simpler terms, by design, pilots interact with switches with a purpose in mind. Equally, as in the world of human factors, unprotected switches can be operated in error, unintentionally or by physical force.
So, what are the chances of two protected Fuel Control Switches moving, within seconds of each other, at the most critical phase of an aircraft’s flight?
[There is a discussion to be had in respect of timing. Remember the record from the flight recorders is a sampling of events. The sampling rate maybe as low as one per second. Note: EASA AMC2 CAT.IDE.A.190.]
These cockpit switches are designed and certificated to perform as intended under specified operating and environmental conditions. That’s a wide range of vibration and temperature (shake and bake).
Switch operation is indicated by their physical position[1]. In addition, operation of these switches will be evident by cockpit indications. The concept being that a flight crew can confirm that the Fuel Control Switches have moved by their effect on the engines. If a crew need to take corrective action it is in relation to the information presented to them by the engine instrument system.
The report makes it clear that both mechanical switches transitioned from ‘RUN’ to ‘CUT-OFF’ almost immediately as the aircraft became airborne. That is a worst-case scenario. The time available to recognise and understand the situation, for training to kick-in, and then to take appropriate corrective action was insufficient.
This leads me to think that there may be a case for disabling the Fuel Control Switch function up until at least an altitude where aircraft recovery is possible. Now, these switches need to be available up until the V1 speed is achieved (Example: aborting a take-off with an engine fire). After that an aircraft is committed to becoming airborne.
I suspect the reason there is no inhibit function is the possibility of adding another potential failure condition. Inadvertent and unrecoverable disabling of ‘CUT-OFF’ are scenarios that would need to be considered. No doubt a reasonableness argument was used. No crew would shut-down both engines down immediately an aircraft became airborne, would they?
POST: I hope I haven’t given the impression that this is a case of simple switches and wires. The Boeing 787 is a digital aircraft. Mechanical fuel technology plays its part but control functions are digital.
[1] Designs that offer switch illumination are not used in this case.
John Vincent 