Blog 3.
Real Engine Room Incidents and How They Were Handled
Introduction
The engine room of a vessel is the heart of its operations, powering the ship through complex machinery and systems. However, it’s also a high-risk environment where incidents can escalate quickly, threatening safety, operations, and the environment. Real engine room incidents provide critical lessons for engineers and crew, highlighting the importance of preparedness, quick thinking, and adherence to safety protocols. This blog explores several documented engine room incidents, their causes, how they were handled, and the lessons learned to prevent recurrence. Drawing from maritime reports, industry guidelines, and best practices, we’ll analyze these events to offer actionable insights for marine engineers.
Incident 1: Main
Engine Failure Due to Fuel Contamination
Incident Overview
In 2018, a bulk carrier experienced a sudden main engine failure while navigating a busy shipping lane. The vessel lost propulsion, drifting dangerously close to a reef. The investigation revealed that the fuel oil supplied during the last bunkering contained water and sediment, clogging the fuel filters and causing fuel starvation.
How It Was Handled
• Immediate Response: The chief engineer ordered an emergency stop of the main engine to prevent further damage. The bridge was informed, and the vessel dropped anchor to avoid grounding.
• Troubleshooting: The engine room crew switched to an auxiliary fuel tank with clean fuel, bypassing the contaminated supply. They drained and cleaned the affected fuel filters and purifiers under time pressure.
• Temporary Fix: After purging the fuel system, the crew restarted the main engine at reduced power to navigate to a safe anchorage.
• Post-Incident Actions: The vessel arranged for fuel testing at a certified lab, confirming water contamination. The contaminated fuel was offloaded, and the supplier was held accountable. The crew implemented stricter fuel testing protocols, including pre-bunkering samples and onboard water detection tests.
Lessons Learned
• Fuel Quality Control: Always test fuel samples before bunkering using portable kits or lab analysis.
• Emergency Preparedness: Maintain spare filters and a reserve of clean fuel for emergencies.
• Communication: Swift coordination between the bridge and engine room prevented a grounding incident.
• Documentation: Detailed logs of the incident and fuel tests supported insurance claims and supplier disputes.
Incident 2: Engine
Room Fire Due to Oil Leak
Incident Overview
In 2020, a container ship reported a fire in the engine room caused by a high-pressure fuel oil leak from a cracked pipe. The leak sprayed onto a hot exhaust manifold, igniting immediately. The fire caused significant damage but was contained before spreading to other compartments.
How It Was Handled
• Fire Suppression: The crew activated the fixed CO2 fire suppression system after evacuating the engine room, extinguishing the fire within minutes.
• Damage Assessment: After ensuring the area was safe, the chief engineer led a team to inspect the damage. They isolated the affected fuel line and secured the area.
• Temporary Repairs: The crew replaced the cracked pipe with a spare and rerouted fuel lines to restore partial engine functionality.
• Investigation: The root cause was traced to a fatigue crack in the pipe, exacerbated by vibrations and inadequate maintenance checks. The crew implemented a revised maintenance schedule for high-pressure fuel systems.
• Regulatory Compliance: The incident was reported to the flag state and port authorities, with a full investigation conducted to meet International Safety Management (ISM) Code requirements.
Lessons Learned
• Preventive Maintenance: Regular ultrasonic testing of high-pressure pipes can detect cracks early.
• Fire Drills: Frequent fire drills ensured the crew’s quick response and familiarity with CO2 systems.
• Hot Work Precautions: Insulate hot surfaces like exhaust manifolds to reduce ignition risks.
• Incident Reporting: Accurate reporting to authorities and the company’s Designated Person Ashore (DPA) ensured compliance and support.
Incident 3: Blackout
Due to Generator Failure
Incident Overview
A passenger ferry experienced a total blackout in 2019 while approaching a port, caused by the simultaneous failure of two auxiliary generators. The vessel lost steering and navigation systems, creating a high-risk situation in a congested area.
How It Was Handled
• Emergency Power: The crew activated the emergency generator, restoring critical systems like steering and navigation within minutes.
• Root Cause Analysis: The engineering team found that the generators failed due to a faulty governor control system, which caused overloading and tripping.
• Temporary Solution: The crew manually adjusted the load sharing between generators and restarted one auxiliary generator to regain full power.
• Permanent Fix: At the next port, the governor control system was repaired, and all generators were tested under load. The crew also implemented a more robust Planned Maintenance System (PMS) for generator controls.
• Training: The company introduced additional training on load management and blackout recovery.
Lessons Learned
• Redundancy Checks: Regularly test emergency generators and ensure they’re ready for immediate use.
• Load Management: Train engineers on proper load-sharing techniques to prevent generator overloads.
• PMS Adherence: Follow the PMS strictly for critical systems like governors and circuit breakers.
• Simulation Drills: Conduct blackout recovery drills to prepare the crew for real scenarios.
Incident 4: Turbocharger Failure Leading to Reduced Power
Incident Overview
In 2021, a tanker experienced a turbocharger failure on its main engine, reducing propulsion power during a transatlantic voyage. The failure was caused by bearing wear due to inadequate lubrication.
How It Was Handled
• Initial Response: The chief engineer reduced engine speed to minimize stress on the damaged turbocharger and prevent further degradation.
• Diagnostics: The crew inspected the turbocharger and found excessive bearing play and oil starvation. They switched to a standby turbocharger (available on this vessel) to restore power.
• Repairs: At the next port, the damaged turbocharger was overhauled, and the lubrication system was flushed to remove contaminants.
• Preventive Measures: The crew revised the lubrication oil sampling schedule to include more frequent turbocharger oil tests and installed vibration sensors for early detection of bearing issues.
Lessons Learned
• Lubrication Maintenance: Regularly sample and test lube oil for contaminants and viscosity.
• Spare Parts: Maintain critical spares like turbocharger bearings or a standby unit for quick swaps.
• Monitoring Systems: Install sensors to detect vibrations or temperature anomalies in turbochargers.
• Crew Training: Ensure engineers are trained to recognize early signs of turbocharger distress.
Best Practices for Preventing and Handling Engine Room Incidents
• Proactive Maintenance: Follow a robust PMS, including regular inspections of fuel systems, pipes, generators, and turbochargers. Use predictive maintenance tools like vibration analysis and thermal imaging.
• Crew Training: Conduct regular drills for fire, blackout, and propulsion loss scenarios. Ensure all engineers are familiar with emergency procedures and equipment.
• Documentation: Maintain detailed logs of maintenance, incidents, and repairs to comply with ISM requirements and support investigations.
• Safety Culture: Foster a culture where crew members report near-misses and potential hazards without fear of blame.
• Technology Integration: Use condition-monitoring systems and real-time diagnostics to catch issues early.
• Supplier Vetting: Work with reputable fuel and spare parts suppliers to avoid quality issues.
Conclusion
Engine room incidents, while challenging, provide invaluable lessons for improving safety and operations. By analyzing real cases like fuel contamination, fires, blackouts, and turbocharger failures, engineers can adopt proactive measures to prevent recurrence. Key takeaways include rigorous maintenance, thorough training, and swift, coordinated responses. By embedding these lessons into daily operations, vessels can enhance safety, compliance, and reliability, ensuring smooth voyages even in the face of adversity.