03 Marine Accidents

Oil leak from fuel pump return line MARS Report 201038

A. Introducing new vocabulary

• UMS mode • duty engineer • engine top, middle and lower platforms• flywheel• ventilation blowers• oil mist• source of the leak

• inlet pipe bosses, boss : an area of increased thickness, usually cylindrical, that strengthens or provides room for a locating device on a shaft, hub of a wheel, etc

• pipeline flange• fuel pump oil return line• fuel pump inlet pipe boss• splash preventing screening • oversight• fuel oil inlet and return pipes• bolt – tighten / tightness

• screeening : a spray seal ; a strip/layer of wood, plaster, or metal placed on a surface to act as a guide to the thickness of the cement or plaster coat to be applied

turbo-charger air intake

• oil mist• oil leak• failed joint - connection• bolts

Reading skills

B.1 Reading for gist: Read the text and discuss with your partner the

main idea of the text.

Oil leak from fuel pump return line MARS Report 201038

• The vessel was en route and operating in UMS mode. The duty engineer entered the engine room at 06:50 to man the engine room. He discovered fuel oil spraying around the main engine top, middle and lower platforms, as well as around the flywheel area. Under the influence of the main engine turbo-charger air intake and the engine room ventilation blowers, the oil mist was being carried right across the machinery space, increasing the fire hazard. The main engine was immediately stopped and the ship's engineers began the job of tracing the source of the leak.

C.1 Vocabulary Development(a) Choose the right term (MCT):

•The vessel was en route and operating in UMS (model, mode, make). •The duty engineer entered the engine room at 06:50 to man the engine room and discovered fuel oil (spreading, splashing, spraying) around the main engine top, middle and lower platforms, as well as around the flywheel area. •Under the influence of the main engine turbo-charger air (intake, input, inflow) and the engine room ventilation blowers, the oil mist was being carried right across the machinery space, (decreasing, increasing, causing) the fire hazard. •The main engine was immediately stopped and the ship's engineers began the job of tracing the source of the (lead, leak, read).

Complete the text below

• The vessel was en route and operating …………… . • The duty engineer entered the engine room at 06:50

to …………… .• He discovered fuel oil spraying around

…………… ., …………… ., as well as …………… ..

• Under the influence of the main engine turbo-charger air intake and the engine room ventilation blowers, the oil mist …………… ., increasing the …………… .

• The main engine was immediately stopped and the ship's engineers began the job of …………… ..

It was soon established that the leak originated from a failed joint at a pipeline flange on a fuel pump oil return line. It was also observed that the joint and the fuel pump inlet pipe bosses were not covered with approved splash prevention screening, as required under Solas. This was apparently due to an oversight in the case of the flange and due to the awkward shapes of the castings on the fuel pump body. All fuel oil inlet and return pipes were checked and it was found that some of the bolts required about half a turn of the nuts to obtain proper tightness.

Supply the right term• It was soon established that the leak originated from a

failed _______ at a pipeline flange on a _______ oil return line.

• It was also observed that the joint and the fuel pump inlet pipe _______ were not covered with approved splash prevention _______ , as required under Solas.

• This was apparently due to an _______ in the case of the flange and due to the awkward shapes of the _______ on the fuel pump body.

• All fuel oil inlet and return pipes were checked and it was found that some of the _______ required about half a turn of the _______ to obtain proper tightness.

MCT - Supply the right term:• It was soon established that the leak originated from a failed

(lever, point, joint) at a pipeline flange on a fuel pump oil return (mine, line, gear).

• It was also observed that the joint (which had been opened during a recent drydocking) and the fuel pump inlet pipe (booms, bosses, bores), were not covered with approved splash prevention screening, as required under Solas.

• This was apparently due to an oversight in the case of the (range, cage, flange) and due to the awkward shapes of the castings on the fuel pump body.

• All fuel oil inlet and return pipes were checked and it was found that some of the (joints, bolts, bosses) required about half a turn of the nuts to obtain proper tightness.

Complete thetext below• The …. ….. …. found a leak on a fuel pump oil return line.• The leak originated from a failed joint …. ….. …. flange on a

…. ….. …. . • It was also observed that the joint and the fuel pump inlet

pipe bosses were not covered with …. ….. …. , as required under Solas.

• This was apparently due to an oversight in the case of the flange and due to the awkward shapes of …. ….. …. .

• All fuel oil inlet and return pipes were checked and it was found that some of the bolts required about …. ….. …. to obtain proper tightness.

Supply the right term: The vessel was en route and operating in UMS ( __________). The duty engineer entered the engine room at 06:50 to man the engine room and discovered fuel oil (__________) around the main engine top, middle and lower platforms, as well as around the flywheel area. Under the influence of the main engine turbo-charger air (__________) and the engine room ventilation blowers, the oil mist was being carried right across the machinery space, (__________) the fire hazard. The main engine was immediately stopped and the ship's engineers began the job of tracing the source of the (__________).It was soon established that the leak originated from a failed (__________) at a pipeline flange on a fuel pump oil return (__________). It was also observed that the joint (which had been opened during a recent drydocking) and the fuel pump inlet pipe (__________), were not covered with approved splash prevention screening, as required under Solas. This was apparently due to an oversight in the case of the (__________) and due to the awkward shapes of the castings on the fuel pump body. All fuel oil inlet and return pipes were checked and it was found that some of the (__________) required about half a turn of the nuts to obtain proper tightness.

B2. Reading for specific information. Read the text and answer the following questions:

In what mode was the vessel operating?

What did the duty engineer discover when he entered the engine room?

Where was the fuel oil spraying? (four areas)

In which direction was the oil mist carried?

What kind of possible risk or hazard was the oil mist causing?

What did the engineers do after stopping the engine?

What should the inlet pipe bosses be covered with (under SOLAS convention)?

What did the engineers/ratings do during the recent drydocking?

Describe the word „oversight“. What does it refer to?

What did the engineers have to check?

What did they find after checking?

Listening skills – Listening for specific information. Listen to the text and supply the missing words or

parts of the text :The vessel was en route and operating ___________. The duty engineer entered the engine room at 06:50 to man the engine room and discovered ______________ around the main engine top, middle and lower platforms, as well as around the flywheel area. Under the influence of the main engine turbo-charger air intake and the engine room ventilation blowers, the oil mist was being carried right _______________, increasing the fire hazard. The main engine was immediately ___________ and the ship's engineers began the job of tracing the _________________.It was soon established that the leak originated from a _____________ at a pipeline flange on a fuel pump oil return line. It was also observed that the joint (which had been opened during a recent drydocking) and the fuel pump inlet pipe bosses were not covered with approved splash prevention screening, as required _____________ . This was apparently due to ___________ in the case of the flange and due to the awkward shapes of the castings on the fuel pump body. All fuel oil inlet and return pipes were checked and it was found that some of the bolts required about ___________ of the nuts to obtain proper tightness.

Filler: Meaning guessing game:

• (four students, leaders of their groups, sit back to the screen (blackboard) and guess (shout out the meaning of the newly acquired term, written on the screen by the teacher).

GrammarSupply the the verb in brackets in the right

place in the text:The vessel was en route and in UMS mode (operating). The duty engineer the engine room at 06:50 (entered) to man the engine room and fuel oil spraying around the main engine top (discovered), middle and lower platforms, as well as around the flywheel area. Under the influence of the main engine turbo-charger air intake and the engine room ventilation blowers, the oil mist was being carried right across the machinery space (was being carried), increasing the fire hazard. The main engine was immediately stopped and the ship's engineers began the job of tracing the source of the leak (began).It was soon established that the leak originated from a failed joint at a pipeline flange on a fuel pump oil return line (originated). It was also observed that the joint (which had been opened during a recent drydocking) and the fuel pump inlet pipe bosses were not with approved splash prevention screening (covered), as under Solas (required). This was apparently due to an oversight in the case of the flange and due to the awkward shapes of the castings on the fuel pump body (was). All fuel oil inlet and return pipes were (checked) and it was found that some of the bolts required about half a turn of the nuts to obtain proper tightness (obtain).

• Practising the four communicative skills. (four groups, four runners)

Follow-up. Wall dictation.

Damage to engine crankshaft and connecting rod MARS Report 201044

The vessel was en route to a loading port, when the chief engineer commenced routine maintenance of no. 1 auxiliary engine, as per the maintenance programme. On opening the crankcase, a crack was found in no. 1 unit cylinder liner, from where jacket cooling water was found to be leaking into the crankcase. This liner was replaced by a spare one. Additionally, all the main bearings were found to be worn out excessively and these were also renewed from ship's spares. No. 5 unit crankpin bearing was found to be damaged and the ship's staff renewed this as well. However, no systematic investigation was made to ascertain the reasons for these serious defects. Ovality measurements for connecting rods or readings of the crankpins were not checked at this stage for any of the units, especially no. 5, the one with the severely damaged bearing.

• The engine was assembled and tested but had to be stopped immediately when loud knocking sounds were heard from the crankcase. On re-inspection, the newly fitted no. 5 crankpin bearing was found to have seized and the crankpin was deeply scored. Instead of conducting a proper investigation to determine the causes for the repeated failure of this bearing, the chief engineer attempted to 'repair' the crankpin by means of emery tape and files, which only caused more damage. At this stage, the chief engineer informed the office about the breakdown and repair work in progress. The office immediately instructed him to measure and report on the ovality of all connecting rod ends. These were all found to be beyond acceptable limits, thus all connecting rods were found unusable. As no. 5 crankpin was seriously damaged, the crankshaft was found beyond use and had to be scrapped.

• As a result of the ship's staff's not observing the maker's maintenance instructions and poor engineering practice, the company incurred an unplanned expenditure of nearly US$ 100,000.

Auxiliary blower failure MARS Report 200907

•While approaching the pilot station of a port with a relatively difficult approach, the sudden failure of the main engine auxiliary blowers resulted in imminent danger due to the close proximity of rocky shoals. A Lloyd's open form (LOF) was signed in haste and salvage tugs were called for immediate assistance. A serious casualty was averted, the vessel anchored safely and both blowers were repaired with shore assistance.

• On investigation, the following facts came to light. Both blowers had been used occasionally for several days prior to approaching port. This was due to insufficient scavenge pressure resulting from inferior fuel from one particular bunker tank. While trying out engines before entering port limits, no.1 blower bearings seized and the motor windings burnt out. At the same time, no.2 blower motor was checked and the insulation was observed to be zero. Despite this, the crew felt that the blower could be operated for the short distance to the berth and the master decided to proceed to embark the pilot with only no.2 auxiliary blower in operation.

• Unfortunately, immediately after the pilot boarded, no. 2 blower motor also burnt out and vessel's main engine was immobilised, leading to an emergency situation.

• Mariners should take note that the auxiliary blowers are meant to be used only during starting and low RPM manoeuvring, when the turbochargers cannot deliver the minimum required scavenge pressure to ensure efficient combustion. Should there be any need to use an auxiliary blower under normal sea speed, it is a definite indication of a fault in the scavenge system and immediate attention to identify and rectify this is needed. Auxiliary blowers are vital for main engine manoeuvring and their planned maintenance schedules should never be compromised.

• Root cause• The crew grossly underestimated the risk involved in attempting to run the blower with zero motor insulation

while proceeding to pick up the pilot in closed waters. •

Oil leak from fuel pump return line MARS Report 201038

• The vessel was en route and operating in UMS mode. The duty engineer entered the engine room at 06:50 to man the engine room and discovered fuel oil spraying around the main engine top, middle and lower platforms, as well as around the flywheel area. Under the influence of the main engine turbo-charger air intake and the engine room ventilation blowers, the oil mist was being carried right across the machinery space, increasing the fire hazard. The main engine was immediately stopped and the ship's engineers began the job of tracing the source of the leak.

• It was soon established that the leak originated from a failed joint at a pipeline flange on a fuel pump oil return line. It was also observed that the joint (which had been opened during a recent drydocking) and the fuel pump inlet pipe bosses were not covered with approved splash prevention screening as required under Solas. This was apparently due to an oversight in the case of the flange and due to the awkward shapes of the castings on the fuel pump body. All fuel oil inlet and return pipes were checked and it was found that some of the bolts required about half a turn of the nuts to obtain proper tightness.