03 Marine Accidents

1. 03 Marine Accidents Oil leak from fuel pump return line MARS Report 201038

2. A. Introducing new vocabulary • UMS mode • duty engineer • engine top, middle and lower platforms • flywheel • ventilation blowers • oil mist • source of the leak

3. 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

4. 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

5. 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

6. turbo-charger air intake

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

8. Reading skills B.1 Reading for gist: Read the text and discuss with your partner the main idea of the text.

9. 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 engineroom. 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.

10. C.1 Vocabulary Development(a) Choosethe 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).

11. Complete the text below • The vessel was en route and operating…………… . • The duty engineer entered the engine room at 06:50 to …………… . • He discoveredfuel oil sprayingaround • …………… ., • …………… ., • as well as…………… .. • Underthe 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 …………… ..

12. It wassoonestablishedthat the leakoriginatedfrom a failedjoint at a pipelineflangeon a fuelpump oil return line. It wasalsoobservedthat the joint and the fuelpumpinlet pipe bosseswerenotcoveredwithapprovedsplash prevention screening, as requiredunderSolas. Thiswasapparentlydue to anoversight in the case of the flange and due to the awkwardshapes of the castings on the fuelpumpbody. Allfuel oil inlet and returnpipeswerecheckedand it wasfoundthat some of the boltsrequiredabouthalf a turn of the nuts to obtainpropertightness.

13. Supply the right term • It wassoonestablishedthat the leakoriginatedfrom a failed _______ at a pipelineflangeon a _______oil return line. • It wasalsoobservedthat the joint and the fuelpumpinlet pipe _______ werenotcoveredwithapprovedsplash prevention _______ , as requiredunderSolas. • Thiswasapparentlydue to an_______ in the case of the flange and due to the awkwardshapes of the _______ on the fuelpumpbody. • Allfuel oil inlet and returnpipeswerecheckedand it wasfoundthat some of the _______requiredabouthalf a turn of the _______ to obtainpropertightness.

14. MCT - Supply the right term: • It wassoonestablishedthat the leakoriginatedfrom a failed (lever, point, joint) at a pipelineflange on a fuelpump oil return (mine, line, gear). • It wasalsoobservedthat the joint (which had beenopenedduring a recentdrydocking) and the fuelpumpinlet pipe (booms, bosses, bores), werenotcoveredwithapprovedsplash prevention screening, as requiredunderSolas. • Thiswasapparentlydue to anoversight in the case of the (range, cage, flange) and due to the awkwardshapes of the castings on the fuelpumpbody. • Allfuel oil inlet and returnpipeswerecheckedand it wasfoundthat some of the (joints, bolts, bosses) requiredabout half a turn of the nuts to obtainpropertightness.

15. Complete thetext below • The …. ….. …. found a leak on a fuelpump oil return line. • The leakoriginatedfrom a failedjoint …. ….. …. flange on a …. ….. …. . • It wasalsoobservedthat the joint and the fuelpumpinlet pipe bosseswerenotcoveredwith …. ….. …. , as requiredunderSolas. • Thiswasapparentlydue to anoversight in the case of the flange and due to the awkwardshapes of …. ….. …. . • Allfuel oil inlet and returnpipeswerecheckedand it wasfoundthat some of the boltsrequiredabout …. ….. …. to obtainpropertightness.

16. 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.

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

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

19. 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).

20. 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).

21. Follow-up. Wall dictation. • Practising the four communicative skills. (four groups, four runners)

22. 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. 

23. 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. 

24. 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 sprayingaround 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.

25. 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 bosseswere not covered with approvedsplash prevention screeningas 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 boltsrequired about half a turn of the nuts to obtain proper tightness.