Engine Accident Report: The Best Analysis of an Unforeseen Incident

Engine Accident Report

Hi there!
In this post, we’re looking at a real story that happened at a place where they make stuff. It’s a reminder to be super careful when moving engines and always follow the safety rules. We’ll chat about what happened, why being safe matters so much, and what we can take away from it. After you read about this incident, you’ll see why safety matters a lot. You’ll also get smart tips for staying safe if you’re in similar situations. Now, let’s get into the story and learn from this report about the engine accident. It’s about taking care of ourselves and everyone else too!

Engine Fallen from Trailer

In this real incident, which happened at a factory, a machine mishap occurred during a shifting process. The staff at the refinery had the task of moving a DG set from their storage area to the power plant site. Unfortunately, the DG set fell from the trailer during transit due to inadequate securing measures.
Neglecting to ensure a sturdy arrangement for loading and securing the DG set on the trailer led to this unfortunate accident.
The importance of correct equipment handling, fastening methods, and strict adherence to safety regulations are highlighted by this event.

Following these steps could have avoided the accident.

To ensure a safe equipment shift, follow these steps:

1. Ground Preparation: Level the loading area, compact jack base, and place plates for even load distribution.
2. Proper Securing: Secure the machine on the trailer to prevent falling.
3. Trailer Positioning: Bring the trailer near the unloading point.
4. Wheel Wedges: Use wedges to prevent trailer movement during unloading.
5. Crane Placement: Position the crane beside the trailer.

All these instructions are crucial and must be followed.

The road was uneven and had ditches and broken sections. During shifting, the tilted trailer caused the DG to slide and fall due to the uneven road. Thankfully, no one was hurt. However, the fall led to significant damage to the DG’s components.

Damages in the Engine

Visual inspection of the Diesel generator revealed the following apparent damages.

1. Exhaust Pipe Assembly;- The internal parts of the pipe ( Exhaust pipe piece and compensator) were broken. Need replacement.
2. Pre- Lubricating Oil Pump;- There were visible crack marks on the pump housing. Other damages to the internal parts were also anticipated.
3. Pre- Heater; The pre-heater was found broken, and internal electrical parts also suffered damage. The complete pre-heater needs replacement.
4. Cylinder head Stud & Hydro Nut;– There is a speculation of impact on the integrity of stud hydraulic nuts. Therefore there were strong recommendations for replacement of all the nuts and studs.
5. Engine Elastic Mountings;- Due to the impact of the engine fall from the trailer, there are chances of elastic mountings damage. All the components need inspection for any damage to the individual parts (Rubber and metallic). A damaged part of the elastic mounting needs replacement.
6. Lubricating oil cooler;- The hydraulic test of the cooler must be undertaken. Change the components or replace the cooler if found beyond the economical repairs.
7. Fuel oil inlet filter;- From the pictures of the accident fuel inlet parts, a few parts of the fuel oil filter are visible with damage and cracks. The complete fuel filter assembly needs replacement.
8. Cylinder Head;- Carry out the hydro and NDT (MGT) test of the cylinder heads and replace the damaged cylinder head.
9. Air Cooler;- Subject the air cooler to hydro test
10. Turbocharger;- Carry out the overhauling of Turbocharger. Overhauling of the turbocharger is to be accomplished by the manufacturer of the Turbocharger. Change the parts as per the advice of the Turbocharger expert.
11. Crankshaft;– Carry out the runout NDT (MPT) and dimensional check of the crankshaft. This check is to be carried out in the OEM’s factory. The crankshaft is to be sent to the factory.
12. Base Frame; A dimensional check of the base frame needs to be carried out. This test is to be carried out in the Base frame manufacturer’s factory. The base frame needs to be sent to the base frame manufacturer.

Manufacturer’s Recommended Inspections and Replacements

Perform the inspections and tests on various components as needed:

1. Flywheel cover
2. Governor drive assembly
3. Turbocharger support
4. Flywheel
5. Front end block
6. Oil throw ring
7. Sealing ring
8. Camshaft
9. Cam thrust case
10. Main bearings
11. Main bearing/Thrust bearing cap
12. Main bearing stud bolt, side bolts
13. Con-rod housing and con-rod bearing
14. Camshaft bearings
15. Thrust washer
16. Crank-gear
17. Idle gear
18. Cam gear
19. Pump drive gear
20. Fuel injection pumps
21. Drive for Fuel Injection Pump
22. Pistons (all tests)
23. Connecting Rod
24. Cylinder liner
25. Push rod
26. Flame ring
27. Air inlet box
28. Torsional Vibration damper
29. Cam/Crankcase cover and relief valve
30. Fuel oil high-pressure block
31. Fuel oil, Lube oil, Cooling water pipelines
32. Turning gear
33. FIP cover
34. Centrifugal oil filter
35. Swing arm roller
36. Starting motor
37. Gallery
38. Flywheel stud bolt
39. Lube oil filter
40. Lube oil, High-temperature water, and Low-temperature water pumps.
41. Speed sensor
42. Lube oil supply tank level switch
43. Fuel oil linkage level switch

The following sensors and instruments need to be replaced after the required checks and tests mentioned against their name. Even if there is no crack appears, an abnormality may occur due to the small internal crack. Therefore all electrical and instrumentation parts need to be replaced.  Cabling will be required due to the breakage or replacement of the parts. Damaged tray reproduction, re-fitting, and re-support will be required.

• Exhaust gas for each cylinder outlet temperature sensor- remove each individual cylinder and subject to calibration.
• Exhaust gas turbocharger inlet temperature sensor;- Subject the sensor to calibration.
• Exhaust gas turbocharger outlet temperature sensor;- carry out the calibration
• Main bearing temperature sensor
• Fuel oil, Lubricating oil, cooling water, and Air pressure sensor

Replace the following instruments

1. Arrangement of Starting Box / Terminal Box: Ensure the proper replacement of the starting box or terminal box, guaranteeing the correct connections for effective engine starting.
2. Governor: Install a new governor to maintain precise engine speed control and optimal performance.

What is an accident report?

An Engine Accident Report is similar to a story about an engine problem. It could discuss details like how the engine was running, its usage, and safety measures. Engineers, mechanics, and those who use engines find these reports helpful. In the end, an engine accident report is all about making engines better, keeping them in good shape, and most importantly, making sure they are safe for everyone.
A document known as an accident report contains information regarding accidents, including their type and how they occurred.

Blog Conclusion

We hope you enjoyed our article The Assessment of Accidental Engine Damage. We want to thank you for taking the time to read our blog post. We are always excited when one of our posts is able to provide useful information on a topic like this! If you have any additional questions about The Assessment accidental Engine Damage, please don’t hesitate to reach out to us at the address in the blog post. Thank you for reading!

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