Marine Accidents Case Study: The Best Study of 24

Marine Accidents Case Study

In this insightful case study, we examine a real incident that underscores the critical importance of secure handling and transportation practices. At a refinery, an unfortunate mishap occurred when a DG (Diesel Generator) set, meant to be relocated from storage to a power plant site, fell off its trailer during transit. The accident was traced back to inadequate securing measures, as the DG set was not properly fastened, leading to a serious safety lapse.

This incident serves as a powerful reminder of the essential role of correct equipment handling, secure fastening techniques, and strict adherence to safety protocols in preventing accidents. By studying such cases, marine and industrial professionals can gain valuable insights into avoiding similar risks and ensuring safer operations, emphasizing that minor oversights can have significant consequences in high-stakes environments like marine and industrial settings.

Engine Fallen from Trailer: A Case of Improper Handling and Transportation

In a recent incident at a refinery, an engine fell from a trailer due to inadequate securing and a lack of expertise in the shifting process. The refinery staff, attempting to move the engine on their own without consulting experts or the Original Equipment Manufacturer (OEM) representative, loaded the engine onto the trailer but did not properly secure it. The uneven road surface, with multiple ditches and bumps, added further risk to the operation.

As the trailer navigated this challenging route, it tipped to one side, causing the engine to slide and ultimately fall from the trailer. This resulted in significant damage to the engine components, impacting both equipment integrity and operational safety.

This incident highlights the importance of engaging skilled personnel and OEM guidance for such tasks. Proper securing methods and planning for adverse road conditions are essential to ensure equipment safety during transit, underscoring that oversight in these areas can lead to costly damages and safety hazards

Preventative Steps That Could Have Avoided the Accident

Following proper protocols for moving heavy machinery can prevent accidents like the one at the refinery, where an engine fell from a trailer on an uneven road. Here are the key steps that, if implemented, could have avoided the incident:

1. Ground Preparation: Ensure the loading area is level and stable. Compact the jack base and place support plates to distribute weight evenly.
2. Proper Securing: Secure the machine firmly on the trailer, using straps or fasteners to prevent any shifting or falling during transit.
3. Trailer Positioning: Position the trailer as close as possible to the unloading point, minimizing the need for movement over challenging terrain.
4. Wheel Wedges: Place wedges under the trailer wheels to prevent any movement during unloading, adding stability to the setup.
5. Crane Placement: Situate the crane next to the trailer for safe and controlled unloading.

In this case, the trailer tilted on an uneven road, causing the unsecured engine to slide and fall. Fortunately, no injuries occurred, but the DG set suffered significant component damage. These simple steps illustrate the importance of securing loads and considering terrain conditions for safe equipment transport.

Diesel Generator Engine Damage Assessment and Required Actions

Component	Damage Details	Action Required
Exhaust Pipe Assembly	Internal parts (exhaust pipe piece and compensator) broken.	Replace the entire exhaust pipe assembly.
Pre-Lubricating Oil Pump	Visible cracks on pump housing; potential internal damage.	Inspect and replace the pump if internal damage is confirmed.
Pre-Heater	Found broken with damaged internal electrical parts.	Replace the complete pre-heater.
Cylinder Head Stud & Hydro Nut	Possible impact on hydraulic nuts’ integrity due to fall.	Replace all cylinder head studs and nuts as a precaution.
Engine Elastic Mountings	Possible damage to elastic mountings (rubber and metal parts) due to impact.	Inspect each component and replace any damaged parts.
Lubricating Oil Cooler	Requires hydraulic testing for leaks or damage.	Perform test and replace cooler or damaged components if beyond economical repair.
Fuel Oil Inlet Filter	Visual damage and cracks on filter parts.	Replace the entire fuel filter assembly.
Cylinder Head	Hydro and NDT (MGT) tests required.	Replace any cylinder heads that fail testing.
Air Cooler	Requires hydro testing to confirm integrity.	Conduct hydro test and replace if necessary.
Turbocharger	Full overhaul required by turbocharger manufacturer.	Overhaul with OEM guidance and replace any damaged parts as advised.
Crankshaft	Needs runout, NDT (MPT), and dimensional checks; OEM assessment required.	Send to OEM’s factory for inspection and possible repair or replacement.
Base Frame	Dimensional check needed for frame integrity; OEM inspection required.	Send to base frame manufacturer for testing and repair if necessary.

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

Sensor and Instrument Replacement Requirements

The following sensors and instruments must undergo thorough checks, tests, and calibrations. Despite the absence of visible cracks, internal faults may still develop, necessitating the replacement of all electrical and instrumentation components to ensure reliability. Cabling will also require replacement due to component breakage, along with reproducing, re-fitting, and re-supporting damaged trays.

• Exhaust Gas Cylinder Outlet Temperature Sensors: Remove each individual cylinder sensor and perform calibration to ensure accurate readings.
• Exhaust Gas Turbocharger Inlet Temperature Sensor: Subject this sensor to calibration to verify measurement accuracy.
• Exhaust Gas Turbocharger Outlet Temperature Sensor: Conduct a calibration check on this sensor for reliable performance.
• Main Bearing Temperature Sensor: Replace and calibrate to maintain optimal monitoring.
• Fuel Oil, Lubricating Oil, Cooling Water, and Air Pressure Sensors: Replace these sensors and calibrate to ensure precise pressure readings for each fluid system.

Each sensor replacement and calibration step is critical for maintaining operational accuracy and safety standards in the system.

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.

A Lesson in Precision: The Mishap of the Diesel Generator Transfer

In a bustling refinery, precision and careful planning govern every task. However, on one seemingly routine day, a costly oversight underscored the importance of expertise and attention to detail in handling heavy machinery.

The refinery team was tasked with moving a Diesel Generator (DG) set from the storage area to the power plant. Confident in their ability to manage the shift, they decided to tackle it themselves, without consulting experts or the Original Equipment Manufacturer (OEM). They loaded the DG set onto a trailer, securing it with what seemed like enough support, and set off across the refinery grounds. The trailer, however, was ill-prepared for the road ahead: a rough path full of ditches and uneven patches that would soon put their setup to the test.

As the trailer rolled over the rugged terrain, a slight shift turned into a dangerous tilt. With each bump, the DG set’s balance was compromised until, finally, the trailer tipped sharply, and the DG set slid off, crashing onto the ground. The sound echoed across the refinery, alerting everyone to the disaster. Luckily, no one was harmed, but as the dust settled, it became clear that the generator had sustained severe damage.

The incident revealed a chain of preventable mistakes. The exhaust pipe, pre-lubricating oil pump, pre-heater, and even the elastic mountings had all been compromised. Main bearing temperature sensors, fuel and oil pressure sensors, cabling, and trays—all needed replacement. Every misstep in the preparation stage added up, resulting in both financial loss and operational delays.

Reflecting on the event, the refinery team learned a valuable lesson: that moving heavy, complex machinery requires more than just manpower. It calls for expertise, precise preparation, and the right equipment. In the days following, the refinery implemented stricter protocols, mandatory consultations with OEM experts for critical tasks, and an emphasis on careful groundwork. The DG set mishap, though costly, reinforced an essential truth: precision in preparation is as crucial as precision in operation.

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!

FAQ on ” Engine Accident Report 

You may like to read our post: Problem Solving Tips for Diesel Engines: 10 Solutions for Smooth Performance