When an auxiliary diesel generator engine aboard the passenger vessel Ocean Navigator exploded without warning in October 2023, it created an immediate crisis. A fire started, and the engine room filled with smoke. The cruise needed to be evacuated, but damage was already done. The vessel sustained $2.4 million in damages, and a crewmember suffered severe burn injuries.
The experienced maritime injury attorneys at Hofmann & Schweitzer represent the seriously injured motorman seaman who was burned by flaming oils in the explosion of the generator. He has experienced excruciating pain, spent time in burn units, and participated in occupational therapy.
All of this was potentially preventable with proper maintenance. Our maritime injury lawyers understand how proper vessel engine maintenance protocols can mean the difference between safe operations and devastating accidents. When vessel owners and operators neglect manufacturer-recommended maintenance schedules, crew and passengers are at serious risk.
Understanding Engine Failure Risks
Engine failures on maritime vessels can happen for various reasons, including improper maintenance. The National Transportation Safety Board (NTSB) investigation of the Ocean Navigator incident revealed several critical maintenance issues that contributed to the catastrophic failure, including:
Neglected Oil Change Intervals
- Ignoring manufacturer recommendations. The Ocean Navigator's crew had last changed the lube oil for the failed auxiliary engine about 13 months before the incident. Then, the engine operated more than 5,000 hours with the same oil, exceeding the manufacturer's recommendation by five times. When oil isn't changed according to schedule, contaminants can accumulate and diminish lubrication quality.
- Abnormal oil consumption. In the two months before the engine failure, the crew had to add 79 gallons of lube oil to the auxiliary engine. By comparison, only five gallons were added to a similar engine operating under the same conditions. This significant difference indicated an underlying problem that went unaddressed.
- Degraded oil properties. Extended oil use reduces the effectiveness of additives designed to protect engine components. When oil breaks down, it can't properly lubricate moving parts, leading to increased friction, heat, and eventually catastrophic failure.
Filter Element Replacement Failures
- Overextended filter use. The crew last changed the lube oil filter elements in May 2023, when the engine had about 11,000 hours. By the time of failure, the engine had accumulated 14,329 hours, meaning the filters had been used for 3,329 hours—more than three times the manufacturer's 1,000-hour recommendation.
- Bypass valve complications. When filters become clogged, the bypass valve remains open, allowing debris particles to circulate freely throughout the engine. These particles can cause scoring and damage to bearings.
- Reduced filtration effectiveness. Dirty filters can't properly remove contaminants from the oil. The contaminants may circulate and cause cumulative damage to engine components.
Consequences of Vessel Engine Failure
The repercussions of a catastrophic engine failure extend far beyond the initial incident.
Immediately after the engine failure, dangers include:
- Fire hazards when atomized oil contacts hot engine surfaces
- Ejection of metal components at high velocity
- Serious injuries to nearby personnel
- Loss of power to critical systems
The consequences may continue long after the initial emergency and result in:
- Substantial repair and replacement costs
- Extended vessel downtime
- Potential regulatory penalties
- Increased insurance premiums
- Possible loss of customer confidence
The best way to avoid these consequences is to take the necessary precautions to prevent engine failure.
Best Practices to Avoid Engine Failure on Your Vessel
To prevent similar incidents, vessel operators should follow the manufacturer's guidelines by:
- Adhering to recommended schedules. Always follow the manufacturer's specifications for lube oil changes, filter replacements, and other maintenance items. These intervals are determined through extensive testing and are critical to equipment reliability.
- Documenting all maintenance. Keep detailed logs of all maintenance activities, including oil changes, filter replacements, and oil analysis results. Regularly reviewing these records can help identify patterns that might indicate developing problems.
- Implementing oil analysis programs. Regular oil analysis can identify contaminants and metals before they cause catastrophic damage. This predictive approach allows for planned maintenance rather than emergency repairs.
While these steps may help prevent engine failure, it’s also essential to monitor key indicators by:
- Tracking oil consumption rates. Sudden increases in oil consumption can indicate developing problems. Establish baselines for normal consumption and investigate when those levels change.
- Installing monitoring equipment. Modern vessels can benefit from real-time monitoring systems that track bearing temperatures, oil pressure, and other critical parameters. These systems can provide early warning of developing problems.
- Conducting regular inspections. Visual inspections of equipment can often identify issues before they cause failures. Look for signs of leakage, unusual noises, or vibrations that could indicate problems.
The Ocean Navigator incident serves as a sobering reminder that maintenance isn't just about keeping equipment running—it's about ensuring the safety of everyone aboard. By following manufacturer recommendations and implementing comprehensive maintenance programs, vessel operators can significantly reduce the risk of catastrophic engine failures, fires, explosions, and resulting injuries.
