Capt. Toru Asai

General Manager of Loss Prevention & Ship Inspection Department

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This column features the article contributed by our Association to "Mariners' Digest Vol.78", published in July 2025 by the Japan Shipping Exchange, Inc.

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This column is the second part of a series. If you haven't read the first part, "Preventing Seafarers’ Personal Injury (No.1)", please do so before continuing.

Highlights

• This article details specific accident examples in the engine departments of vessels and their preventive measures. It highlights the importance of strict adherence to work procedures, thorough risk assessments, and pre-work meetings to ensure effective BRM/ERM based communication, aiming to enhance the safety awareness of seafarers.


• To ensure safety in procedural work, it is recommended to conduct risk assessments, apply mitigation measures, hold pre-work meetings, and formalize future procedures.

1. Introduction

In this column, we would like to introduce five accident examples in the engine department.

2. Prevention of Crew Accidents: Examples and Measures

[Case 1] Finger tips amputation during the main engine maintenance

Vessel Type : Container Vessel

Accident Summary

• In the engine room while at anchor in port, the First Engineer and the three Oilers were replacing the No.2-cylinder exhaust valve of the Main Engine.
• After loosening the nuts with a hydraulic jack, the three Oilers removed them by hand.
• The First Engineer lifted the exhaust valve with a crane. Three fingers of the Oiler (C) were trapped and crushed as the Oiler (C) was still in process of removing the nuts.

Accident Prevention Measures

In the engine department, heavy items of machinery may be removed for servicing. Fingers are often pinched during work such as lifting with a chain block or crane, moving items to a predetermined location, and putting them down. Since such major maintenance work is usually carried out by multiple crew members, the person in charge of the work must pay close attention to the safety of all crew members involved in the work, such as maintaining close communication, constantly checking on potential safety issues and keeping track of the progress of the work (e.g., whether all nuts have been removed), and keeping all crew members away from the parts when they are lifted in case they fall unexpectedly.

[Case 2] The Oiler(B) suffered burn injuries in a backfire caused by oily rag incineration

Vessel Type : Bulk Carrier

Accident Summary

• During navigation, the incineration of waste materials was carried out.
• The Oiler(B) put oily wiping rags into the incinerator.
• It caused backfire and the Oiler(B) suffered burns on both arms.

Accident Prevention Measures

Some garbage may be incinerated on board in accordance with MARPOL. If there is a highly flammable substance in the garbage, such as a rag containing oil, it may flare up violently as soon as it is put into an operating incinerator. In such case there is a risk that the flame will erupt from the inlet port. When putting the garbage into an operating incinerator, it is important to consider the risk of flames erupting and not to stand in front of the inlet port.

[Case 3] Laceration to the leg during maintenance work in the engine room

Vessel Type : Bulk Carrier

Accident Summary

During the work in the engine room while at anchor, the Wiper stepped into a spot where gratings had been removed for maintenance. He suffered a laceration as the leg below the knee hit the lever edge of a drain valve.

Accident Prevention Measures

In the engine room, maintenance work may be performed on the piping and valves installed under the floor. In such cases, sections of the floor (steel plates or gratings) are removed to carry out the work, so there is a risk of unknowingly walking and stepping off the safe area. In the engine room, it is necessary to always walk with caution but specifically when removing the floorboards, use a cone or tape to warn crew so as not to enter an unsafe area by mistake.

[Case 4] An empty drum which had contained the methanol exploded at the beginning of cutting

Vessel Type : Chemical Tanker

Accident Summary

• There were many empty drums on board which contained methanol for cargo tank cleaning.
• During navigation, the engine department made a work plan to cut the empty drums and put them in order.
• The two Oilers were instructed to do that work at the workshop in the engine room.
• A drum exploded at the beginning of cutting.

Accident Prevention Measures

On chemical tankers, crew members often spray methanol on the cargo tank surface as a finishing touch to clean the cargo tank, and they have methanol in drums for this purpose. Used empty drums take up a lot of space, so they are usually cut into small pieces, stored, and unloaded together. In this accident, it is presumed that the spark at the start of cutting ignited the methanol and air mixture in the empty drum and exploded. Since the work of cutting an empty drum is a form of hot work, it is necessary to follow hot work procedures and confirm that the inside of the empty drum is in a gas-free condition before cutting. Used empty drums should be thoroughly cleaned in an appropriate manner and stored in a storage area. The Chief Officer is responsible for supervising the storage, cutting, and unloading of chemical drums for tank cleaning.

[Case 5] Electric shock accident during welding work

Vessel Type : Bulk Carrier

Accident Summary

• The Third Engineer found that the supercharger drain pipe of the main engine was broken and had fallen off, and that exhaust gas and condensate were blowing out.
• The Chief Engineer, upon receiving the Third Engineer's report, decided to carry out a repair by welding, reported this to the Master, and shut down the main engine.
• An engineer switched on the main body of the welding machine and the switchboard, extended the welding holder with a cab tire cable to the vicinity of the supercharger mount, and prepared a plastic sheet, gloves, long-sleeved shirt, and welding rod on the floor.
• The Chief Engineer adjusted the voltage of the welding machine and used the trestle under the supercharger (located about 0.7 m above the plate in the engine room and about 0.5 m square), and instructed the Third Engineer to shine a flashlight on the welding site from the top of the frame.
• The Third Engineer realised that the Chief Engineer had collapsed, and immediately pulled him out and laid him down next to the main engine. He was bleeding from the mouth, and in cardiopulmonary arrest.
• The Chief Engineer was pronounced dead and later examined at the hospital as part of a forensic autopsy where it was determined that he died suddenly due to electric shock, with electric current marks on his chin, chest, and shoulders.

Accident Prevention Measures

If welding is performed in a confined space that is an electrical conductor, parts of the body may come into contact with electrical currents, resulting in electric shock and death. In some cases, people have been electrocuted due to sweat even though they were protected by work attire.

Although the vessel was not equipped with the following equipment under the regulations, it is desirable that a vessel be equipped with an electric shock prevention device, a ground fault circuit breaker, and an AED (automated external defibrillator) in order to prevent the recurrence of similar accidents.

These are five examples of accidents involving seafarers that occurred during the work in the engine department. In the engine department, accidents to seafarers often occur during maintenance work.

These include finger and hand injuries during servicing of main engines, generators, pumps, and electric shocks and burns during welding, and falls in the engine room. The engine room is very noisy, hot, and difficult to work in, but it is important to communicate well and work carefully.

3. Comprehensive Tips for Preventing Seafarers’ Personal Injury Accidents

What is required in order to break the chain of errors leading to accidents

As per BRM/ERM requirements, the following are required.

1. Situational awareness
2. Effective communication
3. Assertiveness
4. Leadership

Here's a brief description of each item

1. Situational Awareness

Situational awareness refers to the ability to act proactively in various situations which enables an individual to accurately assess the presence of hazards, the possibility of environmental pollution, situations that may conflict with laws and regulations, and defects. In order to prevent accidents from occurring and to prevent environmental pollution, it is important to have an accurate awareness of the situation. Situational awareness enables a crew member to proactively take the necessary actions and accident prevention measures.

1. Effective Communication
   
   

• Exchange of information that is necessary for safe operations.
• Includes instructions, responses, information and reports.
• Effective communication means that these exchanges of information are taking place in an effective manner.
• Personality and awareness of each personnel. If these human factors are not considered properly effective communication cannot be established.
• A lack of communication can often be caused by the attitude of personnel (e.g., to assume that 'he/she would already know' and fail to report the situation).
• It is important for each crew member to maintain sufficient information exchange, recognizing the importance of effective communication and information sharing.

1. Assertiveness
   
   

• Assertiveness is the ability to communicate honestly and equally without infringing on the rights of others.
• Personnel may need to make their own decisions clear in their duties. If it is necessary to make a decision in order to maintain safe operations, this must be done without hesitation, irrespective of their position in the company hierarchy.

In the case of personnel in positions of responsibility in operations, decisions in emergency situations or even after time for due consideration must be asserted decisively and clearly. Sometimes it is necessary to ask for an explanation of the reasonableness of a supervisor's order, or even to urge the supervisor to reconsider the decision if it is inappropriate.

1. Leadership

• Leadership is an important human element needed to supervise work.
• It is a necessary skill for working collaboratively with others.
• It is required to understand how to influence and motivate other personnel, as well as to have the situational awareness and ability to lead others.

We hope that everybody strives to eliminate accidents and ensure the well-being of seafarers and their families.