Navigating Through Hurricane-Induced Engine Failure: A Sea Survival Story

This article delves into a harrowing yet survival-filled tale of an engine failure on a merchant ship during a stormy journey. It recounts the events leading up to the incident, the initial challenges faced, and the teamwork that saved lives despite overwhelming circumstances.

The Journey and the Engineers

The voyage in question was part of a 38-year career spent navigating the vast oceans. During this time, the narrator, a 4th Engineer, was responsible for the 8 to 12 watch during a trip from Portland on the U.S. West Coast (possibly to Vancouver) to India. The ship was engaged in transporting wheat as part of the PL-480 scheme.

The Engine Failure and Its Consequences

The engine failures started shortly after the voyage began, with two successive piston crown cracks. These failures occurred due to a combination of factors: the use of limited spare parts, the unpredictable weather conditions, and the harshness of the work environment. The crew's actions were influenced by the dire situation, where it was estimated that they had only about 8 hours before a severe storm hit.

The Crucial Decision and Its Execution

Despite the storm approaching, the decision was made to tackle the engine failure rather than retreat. The team, working in a state of high alert, faced an arduous task. They needed to change the piston with a spare upper crown, risking inclement weather and the ship's rolling and pitching. The entire exercise took 5 hours, but midway through, the storm struck with force, leading to treacherous conditions.

The crew faced numerous challenges, including securing the overhead crane, stabilizing the piston weight, and lowering the piston into the cylinder. Simultaneously, other crew members donned life jackets and stood by in the accommodation corridor as a safety precaution.

The Aftermath and Recovery

Despite the odds, the team managed to successfully complete the repairs and restart the engine. However, the engine's performance was severely hampered by the ongoing storm. Despite efforts to minimize wave and wind impact with the rudder, the ship made no headway for several days. The crew faced even more challenges when three more piston crowns failed, further reducing the engine's operational capacity to six cylinders.

The journey worsened when the ship entered the eye of the hurricane, losing hope of a few shore visits. They chose to head towards Hawaii, hoping for a port of refuge. Their worst fears were realized as the ship approached the open Pacific, with the prospect of waiting for spares in Hawaii prolonging their arduous journey.

Fortunately, the spares arrived simultaneously with the ship's arrival in Hawaii, allowing the crew to work tirelessly for over 90 hours on three piston crown repairs. They also had to overhaul three turbochargers, clean three air coolers, and change all scavenge valves, ending the workday at midnight.

The Journey Home and Post-Voyage Reflections

Although the 30-day voyage stretched to almost two months, the experience was notable for its resilience and camaraderie. The ship eventually reached its destination, and the narrator had the opportunity to see Waikiki Beach under the moonlight, a rare treat amid the grueling journey. Having successfully completed the voyage, the narrator passed the Second Engineer's exam just a month later, attributing his success to the impetus gained from this harrowing experience.

Lessons Learned and Technological Insights

The experience highlighted several critical lessons, including the importance of proper maintenance, the impact of worn-out fuel valve nozzles and guides, and the condition of piston ring grooves. The narrated engine, a MAN KZ 70/120 D loop scavenged pulse system, is a case study for understanding how water-cooled pistons and loop scavenging systems were used in maritime engineering. The transition to uniflow scavenging through exhaust valves and the integration of BW technology by MAN underscore the evolution of engine design.

Conclusion

The story of this navigation through a hurricane-induced engine failure serves as a testament to the resilience, teamwork, and adaptability of maritime engineers. It also highlights the challenges faced in maintaining and repairing vast maritime machinery in the face of extreme weather conditions. The lessons learned remain relevant and provide valuable insights into the ongoing evolution of shipping technology and maritime safety measures.