Maintenance failures resulted in a "catastrophic" engine breakdown on a DFDS ropax that left a seafarer seriously injured.

The UK Marine Accident Investigation Branch (MAIB) found that damage to a connecting rod was not spotted early enough to prevent a fire on the 1,900-dwt Finlandia Seaways (built 2000) off Lowestoft in eastern England in 2018.

The incident took place on 16 April when the ship was 11 nautical miles (20 km) from the English coast en route from Zeebrugge in Belgium to Rosyth in Scotland.

One of the main engine's connecting rods broke and several of the major internal rotating components were thrown through the side of the crankcase into the engine, causing a short but intense blaze.

Within 20 minutes, the crew had conducted a muster, sealed the engine room, activated its CO2 fixed firefighting system and extinguished the flames.

Engineer hurt during escape

The vessel’s third engineer, who was on duty in the engine room at the time, suffered serious smoke-related lung, kidney and eye injuries during his escape.

He was flown to hospital by helicopter and made a successful recovery.

MAIB found the standard and management of maintenance carried out by the vessel's support contractor was a significant causal factor.

The report said connecting rods had not been maintained in accordance with engine manufacturer's instructions.

Defects introduced during component overhauls had not been identified by the ship's crew or the company's technical superintendents.

Lloyd's Register left in the dark

"The significance of the damage caused to the connecting rod small ends during overhaul was not fully appreciated and although a class survey item, class was not kept informed," MAIB said.

The report emphasised that any damage identified to major engine components, no matter how inconsequential it might appear, should be properly assessed, and any actions taken or decisions made should be recorded in the planned maintenance system.

Manufacturer MAN Energy Solutions and class society Lloyd's Register have been asked to provide technical advice to DFDS on the actions the company should take to minimise the risk of a similar incident.

Other recommendations aimed at addressing safety issues have been made to DFDS and engine maintenance support contractor Diesel Service Group.