Critical CO₂ System Safety Pins Left Installed After Maintenance
Introduction
A potentially serious safety failure was identified during a pre-sailing inspection when crew members discovered that safety pins preventing the vessel’s fixed CO₂ firefighting system from operating had not been removed after maintenance work.
The pins had been installed by contractors to avoid accidental discharge during servicing. However, once maintenance was completed, the system was returned without restoring it to operational readiness.
Had an engine room fire occurred, the vessel’s primary fixed firefighting system may have failed to activate.
How the Near Miss Was Discovered
Following maintenance activities, the vessel was preparing to return to operational service when crew members conducted routine pre-departure inspections.
During these checks, it was discovered that the locking safety pins inserted into the CO₂ release system remained in place. These pins physically prevented activation of the firefighting system.
The oversight was corrected before sailing, avoiding what could have become a major emergency during vessel operations.
Key Contributing Factors
Incomplete Equipment Handover
The incident highlighted the importance of proper handover procedures between contractors and ship staff after maintenance work.
A joint verification process confirming:
- System status
- Operational readiness
- Removal of isolation devices
- Safety restoration
could have prevented the oversight.
Pressure During Dry Dock and Return to Service
Vessels returning from maintenance periods often face operational pressure to resume service quickly. Under such conditions, critical checks can sometimes be overlooked.
Poor Visibility of Safety Pins
The safety pins were difficult to identify because they visually blended into surrounding equipment. Improved visual indicators such as:
- Bright paint markings
- Warning labels
- “Remove Before Sailing” tags
could significantly reduce the risk of similar incidents.
Safety Lessons for the Maritime Industry
For Seafarers
Never assume maintenance work has been fully completed. Always verify that safety-critical systems are restored to operational condition before departure.
For Ship Managers
Post-maintenance verification and equipment handover procedures should be strengthened, especially following dry dock periods or contractor involvement.
For Regulators and Operators
Clear identification methods for isolation devices and lock-out components should be encouraged across the industry to improve safety awareness and prevent configuration errors.
Conclusion
This near miss demonstrates how a simple maintenance oversight could have disabled a vessel’s emergency firefighting capability during a real engine room fire.
Strong communication, proper handover procedures, and thorough operational readiness checks remain essential to ensuring critical safety systems function when needed most.