Survitec reveals the most common equipment and servicing failures found on commercial cargo ships—and why addressing them is more urgent than ever

Fires are a common occurrence in commercial shipping, and they occur almost weekly in the container shipping segment.

The latest figures from insurer Allianz highlight the extent of the problem, as while the number of ships lost across the industry is now at a record low, there has still been 55 total losses caused by fires in the past five years. Over 200 fire incidents were reported in 2023 alone.

Industry analysts have pointed to the use of new alternative fuels, the carriage of lithium-ion battery cargoes, and a reported increase in mis-declared dangerous cargoes, especially hazardous containerised cargoes, as being contributing factors.

Metkel Yohannes, Director of Service and Rental Solutions at Survitec, believes that inadequate fire safety inspections are a less obvious but just as important underlying cause.

“The economic downturn and the emphasis on cost reduction post-Covid have had a negative impact on fire safety,” says Yohannes. “We know from experience that some ship owners and operators are maintaining and inspecting safety equipment themselves as a way of making their budgets stretch further. Crew training is also being negatively impacted. We’re finding basic errors and oversights that do not become apparent until either the ship fails an inspection and is detained – or there is a fire.”

Small oversights, big problems: Lessons from inspections

As an Original Equipment Manufacturer (OEM) and fire safety expert, Survitec is often called upon to investigate problems or faults with fire safety equipment. Their specialist fire safety technicians routinely find deficiencies in the routine maintenance and testing of safety-critical equipment that then impact system performance, even leading to equipment failure in some cases.

For instance, Survitec was called out to a vessel after an engine room fire. The crew had managed to extinguish the fire but suspected there was a fault with their high expansion foam firefighting system. The cause of the fault was a blockage in the system. The crew had installed a new foam pump and forgotten to remove one of the protective caps.

Survitec often finds issues that indicate insufficient training or a lack of expertise. For example, the foam proportioner on a high expansion foam system should be removed and inspected regularly, yet Survitec will often find membranes are damaged or broken, which impacts the delivery of foam to the system.

Another common mistake is to mix different types or brands of firefighting foam. When this happens, the foam becomes contaminated. In one inspection of the foam tank for a helideck system, Survitec found the foam had changed from a liquid state to an almost sponge-like, gelatinous state.

The system was therefore inoperable and required major work – and considerable expense – to remove the contaminated foam, deep-clean the system, and recharge it. Fortunately, in this instance, the fault was discovered and rectified before the ship had cause to use the system, because the system would certainly have failed had there been a fire.

The backbone of safety: Routine equipment inspections

Rigorous fire safety inspections of fixed firefighting systems play a vital role in ensuring the safety of a vessel and its crew. Survitec reports that many, if not most, of the inspections they perform reveal issues that require immediate corrective measures.

Furthermore, issues related to poor maintenance or superficial inspections will generally be found across multiple systems, not just one system. For example, valves that have corroded and do not open or close properly can be a common issue across all systems.

This erosion of standards correlates directly with a troubling rise in fire safety-related deficiencies recorded on board ships in recent years. The resulting increase in ship detentions following port state control inspections underscores the real-world consequences of these lapses in safety practices.

Yohannes says: “We clearly see evidence of a slip in standards when it comes to basic safety practices. Approval stamps are being applied to fire systems and appliances that would or should not pass inspection.

“There should be more oversight, more governance, and better quality control procedures. Shipowners and managers need accredited service partners they can trust.”

Technical Sales Manager at Survitec, Jan-Oskar Lid, confirms that while paperwork might indicate that a service inspection has been carried out, the levels of wear and tear on the equipment can sometimes suggest otherwise. “Some issues are self-evident – for example, the rust on a valve or a fire extinguisher is clear to see, but other issues are less obvious and can have catastrophic consequences.”

Lid quotes an example. In early 2024 a bulk carrier left port, having just completed a fire safety inspection and received full certification from a local service provider. Shortly after leaving port, a fire started in the engine room.

The crew released the CO₂ system, which had just been inspected and approved, yet more than half the cylinders failed to activate. The fire was eventually extinguished but there was significant damage to the vessel, with costs of US$2-3 million for off-hire and repairs.

Lid also points out that this is not just an issue for older vessels. Inspections are just as essential for new vessels, to verify that new equipment is fully operational. For example, a CO₂ system will be disabled, for safety, while a ship remains in the shipyard.

It is not uncommon for Survitec service technicians to discover that a new ship has been sailing without a functioning CO₂ firefighting system, because the pilot hoses for the main control valves and release cabinets have not yet been reconnected, and safety pins are still in place.

Procuring the right parts

The procurement of spare and replacement parts can also be a challenge for ship owners and operators. Without the relevant training or expertise, it can be difficult for purchasing personnel to recognise low-quality or counterfeit parts, or even the “right” part.

High pressure hoses for CO₂ fire extinguishing systems are a key example. Hoses approved for use on a high-pressure CO₂ system can be distinguished by the pin pricks that run along the length of the hose, and by the Type Approval Test certificate details which will be stamped into the crimping neck, as mandated by the class societies. Poor-quality or counterfeit parts will not have these features, but the purchaser needs to know what to look for.

Revised guidelines for the maintenance and inspection of CO₂ systems were published in 2021 (MSC 1318 Rev.1), to help protect seafarers against the dangers of leaking gas. Yet, safety inspections often uncover serious issues.

Hydraulic hoses are often mistaken for high-pressure hoses and improperly used in CO₂ systems, risking failure under pressure. Deviations from datasheet specifications, ill-fitting hoses forced with copper washers, over-crimping, blocked or peeling hoses, and the use of multiple connections—all contrary to best practices—highlight lapses in inspection and maintenance routines.

Evaluating service provider credentials

Survey reports from Survitec’s global network of service engineers indicate declining crew competencies and skills in this respect, possibly due in part to the seafarer shortage but also the challenge of keeping on top of the various rules and regulations.

As Yohannes explains: “Service requirements are complex and varied. The International Maritime Organisation’s (IMO) MSC 1432. MSC 1432 is effectively a baseline for servicing. The vessel class and flag may specify additional or stricter requirements, and the Original Equipment Manufacturer (OEM) may have their own requirements too.

“Requirements will also vary depending on the service interval. Specialist fire safety service providers therefore invest heavily in training to provide for this.”

However, it is not always easy to identify the reputable providers. There can be a wide disparity in service quality between service providers. As Lid explains: “Cost can be the determining factor when selecting a service provider, especially when different providers boast the same approvals. Some providers may compete by undercutting their competitors, but they can often only do this by cutting corners.

“They may not invest in training to the same degree, so their technicians may lack knowledge of the different rules and regulations or the requirements for all the different brands.

“They may not even have all the equipment required to complete the inspection beyond a cursory visual check. In extreme cases, certificates may even be issued without an engineer setting foot onboard the vessel.”

Finding a provider you can trust

In its 2024 white paper Why are the fires not going out? Survitec highlights the importance of proactive measures and robust maintenance practices to ensure fire safety systems operate effectively in critical situations, also offering practical advice on what shipping companies should look for in their fire safety providers, and how to assess competency.

As Yohannes maintains, specialist fire safety service providers can play a crucial role in supporting proper and effective maintenance and testing on board ship, however trust is key. “Currently, there are no quality benchmarks, and no training standards in place to help determine competencies,” says Yohannes.

“As an industry, we should review current practices and decide: do we need more oversight, more governance, better quality control procedures around servicing and approvals?

“Ship owners and operators need accredited service partners they can trust. Anything less is not just a false economy, it’s potentially dangerous.”

Why Are the Fires Not Going Out?

Survitec’s recent white paper, Why Are the Fires Not Going Out? explores these key considerations in greater detail, offering practical advice on evaluating providers’ expertise, compliance with safety standards, and ability to deliver effective, long-term solutions. Download your free copy at survitecgroup.com

This article was originally published in the February 2025 issue of International Fire & Safety Journal – to read your FREE digital copy, click here.