Fuel System Maintenance Activities in Engine Rooms of Merchant Vessels and Gaps Between SMS Procedures and Actual Practices

Abstract

This study examines fuel system maintenance practices in the engine rooms of merchant vessels, with a particular focus on the gap between formal Safety Management System (SMS) procedures and actual onboard practices. Fuel systems operate under high pressure and temperature conditions, making them a critical source of fire risk in maritime operations. A mixed-method research approach was adopted, combining quantitative data from a structured questionnaire with qualitative insights from semi-structured interviews conducted with engine department personnel. The questionnaire gathered responses from 35 participants representing different ranks and vessel types, while interviews with one Chief Engineer and two Second Engineers provided deeper understanding of operational practices. The findings indicate that fuel system maintenance is a routine and structured activity, largely managed through Planned Maintenance Systems (PMS). However, the results reveal inconsistencies in the application of safety procedures, particularly during routine maintenance tasks. While major maintenance activities are generally carried out with strict compliance to Risk Assessment, Permit to Work, and Lockout/Tagout procedures, routine tasks often involve reliance on experience and informal practices. Human factors such as workload, time pressure, and operational demands were identified as key contributors to procedural deviations. The study concludes that improving safety requires not only effective maintenance systems but also stronger integration of safety management, enhanced training, and a reinforced safety culture.