KOMMANDOR ORCA

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Accident investigation revealed major flaws in safety management

The second officer aboard the 'Kommandor Orca' sustained serious crush injuries to his lower left leg while operating the deck crane on August 16, 2022, while the vessel was docked in Portland, UK, preparing for its first research charter after a year-long conversion. The officer’s leg had to be amputated below the knee after being trapped in the crane’s rack and pinion system. The incident happened while the ship’s second officer used the rail-mounted crane to relocate equipment on the main deck. During the process, he used emergency controls located 12 feet above deck, which had become common on the ship. The Marine Accident Investigation Branch (MAIB) found out in its investigation that the method of operation was risky and did not comply with the manufacturer’s guidelines. The crane’s controls, designed only for emergencies, were concealed in an unobtrusive hatch on the crane’s base. According to the MAIB, the second officer was instructed by senior officers to operate these controls but was unaware of the remote or bridge-based operation options. As he operated the crane, his foot got stuck in the unprotected pinion gear. A fellow crew member provided immediate help, and the officer was taken to a hospital, where doctors found his leg could not be saved. The 'Kommandor Orca', formerly sailing as 'Bourbon Orca', had just been acquired by its present owners. A lack of handover from the previous crew led to poor operational procedures. The vessel’s safety management system (SMS) failed to address proper crane operation, leading to unsafe practices and inadequate training. The MAIB investigation found that operating the crane with emergency controls, standing on the unguarded motor, and working at heights without guardrails all led to the accident. The incident revealed major flaws in safety management, as the crew was unaware of the risks posed by this method of operation. The investigation found that senior officers’ training unintentionally encouraged dangerous practices. The vessel operator has updated the SMS and installed safety guards and an emergency stop option on the crane since. A third-party crane training provider retrained the crew, and remote control tools were made mandatory for crane operations. The company also provided the injured officer with employment and support.