The Ship
Facts and figures for the MV Dali
- Named after Salvador Dali
- Built in South Korea from October 2014 to March 2015
- Displacement of 149,000 tons
- 984 feet length by 158 feet wide
- 49 foot draft (hull depth in the water fully loaded)
- Propulsion is a single shaft with a fixed pitch propeller
- Power is from a MAN-B&W 9S90ME-C9.2 two stroke diesel engine of 55,000 hp
- Design speed is 22 knots or 25 mph at 82 RPM
- Fuel usage is around 200 tons per day
- Engine cylinder bore is 900 mm and stroke is 3260 mm (I think 9 cylinders)
I was not able to find a trustworthy number for fuel consumption but 200 tons of heavy fuel oil per day is close. At that rate of fuel burn it is obvious why optimizing the engine and propeller is an important design task.
The Engine Room
The cargo type ships (bulk, oil, container, LNG, etc) usually have just one propeller and one engine. In this ship the engine turns at just 82 RPM, matching the optimal rotational speed of the propeller, so no reduction gear is needed. There is also no reversing gear so, to generate reverse thrust, the engine is stopped and restarted turning the opposite direction.
In a big ship it is most accurate to think of all the equipment in the engine room as the engine. The ship’s main engine can not operate without all of the other equipment around it. The main engine does only one thing — it turns the propeller. This is very different from a car engine where the engine provides all the power to operate the vehicle. In addition to the main engine is three or more auxiliary engines and all they do is generate electricity. That electricity is used to power everything on the ship (except turning the prop). Everything includes systems needed to operate the main engine itself.
This is a cutaway of a cargo ship (not exactly like the MV Dali but close enough). You can see the main engine attached to the propeller shaft and behind it are three purple things which are the auxiliary engines. Ships can certainly have more than three aux engines depending on how much power is needed and the MV Dali has four.
The Operation and Power Loss
Everything is run from the aux engines including the fuel feed pumps, lubricating oil pumps, cooling water pumps, and the exhaust valves (hydraulic actuators controlled by computer). Without the aux engine electric power that huge beast of a main engine is dead weight. The other systems run by the aux power are the rudder hydraulic pumps (two units), lights, navigation, communication, and almost everything else on the ship.
During port maneuvering at least three aux engines are operating and synched to the power bus so even if two engines go down the third engine can still run the ship. It looks to me like all the power was lost over the entire ship which means that all the aux engines shut down or the entire aux power bus tripped of line. After that the main engine would have shut down and the rudder locked in place. At that point the Francis Scott Key bridge was doomed. There was not enough time to restart the aux systems and restart the main engine before hitting the bridge pier - although the crew really tried.
The rudder locked at whatever position it was when power was lost since both hydraulic pumps (for redundancy) need electric power from the aux engines. The ship was coasting but something started the bow turning right. Maybe it was a cross current or maybe the helm had turned the wheel slightly to the right for a small course correction. It takes a few seconds for the 100,000 ton ship to actually start turning but eventually it did and headed directly into the bridge pier.
The Worst Possible Timing
It’s hard to say how bad the timing was for losing all power. If the incident had happened a minute earlier the engine room crew could have recovered power (at least to the rudder) and avoided the impact. If the power loss had happened maybe 15 seconds later the ship would have coasted under and through the bridge without striking anything (maybe a very close call though). But that is not what happened and now we clean up the horrible mess.