Free-Fall Lifeboat Risk: Lessons from an Accidental Release Incident

Introduction

Free-fall lifeboats are designed to provide rapid evacuation during emergencies at sea. However, when safety protocols are overlooked, these lifesaving devices can become a source of severe injury or even death. A recent incident aboard the Golden Zhejiang bulk carrier highlights the critical importance of proper maintenance, training, and risk assessment in lifeboat operations.

The Incident

On 2 September 2023, while anchored in Trincomali Channel, British Columbia, the Hong Kong-flagged Golden Zhejiang experienced a catastrophic safety failure. During a routine weekly check, the vessel’s free-fall lifeboat—weighing 4,400 kg and positioned 19 metres above water—was accidentally released with an engineer inside. The engineer, who was not secured in a seat, suffered life-altering injuries and partial memory loss.

Investigation Findings

The Transportation Safety Board of Canada (TSB) identified several contributing factors:

• Control Confusion: The engineer mistook the emergency release wheel for a steering control.
• No Risk Assessment: The vessel’s safety management system did not require a risk evaluation before entering the lifeboat.
• Faulty Securing: Cables used to hold the lifeboat were not certified as load-bearing and failed under stress.
• Maintenance Gaps: A hydraulic leak noted in monthly checks since June 2023 was never repaired, preventing proper drills.
• Training Deficiency: The injured engineer had not received lifeboat familiarisation training after joining the vessel.

Recurring Safety Challenges

This was not an isolated event. Since 1996, the TSB has investigated seven similar accidents, all involving serious injuries during lifeboat drills or maintenance. In December 2020, a drill aboard Blue Bosporus resulted in injuries when wire rope slings failed during lowering.

Regulatory Framework

International Maritime Organization (IMO) and SOLAS regulations mandate:

• Dual-release systems and accidental-release protection.
• Regular drills and inspections: monthly checks, quarterly launches, and annual full launches.
• Certified equipment and proper maintenance of release gear.

Despite these requirements, implementation gaps continue to pose risks.

Operator Response

Following the incident, Columbia Shipmanagement Ltd. introduced:

• Clear labelling on release controls.
• Updated familiarisation checklists.
• Installation of turnbuckles to secure lifeboats during checks.
• Enhanced crew training seminars on lifeboat safety.

Prevention Checklist

To prevent similar accidents, operators should adopt the following best practices:

Before Entering Lifeboat

• Conduct a formal risk assessment.
• Install Fall Preventer Devices (FPDs).
• Verify release mechanism is locked and clearly labelled.
• Ensure crew familiarisation training is complete.

Maintenance & Inspection

• Log and repair defects immediately.
• Use certified load-bearing securing cables.
• Follow SOLAS drill schedule:
  • Monthly visual checks
  • Quarterly launch drills
  • Annual full launch

During Drills or Checks

• Secure personnel with seat belts.
• Assign supervisor oversight.
• Maintain communication with the bridge team.

Conclusion

The Golden Zhejiang incident underscores the need for a rigorous safety culture aboard ships. Lifeboats are critical for survival, but without proper procedures, they can become hazards. By enforcing training, maintenance, and risk assessment, operators can significantly reduce the likelihood of accidents and protect crew lives.

Are Free Fall Lifeboats dangerous, check the following incidents:

1. Golden Zhejiang – British Columbia (2023)

• Primary Cause:
  • Engineer mistook the emergency release wheel for a steering control.
• Contributing Factors:
  • No risk assessment before entering the lifeboat.
  • Securing cables not certified as load-bearing; failed under stress.
  • Hydraulic leak noted for months but not repaired, preventing drills.
  • Crew training gap: Engineer lacked lifeboat familiarisation.
    (Source: TSB Report M23P0235)

2. Blue Bosporus – English Bay (2020)

• Primary Cause:
  • Wire rope slings failed during lowering due to stress-corrosion cracking of crimp sleeves.
• Contributing Factors:
  • Improper attachment of slings to lifeboat.
  • Lack of inspection for corrosion damage.
    (Source: TSB Report M20P0353)

3. Maintenance Accident – Case Study (2025)

• Primary Cause:
  • Simulation wires failed during hydraulic system maintenance.
• Contributing Factors:
  • Wires installed incorrectly.
  • Release mechanism partially reset, creating risk of accidental launch.
    (Source: MARS Safety Case Study)

4. MV Louise Russ – Gibraltar (2011)

• Primary Cause:
  • Accidental release during maintenance due to procedural gaps.
• Contributing Factors:
  • No formal risk assessment.
  • Crew unfamiliar with release system design.
    (Source: Gibraltar Maritime Administration)

5. Maersk Pomor – Gladstone, Australia (1998)

• Primary Cause:
  • Lifeboat released during engine test under Port State Control inspection.
• Contributing Factors:
  • Misinterpretation of release mechanism.
  • Lack of secondary securing device.
    (Source: ATSB Report)

6. Shell Auger Platform – Gulf of Mexico (2019)

• Primary Cause:
  • Equipment failure during lifeboat lowering in a drill.
• Contributing Factors:
  • Inadequate maintenance of release gear.
  • Crew inside lifeboat during drill without proper securing.
    (Source: Industry Safety Reports)

Common Themes Across All Incidents

• Human Error: Misidentification of controls or incorrect procedures.
• Maintenance Failures: Hydraulic leaks, corroded components, or worn slings.
• Training Gaps: Lack of familiarisation with lifeboat systems.
• Design Vulnerabilities: Release mechanisms prone to accidental activation.
• Missing Risk Assessments: No formal hazard evaluation before drills or checks.