The maritime industry is facing a sharp rise in machinery failures and engine-room incidents that modern monitoring systems could help prevent, warns CM Technologies (CMT).

With classification society DNV reporting a 20% increase in machinery damage failures during 2024, and engineroom fires accounting for more than half of all marine equipment-related insurance claims, Germany-based CMT says advanced diagnostics and monitoring solutions are not just a nice to have but should be considered as essential safety tools.

Referring to recent maritime casualties, some of which fatal, Uwe Krüger, Managing Director at CM Technologies, said: “Engine and machinery failures continue to catch crews and operators off guard, but effective system monitoring will alert crews to looming catastrophe.”

Citing as an example the root cause of the engine-room fire aboard the cargo vessel Stride in January, Krüger said that even small oversights, such as an incorrectly installed or damaged valve, can result in fatal accidents.

“Modern acoustic sensors could have picked up abnormal pressure signatures or vibration patterns as soon as the valve began to operate,” explained Krüger. “That kind of early warning can be the difference between a manageable maintenance event and catastrophic failure,” he said.

According to DNV’s Maritime Safety Trends 2014-2024 Preparing for Future Risks, published during the Nor-Shipping 2025 trade fair, the number of maritime safety incidents increased by 42% between 2018 and 2024, despite the global fleet growing by just 10%.

CMT’s Co-Managing Director David Fuhlbrügge added: “Machinery failures remain the leading cause of shipping casualties, accounting for 60% of all marine equipment-related incidents. Ships aged 25 years or older are particularly vulnerable but failures are caused by issues that engine and machinery performance optimisers can easily detect.”

Referring to the fire onboard Ocean Navigator earlier this year, Fuhlbrügge said an effective monitoring programme could have identified contamination and debris in the auxiliary diesel’s lube oil before it caused the failure that sparked the fire.

“Advanced real-time monitoring solutions can detect early signs of wear, contamination, and mechanical stress, issues that can contribute to machinery failures and subsequent engine-room fires,” he said.

Ship operators can no longer afford to treat condition monitoring as an optional extra, he said. “Too often, we see cases where seemingly minor issues spiral into significant failures. By the time these problems are identified during scheduled maintenance, the damage is already done. The early warning technology to detect these signs in real time already exists.”

Commenting on the risks associated with older vessels, where maintenance is deferred or relies solely on periodic inspections, Fuhlbrügge said continuous monitoring can reveal the “subtle degradation” that leads to unexpected breakdowns.

While no single technology can eliminate every risk, the maritime sector has access to a range of diagnostic tools capable of measuring key performance indicators, such as cylinder pressure, fuel injection timing, vibration signatures and acoustic emissions.

By applying these tools in tandem with rigorous maintenance regimes, operators can detect wear patterns, combustion anomalies and lubrication issues that would otherwise go unnoticed.

“Machinery failures rarely happen overnight; they are consequent of a series of events over a period of time,” Krüger said. “Every percentage point of efficiency lost, every small increase in vibration, every piece of debris in the lube oil system is a warning sign. We need to pay closer attention to these details.”

DNV’s recent finding about the rise in machinery damage incidents align with what CMT is also seeing in the field.

“The emphasis on stricter maintenance and improved safety regimes highlights the urgency for ship operators to move beyond traditional inspection intervals and embrace a data-driven approach, said Krüger. “It is clear real-time insight and predictive diagnostics are key to preventing the kinds of failures that DNV warns about.

“Advanced condition monitoring is not just about saving money, it’s about protecting people, cargo, and the environment from the very real consequences of shipboard machinery failure.”

CM Technologies (CMT) is advising shipowners and operators to urgently review their fuel and lubricating oil sampling practices following the entry into force of revised IMO guidelines. Recent amendments to MARPOL Annex VI and SOLAS Chapter II-2, which include a 50% increase in the required sample volume and stricter expectations around equipment, handling, and record-keeping. The International Maritime Organization’s updated protocol, MSC-MEPC.2/Circ.18, mandates that fuel samples collected for MARPOL compliance now be a minimum of 600ml, up from the previous 400ml. This change ensures there is sufficient material to perform both sulphur content testing under MARPOL and flash point testing under SOLAS requirements. It also reinforces proper sampling procedures, including the use of tamper-evident containers, accurate labelling, and secure onboard storage. “Sampling is often regarded as a technicality, but it is the foundation for effective compliance and dispute resolution,” said David Fuhlbrügge, Managing Director of CM Technologies. “Too often, we see crew improvising with makeshift containers due to a lack of proper gear onboard. Samples are often sent to labs in recycled beverage bottles – which can invalidate test results.” Soft drink bottles frequently contain plasticizers – chemical additives designed to make plastic bottles flexible. These and other contaminants such as residual sweeteners, flavourings, or cleaning agents can alter the properties of the sample. This not only undermines test accuracy but can also lead to delays, re-sampling, or even the rejection of results by the laboratory. “Labs may refuse to analyse non-compliant samples and, in some cases, will charge extra to transfer samples to proper containers, creating additional delays and cost,” said Fuhlbrügge. But beyond the laboratory implications, poor sampling practices can carry serious legal and commercial consequences. “Proper sampling is not only about proving fuel quality but also about maintaining a defensible chain of custody,” he said. Contaminated or poorly documented samples cannot be presented in bunker disputes or during Port State Control (PSC) inspections and any results labelled ‘indicative only’ would not be used to support compliance claims. “With the new IMO regulations in place, ship managers and crews can’t afford to take shortcuts,” Fuhlbrügge furthered. “Proper sampling verifies that delivered fuel and oil conform to operational standards. If disputes arise, the integrity of that sample becomes critical. Any sign of tampering, contamination, or inadequate documentation could trigger fines, detention, or liability.” The revised guidelines also transfer responsibility for tracking and storing MARPOL Delivered Samples from the ship’s master to the ship owner or management company. “This shift underscores the importance of fleet-wide procedures and oversight,” said Fuhlbrügge. “Crews must be trained in how to operate sampling equipment, seal and label containers, and store samples correctly –typically for up to 12 months or until the fuel is consumed.” CM Technologies offers a comprehensive range of MARPOL-compliant solutions, including drip-type bunker samplers, certified sample bottles, tamper-evident seals, and lockable storage cabinets. The company is also preparing additional training resources and documentation to support shipowners and crew during the transition. “The new sample volume requirement may seem minor, but it’s part of a broader shift toward stricter enforcement,” Fuhlbrügge said. “Authorities and labs are paying closer attention to how samples are taken and handled. Having the right equipment – and using it properly – is no longer optional. It’s a core part of regulatory readiness and risk mitigation.” CMT believes these changes offer the industry an opportunity to raise standards, reduce risk, and improve transparency throughout the fuel supply chain.