How to Safely Isolate Machinery Onboard Ship? (Lock-Out Tag-Out System)
Summary
TLDRThis maritime training video outlines the critical lockout and tag out system for safely isolating machinery on ships during maintenance. It emphasizes the importance of administrative control through warning tags and physical prevention methods like lockout devices. The video demonstrates correct procedures, documentation, and authorization processes for electrical, hydraulic, and other pressurized systems, ensuring safety and compliance with regulations.
Takeaways
- 🔒 The lockout and tag out system is a crucial safety measure to control machinery on board a ship when it is switched off for repair or maintenance.
- 📝 A tag out system is an administrative control that involves placing warning tags on the means of machine or power isolation to inform others that the machinery is being worked on and should not be restarted.
- 🚫 Violation of the lockout and tag out rules should be met with severe disciplinary action and retraining to ensure the safety protocol is strictly followed.
- 📜 The tag must include the name of the person who placed it, the reason for isolation, the date, and contact details, and should be recorded in the logbook upon completion of work.
- ⚠️ Operating machinery on a ship carries inherent risks, and safety measures are essential to prevent injury or death when machinery is being serviced.
- 🚫 Inadequate safety measures, such as using loose pieces of paper for isolation, are unacceptable and do not meet the required safety standards.
- 🔌 When machinery is being serviced, it must be effectively isolated from its power source, and a warning tag must be placed at the point of connection to prevent accidental reactivation.
- 🔐 Physical preventive methods, such as lockout provisions on switches and valves, are essential to ensure that machinery cannot be reconnected to its power source during maintenance.
- 🔑 The lockout and tag out procedure must be authorized, especially in planned maintenance or shipyard repair work, within the framework of a recognized safety system like permit to work.
- 👥 In situations where multiple engineers work on the same equipment, each must place their own lockout device and tag, ensuring that isolation is only removed by the person who applied it.
- 📋 The lockout tag out record sheet is vital for documenting the equipment being worked on, the locking devices and tags used, their locations, applicators, and installation dates, ensuring traceability and accountability.
Q & A
What is the primary purpose of the lockout and tag out system on board a ship?
-The primary purpose of the lockout and tag out system is to ensure safety during repair or maintenance by controlling machinery that has been switched off, preventing it from being reactivated accidentally.
What does the tag out system represent in terms of safety measures?
-The tag out system represents the administrative control of the lockout and tag out system, involving placing a warning tag on the machinery or power isolation to inform others that the system is being worked on and should not be reactivated.
What should be included on a warning tag in a lockout and tag out system?
-A warning tag should include the name of the person who placed it, the reason for the isolation, the date it was placed, and additional information such as department and contact details.
What are the consequences of violating the lockout and tag out rules?
-Violation of the lockout and tag out rules can result in severe disciplinary action and retraining for the individual responsible.
Why is it necessary to record the lockout and tag out safety system in the logbook?
-Recording the lockout and tag out system in the logbook ensures that there is a documented record of when and by whom the machinery was isolated and when it was safe to reactivate, enhancing traceability and accountability.
What are the potential hazards of machinery that has been switched off for maintenance or repair?
-The potential hazards include the risk of someone restarting the machinery unaware that it is being worked on, which can lead to damage, injury, or even death.
What is considered an inadequate method for enforcing a major safety measure in the context of the script?
-An inadequate method mentioned in the script is the reliance on handwritten pieces of paper loosely attached to the means of energy isolation.
What is the golden rule when it comes to warning tags in the lockout and tag out system?
-The golden rule is that if you did not place the tag yourself, you must not remove it.
What is the second tier of safety in the lockout and tag out system?
-The second tier of safety is the physical prevention system, which involves locking the isolating device in the shut-off position, removing the key, and placing a warning tag on the device.
What is required for a lockout and tag out procedure in the case of planned maintenance or shipyard repair work?
-A lockout and tag out procedure must be determined within the framework of a recognized safety system such as a permit to work, authorized by the chief engineer and the superintendent.
What steps should be taken before starting work on isolated equipment?
-Before starting work, verify that the equipment has been disconnected from all energy sources, isolated, and locked out, and use the appropriate test method to confirm the system is no longer energized.
How should multiple engineers working on the same equipment handle the lockout and tag out system?
-Each engineer should place their own lockout device and tag on the isolator, to be removed only by themselves after their job has been completed.
What is the final step in the lockout and tag out process after completing the work?
-The final step is to clear the lockout action by recording completion on the lockout tag out record sheet and re-energizing the equipment safely.
Outlines
🔒 Lockout and Tag Out System Basics
This paragraph introduces the lockout and tag out system, emphasizing its importance in maintaining safety aboard ships. The system is designed to control machinery even when it is switched off for repair or maintenance. It involves administrative control through warning tags and physical control through lockout devices. The tags must be placed on the means of machine or power isolation, prohibiting others from reactivating the system. The paragraph also highlights the potential hazards of powerful machinery and the legal requirements for effective isolation methods. It illustrates the use of the system in special cases, such as when multiple engineers work on the same machinery or during shift changes.
🛠️ Recommended Procedures and Documentation
This section delves into the recommended lockout tag out procedures, documentation, and authorization processes necessary for maximum safety. It covers the physical preventive methods, such as lockout provisions on switches and valves, and the administrative prohibition through warning tags. The paragraph explains that any equipment shut down for repair or maintenance must be prevented from reconnecting to its power source. It also discusses the use of lockout and tag out systems in various scenarios, including electrical equipment, hydraulic motors, steam-driven winches, and compressed air systems. The importance of obtaining a permit to work and following a recognized safety system is emphasized, especially in the context of planned maintenance or shipyard repair work.
🔗 Lockout Methods and Record Keeping
This paragraph discusses the various lockout methods that can be used on different types of valves, switches, and breakers. It explains the need to select the right lockout device for each application and to record the details in a lockout tag out record sheet. The record sheet identifies the equipment being worked on, the locking devices and tags used, their location, who applied them, and the date of installation. The paragraph also emphasizes the importance of securing the energy source in the off position with a lockout device, attaching the completed tag to the device, and verifying that the system is no longer energized. It highlights the need to release or restrain residual or stored energy before work can commence and to ensure that the isolated equipment isn't capable of being energized from another power source.
👷♂️ Multiple Engineers and Shift Changes
This final paragraph addresses the application of the lockout system when more than one engineer is working on the same equipment, such as in a shipyard. It stresses the importance of each engineer placing their own lockout device and tag on the isolator, which can only be removed by them after their job is completed. The paragraph also discusses the procedure during shift changes, where the incoming operator should put their own lockout on the system before the outgoing operator removes his. The record sheets in the logbook provide all the information regarding the multiple lockout to the chief engineer. The paragraph concludes by emphasizing the critical role of the person who placed the lockout device and tag in removing them and the importance of recording completion on the lockout tag out record sheet for effective safety management.
Mindmap
Keywords
💡Lockout and Tag Out System
💡Machinery Isolation
💡Warning Tag
💡Safety Measures
💡Energy Sources
💡National Regulations
💡Physical Preventive Methods
💡Record Sheet
💡Residual Energy
💡Shift Work
💡High Voltage Installations
Highlights
Introduction to the lockout and tag out system for machinery on board ships to ensure safety during maintenance or repair.
Explanation of the administrative control of a tag out system, including the placement of warning tags to prohibit system reinstatement.
The necessity of severe disciplinary action and retraining for any violation of the lockout and tag out rules.
Details required on a warning tag, such as the name of the person who placed it, the reason for isolation, and the date.
The importance of recording the safety system in the logbook and canceling it once work is completed and devices are removed.
The risks associated with powerful machinery on ships and the legal requirements for effective isolation during maintenance.
The inadequacy of using handwritten pieces of paper as a safety measure for machinery isolation.
The requirement for lockout devices to be engaged on powered equipment during work to prevent unintentional activation.
The use of physical preventive methods such as lockout provisions on switches and valves to ensure machinery cannot be reconnected.
The recommended lockout tag out procedures and documentation related to their use for various types of equipment.
The golden rule of not removing a tag unless you placed it yourself and the consequences of ignoring this procedure.
The second tier of safety involving the physical prevention system where the isolating device is locked with a key and tagged.
The process of obtaining a permit to work within a recognized safety system for planned maintenance or shipyard repair work.
Different types of lockout methods that can be used on various types of valves, switches, and breakers onboard ship.
The importance of selecting the right lockout device for each application and recording it in the lockout tag out record sheet.
The steps to secure energy sources, verify isolation, and ensure no residual energy remains before commencing work.
The critical variation of the lockout system when multiple engineers work on the same equipment, requiring individual lockout devices and tags.
The procedure for shift changes involving the placement of a new lockout by the incoming operator before the previous one is removed.
The final steps for reconnecting equipment after lockout, including checking for safe operational status and clearing the lockout action.
The conclusion emphasizing the effectiveness of the lockout and tag out system for ensuring safety on merchant vessels.
Transcripts
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welcome training campers today i will
share some key notes on how to safely
isolate machinery on board ship that is
the lockout and tag out system
one of the facts surrounding the
operation of powerful machinery on board
ship is that when it is switched off for
repair or maintenance it must still be
controlled by safety measures a lockout
and tag out system has been designed to
provide this safety
a tag out system represents the
administrative control which involves
placing a warning tag on the means of
machine or power isolation informing
others that the machinery or power
system is being worked on the tag should
prohibit the reinstatement of the system
by anyone other than the person who
placed the tag severe disciplinary
action and retraining should follow any
violation of this rule a tag must be
attached to the locking device informing
others of the name of the person who
placed it the reason for its isolation
and the date on which it was placed
other information which may be given on
the warning tag includes the department
and contact details of the person who
placed the device this safety system
must be recorded in the logbook and
canceled when the work has finished and
the lockout device and tag have been
removed
this video clip illustrates the use of
the lockout and tag out system in some
special cases for example when the same
machinery is being worked on by several
different engineers and when shift work
is involved and the new shift arrives
before the last one has finished working
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so
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operating a modern ship means using
energy in its many forms
main propulsion
auxiliary machines
electrical steam hydraulic compressed
air and other pressurized systems
the machine that use this energy are
powerful tools capable of very hard work
but they are also capable of causing
death
injury and damage if misused
the risks associated with their use are
well known
for this reason their normal operations
are strictly controlled by your own
national regulations as well as by
company rules
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an additional hazard arises when these
machines have been switched off for
maintenance or repair or are being taken
out of service
why
because someone could restart one
unaware that the machine and its supply
system are being worked on
the result can be damage
injury or even death
in commercial shipping there is a great
need and a legal requirement to employ
effective means of isolating machinery
while it is being maintained or repaired
incredible but true however some ships
today rely only on hand written pieces
of paper loosely attached to the means
of energy isolation as a method of
enforcing such a major safety measure
this is clearly an inadequate and
unacceptable precaution or means of
hazard communication
in common with most national regulations
in force around the world
if an item of powered equipment has a
lockout or other device designed to
prevent unintentional activation
such devices must be engaged while any
work is being performed on it
the only exception to this rule is if
the nature of the work requires the
equipment to be activated
further an appropriate warning tag must
be placed at the point where the
equipment connects to the power source
and on its control panel
the basic approach is clear
any equipment that is shut down and
isolated from its energy source for the
purposes of repair or maintenance
must be prevented from being reconnected
to its power source while that work is
carried out
there are physical preventive methods
that can be applied
such as lockout provisions on switches
and valves
and there is an administrative
prohibition in the form of warning tags
placed on the means of isolation
if only chains or ropes are used on
valves these must ensure that the valves
are kept securely in the shut position
during the course of this video we will
look at the recommended lockout tag out
procedures
the documentation related to their use
and the authorization procedures
necessary to ensure maximum safety in
applying the lockout tag out systems to
electrical equipment
hydraulic motors
steam driven winches and compressed air
systems
there are occasions when an electrical
circuit for example is isolated briefly
for periodic testing
having isolated the circuit the engineer
places a tag on the switch
warning that the circuit is isolated
and informing everyone that work is
being performed on it
further the tag should forbid anyone
from reconnecting the circuit
the golden rule is
if you didn't place the tag yourself
you must not remove it
the sanction against ignoring this
procedure should be serious disciplinary
action
followed by retraining
this is the first tier of safety control
the second tier of safety the physical
prevention system is operated when the
isolating device is locked in the shot
off position with the key removed and a
warning tag placed on the device
this is to ensure that the system cannot
be reconnected without the active
approval of the key holder
the tag in this case informs everyone of
the details of the key holder
and sometimes the circumstances of the
shutdown as well as serving as a warning
that the system is being worked on
in the case of a planned maintenance
process or of shipyard repair work
a lockout and tag out procedure is
determined within the framework of a
recognized safety system such as permit
to work
the chief engineer and the
superintendent will have decided on the
necessity of the work to be done and the
circumstances in which the work must be
carried out
in this context the lockout and tag out
is authorized
i'm gonna i'm gonna need to secure the
windlass
i understand somebody's working on it up
here okay
uh you guys are going to be working up
on deck
in situations where an emergency repair
is required due to an unexpected
breakdown
the engineer who will carry out the work
must discuss it with the chief engineer
and the ship's designated safety officer
or supervisor
and obtain a permit to work by which to
control the risks involved
they will check that the proposed
lockout will not cause unacceptable
operational difficulties elsewhere on
board ship put his lock on it as well
for example interfering with navigation
or with the main propulsion
or were still the galley
if there are no limiting reasons the
permit will be issued and will describe
the necessary lockout tag out procedure
the type of lockout devices to be used
and their method of application
this authorization must be obtained
before lockout takes place
you familiar with uh have you seen these
before no not these ones exactly okay
just as there are different types of
valves switches and breakers employed
onboard ship
there are a number of different types of
lockout methods that can be used
the devices may be incorporated in the
design of the isolator or chains and
padlocks may be applied
fuses or circuit breakers may be removed
or simply a rope may be used to secure a
valve in the closed position
sometimes if locking or tagging out is
not practical
the best form of protection is to trace
the lead back to the supply
disconnect it
and take it back to the machinery being
serviced
now let's illustrate how the system
works in particular situations
the right lockout device must be
selected for each application
and in accordance with the company's
safety management system
the number of the lock and its details
must be entered into the lockout tag out
record sheet
the record sheet identifies the
equipment being worked on
the identification numbers of all
locking devices and tags used
where they are located
who applied them
and the date of installation
the record sheet is kept in a log book
for signing off when the job for which
the lockout tag out was authorized has
been completed and the system has been
made operational again
a tag including the name of the person
placing the locking device and the
reason for the isolation must be placed
on the lockout device
in all cases secure the energy source in
the off position with a lockout device
so that power cannot be accidentally
restored
attach the completed tag to the lockout
device
we're going to be replacing this
transformer here
before starting any work verify that the
right equipment machinery or system has
been disconnected from all energy
sources
isolated and locked out
then verify by the appropriate test
method that the system is no longer
energized
but always remember that residual or
stored energy may remain in some
equipment or systems such as capacitors
rotating flywheels
hydraulic pressurized air gas steam or
water systems
such energy must be released or
restrained by grounding
repositioning
blocking or bleeding before work can
commence
remember also that some power systems
also act as breaks
so if disconnected for example in the
case of a hatch cover opening mechanism
you must ensure that the hatch cover is
secured in the open position
physically being prevented from moving
it is most important to check that the
isolated equipment isn't capable of
being energized from another power
source
if it is then this power source must
also be isolated and verified to be
isolated before work can begin
if the secondary isolation takes a
different form such as the removal of
fuses for example
the person isolating the system must
retain the fuses and place another tag
on the equipment
so
safe isolation secure lockout and the
verification of isolation are
particularly important in the case of
high voltage installations
a crucial variation on the application
of the basic lockout system arises when
more than one engineer is working on the
same
equipment in a shipyard for example it
often happens that a mechanical engineer
an electrical engineer and an electronic
engineer wish to work on the same
equipment at the same time
it is critical that each engineer places
their own lockout device and tag on the
isolator to be removed only by
themselves after their job has been
completed
similarly during a shift change the
incoming operator should put his own
lockout on the system before the
operator leaving the shift removed his
this will ensure that at no time will
the isolation be reconnected when the
equipment is still being serviced
the record sheets in the logbook provide
all the information regarding the
multiple lockout to the chief engineer
work safely completed the chief engineer
must be notified when everything is
ready to remove the locks and return the
equipment machinery
now if it was you who placed the lockout
device in tag you can remove them and
re-energize the equipment
for effective safety management it is
critical that only the person who placed
the lock-up device and tag may remove
them from a locked out system
removal of any locks or tags is
extremely dangerous and must be
forbidden
before reconnecting the equipment check
that it can now be made operational
safely
finally clear the lockout action by
recording completion on the lockout tag
out record sheet
this is an effective lockout and tag out
system that can be easily operated on
board merchant vessels and which will
make your work safer and will satisfy
the safety requirements prescribed in
most national regulations
thank you for watching please do not
forget to like share and subscribe to
the channel for more maritime education
and training videos
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