How to Safely Isolate Machinery Onboard Ship? (Lock-Out Tag-Out System)

MARITIME TRAINING CAMP

12 Jan 202219:11

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

00:00

🔒 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.

05:06

🛠️ 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.

10:18

🔗 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.

15:20

👷‍♂️ 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

The Lockout and Tag Out System is a safety procedure designed to ensure that machinery or equipment is isolated from its energy source during maintenance or repair. This system is crucial in preventing accidental activation of machinery, which could lead to injury or death. In the video, it is emphasized that this system must be followed to maintain safety on board ships, with tags providing administrative control and locks providing physical prevention.

💡Machinery Isolation

Machinery isolation refers to the process of disconnecting machinery from its power source to prevent it from being activated during maintenance or repair. This is a critical step in ensuring safety, as it prevents the machinery from being turned on accidentally. The video script mentions that machinery isolation must be controlled by safety measures, highlighting the importance of this process in preventing accidents.

💡Warning Tag

A warning tag is a part of the tag out system used to inform others that machinery or a power system is being worked on and should not be activated. It typically includes the name of the person who placed the tag, the reason for isolation, and contact details. In the script, it is mentioned that severe disciplinary action and retraining should follow any violation of the rule regarding the use of warning tags.

💡Safety Measures

Safety measures are procedures and protocols put in place to protect workers from potential hazards. In the context of the video, safety measures include the lockout and tag out system, which is designed to prevent machinery from being activated during maintenance. The script emphasizes the importance of these measures in controlling the risks associated with operating powerful machinery on board ships.

💡Energy Sources

Energy sources in the context of the video refer to the various forms of power that machinery on a ship might use, such as electrical, steam, hydraulic, compressed air, and other pressurized systems. The video script highlights the need to isolate these energy sources during maintenance to prevent accidents, emphasizing the importance of controlling these powerful tools.

💡National Regulations

National regulations are laws and rules set by a country's government that govern safety practices, including those related to machinery operation and maintenance. The video script mentions that the operation of machinery on board ships is strictly controlled by national regulations, indicating the legal requirements for employing effective means of isolating machinery during maintenance.

💡Physical Preventive Methods

Physical preventive methods are tangible actions taken to prevent machinery from being activated during maintenance. These can include lockout provisions on switches and valves, or using chains or ropes to secure valves in the shut position. The video script discusses these methods as part of the lockout and tag out system, emphasizing their role in ensuring safety.

💡Record Sheet

A record sheet is a document used to log the details of the lockout and tag out procedures, such as the equipment being worked on, the identification numbers of all locking devices and tags used, and the date of installation. The video script mentions that this sheet is kept in a logbook and is used for signing off when the work is completed, indicating its importance in tracking and verifying the safety procedures.

💡Residual Energy

Residual energy refers to the remaining energy in a system after it has been disconnected from its power source. The video script warns that even after machinery is isolated, residual energy such as in capacitors or rotating flywheels can still pose a risk, and must be released or restrained before work can commence.

💡Shift Work

Shift work involves dividing the work hours of a day into shifts, which can complicate the lockout and tag out process. The video script discusses the need for the incoming operator to place their own lockout on the system before the operator leaving the shift removes his, ensuring that the isolation is maintained and the equipment is not reconnected while still being serviced.

💡High Voltage Installations

High voltage installations are systems that operate at voltages higher than the standard household or industrial levels. The video script highlights the importance of safe isolation, secure lockout, and verification of isolation in these cases, emphasizing the increased risks associated with high voltage systems and the need for extra caution.

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.