Inspecting and Tagging Out Damaged Tools
Damaged tools are a major cause of offshore injuries, equipment damage, and failed maintenance tasks.
All crew members must be able to identify a defective tool and remove it from service immediately.
This scenario teaches the correct procedure for inspection, tagging, and reporting.
1. Why Tagging Out Tools Is Critical
Using damaged tools can lead to:
- Slips and loss of control
- Struck-by injuries
- Pinch points
- Component failure
- Equipment leaks or breakdowns
- Delays and rework
Offshore environments accelerate tool wear due to salt, moisture, vibration, and heavy mechanical use.
2. Identifying Tool Defects
Common defects include:
Wrenches
- Rounded jaws
- Cracks in handle
- Bent alignment
- Excessive slop on fasteners
Screwdrivers
- Worn or broken tips
- Bent shafts
- Loose handles
Pliers & Cutters
- Stiff or loose pivot
- Cracked jaws
- Broken cutting edges
Impact Tools (Hammers, Chisels, etc.)
- Mushroomed heads
- Splintered handles
- Loose heads
- Cracks in striking surfaces
Sockets & Ratchets
- Cracked walls
- Worn internal drive
- Slipping ratchets
3. Tag-Out Procedure
Step 1: Stop Work
As soon as a defect is identified, stop using the tool.
Step 2: Attach Tag-Out Label
Use a red “Do Not Use” tag or company-approved tagging system.
Tag should include:
- Worker’s name
- Date
- Defect description
- Location
Step 3: Inform Supervisor or Tool Room
Communicate the issue clearly.
Step 4: Remove Tool From Service
Move the tool to designated “Rejected Tools” area.
Step 5: Document the Issue
Record in tool log system (digital or paper):
- Tool ID
- Defect found
- Action taken
- Replacement required
4. When to Replace vs. Repair
Replace Immediately if:
- Structural cracks are visible
- Impact tools show mushrooming
- Handles are bent or fractured
- Tool cannot grip securely
- Tool fails inspection more than once
Repair Only if:
- Company-approved technician is available
- Tool is designed for repair (e.g., ratchet rebuild kits)
- No safety-critical defect exists
Never attempt “field repairs” on tools.
5. Common Mistakes to Avoid
- Continuing work with a damaged tool
- Using a defected tool “just one more time”
- Removing tags without authorization
- Not documenting tool issues
- Ignoring rust or wear
6. Learning Objectives
By completing this scenario, trainees will:
- Identify tool defects quickly
- Know when and how to tag out tools
- Understand the importance of formal reporting
- Prevent injuries caused by improper tool use
- Maintain high safety standards offshore