Captive key interlocks – potential risks from existence of keyed alike and master keys
COUNTRY OF ORIGIN
ACCIDENT / INCIDENT DETAILS
Guarding to a new equipment installed by a contractor incorporated a trap key system. It was manufactured by Fortress, but supplied by a third party wholesaler.
Concern was raised during commissioning, when it was identified that there was a spare key for the new interlock system; further significant concern was raised when it was identified that the keys would also open other existing interlocks around the site, presenting a significant risk of major injury or death.
Investigation confirmed that Fortress offer 2 ranges of keys; (CL) - which are non-masterable and (ML) - which are masterable.
When obtained from wholesalers, only a limited number of lock and key combinations are available, giving rise to a risk of having duplicate keys on site.
It has also been established that a similar risk exists with trap key systems from other manufacturers.
ACCIDENT / INCIDENT IMAGES
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LEARNING POINTS / ACTIONS TAKEN
• Duplicate and / or master keys for interlock systems are prohibited on our sites.
• In this case, the systems should have been ordered direct from the manufacturer, who keep a database of the locks they supply to individual sites to ensure they are unique and not keyed alike.
• If your site use Fortress interlocks, ensure they are from the CL range.
• Verify that trap key systems are non-masterable, that there are no duplicate locks and no spare keys. Spare keys should have been destroyed.
• Log and compare the serial numbers on the lock and key sets to ensure they are unique; share this information with contractors if they are quoting to install additional interlocks.
• Always read and understand the any warnings / disclaimers associated with critical safety equipment.
LEARNING POINTS / ACTIONS IMAGES
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