RQ4_Maintenance_Platform.pdf

Airpower is the power of airmen

DEPARTMENT OF THE AIR FORCE

9TH MAINTENANCE SQUADRON (ACC)

BEALE AIR FORCE BASE, CALIFORNIA

MEMORANDUM FOR 9 CONS/LGCB

FROM: 9 MXS/RA

SUBJECT: Statement of Need for RQ4 Maintenance Stands

1. Purpose: Stands will be used for corrosion control maintenance operations.

2. Scope or mission: Aircraft Structural Maintenance is tasked with organic coating refurbishment and corrosion control of the RQ4 airframe.

3. Impact: Will provide mandatory aircraft corrosion control capabilities.

4. Background: Beale AFB does not have appropriate maintenance stands to perform tasking.

5. Special Requirements: Please see specifications listed below.

• The stands must be constructed of steel and/or aluminum coated with industrial grade primer and epoxy or urethane paint. Paint color scheme must be Age Gray 26173 for all paintable surfaces and Safety yellow, color code 23538, on and around all pinch points and handrails to industry standard. Addition hazard markings will be painted to industry standard. Stands must meet all OSHA/industry safety standards and meet requirements in AFI 91-203 Chapter 16. AFI 91-203 will be attached to this Statement of Need.

• Compressed Air hook ups with pre filter/air water separator and air regulator with min 150 CFM with two 3/8

in. industrial interface quick disconnect fittings every 15 feet. Stand air must be able to connect through all stands from one of four MC7 air fitting attach points (Dixson USA V$C 33x 13 example). Each connection of compressed air must have a ball valve in beginning and end of connections.

• Removable/ adjustable guard rails(industry standard height) capable of sliding/ folding in increments shorter than 6ft

• Manual jack stands with range up to 2 feet.

• The stands must be modular in nature and have the ability to lock into each other to form one unit that encompasses the aircraft. The area directly in front of the aircraft nose and wingtips do not need stand coverage. The dimensions of each individual section must be no larger than 5 feet wide by 6 feet long. Each

Airpower is the power of airmen individual section must have a minimum 500lbs weight capacity. The edge of the stands that will mate with the surface of the aircraft must have padding installed to reduce damage to aircraft surface. The starting height of the stands will be determined at post contract award site visit.

• Each individual section must have casters with sealed bearings. All casters must have a locking mechanism.

• Dust/overspray guards/scraper covers over any moveable items (hydraulic rams, bearings, tracks ect.)

• Anti skid/slip surface on all working/walking surfaces with draining capabilities.

6. POC: Please direct any questions regarding this information to TSgt Nicholas Bahler at DSN 368-8620

NICHOLAS D. BAHLER, TSgt, USAF Resource Advisor

AFI91-203_AFGM2015-04

17 September 2015

MEMORANDUM FOR DISTRIBUTION __

MAJCOMs/FOAs/DRUs

FROM: AF/SE

SUBJECT: Air Force Guidance Memorandum to AFI 91-203, Air Force Consolidated

Occupational Safety Instruction

By Order of the Secretary of the Air Force, this AF Guidance Memorandum is reissued to immediately change AFI 91-203. This AFGM supersedes AFI 91-203_AFGM3 that was issued on 19 August 2014. Compliance with this Memorandum is mandatory. To the extent its directions are inconsistent with other Air Force publications; the information herein prevails, in accordance with AFI 33-360, Publications and Forms Management.

In advance of a rewrite of AFI 91-203, the Attachment to this Memorandum is updated to provide guidance changes that are effective immediately. An asterisk (*) indicates newly revised material.

The Memorandum becomes void after one-year has elapsed from the date of this

Memorandum, or upon incorporation of an Interim Change or rewrite of AFI 91-203, whichever is earlier.

ANDREW M. MUELLER, Maj Gen, USAF

Chief of Safety

Attachment:

Guidance Changes

DEPARTMENT OF THE AIR FORCE

HEADQUARTERS UNITED STATES AIR FORCE

WASHINGTON, DC

Attachment

Guidance Changes

The below changes to AFI 91-203, dated 15 June 2012, are effective immediately.

1.3.1. The Air Force publishes industrial and general ground safety guidance as Air Force instructions, which implement OSHA standards. The use of this instruction covers hazards which exist in a wide variety of situations and is therefore considered to be applied as a horizontal standard, the same as OSHA does with 29 CFR 1910. Area-specific instructions and technical data include other safety criteria. When AFOSH guidance or safety criteria does not cover a situation, use non-Air Force standards, including national consensus standards, professional safety and health standards, and other Federal agency standards. Air Force activities must comply with OSHA requirements at all times unless the military-unique exemption applies according to DoDI 6055.1, DoD Safety and Occupational Health Program. Note: AFOSH guidance must be followed at all times. They implement parts of 29 CFR, and include additional requirements not addressed by the OSHA standards. In addition, safety, fire prevention and occupational health requirements in equipment technical orders (TO) must be followed at all times.

4.14.8. Is PPE provided and used when needed to protect the hands and feet of workers involved in manual materials handling activities? Reference 4.7.1

4.14.9. Are wheeled hand trucks and dollies loaded so the cargo is stable and the loads won't slip, shift or fall? Reference 4.9.1.5

4.14.10. Is the rated capacity on all lever operated hoists permanently and conspicuously marked and easily visible? Reference 4.9.3.1.1

4.14.11. Are hoists equipped with a device (ratchet and pawl or load brake) that prevents a suspended load from self-lowering and ensures loads are only lowered by operation of the hoist lever? Reference 4.9.3.1.2

4.14.12. Are hoists inspected daily or prior to each use for items such as loose or worn parts, cracked or broken welds, deformed hooks or chain, and bent or deformed pawls? Reference

4.9.3.2

4.14.13. Is an annual inspection accomplished on all MHE? Reference 4.9.3.3

4.14.14. Are identification tags attached to hoists indicating date of inspection, date of proof test, capacity of hoist and identification number of hoist? Reference 4.9.3.4

4.14.15. Do hoist users maintain records of all tests? Reference 4.9.3.5.1

4.14.16. Are only approved lifting devices like slings used to lift loads? Reference 4.9.3.6.2

4.14.17. Do material handlers remove finger rings and jewelry prior to working with materials or moving machinery? Reference 4.11.6

4.14.18. Are materials neatly stacked and the height limited to minimize the possibility for the materials to fall or collapse? Reference 4.13.1

4.14.19. Delete.

5.2. Scraps and Combustible Waste. Provide sufficient metal or noncombustible containers with self-closing lids for disposal or recycling of combustible wastes, rags or other items contaminated with combustible or flammable materials. These containers shall be marked IAW

AFI 32-7042, Waste Management, and AFI 90-821, Hazardous Communications. Dispose of contents IAW approved hazardous waste disposal procedures. Contact the installation environmental management office for guidance. Ground areas around facilities where liquids are stored, handled or used shall be kept free of weeds, trash or other unnecessary combustible materials.

5.3. Combustible Materials. In industrial operating areas where flammable or combustible liquids and other combustible materials, to include non-soiled excelsior (fine wood shavings), straw, recyclable cardboard or paper, are used or stored, combustible materials shall be kept to a minimum, stored in covered metal containers and disposed of daily. This requirement is applicable when storage of flammable and combustible liquids exceeds:

5.3.1. 60 gallon capacity in fixed tanks.

5.3.2. 660 gallon capacity in portable tanks.

5.3.3. 793 gallon capacity in intermediate bulk containers.

5.9.7. Noncombustible materials shall be neatly kept in designated cabinets with their contents plainly marked).

5.9.8. Clothing lockers shall be maintained in a clean, orderly condition. Apparel not needed to perform official duties shall be stored in lockers. Objects shall not be stored on top of or under clothing lockers and no flammable liquids shall be stored in lockers.

5.9.9. Machinery and equipment shall be kept clean of excess grease and oil and free of excessive dust. Pressure gauges and visual displays shall be kept clean, visible and serviceable at all times. Drip pans and wheeled or stationary containers shall be cleaned and emptied at the end of each shift.

5.9.10. Certain cleaning compounds used in housekeeping activities may pose a hazard to workers. To protect eyes, skin and clothing from these compounds, workers shall wear (as required) safety glasses, face shields, aprons and gloves. Installation Ground Safety office and

BE shall be consulted with questions pertaining to PPE. Refer to Chapter 14 for additional guidance.

5.9.11. All surfaces shall be maintained as free as practicable of accumulations of dust, lead, chromium, cadmium or any other foreign particles. Floors shall be kept clean. Spills shall be cleaned up as soon as possible.

5.9.12. Delete.

5.9.13. Delete.

6.2.3. Health Care Facilities. Facility managers and/or safety officers of health care occupancies shall have in effect a written fire plan that addresses appropriate staff response to a fire emergency and appropriate education and training for all elements of the fire plan. The plan will address facility-wide needs in response to fire, area-specific needs for all areas, training for all staff, employees and volunteers, and appropriate training for other non-staff personnel required to participate in the fire plan. This fire plan shall be approved by the Installation Fire Chief.

Facility managers shall ensure fire exit drills are conducted IAW NFPA 101.

6.2.4.7. Visual Inspection. Managers and supervisors at all levels shall ensure a visual inspection is performed and documented monthly for all fire extinguishers under their control.

Extinguishers with discrepancies shall be removed from service until repaired. This inspection includes:

7.2.1.7.6. Newly constructed guard railings shall consist of securely mounted top rails, intermediate rails and posts. The top rail vertical height shall be 42 inches, nominal, from the upper surface of the top rail to the floor, platform, runway or ramp level. The intermediate rail shall be approximately halfway (minimum of 21 inches high) between the top rail and the floor, platform, runway or ramp.

7.5.2.7. Personnel Training. Personnel who use ladders at any working height shall be adequately trained in the care and use of different types of ladders. The supervisor or a designated trainer shall conduct this training when a worker is first assigned. Refer to paragraph 7.4.6 for additional information on ladder training. Information presented during safety briefings shall satisfy the periodic training requirement. All training shall include hands-on instruction to include inspection of ladders for defects, possible electrocution hazards, proper positioning and placement of ladders for various job sites. Training shall be documented IAW instructions in AFI

91-202, The US Air Force Mishap Prevention Program (paper or electronic system may be used).

7.7.59. Are personnel who use ladders adequately trained by the supervisor in the care and use of different type ladders when a worker is first assigned? Reference 7.5.2.7

7.7.60. Are ladders stored in a way that provides easy access for inspection and permits their safe withdrawal for use? Reference 7.5.2.5.3

7.7.61. Are wood ladders stored in a location free from exposure to the elements and excessive heat or dampness? Reference 7.5.2.5.3

8.9.7. Ground Fault Circuit Interrupters (GFCI) shall be used on all 125-volt, single-phase, 15-, 20-, and 30-ampere receptacle outlets at job sites where the receptacles are not part of the building/structure permanent wiring. Receptacles on a two-wire, single-phase portable or vehicle-mounted electrical generator rated not more than 5 kilowatts (kW), where electrical generator conductors are insulated from the generator frame and other grounded surfaces, shall be permitted without GFCI protection. Receptacles shall be located outside wet process areas or protected by a GFCI. To protect large areas, GFCI breakers shall be located in the circuit panel.

125-volt, single-phase, 15- and 20-ampere receptacles installed in locations below shall include

GFCI protection. See NFPA 70, National Electrical Code, Article 210.8, for exceptions, i.e., for locations where GFCIs are not required.

8.9.7.2.6. Sinks – where receptacles are installed within six (6) feet of the outside edge of the sink.

8.9.7.2.7. Indoor wet locations.

8.9.7.2.8. Locker rooms with associated showering facilities.

8.9.7.2.9. Garages, service bays and similar areas where electrical diagnostic equipment, electrical hand tools or portable lighting equipment are to be used.

8.9.9. Delete.

8.11.5.2. Supervisors shall consult with installation Ground Safety office to determine if insulating matting is required in their areas of responsibility. This includes areas where potential shock hazards exist and additional protection is needed, floor resistance is lowered due to dampness and where high voltage (greater than 600 volts, nominal) may be encountered, such as high voltage consoles. Areas with electrical repair or test benches (shops), motors or equipment and control panels require insulating matting.

8.12. Emergency Equipment (Electrical Safety). In addition to electrical PPE provided to workers, functional managers shall ensure emergency equipment is available at each operating location where maintenance is performed on energized circuits. High voltage is defined as over

600 volts, nominal. Equipment variations depend on local conditions and the squadron commander or functional manager may add additional items. The equipment may be displayed on a board, stored in an unlocked cabinet or made available in a portable kit, and shall be situated in a conspicuous and prominent location at each site, well marked and readily accessible.

Equipment shall be protected against chemical, mechanical or environmental deterioration and shall be inspected or tested for serviceability. Emergency equipment shall consist of:

8.12.8. High voltage insulated lineman’s rubber electrical gloves (both inner and outer gloves) – if rescuer(s) is(are) likely to contact live wires, conductors or current carrying parts while performing rescue. Voltage rating shall be suitable for voltages encountered in the work area.

Note 1: Electrical gloves shall be checked before use IAW UFC 3-560-01, Electrical Safety O

& M, and American Society for Testing Materials (ASTM) F496-85, Specification for In-service

Care of Insulating Gloves and Sleeves, and shall be tested and marked with the next test due date.

Note 2: High voltage is defined as greater than 600 volts, nominal.

8.18.2.3. Arc flash protection shall be provided for all Air Force operations exposing personnel to energized parts greater than 50 volts. Protective clothing required, if any, shall be based on the procedures outlined in UFC 3-560-01 and AFI 32-1064.

8.19.12. Are only qualified operators who are designated in writing by the supervisor allowed to work on electrical installations and equipment? Reference 8.9.1

8.19.13. Delete.

10.4. Lifting Requirements. Procedures in Chapter 4, Manual Material Handling and Lifting

Techniques, shall be used when personnel lift heavy objects, such as files, books, paper, etc.

Team lifting shall be evaluated when the person doing the lifting (or their supervisor) considers the item to be too heavy or awkward to lift safety, or the item or lifter is in an awkward position or location. Use a dolly or other material handling equipment, if available, to move heavy or awkward objects. Refer to Chapter 4 prior to using material handling equipment, as required.

11.3.8. Do all outside activities cease and do personnel seek adequate shelter during a lightning warning? Reference 11.2.3.2

13.8. Additional Rescue Guidance. Where non-Air Force professional rescue agencies cannot promptly rescue a fallen AF worker, the installation Ground Safety office and Fire Emergency

Services (FES) Flight may establish training for fire protection workers and adequate installation personnel as authorized or competent rescuers. Training shall be documented IAW AFI 91-202.

Coordination with the installation Fire Chief is required to determine if the FES Flight is able to support a fall rescue operation.

14.4.8.3. Arc-Flash Resistant Clothing. A flash hazard analysis (FHA) shall be performed for all

Air Force operations exposing personnel to exposed energized parts at 50 or more volts IAW

NFPA 70E, Electrical Safety in Workplace, Section 130.3, and UFC 3-560-02, Electrical Safety.

Protective clothing required, if any, shall be based on the FHA performed.

14.5.2. Upon request, the supervisor, with the assistance of the installation Ground Safety office, shall inspect areas with electrical facilities and determine if insulating matting is required for worker protection. Typical examples of areas where insulating matting is required include locations where potential shock hazards exist and additional resistance is required, floor resistance is lowered due to dampness, high voltages (greater than 600 volts, nominal) may be encountered, such as high voltage consoles, and areas with electrical repair or test benches

(shops), motors or equipment and control panels.

14.6.2. Do supervisors ensure required PPE job safety training is documented as required by

AFI 91-202? Reference 14.3.2.1

16.4.3.1.2. For lines rated over 50 kV, the minimum clearance between lines and any part of the aerial lift shall be at least 10 feet (305 cm) plus 4 inches (10 cm) for each 10 kilovolt over 50 kV, or twice the length of the line insulator, but never less than 10 feet (305 cm).

16.4.4. Proximity Warning Devices. Proximity warning devices may be installed on aerial platforms but will not release the operator from assuring safe clearance IAW paragraph 16.4.3.

16.5.1. Work platforms with work levels four (4) feet or higher and accessed by a ladder or stairway at an angle over 60 degrees, shall have guardrails, midrails and toeboards IAW paragraph 16.4.6.10 on all three (3) sides of the work platform, not including work platform access opening. Refer to ANSI 92.3, paragraph 4.12.3.

16.5.3.8. Self-propelled elevating work platforms shall be in the lowered position prior to being moved. Manually-propelled mobile work platforms shall not be moved with personnel on the working platform unless allowed by manufacturer’s instructions. Locking pins or other devices, as required, shall be in place before anyone is allowed to ascend the stairs or ladder. Tools and equipment left on the work platform while the unit is moved shall rest securely on the floor of the platform and be protected by a rail and toeboard IAW paragraph 16.4.6.10.

16.5.11.6. Mobile work platforms shall be operationally inspected IAW TO 00-20-1 by the user daily, before use, for serviceability and leaks. Items to be inspected will include brakes, jacks, wheel locks, cables, locking pins, hydraulic systems, anchor connections, railings and removable attachments, including bolts, pins or other locking devices and overall equipment condition.

Maintenance work stands shall have at least two operational brakes, locks or permanently installed jacks. At least two brakes shall be set and all wheel casters locked before any action, i.e., maintenance, inspections, etc., is performed. Wheel chocks may be used in conjunction with these requirements. Vehicle chocks may be constructed or locally manufactured IAW TO 00-25-

172, Ground Servicing of Aircraft and Static Grounding/Bonding, Section 4.1.2. Platforms shall be locked when not in use to avoid rolling down slanted surfaces or being moved by wind.

Stands with defects shall be tagged as unserviceable. Inspection should be documented on AFTO

Form 244, Industrial/Support Equipment Record. Note: A daily inspection is not required for days the stand is not used.

16.6.1. Do operators of aerial lifts near electric power lines maintain proper clearances?

Reference 16.4.3

16.6.25. Are work platforms secured against movement when not being transported? Reference

16.5.11.5

18.5.2.1.1. Supervisors will ensure either a fixed barrier guard, safeguard device or combination of both is installed and used on every operation when the opening between the die (tool) and base (anvil) is more than ¼ inch. The functional manager and installation Ground Safety office must approve guarding by location. The use of hand-feeding tools, regardless of size, does not replace a guard or device. Refer to 29 CFR 1910.212 and 1910.217 for additional safe distance and maximum opening requirements.

18.5.2.21.4. Belt dressing should not be applied when the belt or rope is in motion. However, if necessary, it shall be applied where belts leave the pulleys, not where they approach them.

21.3.3.1. AF Form 983, Danger – Equipment Lockout Tag. The AF Form 983 and equivalent

DoD and commercial tags are authorized for lockout purposes and shall be used for lockout situations. This tag shall be placed on equipment that has been removed from service for maintenance purposes. All employees shall be instructed that these tags indicate that equipment is locked out for maintenance.

21.4. LOTO Procedures. Only authorized workers shall perform LOTO procedures. Personnel directly affected by the operation or shutdown of the equipment or machine shall be notified of

LOTO devices. Notification shall be given before controls are applied and after they are removed. Refer to paragraph 21.7 for sample procedures. Procedures for applying locks or tags shall include and be performed in the following order. Note: If not specifically called for by governing directives for the task being performed, it is recommended that workers be assigned in teams (minimum of two [2] people), one serving as a safety observer.

21.4.2.7.2. When the equipment to be worked on does not have normal controls, e.g., on/off switch, etc., use the following procedure for isolation confirmation. Test potential energy sources using appropriately rated and calibrated instruments or testers. Instruments used to test voltage, pressure or temperature shall be checked for proper operation both before and after use. If the authorized worker is not qualified to test the energy being isolated, he or she shall ensure the energy is tested by a qualified person.

21.4.2.9. Step Nine – Before restoring machines and equipment to service, the supervisor or authorized employee will:

21.4.2.9.1. Ensure all personnel, tools and maintenance or servicing equipment have removed and guards have been reinstalled.

21.4.2.9.2. Notify personnel the locks or tags have been removed and equipment is in service.

21.4.2.9.3. Remove all locks or tags and restore the energy isolating device to the ‘ON’ position.

21.6.1. Self-Assessments. Shop LOTO self-assessments shall be conducted by an authorized worker or supervisor annually, to ensure compliance with all program elements. Self-assessments shall be designed to correct any deviations or inadequacies observed. Refer to

Figure 21.10 for a sample assessment sheet. The assessment shall be documented, provide for a demonstration of the procedures and include, as a minimum:

EQUIPMENT SPECIFIC LOTO CHECKLIST

Figure 21.9. Equipment Specific LOTO Checklist. This is a tool and shall not replace a written LOTO program.

A. Equipment Identification: Location:

B. This procedure covers servicing and maintenance of machines and equipment in which “unexpected” energization or start up of the machines or equipment, or release of stored energy could injure employees. Authority: 29 CFR 1910.147(c)(4)

SCOPE OF THIS PROCEDURE:

C. HAZARDOUS ENERGY TYPE (Hazard): (Check All That Apply)

1. Electrical: (shock, electrocution, arc flash)

a. Voltage: AC < 30 or DC < 50 volts

b. Voltage: AC or DC but ≤ 600 volts

c. Voltage: > 600 volts

d. High current: > 25 amperes at any voltage

Include: Capacitors and Batteries

IAW AFI32-1064, Electrical Safe Practices

2a. Pneumatic / Hydraulic: > 1 Atmosphere which results in hazardous energy (crush, whipping, noise, shrapnel)

Include: Reservoirs, Receivers, Tanks

2b. Mechanical: ( crush, drop, punch, pinch, grab, cut, rotate )

Include: Springs, Platforms (raised), Pendula, Bungees, Flywheels

2c. Vacuum: < 1 Atmosphere (crush, whipping, noise, shrapnel)

Include: Reservoirs, Receivers, Tanks

2d. Thermal, High temperature: > 120° F surface temperature (burns)

2e. Thermal, Cryogenic: Unguarded delivery line or conduction to a part where exposure potential exists, potential contact with a cryogenic liquid. (extreme freezing, asphyxiation)

3. Chemical: Explosion, Fire, Corrosion, Oxidization, Toxin, Asphyxiation, Mutation, Instability

4. Radiation: Electro-magnetic, Microwave, Infrared, LASER, Ultraviolet, Ionizing.

5. Other: Specify:

D. JOB SPECIFIC LOCKOUT INFORMATION

D.1 Specific Lockout Locations Lockout Procedure Order D.2 Dissipate stored energy at these points:

Identification Location/Isolation Device

D.2 Block these parts/remove linkages:

E. NAMES OF AUTHORIZED WORKERS PERFORMING THIS LOCKOUT:

F. NAMES OF PERSONNEL AFFECTED BY THIS LOCKOUT:

G. VERIFICATION REQUIREMENTS:

H. SAFETY MEASURES/SPECIAL INSTRUCTIONS: (i.e. PPE)

I. LIST ADDITIONAL INFORMATION AS REQUIRED:

J. BASIC LOCKOUT PROCEDURES

1.

Preparation.

2.

Notification.

3.

Shutdown.

4.

Isolation/Verification.

LOTO Device Application.

6.

Additional Measures.

7.

Isolation Confirmation.

8.

Keep LOTO Devices in Place.

K. RELEASE FROM LOCKOUT/TAGOUT

Notes/Comments:

1.

Preparation and Notification.

2. Removal of Additional Devices.

3. Remove ALL Locks and Tags.

L. SIGNATURE

Signature: Date:

Checklist Instructions:

A.

EQUIPMENT IDENTIFICATION: Identify equipment to be serviced or maintained and list location (i.e., Site, Bldg, Rm.).

B.

SCOPE: Write brief description of work activity.

C.

IDENTIFICATION OF HAZARDOUS ENERGY: Identify all hazardous energy sources associated with the equipment to be serviced or maintained including those that may not require LOTO for activity being performed.

D1.

JOB SPECIFIC LOCKOUT OR TAGOUT INFORMATION. Identify and state location of specific hazardous energy sources associated with equipment that requires lockout or tagout to ensure personnel performing maintenance or service and personnel working near the equipment are protected from unexpected release of hazardous energy.

D2.

List locations where stored energy requires de-energization.

D3.

List parts/equipment/components that require blocking.

D4.

List any other related system that may require shutdown during maintenance or servicing activity.

E.

NAMES OF AUTHORIZED WORKERS PERFORMING THIS LOCKOUT: List names of all authorized workers performing LOTO (attach continuation sheet, if needed).

F.

NAMES OF PERSONNEL AFFECTED BY THIS LOCKOUT: List names of personnel affected when performing this LOTO.

G.

VERIFICATION REQUIREMENTS: Specific requirements for testing a machine or piece of equipment to determine and verify effectiveness of LOTO devices and other energy control measures.

H.

SAFETY MEASURES/SPECIAL INSTRUCTIONS: List any special safety concerns associated with this work activity (i.e., electrically rated gloves, hearing protection, safety glasses, face shields, etc.).

I.

ADDITIONAL INFORMATION: (Optional) List any additional information not identified elsewhere on this form (i.e. special sequencing, reference manuals, reference other TOs, etc.)

J.

BASIC LOCKOUT PROCEDURES. Complete steps 1-8, as applicable.

K.

RELEASE FROM LOCKOUT/TAGOUT: Complete steps 1-3, as applicable.

L.

SIGNATURE: Signature of Authorized Worker completing form.

RESTRICTIONS

All workers shall comply with restrictions/limitations imposed on them while using LOTO.

Authorized Workers shall perform the LOTO activities as prescribed in this procedure

Only Authorized Workers are permitted to perform lockout activities prescribed by this procedure.

This procedure shall be used during all activities involving maintenance (repair) or servicing (adjustments, modifications, cleaning, or inspections) of equipment. No worker shall attempt to start/energize or use/operate locked out equipment.

If the designated Authorized Worker is replaced, relieved, or augmented, the new Authorized Worker(s) shall place his/her own lock & tag on the lockout devices before the relieved worker removes his/hers.

No worker shall provide locks/tags nor vouchsafe for another worker for any or all isolation points at any time.

If the Authorized Worker leaves sight of the job, even momentarily, that worker shall re-verify the lockout and zero energy state of the equipment before resuming work.

In an emergency, the supervisor shall apply his lock over that of the Authorized Worker until the Authorized Worker can verify a safe state for the operation

In the event of undetermined (long-term) absence of an Authorized Worker who has not released the equipment from LOTO, the supervisor may remove the lock.

Removal shall be performed under the provisions of, paragraph 21.4.5., Release from Lockout/Tagout.

If this procedure is part of a larger, more general procedure, energy sources that are part of the larger procedure, but not applicable to this procedure, shall be identified and listed, with an explanation of why they are not a hazard and not applicable or relevant to this procedure.

Lockout of High Energy Electrical Sources

High energy electrical sources (over 600 volts) require special caution and attention to detail. The following steps are in addition to those required for a normal lockout whenever equipment connected to high energy electrical sources is to be worked on.

1. Workers should be assigned in teams (minimum of two [2] people) whenever high energy electrical sources are to be locked out.

2. The high energy source shall be isolated from the equipment by at least two (2) energy isolating devices placed electrically in series unless otherwise authorized by URC 3-560-01. Both devices shall be locked open and tagged out before work begins. Each member of the team may elect to place one lock or two.

3. Standard voltmeters shall not to be used to determine that the high energy source has been disconnected. Appropriately rated high energy non-contact voltage detectors or phasing voltmeters, i.e., tools suitable for use with “hot sticks,” with both audible and visual indications are the preferred instruments.

4. After both locks are placed (following lockout procedure outlined above), the LINE side of the second energy isolating device shall be grounded. The grounds shall remain in place for the entire duration of the work.

5. Workers shall ensure all stored energy, particularly from stray capacitance (in cables, lightning arrestors, power factor correction capacitors, etc.), is safely discharged from all parts of the circuit to be locked out. Grounds shall be in place on all conductors in the work area whenever work is in progress.

If grounds are removed for any reason, they shall be replaced before continuing work.

6. When removing locks from a high energy source, at least two (2) people shall independently perform complete inspections of the work area, the equipment worked on, and the entire circuit from the first lock to the equipment. All grounds shall be removed, all tools and parts stored, all areas clean, and all covers and other safety devices installed and secured.

22.5.2. Containers. Containers and portable tanks shall meet handling, storage and dispensing requirements specified in this instruction for the product concerned. Refer to NFPA 30 for additional guidance. Tanks and vats shall be installed so rupture or overflow is contained or controlled through dikes, sumps, etc., per 29 CFR 1910.106, Flammable and Combustible

Liquids.

23.2.4.6. Evaluate potential worker exposure related to confined spaces IAW AFI 48-145, Occupational and Environmental Health Program.

23.5.6.2. Non-permit confined spaces will be reviewed prior to each entry, but no less than annually, to determine if changed conditions in or around the space could have introduced a hazard that is immediately dangerous to life or health, thus changing the classification of the space to permit-required. Well-ventilated, frequently-entered non-permit confined spaces such as aircraft engine inlets/intakes/exhausts and avionics bays can normally rely on a visual review prior to each entry, unless a changed condition in or around those spaces could have introduced an atmospheric or other non-visual hazard, in which case, instrumented testing is warranted.

23.9. MAJCOM Mandatory Aircraft Confined Spaces (Reference Table 23.2 below). The following figure identifies confined spaces contained within each aircraft weapons system as defined by the MAJCOM Ground Safety office. This is not an all-inclusive list and is subject to change based on modifications in procedures and weapons system design. The all-inclusive list shall be maintained by each MAJCOM Ground office for each installation under its purview and by the installation CSPT. Warning: Proper classification of a confined space depends heavily on the activity that occurs within the space. Therefore, while confined spaces with no hazards inherent within or introduced into the space are categorized as Non-Permit Required (NPR) in the table below, all have the potential to contain a hazard that could change the classification to

Permit-Required.

23.9.1. If activity in the space introduces or generates any hazards, the installation CSPT must be notified to assess the classification. The installation CSPT may upgrade the classification to

PR for that activity if there is potential to create a hazard.

23.9.2. Some confined spaces contain fuel lines that are normally intact and not designed to release fuel into the space. In general, most of these spaces are classified as NPR in the table below on the basis that leaks of fuel are a rare event and the entrant would be able to detect the presence of fuel prior to entry. If there is any indication of fuel leakage (odor, visual evidence), the space must be upgraded to PR. Entrants are strongly encouraged to sample air for fuel vapor before entry into NPR confined spaces containing fuel lines as an additional means to verify no leakage has occurred. Check with BE for assistance in selecting fuel vapor detection equipment.

23.9.3. In some confined spaces, lines containing nitrogen in liquid or gaseous form pass through the space. These lines are normally intact and not designed to intentionally release nitrogen into the space. In general, most of these spaces are classified as NPR in the table below on the basis that nitrogen leaks are a rare event and the entrant can verify the integrity of the nitrogen distribution system prior to entry. Any evidence of potential nitrogen leakage, e.g., pressure drops or maintenance history, drives an immediate upgrade of the space to PR.

Additionally, due to the odorless and colorless properties of nitrogen, entrants into NPR confined spaces where nitrogen lines or bottles are present must continuously monitor for oxygen levels while in the space to verify no leakage has occurred. Refer to TO 1-1-3, Inspection and Repair of

Aircraft Integral Tanks, and Fuel Cells, for additional guidance.

23.11.2. Does the commander and/or functional manager ensure personnel who support the permit-required confined space program are properly trained, equipped and qualified? Reference

23.2.7.2

23.11.13. Do functional managers or commanders, in coordination with the CSPT, ensure the organization’s confined spaces are evaluated and tested prior to being classified? Reference

23.3.2

23.11.22. Does the entry supervisor ensure a qualified on-site rescue team is present during all known IDLH space entries? Reference 23.5.3.9

23.11.27. Is an AF Form 592, USAF Hot Work Permit, obtained by workers prior to performing hot riveting, welding, cutting, burning or heating operations within a confined space? Reference

23.5.5

24.2.5.1. Compressed air shall not be used for cleaning purposes except when regulated to 30 psi or less, and then only when effective chip guarding, air diffuser, and face shield and safety goggles are used.

24.5.1. Strict adherence to standards ensures the safety of parked aircraft. Specific parking locations shall be designated for each aircraft IAW AFMAN 32-1084, Facility Requirements.

Generally, distances between parked aircraft, wingtip to wingtip, shall allow immediate access of emergency vehicles and permit free movement of equipment and materials. Refer to AFMAN

32-1084 for specific aircraft wingtip distances. Also see UFC 3-260-01, Airfield and Heliport

Planning and Design. Refer to AFMAN 91-201, Explosive Safety Standards, and TO 11A-1-33, Handling and Maintenance of Explosives Loaded Aircraft, for parking explosives loaded aircraft.

24.14.9. Roll-up Hangar Doors. Roll-up hangar doors shall be maintained in good operating condition with door tracks free of debris and obstructions to allow smooth operation. Operators shall conduct a visual inspection of door path and track-way and correct any discrepancies before operating door. Individuals shall remain clear of door path while door is in motion. Hangar auxiliary service roll-up doors, to include tow vehicle exit doors, shall meet the following requirements:

24.14.9.2. Powered roll-up hangar doors equipped with one touch open or close buttons shall have a crush sensor on the bottom of the door installed and operational. Note: Manual roll-up hangar doors or powered roll-up doors equipped with dead man switches do not require crush sensors.

24.15.1.3. Face shield and safety goggles are required when using compressed air for cleaning. All shop and aircraft maintenance personnel authorized to use air compressors shall be trained in operation and maintenance of air compressors. Compressed air for general cleaning purposes shall be limited to less than 30 psi. Effective chip guarding shall be provided and have a finger-actuated press

(on)/release (off) control. Compressed air shall not be used for cleaning benches, floors, work areas, aircraft interior, clothing or exposed body surfaces. Aircraft pitot-static systems shall not be cleaned with compressed air to prevent instrument diaphragm damage. Refer to paragraph 24.2.5 for additional information on cleaning with compressed air.

24.16.7.3. No stand will be used unless all brakes are set and all wheel casters locked. Wheel will be locked either 90 or 180 degrees from the caster lock pin if it interferes with the wheel brake handle.

Wheel chocks may be used to supplement these requirements. Stands will be locked when not in use to avoid rolling down slanted surfaces or being moved by the wind when outdoors. Chocks will be constructed or locally manufactured IAW TO 00-25-172, Ground Servicing of Aircraft and Static

Grounding/Bonding.

24.16.7.4. Self-propelled elevating work platforms shall be in the lowered position prior to being moved. Manually-propelled mobile work platforms shall not be moved with personnel on the working platform unless allowed by manufacturer’s instructions. Locking pins or other devices, as required, shall be in place before anyone is allowed to ascend the stairs or ladder. Tools and equipment left on the work platform while the unit is moved shall rest securely on the floor of the platform and be protected by a rail and toeboard IAW paragraph 16.4.6.10.

24.18.36. Are passengers prevented from riding on tow tractors unless adequate seats are provided for that purpose? Reference 24.13.21

24.18.37. Are pintle assemblies and towing connections secured with a pintle hook safety locking device or cotter pin that will positively lock towing connections? Reference 24.7.16

24.18.55. Are locking pins installed, hydraulic pressure released, platform eased down onto the locks and the hydraulic valve closed before anyone is allowed on the maintenance stand?

Reference 24.16.7.4

25.5.2. Fire extinguishers with a rating of at least 2A:20BC shall be installed in shop areas located so an extinguisher is available within 50 feet. The number of extinguishers depends upon the size and layout of the facility. The installation FES Flight shall be consulted for more detailed information on the type, selection, installation, inspection, maintenance and hydrostatic testing of portable fire extinguishers. Fire extinguishers will:

25.12.2.3.11. All controls shall be tested by the operator at the start of a new shift. If any controls do not operate properly, they shall be adjusted or repaired before the operation is continued.

25.18.1.1. Explosive Gases. The most common sewer gases are methane, carbon monoxide and hydrogen sulfide. These gases, when mixed with air and a spark, can explode with great force.

Such explosions are most common and dangerous in confined spaces such as tanks, underground lift stations or manholes. Hydrogen sulfide (H2S) is generally encountered more frequently in wastewater systems than any other hazardous gas. In light concentrations, it has a foul odor similar to rotten eggs. After continued exposure, H2S will over-stimulate the olfactory sensors and will no longer register as an odor. It is heavier than air and usually collects in low areas.

Methane is lighter than air and will escape with proper ventilation. Closed tanks and tight rooms are the greatest danger areas. They shall be tested for oxygen and methane or H2S with approved meters.

25.18.1.5. Federal and some state agencies set exposure limits to protect workers against exposure to hazardous substances. The Air Force incorporates the most appropriate limits as the

Occupational and Environmental Exposure Limits (OEEL). OEELs are the Air Force limits on the amount or concentration of a substance in air. OEELs may also contain a skin designation.

Contact BE for questions related to OEELs.

26.3.5. Do supervisory personnel ensure operators have PPE such as head, eye and ear protectors, gloves, respirators, etc.? Reference 26.2.3.1

26.3.11. Are all guards secured in place and kept in place during machine use? Reference

26.2.3.2

26.3.12. Are items not permanently installed, such as tools, radios, water coolers, etc., secured so they do not pose a hazard to operators or equipment should the tractor malfunction or overturn? Reference 26.2.3.3

26.3.13. Does the operator prohibit other riders from riding on the tractor? Reference 26.2.3.4

26.3.14. Does operator clean the windshield and other transparent surfaces of ice, snow, dirt, grass and other obstructions from tractors equipped with cabs to ensure clear vision prior to use?

Reference 26.2.3.5

26.3.15. Does the operator ensure cracked or severely scratched windshield or transparent surfaces for vision are reported and repaired or replaced? Reference 26.2.3.5

26.3.16. Does the operator keep personnel clear of operating machinery or attachments?

Reference 26.2.3.6

26.3.17. Does the operator stop the engine, disconnect the power sources, and wait for all machine movement to stop before servicing, adjusting, or cleaning the equipment (except where the machine must be running to properly service or maintain the equipment)? Reference 26.2.3.7

26.3.18. Do mowing machine operators refrain from attempting to mow on slopes that exceed 4 inches (20-25°) of drop or rise per foot of travel? Reference 26.2.3.8

26.3.19. When using a sickle bar attachment for mowing, does the operator always position the sickle bar on the up-slope side of the tractor? Reference 26.2.3.8

26.3.20. Does the operator park the tractor on a level surface, lower the attachment so it rests on the surface, place the transmission in low or reverse after the engine has stopped (automatic transmission in “park”) and shut the engine off, before the operator dismounts the vehicle?

Reference 26.2.3.9

26.3.21. For flex-winged mowers, does the operator ensure the appendages are folded in the

“up” position and the locking pins are securely in place when parking? Reference 26.2.3.9

26.3.23. Are all ROPS-equipped tractors fitted with seatbelts? Reference 26.2.7

26.3.24. Have all tractors and attachments been subjected to a noise hazard survey and those whose noise level exceeds 85 dBA placarded with noise hazard warning? Reference 26.2.8

26.3.25. Are approved “Slow Moving Vehicle” emblems and flashing amber light units installed on agricultural tractors used at night in high traffic areas? Reference 26.2.9

26.3.26. Are all power takeoff shafts shielded? Reference 26.2.10.1

26.3.27. Are guards capable of withstanding 250 pounds of downward or inward force?

Reference 26.2.10.2

26.3.28. Are guards free of burrs and sharp edges or projections and securely fastened to the unit? Reference 26.2.10.3

26.3.29. Are all guards that were removed for servicing and maintenance reinstalled prior to placing units in use? Reference 26.2.10.4

26.3.30. Are batteries, fuel tanks, oil reservoirs, and coolant systems constructed and located or sealed to assure that spillage will not occur in the event of an upset? Reference 26.2.11

26.3.31. For flight line operations, does the operator ensure a “Slow Moving Vehicle” placard is affixed to the rear of the tractor, have a radio and keep in contact with the tower at all times?

Reference 26.2.12

27.3.13. An AF Form 592, USAF Hot Work Permit, (see Figure 27.1) is required whenever there is cutting ,welding or brazing being accomplished outside of the designated shop area. The directions for filling out and signing the AF Form 592 are contained in Table 27.2. The hot work permit must be obtained from the installation FES Flight prior to starting welding operations. The requirements for usage of the AF Form 592 are outlined in Table 27.2. Note:

BE assistance and coordination may be required, i.e., BE survey report, PPE listing/recommendation, etc.

27.5.1. Inside Areas. A specific area shall be designated and approved by the installation FES

Flight, Ground Safety office and BE for welding and cutting operations. It shall be of fire resistant or noncombustible construction appropriate for its hazard classification, free of combustible and flammable materials, and segregated from adjacent areas. This area shall be exempt from requiring an AF Form 592 on a daily basis.

27.19.35. Is only approved respirator equipment used when working in atmospheres of hazardous concentrations of airborne contaminants? Reference 27.7.8

27.19.36. Do all welding helmets meet 29 CFR 1910.252, Welding, Cutting, and Brazing -

General Requirements, requirements? Reference 27.7.9.1

27.19.37. When two or more welders are exposed to each other's arc, are filter lens goggles worn under the welders‘ helmets to protect them from the harmful rays? Reference 27.7.9.2

27.19.38. Are goggles or other suitable eye protection used during all gas welding or oxygen cutting operations? Reference 27.7.9.3

27.19.39. Is eye protection in the form of suitable tinted goggles or spectacles provided for brazing operations? Reference 27.7.9.5

27.19.40. Are workers trained to arrange helmets to protect the face, neck and ears from the arc's radiant energy? Reference 27.7.10.2

27.19.41. Are ventilated goggles used to prevent fogging of the lenses? Reference 27.7.10.5

27.19.42. Are hand-held shields, designed to shield the face and eyes, prohibited from use?

Reference 27.7.10.10

27.19.51. Is the fire guard informed to stop the welding operation if a hazardous condition develops? Reference 27.10.16.10

28.19.65. Are only non-copper beryllium spark-resistant tools used during cleaning operations?

Reference 28.13.3

28.19.68. Are only properly trained, qualified and physically-fit personnel permitted to work around electrostatic apparatus? Reference 28.14.7

28.19.69. Are warning signs posted designating the spray process zone as dangerous ?

Reference 28.14.8

28.19.70. Is a red “ON” light installed in the interlocked power transformer circuit? Reference

28.14.8

30.4.2.3. Hazard Communication Training. All workers who may be potentially exposed to chemical hazards during the course of work shall require hazard communication training IAW

AFI 90-821 upon initial assignment and thereafter when a new hazard or chemical is introduced into the work area/shop or a worker is assigned new or different tasks with new hazards. Prior to any task requiring the use of or exposure to hazardous materials, safety precautions for materials shall be covered in the pre-task safety briefing.

30.7. High Voltage. High voltage is defined as greater than 600 volts (root-mean-square

[RMS]), nominal, or greater. However, much lower voltage can be lethal. The design and development of all military electronic equipment shall provide fail-safe features for safety of workers during the installation, operation, maintenance or interchanging of a complete equipment assembly or component part. Operators and technicians shall not attempt to adjust any electronic equipment when there is a possibility of injury from unprotected high voltage.

Adjustments on operating high voltage equipment, other than those specified by TO or manufacturer‘s manuals, shall only be authorized by the unit commander. The unit commander shall consider all operational requirements, TOs, manufacturer‘s guidance, safety precautions and emergency procedures before authorizing work to proceed. Workers using high voltage to troubleshoot and/or test cables shall be instructed in the precautions necessary for their safety and the safety of others. Workers shall be warned to stay clear while voltage is applied.

31.1.2. The battery shop, room or area shall be designed to eliminate certain hazards associated with battery maintenance and shall conform to the specific requirements in this document and 29

CFR 1910.178, Powered Industrial Trucks, 29 CFR 1926.403, General Requirements

(Electrical), 29 CFR 1926.441, Batteries and Battery Charging, NFPA 70, National Electrical

Code, including Articles 480, Storage Batteries, and Chapter 5,…