Q_AND_A_Responses_2.docx

MILITARY SEALIFT COMMAND

N32205-16-R-4307

QUESTIONS AND ANSWERS #2

The following are answers to questions received from potential offerors. The answers provide clarification only and DO NOT constitute an amendment to the solicitation.

QUESTION #1:

Room (3-75-1) & (3-75-2) (4) locations

The Contractor Submit the following questions

1. For the upcoming USNS Wally Schirra ROHDD why is the MSC Safety Procedures Manual “ISM 2.1-016 AKE Revision 0.3” not included within the Work Item #309 references? PLEASE SEE ATTACHED.

2. Without this MSC Safety Procedures Manual “ISM 2.1-016 AKE Revision 0.3” being referenced in the contract are we now able to use a certified Thermographer from any contractor of our choosing without regard to the requirements of para 3.4.11 for repair availabilities and overhauls? NO, ONLY AUTHORIZED THERMOGRAPHER

3. Can we disregard the HV qualification standards outlined in MSC’s Fleet Support Command Safety Management Procedures Manual “ISM 2.1-016 AKE Revision 0.3” for this contract? NO

4. Can we disregard the Limitation of Access Permit requirements as per para 3.4.10 for this contract? NO

5. Can we take exception to these MSC requirements for High Voltage work? NO

6. At the end of the enclosure 2.2 the survey list includes removal of the inspection covers for the 1A, 1B, 2A, & 2B propulsion motors as well as the drive transformers. To accomplish a thermographic survey of those components would require extreme safety precautions and preparations. Is the Chief Engineer and Captain of the ship aware of the complexities and potential hazards involved and willingly support this? YES

7. Within enclosure 2.2 there are (143) data duplications in the (375) item total, which drops the total to (234) actual for this survey. Why All the Duplication? OMMIT THE DUPLICATIONS

8. There are approximately (500) known panels and controllers in every T-AKE. Some very critical ones are missing from this Enclosure. Is accomplishing less than 47% acceptable? IT IS ACCEPTABLE; ANY NEW WORK REQUIRED WILL BE PAID WITH AN RFP

ANSWER: Answers next to questions

1. MSC Safety Procedures Manual “ISM 2.1-016 AKE Revision 0.3”

2. SMS 2.1-004 All Lockout Tag-out image1.emf

ISM 2.1-016 AKE Revision 0.3 High Voltage Systems.doc

MILITARY SEALIFT FLEET SUPPORT COMMAND’S SAFETY MANAGEMENT PROCEDURES MANUAL

Endorsed by:

ISM Steering Committee

Approved by:

Date:

6 June 2006

C.M. POTTENGER

Rear Admiral, U.S. Navy

2.1-016-AKE

Revision 0.3

High Voltage (HV) Systems

1 PURPOSE

To establish procedures for the safe installation, maintenance, repair, alteration, or service of high voltage (HV) electrical equipment and systems.

2. APPLICABILITY: Current release date: August 2008

HV safety procedures shall be observed for all installation, maintenance, repair, alteration, or service performed on shipboard HV (1000 volts or greater) equipment, machinery, or systems. For systems under 1000 volts, the Lock Out / Tag Out Procedure, SMS Procedure 2.1-004-ALL applies.

3 BACKGROUND & PROCEDURES

3.1 Background. 29 CFR establishes requirements for procedures governing the safe operation, maintenance, and repair of electrical systems. This CFR does not specifically apply to shipping, but Commander, Military Sealift Fleet Support Command has determined that an unacceptable level of risk exists without a similar basis for safety when working with HV systems. This procedure establishes safeguards for administering a HV program.

3.2 Responsibilities.

3.2.1 The Ship’s Master shall designate the Chief Engineer in writing as the Authorizing Engineer (AE) using SMS Form 2.1-016-02-AKE, High Voltage Authorizing Engineer Appointment Letter. The letter will be kept in the Chief Engineer’s HV file.

3.2.2 The Chief Engineer (AE) shall:

· Ensure shipboard personnel are trained in accordance with paragraph 2.3 below.

· Designate in writing Engine Department personnel who have been trained to the level of Qualified Personnel (described in paragraph 3.3) and whose duties include those of Authorized Persons (AP) and Competent Persons (CP). SMS Form 2.1-016-03-AKE, High Voltage Authorized Person Appointment Letter and SMS 2.1-016-04-AKE, High Voltage Competent Person Appointment Letter shall be used for these appointments.

· Ensure that all other crewmembers have obtained minimum HV training (described in paragraph 3.3).

· Maintain security and control access on all spaces/ boundaries designated as HV spaces/ boundaries.

· Maintain HV specific lockout procedures and separate HV lockout equipment.

3.3 Training.

3.3.1 Qualified Personnel. The Chief Engineer, 1st Assistant Engineer, 2nd Assistant Engineers, 3rd Assistant Engineers, Electronics Technician, and Chief Electrician will be trained to the level of Qualified Personnel. To achieve “qualified” status, the individual must have had the Faraday, MEBA HV, or an equivalent course. Letters of Designation as Authorized Persons (AP) or Competent Persons (CP) will not be issued without record of training.

3.3.2 High Voltage Aware Personnel (HVAP). All other crewmembers will be trained to the level of HVAP. HVAP training must be at least equivalent to that which is available from the onboard training module. This training shall be accomplished within 5 days of reporting aboard and shall be logged on Checklist 6.2-001-01, SOLAS New Crew Member Indoctrination Checklist.

3.3.3 Embarked personnel (such as visitors and contractors) will be trained the level of HVAP or shall be escorted by someone who is trained to the minimum level of HVAP (additional information in paragraphs 3.4.12 and 3.4.13)

3.3.4 The Chief Mate shall be the custodian of HVAP and “Qualified Personnel” training records for shipboard personnel.

3.4 Operational Procedures. The Authorizing Engineer (AE) is the administrator of the HV safety program. This responsibility cannot be delegated. Authority to execute functions of the program may be effected through letters of delegation.

3.4.1 Precautions Before Working On HV Systems. Repair, maintenance, cleaning, alteration, or any other such work shall not be accomplished on any part of a HV apparatus unless:

· The person performing the work is fully conversant with the nature and the extent of the work to be done.

· The person performing the work is approved for work by the completion of a HV Lockout / Tagout (HVLOTO) Plan, and the issue of a HV Permit to Work (HVPTW) or HV Sanction for Test (HVSFT).

· The apparatus is in an Electrically Safe Working Condition (ESWC). ESWC is defined as all parts on the apparatus:

· Are electrically dead or zero potential phase to phase and to ground (earth).

· Are isolated and all steps taken to lock off from live conductors.

· Are connected to ground at all points of isolation. Where necessary, additional grounds are to be connected between the point(s) of isolation and the point(s) of work.

· Have Danger tag(s) affixed at all points of isolation from live conductors and Caution tag(s) affixed to all points of grounding.

· The area is screened or taped where necessary to prevent a hazard, and appropriate warning notices are affixed.

3.4.2 The Authorized Persons (AP) who approves and issues the HVPTW or HVSFT shall ensure that the conditions described above are complied with. Where the design of apparatus precludes the strict compliance with all details of these precautions, the work shall be carried out according to the instructions of the AP, who must be present, and after agreement with the instructions by the Authorizing Engineer (AE).

3.4.3 Individuals will not use HV instrumentation unless they have received training from a supervisor or a formal HV instructional course in its use.

3.4.4 HV Personal Protective Equipment (PPE) will be worn as follows:

· When taking initial voltage readings to determine the electrical potential on HV components properly rated PPE, including coveralls, gloves, and face shield will be worn.

· While working on ESWC components, PPE will be minimized to improve dexterity.

3.4.5 HV Space Access Control and Security.

· The Authorizing Engineer (AE) will establish a list of all spaces containing HV. All entrance/egress ways into these spaces will be labeled “High Voltage”. The entrances will be locked and the keys will be held by the Engineering Watch/Duty Officer (minimum designation of Competent Persons (CP). The AE will retain a copy of the Master Key. On spaces where locking is impractical, boundaries will be established within the space around HV equipment to protect personnel from exposure. These boundaries can include, but are not limited to, expanded metal “cages” with lockable entrance/egress ways. Warning signs will be posted on these boundaries indicating presence of HV equipment or systems within.

· Routine access to HV designated spaces/ boundaries will be restricted to Qualified Persons.

· When those trained only to the level of HVAP (i.e. Unqualified Persons) require access to HV spaces to perform routine non-HV maintenance, they will be issued a HV Limitation of Access (paragraph 3.4.10) permit delineating their duties and the times they are allowed in the space.

· The AE will establish a list of all spaces that have HV cables transiting them. All HV cable will be maintained with identifying color coding (red).

3.4.6 HV Lock Out/Tag Out Equipment.

· The Authorizing Engineer (AE) will establish a dedicated locker containing ONLY HV lockout equipment, instrumentation, and tools.

· All HV Lockout equipment, tools, and instrumentation on the ship will be color coded (orange).

· A method to inventory tools will be established to avoid misplaced tools after maintenance or repair has been accomplished.

· Lock out key sets will be controlled by the AE. The AE will locate a lockable “lock and key” storage box in a location under his direct control over. Keys for locks in use will be kept in a dedicated separate lockable key storage box (“Key Safe”) whose sole content will be the keys for a given event. The Competent Persons (CP) executing the event will hold the key for the event’s Key Safe. A master key for the Key Safe will be held by the AE.

· Figure 1 provides a template for HV Lock out tags. The tags will be color coded orange and contain a photograph of the maintainer. The ship will print and laminate tags as needed. There will be two types of tags, “Danger Tags” and “Caution Tags”. Danger Tags will be used on all connections where the possibility of introducing a voltage source exists. Caution Tags will be used on ground connections where removal of said tag could create a safety risk due to grounding protocols being violated.

· Devices for cordoning off areas, including portable stanchions with plastic chain, safety tape, plastic warning placards, etc. will be used to identify areas under maintenance or repair.

3.4.7 High Voltage Lock Out/Tag Out (HVLOTO) Plan.

· The purpose of the HVLOTO Plan is to formally identify the steps needed to place the system in an ESWC. Data on the checklist includes a “one line” schematic of the circuit to be effected, purpose of the work to be accomplished, and a list of all devices to be locked out or tagged out.

· When the need arises to perform maintenance, repair, or testing on a HV system, an Authorized Person (AP) will be notified. The AP will direct a CP to complete Part 1 of Checklist 2.1-016-01-AKE, HVLOTO Plan.

· The AP will review the completed checklist for accuracy and completeness before approving it.

· Active HVLOTO checklists will be maintained in a HVLOTO Binder in the Engine Log Office.

· On completion of the work described in Part 1 of the HVLOTO Plan, the CP will complete Part 2 of the HVLOTO Plan and return the HVLOTO Plan and keys to the AP. The AP will verify the system has been restored to operational condition and clear the HVLOTO Plan.

· HVLOTO Plans whose work has been completed and cleared are to be kept in a separate binder in the Engine Log Office for a period of three (3) years.

· The ship will create template HVLOTO Plans for different circuits. These templates, once proven, will then expedite the re-issuance of HVLOTO Plans for similar future events and reduce inconsistencies. Part 1 of the template HVLOTO Plan will include the sketch with switches, equipment, and the list of devices to be locked/tagged out.

AT NO TIME is the HVLOTO Plan to be completed by the person who is actually executing the maintenance, repair, testing, or operation event. This is to ensure that an objective and careful review of the plan takes precedence over the interest of expediting the work.

3.4.8 High Voltage Permit To Work (HVPTW).

· After a HVLOTO Plan has been completed, the Authorized Person (AP) who authorized the HVLOTO Plan will complete Part 1 of Checklist 2.1-016-02-AKE HV Permit to Work.

AT NO TIME is the HVPTW to be completed by the person who is actually executing the maintenance, repair, testing, or operation event. This is to ensure that a properly executed the Permit to Work takes precedence over the interest of expediting the work.

· The AP will then present the HVPTW and the key to the Key Safe identified in the HVPTW to the Competent Persons (CP) who is designated to execute the work listed on the permit. Note: the CP completing the HVLOTO Plan is referred to as CP(1); the CP executing the HVPTW is referred to as CP(2). The AP will brief CP(2) regarding the details of the Permit, physically show CP(2) the locations of Lockouts, and prove to CP(2) by touch that the circuit in question is in an ESWC. CP(2) will complete Part 2 of the HVPTW and retain custody of the HVPTW and Key Safe key until completing Part 3 of the Permit.

· On completion of the work described in the HVPTW, CP(2) will Complete Part 3 of the HVPTW and return the HVPTW and Key Safe key to the AP who will verify all work has been completed.

· If the scope of the work changes from the original work authorized under the HVPTW, CP(2) must stop all work, complete Part 3 of the HVPTW, and return the HVPTW and Key Safe key to the AP. If work is still required on the circuit/system a new HVLOTO Plan and a new HVPTW will be issued in accordance with the standard process.

· The AP will verify that work is complete and “Cancel” the permit to work by completing Part 4 of the HVPTW.

· The AP will give the completed HVPTW to CP(1), the initiator of the HVLOTO Plan, to restore the system to its original condition in accordance with Part 3 of the HVLOTO Plan.

· The completed HVLOTO Plan and canceled HVPTW shall be retained in the HV file in the ship’s engine log office for three (3) years.

3.4.9 HV Sanction for Test (HVSFT).

· A HVSFT is required any time a ground, permanent or temporary, must be removed in order to execute a test

· Only an Authorized Person (AP) can execute a “Sanction for Test”. This instruction will refer to the two APs involved in this process as AP(1) and AP(2).

· When a HVSFT is required, a HVLOTO plan must be completed in accordance with 3.4.7 above.

· The AP authorizing the event’s HVLOTO Plan, AP(1), will complete Part 1 of Checklist 2.1-016-03-AKE HV Sanction for Test. AP(2), who will be executing the test, will complete Part 2 of the HVSFT.

· On completion of testing, AP(2) will complete Part 3 of the HVSFT and return it to AP(1). AP(1) will complete Part 4 of the HVSFT and file it in the HV file in the ship’s engine log office. It shall be retained for three (3) years.

· Any grounds removed to execute measurements will be reinstalled immediately after said readings. A check for voltage potential between phases and ground will be made before reinstalling grounds to ensure residual voltage from testing or induced voltage has not accumulated on system. If residual voltage exists it must be allowed to reach the same potential as ground prior to reinstalling grounding devices.

· Any time a voltage source is used to execute measurement the voltage source will be equipped with the ability to “discharge” any residual voltage potential imparted to the system.

AT NO TIME is the HVSFT to be completed by the AP who is actually executing the testing event. This is to ensure that a properly executed procedure takes precedence over the interest of expediting the work.

ONLY AUTHORIZED PERSONS CAN EXECUTE A HVSFT.

3.4.10 HV Limitation of Access Permit (HVLOA).

· Checklist 2.1-016-04-AKE HV Limitation of Access Permit is to be completed before allowing anyone who is not designated as a Qualified Person to enter the HV space/boundary to accomplish work not related to HV systems or equipment. Examples of this work may be cleaning of decks or bulkheads in the space, replacing lamps in lighting fixtures, etc. This is to ensure that those trained only to the level of HVAP (i.e. Unqualified Persons) are under direct supervision of a Competent Persons (CP) so as not to endanger them or the vessel by inadvertent contact with HV equipment or systems. Note that this applies to all MSC shore staff and contractors.

· An Authorized Person (AP) will complete Part 1 of Checklist 2.1-016-04-AKE HV Limitation of Access and will personally brief all Unqualified Persons before they enter the space. The CP supervising the event will then complete Part 2 and retain the HVLOA until the event is complete or work is stopped.

· On completion of the event or stopping work, the CP will complete Part 3 of the HVLOA and return the HVLOA to the authorizing AP. The AP will complete Part 4 and file the completed form in the HV folder in the ship’s engine log, retaining it for three (3) years.

AT NO TIME is the HVLOA to be authorized by the person who is actually acting as the CP for the event. This is to ensure that a properly executed HVLOA procedure takes precedence over the interest of expediting the work.

A COMPETENT PERSON MUST REMAIN PRESENT AT ALL TIMES WHEN AN UNQUALIFIED PERSON IS IN THE SPACE/BOUNDARY.

3.4.11 Repair Availabilities, Overhauls, Drydockings, etc.

· The ship will maintain the HV Safety System in ALL repair events.

· The Watch Engineer and/or Duty Engineer shall be notified of all high voltage work to be performed as per the HVLOTO Plan.

· All contractors working aboard the vessel will be required to have either received High Voltage Awareness Personnel (HVAP) training establishing them as a HVAP prior to being allowed on the vessel, or be required to be continuously escorted by a contractor supervisor who is HVAP or “Qualified” trained.

· All contractors working on HV Systems will be Qualified Personnel with documented formal certification in training to an appropriate level for the HV work they are tasked to perform. This includes laborers and assistants.

· The contractor will provide the Authorizing Engineer (AE) a list of all personnel and their training to either HVAP or Qualified Personnel level at the commencement of any contract event. The AE will maintain a file of all contractor HV training submittals for 1 year.

· All contractors requiring access to spaces/boundaries listed on the HV Space/Boundary list will be required to adhere to applicable requirements for access forms and records that will be issued by a crew member designated as an AP under the authority of the AE.

· The ship will control all events requiring establishment of an ESWC. All “lock out / tag out” devices will be installed by the ship. A Competent Person (CP) will be assigned to each event and as such will remain in the space/boundary to observe/assist contractors until the work is complete, i.e. the HVPTW/ HVSFT/ HVLOA is closed.

· If the contractor wishes to use his own HV procedures, the procedures will be subordinate to, or in addition to the ship’s HV procedures. In any event where contractor LOTO devices are placed on HV equipment or systems the ship’s LOTO devices will be installed first and removed last before a HVPTW/ HVSFT/ HVLOA is canceled.

3.4.12 Repairs, Inspections, Trials, and Training Events. All government and non-government personnel laying aboard for the purpose of repair, inspections, trials, or training (e.g.: SMART, Command Inspection, INSURV, etc.) will be required to have either received High Voltage Awareness Personnel (HVAP) training or be escorted by a HVAP trained individual or ship’s force. A log will be maintained at the gangway indicating the aforementioned personnel’s training level.

3.4.13 Visitors. All non crewmembers laying aboard as visitors will be required to have either received High Voltage Awareness Personnel (HVAP) training or be escorted by a HVAP trained individual.

3.5 HV Equipment and Tools: Form 2.1-016F0201016.xls-AKE, High Voltage Safety Tools/Equipment lists the minimum outfitting requirements for HV tools and equipment.

4 RECORDS & REPORTS

4.1 Checklist 2.1-016-01-AKE, HV LOTO Plan

4.2 Checklist 2.1-016-02-AKE, HV Permit to Work

4.3 Checklist 2.1-016-03-AKE, HV Sanction for Test

4.4 Checklist 2.1-016-04 AKE, HV Limitation of Access

4.5 Form 2.1-016-01-AKE, High Voltage Safety Tools/Equipment

4.6 Form 2.1-016-02-AKE, High Voltage Authorizing Engineer Appointment Letter

4.7 Form 2.1-016-03-AKE, High Voltage Authorized Appointment Letter

4.8 Form 2.1-016-04-AKE, High Voltage Competent Person Appointment Letter

4.9 Figure 1 - HV Lock Out Tags

4.10 Figure 2 - HV Process Hierarchy

4.11 Figure 3 - HV Process Flow Chart

4.12 Checklist 6.2-001-01 SOLAS New Crew Member Indoctrination

5 REFERENCES (References 5.1 – 5.4 are retained in external library. Copyright restrictions preclude incorporating Reference 5.5 in the external library)

5.1 CFR Title 29, Part 1910

5.2 ABS Rules for Steel Shipbuilding; Part 4; Vessels Systems and Machinery

5.3 OPNAV INSTRUCTION 5100.17D

5.4 NFPA 70E

5.5 Electrical Safety Handbook, 2nd Edition. John Cadick, ISBN 0-07-012071-4

6 DEFINITIONS

6.1 High Voltage (HV): In this document refers to voltages above 1000 V up to and including 15 kV AC in accordance with ref. 5.5: Chapter 8, Section 1.7.3.2 of American Bureau of Shipping rules for Steel Ship Building.

6.2 Qualified Person (re: 29 CFR 1910.331(a)): Those who have training in avoiding the electrical hazards of working on or near exposed energized parts.

6.3 Unqualified Person (re: 29 CFR 1910.331(a)): Those with little or no training in avoiding the electrical hazards of working on or near exposed energized parts.

6.4 Authorizing Engineer (AE): A Qualified Person who is the senior engineering officer aboard the vessel and who is responsible for the administration, and execution of the Command’s HV policies and procedures.

6.5 Authorized Person (AP): A Qualified Person designated by the AE who is of senior engineering rank, 1ST Assistant Engineer or 2nd Assistant Engineer, with sufficient technical knowledge and training to review for technical accuracy and approve a HVLOTO Plan, HVPTW, create an ESWC, and carry out a HVSFT.

6.6 Competent Person (CP): A Qualified Person designated by the AE with sufficient technical knowledge and training to create and execute a HVLOTO Plan, establishes an ESWC, and performs maintenance and repair to HV systems.

6.7 High Voltage Aware Personnel (HVAP): An Unqualified Person who has received HV Awareness training.

6.8 Electrically Safe Working Condition (ESWC): An electrical system which has been made dead, proven dead by testing, isolated, locked, grounded, properly tagged, and for which a HVPTW or HVSFT has been approved.

6.9 Ground: Defined as having a voltage equal to the voltage potential of the hull of the ship. When a device is grounded it is electrically connected to the hull establishing it as the same voltage potential as the hull.

6.10 Earth: A European term defined the same as “Ground” and used interchangeably with the term “Ground” on some devices and in some manuals.

6.11 High Voltage Lock Out / Tag Out (HVLOTO) Plan: The purpose of SMS Checklist 2.1-016-01-AKE, HVLOTO Plan is to identify the work required to place a circuit in an ESWC. It is to be prepared by a CP and then reviewed for accuracy and issued by an AP.

6.12 High Voltage Permit To Work (HVPTW): The purpose of SMS Checklist 2.1-016-02-AKE, HV Permit to Work is to identify to a worker that a circuit is in an Electrically Safe Working Condition and to describe to him the specific work he is authorized to do.

6.13 High Voltage Sanction For Test (HVSFT): The purpose of SMS Checklist 2.1-016-03-AKE, HV Sanction for Test is to provide a means for certain testing events to occur where grounding conventions have to be violated in order to execute said test. It identifies the grounds which may be removed in order to execute the test.

6.14 High Voltage Limitation Of Access Permit (HVLOA): The purpose of SMS Checklist 2.1-016-04-AKE, HV Limitation of Access Permit is to allow Unqualified HVAP to execute routine non-HV maintenance within HV spaces under the direct supervision of a CP.

7 REVISION HISTORY

Original 6 June 2006

Revision 0.1 6 June 2007 – removed List 1 and replaced with Form 2.1-016-AKE, High Voltage Safety Tools/F0201016.xlsEquipment.

Revision 0.2 7 December 2007- Section 2, Applicability-Changed to reflect current release date.

30 March 2008 - Added appointment letters for high voltage authorizing engineer, authorized person, and competent person.

DO NOT

OPERATE

CAUTION

DANGER

Picture

Here

This system is turned off to protect my life

NAME: ________________

Rank: _________________.

MSC 5100/23 (10/05)

Picture

Here

This system is turned off to protect my life

DO NOT

OPERATE

NAME: ________________

Rank: _________________.

MSC 5100/22 (10/05)

Suffix number after position title is used to distinguish between two separate individuals of the same title, i.e., CP(1) and CP(2), performing different portions of the same HV event.

MILITARY SEALIFT FLEET SUPPORT COMMAND’S

SAFETY MANAGEMENT PROCEDURES MANUAL

2.1-016-AKE

High Voltage Systems

_1208177655.vsd text

HV Event Requirement (SAMM, Repair, HV Space Cleaning)

HVLOTO Plan Filled Out by: CP(1) Authorized by: AP(1) Executed by: CP(1)

HV Event or Non-HV Event

Work or Test

HVPTW

Filled Out by: AP(1)

Given to: CP(2)

HV Event (Maintenance/Repair Work) Executed by: CP(2)

Requirement for HVSFT work?

Cancel HVPTW Who: CP(2)

Clear HVLOTO Plan Who: CP(1)

End

HVSFT

Written by: AP(1)

Given to: AP(2)

Event that required HVSFT Executed by: AP(2)

Cancel HVSFT Who: AP(2) Approved by: AP(1)

HVLOA

Filled Out by: AP(1)

Given to: CP(1)

Cancel HVLOA Who: CP(1) Approved by: AP1

Event that required HVLOA Monitored by: CP(1)

Test

Work

No

Yes

HV space entry for non-HV event

HV work

_1208180874.bin image2.emf

SMS 2.1-004 All Lockout Tagout.doc

MILITARY SEALIFT COMMAND’S

SAFETY MANAGEMENT SYSTEM

2.1-004-ALL

Revision 0.7

Issued by:

ISM Steering Committee

Approved by:

Date:

_______________________ 17 March 2004

RADM Loewer

Lockout / Tagout

Lockout/Tagout procedures shall be observed for all installation, maintenance, repair, alteration, or service performed on shipboard equipment, machinery, or systems.

1 PURPOSE

To establish procedures for locking out and/or tagging out equipment, machinery, or systems to safeguard workers from the unexpected energizing or release of stored energy.

2 APPLICABILITY: Current release date: February 2009

2.1 CIVMARS aboard USS MOUNT WHITNEY will follow this procedure where they are cognizant of the work conditions; however, US Navy crew will use their NAVOSH developed procedures for tag out as appropriate.

2.2 Personnel aboard T-AKE vessels shall follow SMS Procedure 2.1-016-AKE, High Voltage Systems for voltages of 1000V or greater.

3 BACKGROUND & PROCEDURES

3.1 Background:

Lockout/Tagout Procedures are necessary to prevent the unexpected energizing of equipment, machinery or systems or the release of stored energy that could cause injury or death. Lockout is accomplished by installing lockout devices and locks that physically isolate an energy source so installation, maintenance, repair, alteration, or servicing can be safely carried out. An energy-isolating device (such as a valve or circuit breaker) is capable of being locked out if it has a hasp or other means of attachment to which a lockout device and lock can be affixed, or it has a locking mechanism built in. Other energy-isolating devices are capable of being locked, if lockout can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy control capability. When energy-isolating devices are not lockable, tagout shall be used. Lockout is always preferable to tagout.

3.2 Procedures:

3.2.1 The Shore Staff shall verify shipboard compliance with Lockout/Tagout Procedures and include lockout/tagout requirements in work packages and service orders for industrial assistance contractors and manufacturers’ technical representatives for installation, maintenance, repair, alteration, and servicing of equipment, machinery, or systems.

3.2.2 The Chief Engineer shall:

3.2.2.1 Administer the Lockout/Tagout Program and monitor its use.

3.2.2.2 Identify and place the MSC “Lockout Before Servicing” (MSC 5100/21) labels, Attachment 1, on equipment, machinery or systems that are routinely serviced at or near its energy source.

3.2.2.3 Provide training on these Lockout/Tagout Procedures.

3.2.2.4 Maintain a master key or copy set for all locks used in the Lockout/Tagout Program.

3.2.2.5 At his discretion, assign qualified personnel to act as Authorizing Officer(s). When a Military Detachment (MilDet) is embarked, the Chief Engineer may appoint the Officer in Charge (OIC) or the Ship’s Communication Officer as the Authorizing Officer for lockout/tagouts that occur only in MilDet spaces. The Communications Officer may also be appointed as an Authorizing Officer for lockouts/tagouts relating to radio and communication equipment. A Letter of Appointment as Lockout/Tagout Authorizing Officer, Form 2.1-004-01-ALL or Collateral Duty Assignment Form 3.2-001-01-ALL, should be used to officially document this appointment.

3.2.2.6 Establish a Lockout/Tagout Log that includes:

· Lockout/Tagout Record Sheets, Form 2.1-004-02.

· The procedures listed in Lockout/Tagout Procedures, Attachment 2, with amplifying ship directions, as necessary, to administer the program.

· Names of Authorizing Officers and those personnel authorized to conduct lockout/tagout actions.

· A consolidated list of all lockout/tagout actions aboard that ship.

NOTE: A separate log may be maintained for lockout/ tagout actions in Radio/MilDet spaces only.

3.2.2.7 Verify that system label plates and diagrams that depict system energy sources are correct. Discrepancies shall be reported as a non-conformity (in accordance with SMS Procedure 9.1-001-ALL, Documentation and Tracking of Findings) and forwarded to the Designated Person for logging and tracking.

3.2.2.8 Evaluate planned work to determine if it is of a “small task” nature. A small task is a minor electrical repair/maintenance task that does not affect other ship controls or systems, such as replacing a light switch or fixture. A small task does not require entry into the Lockout/Tagout Log but must still be locked out / tagged out per this instruction to afford the worker the maximum amount of safety and protection. Further, to qualify as a “small task”, the task must be capable of being completed without the worker leaving the work site. If a small task cannot be completed before the worker leaves the site, it is no longer a “small task” and must be handled in accordance with the entirety of this procedure including entry into the Lockout/Tagout Log.

3.2.2.9 Ensure that the policy for using CAUTION tags (see section 3.2.6) versus DANGER tags is understood.

3.2.2.10 Ensure that outside servicing personnel such as contractors, shipyards or technical representatives fully understand and comply with these Lockout/Tagout Procedures.

3.2.2.11 Ensure that locked out/tagged out equipment, machinery, and systems are reviewed during shift or personnel changes to ensure the continuity of lockout/tagout protection between off-going and oncoming workers.

3.2.3 Department Heads including the MilDet shall ensure their personnel are familiar with these Lockout/Tagout Procedures.

3.2.4 The Authorizing Officers shall:

3.2.4.1 Be aware of all ongoing lockout/tagouts. Review the nature of work planned and the proposed lockout/tagout with the individuals (including outside servicing personnel) performing the installation, maintenance, repair, alteration, or service to ensure that the work does not adversely impact operations and that plans for de-energizing and isolating equipment, machinery, or systems are complete and accurate.

3.2.4.2 Verify and sign entries on the Lockout/Tagout Record Sheet.

3.2.4.3 Notify Department Heads of lockout/tagout actions that will affect equipment, machinery, or systems under their authority before performing the lockout/tagout action.

3.2.4.4 Lockout/tagout equipment, machinery, or systems which have been rendered inoperable due to casualty or malfunction and make the appropriate entry on the Lockout/Tagout Record Sheet.

3.2.4.5 When necessary, verify system lineup after installation, maintenance, repair, alteration, or servicing has been performed.

3.2.4.6 Have actions cleared from the Lockout/Tagout Record Sheet and ensure tags are ready for reuse. Note that only the individual who installed the lock or tag may remove it.

3.2.5 All hands including the MilDet shall comply with these Lockout/Tagout Procedures. When crewmembers observe locked out and/or tagged out equipment, machinery, or systems, they shall not attempt to operate them until the lockout/tagout has been cleared.

3.2.6 CAUTION Tags (Attachment 4) shall be used as a precautionary measure to provide temporary special instructions or to indicate that unusual action must be used to operate equipment, machinery, systems, or components. These instructions must state the reason the CAUTION tag is installed. CAUTION tags shall NOT be used if personnel or equipment can be endangered while operating the equipment. In such cases, these Lockout/Tagout Procedures shall be used.

3.2.7 Lockout/Tagout Procedures: Lockout/Tagout Procedures are found in Attachment 2.

3.2.8 Auditing: The Chief Engineer or First Engineer shall conduct an audit of the Lockout/Tagout log at least biweekly by checking lockout devices, MSC DANGER Tags (Attachment 3) and the Lockout/Tagout Log. This check shall be recorded in the Engine Room Log. Completed Lockout/Tagout Record Sheets, Form 2.1-004-02, shall be maintained in the Lockout/Tagout Log for 30 days. During this check, completed Lockout/Tagout Record Sheets over 30 days old shall be removed from the Lockout/Tagout Log and retained aboard ship for 1 year, after which, they may be destroyed.

4 RECORDS & REPORTS

4.1 Form 2.1-004-01, Letter of Appointment as Lockout/Tagout Authorizing Officer or Collateral Duty Assignment Form 3.2-001-01-ALL.

4.2 Form 2.1-004-02, Lockout/Tagout Record Sheets

4.3 Lockout/Tagout Log

5 REFERENCES

5.1 COMSCINST 5100.17, Afloat Safety And Occupational Health Program Manual

5.2 29 CFR 1910.147

6.

DEFINITIONS

6.1 Lockout - The practice of using lockout devices and locks to physically isolate energy sources from workers performing installation, maintenance, repair, alteration, or servicing of equipment, machinery, or systems.

6.2 Tagout - The practice of using MSC DANGER tags with locks and lockout devices or alone when lockout is not feasible, to increase the visibility and awareness that equipment, machinery, or systems are not to be energized or activated until locks and/or tags are removed.

6.3 Authorizing Officer - A qualified person designated by the Chief Engineer to perform the duties identified in the Collateral Duty Assignment Form 3.2-001-01 or Letter of Appointment, Form 2.1-004-01.

6.4 Capable of being locked out - An energy-isolating device is capable of being locked out if it has a means of attachment through which a lock can be affixed or has a locking mechanism built into it. Lockout must be achieved without dismantling, rebuilding, or replacing the energy-isolating device.

7.

REVISIONS

Original 17 March 2004

Rev. 0.1 6 December 2006 – COMO may be Authorized Officer for communications gear LOTO. Responsibility of LOTO biweekly audit may be Chief Engineer or First Engineer. Changes determined to be editorial, not requiring signature re-approval.

Rev. 0.2 6 June 2007 - Added following verbiage to Attachment 2 in response to near miss incident. “Verify that the energy source has been deactivated and that the equipment, machinery, or system is isolated. Attempting operation using the normal controls, by using test equipment, or by conducting a visual inspection to verify that the stored energy sources have been been effectively isolated or discharged may achieve this.” Added SCO authority to act as Authorizing Officer in Comm Spaces. Added on Attachment 3 that DANGER tags may be obtained commercially.

Rev. 0.3 7 December 2007- Section 2, Applicability-Changed to reflect current release date.

Rev. 0.4 1 February 2008 – Use of Collateral Duty List provided as option to Appointment Letter.

Rev. 0.5 9 April 2008 – Reflected in attachement 3 & 4 alternate source for tags through MSC ASC.

Rev. 0.6 22 August 2008 – Modifiied section 2 to identify Navy Crew Tag-Out procedures for the USS MOUNT WHITNEY.

Rev. 0.7 1 December 2008 – Modified section 2 to identify T-AKE High Voltage procedure. Reformatted definitions.

ATTACHMENT 1

MSC LOCKOUT BEFORE SERVICING LABEL

LOCK OUT

BEFORE SERVICING

MSC 5100/21

ATTACHMENT 2 – LOCKOUT/TAGOUT PROCEDURES

LOCKOUT/TAGOUT PROCEDURES: The following minimum requirements for lockout and/or tagout of energy isolating devices shall be adhered to whenever installation, maintenance, repair, alteration, or servicing is done on equipment, machinery, or systems.

TASK

1. Identify all energy sources:

Conduct an initial survey to identify sources of power or energy for the equipment, machinery, or system so that each energy source can be isolated. Ensure that the survey considers guards, interlocks, or other safety devices that must be removed to conduct the installation, maintenance, repair, alteration, or servicing. Ensure that the survey considers the potential to place any part of the body into an area where the machinery or equipment could be rotated, lowered, or dropped.

Review circuit schematics or system diagrams to ensure all energy sources are identified for lockout and/or tagout.

2. Obtain the approval of the Authorizing Officer for all installation, maintenance, repair, alteration, or servicing of equipment, machinery or systems that requires lockout and/or tagout.

3. Notify all personnel who may be affected by securing and locking systems:

All personnel who would normally use the equipment, machinery, or system being serviced or repaired must be informed of systems being locked out/tagged out and instructed not to attempt to start or energize the equipment, machinery, or system.

Key personnel to inform would likely include: Department Heads, Engineering Duty Officer, Duty Deck Officer, Chief Steward, and, if applicable, the MilDet OIC.

4. Secure the equipment, machinery, or system. Stored or residual energy such as capacitors, rotating flywheels, hydraulic systems, air, gas, steam or water pressure, must be dissipated or restrained by methods such as grounding, repositioning, blocking or bleeding.

“Verify that the energy source has been deactivated and that the equipment, machinery, or system is isolated. Attempting operation using the normal controls, by using test equipment, or by conducting a visual inspection to verify that the stored energy sources have been been effectively isolated or discharged may achieve this.”

STEP 5A IS TO BE FOLLOWED ONLY WHEN LOCKING OUT EQUIPMENT, MACHINERY, OR SYSTEMS

5A. Lockout the energy source with the appropriate lockout device and lock. Before securing the lock, install a completed MSC DANGER Tag. (The tag must be attached at the same time the lock is placed on the system.) The tag must indicate at a minimum the reason the lock is there, the name of the person putting on the lock and tag, the department conducting the work, the date, and the equipment or system the lock and tag is isolating. The tag must be attached by a strong, durable, non-reusable, self-locking cord that can be attached by hand (electrical tie wrap or “zip tie”). Use only the locks and MSC DANGER tags with photo ID supplied from the lockout equipment locker.

Apply one lock and one DANGER Tag for each person working on the equipment so that removal of one worker’s lock and tag does not put the other workers in jeopardy. Special hasps are available to allow multiple locks at each location. Upon completion of the task, that person shall remove only his own lock and tag.

Secure piping systems by locking valve handles or wheels, or installing blank flanges.

The following equipment is available to assist in locking out equipment, machinery, or systems:

¾ inch Padlocks

2 inch Padlocks

Labeled Multi Lockout Hasp

Gate Valve Lockouts (sizes 1 – 13 inch)

Small and Large Ball Valve Lockouts

Butterfly Valve Lockout

Cable Lockout Device

“No Hole” Circuit Breaker lockout 480/600 Volt Device

“No Hole” Circuit Breaker lockout 220 Volt Device

Multi Pole Breaker Lockout

“EZ Panel Loc” Circuit Breaker Lockout Systems

Wall Switch Lockout

Small Plug Lockout

1 inch Diameter Jaw Type Multi Lockout Hasp

MSC Lockout/Tag Out Tags (MSC 5100/20)

MSC Lockout Labels (MSC 5100/21)

An MSC Lockout/Tagout DANGER Tag shall always accompany a lockout device.

STEP 5B APPLIES WHEN LOCKOUT OF EQUIPMENT, MACHINERY, OR SYSTEMS IS NOT FEASIBLE.

5B. Secure a completed MSC DANGER Tag. The tag must indicate the reason it is there, the name of the person putting on the tag, the department conducting the work, the date, and the equipment, machinery, or system the tag is isolating. The tag must be attached by strong, durable, non-reusable, self-locking cords that can be attached by hand (e.g. electrical tie wrap or "zip ties"). Use only the tags supplied from the lockout equipment locker.

Apply one tag for each person working on the equipment so that removal of one worker’s tag does not put other workers in jeopardy. Upon completion of the task, that person shall remove only his own lock and tag.

6. Enter the tagged out or locked out equipment, machinery, or system on the Lockout/Tagout Record Sheet. The Authorizing Officer shall verify and sign the Record Sheet before it is entered into the Lockout/ Tagout Log. The Lockout/Tagout Record Sheet shall include the number of the lock and tag.

Note: When different personnel are working on the same equipment, machinery, or system, there will be multiple entries for the same equipment, machinery, or system.

RESTORING NORMAL OPERATION: When installation, maintenance, repair, alteration, or servicing of the equipment, machinery, or system is completed and the equipment, machinery, or system is ready to return to normal operating condition, the following steps shall be taken:

TASK

1. Verify the equipment, machinery, or system is safe for re-energizing:

Notify the Authorizing Officer when the locks and tags will be removed and the equipment, machinery, or system will be returned to normal.

Only the individual who installed the lock or tag may remove it. The Chief Engineer or Master is the ONLY other person authorized to remove another’s lockout device and/or tag provided the Chief Engineer or Master personally verifies that no one is working on equipment, machinery, or system that is locked and/or tagged out and that in the opinion of the Chief Engineer or Master, the circumstances require the removal of the lockout device and lock or tag.

2. Before energy is restored to the equipment, machinery, or system, visually inspect it to ensure that everyone is safely clear of the operating area; that equipment components, covers, and guards are in place, that tools or debris are removed, that controls are off or in neutral, and that the equipment, machinery, or system is properly lined up.

3. Remove the lock, lockout device and DANGER Tag, and re-energize the equipment, machinery, or system.

4. Notify affected departments that installation, maintenance, repair, alteration or servicing action is complete and that system, equipment, machinery or system is ready for use and operation.

5. Clear the lockout action on the Lockout/Tagout Record Sheet. For multiple lockout/tagout actions, only the lock/tag that is being removed shall be logged as completed. If the Master or Chief Engineer removed and cleared someone else’s lockout, an explanation shall be made on the Lockout/Tagout Record Sheet.

ATTACHMENT 3

MSC DANGER TAG (Note: DANGER Tags may be obtained commercially or through MSCHQ Administrative Support Supervisor (Ken Williams, 202-685-5092, kenneth.j.williams1@navy.mil).

1.

The MSC DANGER Tags, (MSC 5100/20 (Rev 5-96)) or their commercial equivalents are reusable laminated tags that shall be used for all MSC Lockouts and Tagouts. The tag shall be completed as follows:

a.

At a minimum, the crewmember’s name and department shall be entered on the face of the tag and laminated to permanently protect the tag. Crewmembers are encouraged to place a photo ID picture in the space provided before laminating the face of the tag. (This may not be accommodated on commercial tags) b.

On the back of the tag, the user shall indicate whether Lockout or Tagout is being used by marking the appropriate box with an erasable grease pencil or other means. Any remarks are to be added in the remarks section, which must be readable and understandable.

c.

Upon removal of the MSC DANGER Tag when completing Lockout or Tagout, the back of the tag can be erased and reused.

2.

Sample DANGER Tags:

DANGER

DANGER

This system has been

DO NOT

Locked out

Tagged out

OPERATE

Unauthorized removal of

This system is turned off to protect my life.

PLACE

PHOTO

HERE

this lock/tag may result in immediate discharge.

Remarks: _______________

Name:_________________

Dept: _________________

MSC 5100/20 (5/96)

ATTACHMENT 4

CAUTION TAG (Commercial)

1.

CAUTION Tags may be obtained commercially or through MSCHQ Administrative Support Supervisor (Ken Williams, 202-685-5092, kenneth.j.williams1@navy.mil). They are reusable and can be used to provide temporary special instructions or to indicate that unusual action must be used when operating machinery, systems or components. CAUTION tags SHALL NOT be used as a substitute for MSC DANGER Tags. The tag shall be completed as follows:

a.

The Crewmember’s name, department, date applied and the equipment the tag applies to shall be entered on the face of the tag.

b.

On the back of the tag, the user shall indicate special instructions and/or precautions to be followed when operating the tagged equipment.