SMS 2-1-004.pdf

MILITARY SEALIFT COMMAND’S

SAFETY MANAGEMENT SYSTEM

SAFETY MANAGEMENT PROCEDURES

MANUAL

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

MILITARY SEALIFT COMMAND’S SAFETY MANAGEMENT SYSTEM

SAFETY MANAGEMENT PROCEDURES MANUAL

2.1-004-All Revision 0.7

Lockout / Tagout Page 2 of 13 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.

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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

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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.

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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

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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.

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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.

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ATTACHMENT 1

MSC LOCKOUT BEFORE SERVICING LABEL

LOCK OUT

BEFORE SERVICING

MSC 5100/21

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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.”

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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

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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.

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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)

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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. Remarks must be readable and understandable.

c. Upon removal of a CAUTION Tag, the tag should be discarded.

2. Sample CAUTION Tag:

CAUTION CAUTION

DO NOT OPERATE THIS

EQUIPMENT UNTIL

SPECIAL INSTRUCTIONS ON

REVERSE

SIDE ARE THOROUGHLY

UNDERSTOOD

DO NOT OPERATE THIS

EQUIPMENT UNTIL SPECIAL

INSTRUCTIONS BELOW ARE

THOROUGHLY UNDERSTOOD

EQUIPMENT APPLIED TO:

TAG APLIED BY: __________

DEPT: ___________________

DATE APPLIED:

Back face

Front face

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