N42158-17-R-0001_Attachement_8_OSHECM_Hazardous_Energy_Control.pdf

OCCUPATIONAL SAFETY, HEALTH

AND ENVIRONMENT OFFICE

NORFOLK NAVAL SHIPYARD

CHAPTER SUPPLEMENT RECORD

OSHE CONTROL MANUAL CHAPTER 250

LOCAL SUPPLEMENT APPENDIX H ORIG

Title of Chapter: Hazardous Energy Control (HEC) Program

1. Description/Reason for Revision: This is a Norfolk Naval Shipyard local Supplement to the Corporate OSHE

Control Manual Chapter 250.

2. Effective Implementation Date: Upon issue. Recipients are requested to review this chapter and note their responsibilities. Additional implementation requirements provided below:

1. LOTP Coordinators (LOTCs) shall complete these requirements by end of the 1 st FY quarter after LOTP implementation (i.e. the period ending June 30, 2012).

A. Have assembled a new NNSY LOTP & SOT Log Book in accordance with the requirements of

Enclosure (6). Keep the existing Lockout/Tagout Log Book for history and recordkeeping use. The

Lockout/Tagout Log Book may be discarded after April 30, 2013.

B. Etch/engrave HEC locks IAW the requirements of section 250H.4, Specific Policy, sub-step H.3.

C. Review existing P5090.2 LOTO Logbooks for location(s) of hanging DANGER tags. Replace the

DANGER tag(s) by installing a HEC lock with lock ID tag or label identifying the AE in accordance with OSHECM Chapter 250. After lockouts have been performed, remove and clear DANGER tags in the Logbook.

D. If the DANGER tag was being used to protect the MES only, i.e. not for HEC to protect a person, the

LOTP Coordinator shall install a SOT tag or provide administrative control by other means.

E. Review existing P5090.2 LOTO Logbooks for location(s) of CAUTION tags. Install a new SOT tag to replace each CAUTION tag and clear the CAUTION tags in the Logbook.

2. Technical work documents (TWDs) requirements for Hazardous Energy Control (HEC):

A. Until TWDs are changed to specify OSHECM Chapter 250 HEC requirements, AEs and LOTCs shall use OSHECM Chapter 250 as the HEC reference whenever P5090.2 OSHE PROGRAM MANUAL

II-16 is referenced. The P5090.2 OSHE PROGRAM MANUAL II-16, Rev B, Change 1, on the

C106 webpage will be redirected to OSHECM Chapter 250. After 6 months, whenever P5090.2 is referenced, a DR/DL shall be written to specify OSHECM Chapter 250 requirements in the TWD.

B. For all TWDs issued prior to the implementation date of 30 April 2012, within 6 months & NLT 31

October 2012, ensure reference to P5090.2 OSHE PROGRAM MANUAL II-16 HEC requirements is changed to provide LOTP HEC wording of Enclosure (8). After this 6 month timeframe, a DR/DL will be written to specify OSHECM Chapter 250 as the HEC reference in the TWD.

C. All TWDs issued after the 30 April 2012 implementation date shall use the TWD wording of

Enclosure (8) and reference OSHECM Chapter 250 for HEC work.

3. Existing contracts invoking HEC are not required to be changed to LOTP if the contract was awarded prior to 30

April 2012. These contracts will honor the safety specification in the contract through completion and customer acceptance of product.

3. Training Required: Training is as noted in the chapter.

4. Action: Addressees are requested to add this Supplement Appendix H to OSHE Control Manual Chapter 250.

Shops and codes are to review the appropriate responsibilities sections to ensure they are in compliance. If any discrepancies are noted in the entry of this change, contact Code 106.22 at 396-4482 for resolution.

5. Concurrence: See cover sheet.

OSHE CONTROL MANUAL

NAVSEA

OCCUPATIONAL SAFETY,

HEALTH AND ENVIRONMENT

CONTROL MANUAL

FOR NAVAL SHIPYARDS

CHAPTER 250

HAZARDOUS ENERGY CONTROL

Naval Seas Systems Command

Environmental Protection, Occupational Safety and

Health Office, NAVSEA 04R

CHAPTER 250 OSHE CONTROL MANUAL

OSHE CONTROL MANUAL 250 Rev I Sheet 250-1

CHAPTER 250 HAZARDOUS ENERGY CONTROL

250.1 DISCUSSION:

A. Purpose: To establish the performance requirements for the control of hazardous energy for personnel protection while servicing machinery, equipment, and systems.

B. Standardization: To implement a standard Lockout/Tags-Plus (LOTP)

Program in accordance with reference

250.3.A for all Department of Navy shipyards and their associated activities that perform shipyard employment work.

C. Scope: To provide the requirements for hazardous energy control during servicing when startup of machinery, equipment, or systems or the release of hazardous energy could endanger an employee.

D. Applicability:

1. This chapter provides hazardous energy controls for employees when servicing machinery, equipment, or systems that employees use in the course of shipyard employment work conducted:

a. In any landside facility that performs shipyard employment work; and

b. On any vessel or vessel section.

2. This chapter meets the hazardous energy control requirements of references 250.3.B and C.

3. Contractors and other non-shipyard government organizations performing work in Naval Shipyards must follow the shipyard‟s lockout/tags-plus program and procedures.

E. Exceptions: This chapter DOES NOT apply to the following:

1. Uniformed Navy military personnel stationed shipboard.

2. Shipboard servicing operations under ship‟s force control, covered by the Tag-out

Users Manual (TUM), reference 250.3.D, which meet the requirements of Reference

250.3.A. Note: This exception does not obviate the requirements for Tier 1 training of shipboard personnel per 250.5.C.3 and program audits that must be performed for shipboard hazardous energy control operations per 250.4.N.

3. Maintenance of diving equipment performed by diving personnel using

Reference 250.3.D for hazardous energy control

4. Work on cord and plug machinery, equipment, or system, provided the machinery, equipment, or systems is unplugged and the plug is under the exclusive control of the employee performing the servicing. Note: See requirement for removing load prior to disconnecting in reference 250.3.E.

5. Minor servicing activities performed during normal production operations, including minor tool changes and adjustments, that are routine, repetitive, and integral to the use of the machinery, equipment, or systems, provided the shipyard ensures that the work is performed using measures that provide effective protection from energization, startup, or the release of hazardous energy.

6. Equipment removed for reasons other than servicing, as long as all hazardous

OSHE CONTROL MANUAL 250 Rev I Sheet 250-2 energy sources have been disconnected and there is no potential for reaccumulation of hazardous energy.

7. Specialized facilities that support refueling and defueling work once these facilities are integrated with shipboard

F. Background:

1. On May 2, 2011, OSHA published

Subpart F of 29 CFR 1915 (General working conditions in shipyard employment), which included section 1915.89 (Reference

250.3.A). Reference 250.3.A establishes new requirements for the control of hazardous energy, also known as

Lockout/Tags-plus. NAVSEA has established this chapter to enable compliance with these new requirements.

2. Appendix A (Table of Acronyms) provides a list of acronyms used in this chapter.

250.2 APPENDICES:

A. Table of Acronyms

B. Hazardous Energy Control Decision

Matrix

C. Hazardous Energy Control Decision

Flowcharts

D. Hazardous Energy Control Tag

E. Lockout/Tags-Plus Coordinator

(LOTC) Log Form

F. Energy Control Procedure Form

G. Primary Authorized Employee (PAE)

Log

250.3 REFERENCES:

A. 29 Code of Federal Regulations (CFR)

1915.89, Control of hazardous energy

(lockout/tags-plus)

B. 29 CFR 1910.269, Electric Power

Generation, Transmission, and

Distribution

C. 29 CFR 1910.331-333, Electrical

D. NAVSEA S0400-AD-URM-010/TUM

Tag-out Users Manual

E. NFPA 79 Electrical Standard for

Industrial Machinery

F. SECNAVINST 5030.1L Classification of Naval Ships and Craft

G. COMFLTFORCOMINST 4790.3,

Joint Fleet Maintenance Manual

H. OPNAVINST 5100.23 (Latest

Revision) Navy Safety and Occupational

Health Program Manual

I. UIPI 0090-002 Self Assessment

J. UIPI 0900-453 Critique and Problem

Analysis Matrix Processes; Problem

Identification and Investigation

K. NAVSEA ltr 5100 Ser 04R/035 of 8

Sep 10, Reporting Criteria for Level 1 and 2 Safety Incidents; Approval of

250.4 OVERVIEW OF SUBJECT

MATTER AND SPECIFIC POLICY:

A. Definitions:

1. Additional Safety Measure. A component of the tags-plus system that provides an impediment (in addition to the

OSHE CONTROL MANUAL 250 Rev I Sheet 250-3 energy-isolating device) to the release of energy or the energization or startup of the machinery, equipment, or system being serviced. Examples of additional safety measures include, but are not limited to, removing an isolating circuit element;

blocking a controlling switch; blocking, blanking, or bleeding lines; removing a valve handle or wiring it in place; and opening or guarding an extra disconnecting device. A hazardous energy control (HEC) tag may be installed on the additional safety measure or at the location of the additional safety measure, if the authorized employee

(AE), primary authorized employee (PAE), or Lockout/Tags-Plus coordinator (LOTC) thinks it is beneficial in providing additional information on the Tags-Plus system being used.

2. Affected Employee (AFE). An employee who normally operates or uses the machinery, equipment, or system that is going to be serviced under lockout/tags-plus or anyone in the area where servicing is being performed under lockout/tags-plus.

3. Authorized Employee (AE). A trained and knowledgeable employee who performs one or more of the following lockout/tags-plus responsibilities:

a. Executes the lockout/tags-plus procedures.

b. Installs a lock or tags-plus system on machinery, equipment, or systems.

c. Services any machine, equipment, or system under lockout/tags-plus application.

Note: Managers, engineers, inspectors, technical representatives, other production personnel, etc, must be AEs if they might be exposed to hazardous energy from any machine, equipment or system under lockout/tags-plus application.

4. Boat. A self-propelled craft suitable primarily to be carried on-board ships and to operate in and around naval activities. Boats include landing craft and standard Navy design commercial and non-developmental small boats, including Rigid Inflatable Boats

(RIBs). Other inflatable boats and rafts are not managed as boats. Punts are plant property and not part of the boat inventory.

5. Capable of Being Locked Out. An energy-isolating device is capable of being locked out if it has a locking mechanism built into it, or it has a hasp or other means of attachment to which, or through which, a lock can be affixed. Other energy-isolating devices are capable of being locked out if lockout can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy-control capability.

6. Contract Employer. An employer, such as a painting, joinery, carpentry, or scaffolding contractor, that performs shipyard-related services or work under contract to the host employer or to another employer under contract to the host employer at the host employer‟s worksite.

This excludes employers who provide services that are not directly related to shipyard employment, such as mail delivery, office supply, and food vending services.

7. Energy Control Procedure (ECP).

Detailed, written instructions to identify and prevent the energization or startup, or the release of hazardous energy, during the servicing of any machinery, equipment, or system. Other technical work documents, such as TGIs, SOPs, or IPIs, can be used as

ECPs if they contain the information in an

ECP and provide an equivalent level of protection from hazardous energy.

Appendix F is an ECP form that can be used

OSHE CONTROL MANUAL 250 Rev I Sheet 250-4 to describe and document LOTP hazardous energy control procedures for a specific machine, equipment, or system.

8. Energy-Isolating Device. A mechanical device that, when utilized or activated, physically prevents the release or transmission of energy. Energy-isolating devices include, but are not limited to, manually operated circuit breakers; machine disconnects; line valves; blocks; blank flanges; bolted slip blinds and any similar device used to block or isolate energy.

Control-circuit devices (for example, push buttons, selector switches) are not considered energy-isolating devices.

9. Exclusive Control. The employee has the authority to and is continuously in a position to prevent (exclude) other individuals from re-energizing the machinery, equipment, or system during the servicing activity.

10. Full Employee Protection. Use of a lock or tags-plus system and measures to mitigate, dissipate, prevent restoration

(energization) and release of hazardous energy in order to ensure that an employee is not exposed to hazardous energy during the course of the servicing activity.

11. Group LOTP. When more than one AE services the same machinery, equipment, or system at the same time and performs work in accordance with 250.4.J (Group Lockout) or 250.4.K (Group Tags-Plus) of this

12. Group Lockout. A method where a PAE controls each source of hazardous energy with a lock, the keys of each lock are placed in a Group Lockbox, and AEs hang their personal locks on the Group Lockbox.

13. Group Tags-Plus. A method where a

PAE controls each source of hazardous energy, but at least one Tags-Plus application is used, and AEs are logged on the PAE Log while performing servicing.

14. Hazardous Energy. Any energy source, including mechanical (for example, power transmission apparatus, counterbalances, springs, pressure, gravity), pneumatic, hydraulic, electrical, chemical, and thermal

(for example, high or low temperature) energies that could cause injury to employees.

15. Hazardous Energy Control (HEC) Tag and Tag Attachment. A prominent warning device that includes a means of attachment that can be securely fastened to an energy-isolating device in accordance with an established procedure to indicate that the energy-isolating device and the equipment being controlled must not be operated until the tag is removed by the AE who installed the tag. Each tag shall be capable of withstanding the existing environmental conditions for the maximum period of time that servicing is expected to last, and is made so that weather conditions, wet or damp conditions, corrosive substances, or other conditions in the work area where the tag is used or stored will not cause it to deteriorate or become illegible. Each tag and tag attachment shall be sturdy enough to prevent inadvertent or accidental removal.

Each tag attachment shall have the general design and basic safety characteristics of a one-piece, all-environment-tolerant nylon tie, be non-reusable, attachable by hand, self-locking, and non-releasable, and have a minimum unlocking strength of 50 pounds.

See Appendix D for illustrations of the front and back of the HEC tag.

16. Host Employer. An employer that is in charge of coordinating shipyard-related

OSHE CONTROL MANUAL 250 Rev I Sheet 250-5 work, or that hires other employers to perform shipyard-related work or to provide shipyard-related services, at a multi-employer worksite.

17. Individual Lockout. A method where each AE controls each source of hazardous energy with a lock.

18. Individual Tags-Plus. A method where each AE controls each source of hazardous energy, but at least one Tags-Plus application is used.

19. Interface Work. Work that involves

LOTP controls and Navy tag-out controls.

Example: A ship‟s temporary support system that is controlled landside via LOTP and controlled shipboard via the Navy tag-out system.

20. Lock. A keyed device that utilizes a positive means to hold an energy-isolating device in a “safe” position that prevents the release of energy and the startup or energization of the machinery, equipment, or system to be serviced. A lock must be:

a. Red in color and identifiable to the

AE attaching the lock and exclusively used for lockout applications.

b. Individually keyed with that key under the exclusive control of the AE. A second key may be retained under the control of the LOTP Coordinator or other personnel designated by the shop/code. No more than two keys per lock are allowed to be made.

c. Each lock shall be capable of withstanding the existing environmental conditions for the maximum period of time that servicing is expected to last and shall be sturdy enough to prevent removal without the use of extra force or unusual techniques, such as bolt cutters or other metal-cutting tools.

21. Lockout. The placement of a lock on an energy-isolating device in accordance with this chapter, thereby ensuring that the energy-isolating device and the equipment being controlled cannot be operated until the lock is removed.

22. Lockout Device. A mechanism that attaches to an energy isolating device and holds it in a safe position when the lock is installed, preventing the energization to that machine, equipment, or system. Examples include circuit breaker lockout devices, multiple person hasps, valve restraining devices, plug covers, chains, or cables. The lockout device must be capable of withstanding its environmental exposure for the maximum period of time that servicing is expected to last and be substantial enough to prevent removal without the use of excessive force or unusual techniques, such as with the use of bolt cutters or other metal cutting tools.

23. Lockout/Tags-Plus Coordinator (LOTC).

A designated employee who coordinates and oversees all lockout and tags-plus applications on vessels or vessel sections and at landside work areas when employees are performing several servicing operations on the same machinery, equipment, or system at the same time and when employees are servicing multiple machinery, equipment, or systems on the same vessel or vessel section at the same time. A

Lockout/Tags-Plus Coordinator always coordinates and oversees multiple employer work, i.e. work involving non-shipyard government organizations, lead contractors and their sub-contractors. The lockout/tags-plus coordinator maintains the

Lockout/Tags-Plus Coordinator Logbook.

OSHE CONTROL MANUAL 250 Rev I Sheet 250-6

24. Lockout/Tags-Plus (LOTP) Logbook. A logbook used to document the application and removal of lockout or tags-plus systems when LOTP coordination is required. A unique serial number will be used to document each group lockout or tags-plus isolation when LOTP coordination is required. The format for the LOTC

Logbook form is provided in Appendix E.

Other pertinent LOTP information identified in paragraph 250.5.B is also required to be in each LOTC Logbook.

25. Lockout/Tags-Plus System. The use of energy isolation locks or tags-plus applications (including lockboxes and logs) that provide AEs the means to control hazardous energy. Examples include individual AEs applying LOTP at hazardous energy-isolating device(s), LOTP locks being applied at hazardous energy-isolating device(s), and the keys being held in a group lockbox (with at least one PAE lock applied), or a group tags-plus applied (with at least one PAE assigned).

26. Multiple Employer. Host employer, such as Navy Shipyards, and at least one additional employer (e.g., contract employers and/or other outside activities, NAVFAC (unless MILCON work), NAVSEA, Defense Logistics Agency

(DLA), Navy Crane Center (NCC), etc.)

27. Multiple Energy Sources. Any combination of energy sources which require multiple isolation devices to control all hazardous energy from the area where the AE will be servicing machinery, equipment, or systems. Examples would be a large boiler that has gas, electrical and pneumatic energy sources or electrical machinery, equipment, or systems with multiple electrical feeds/sources.

28. Multiple Servicing.

a. When two or more people are performing different servicing operations on the same machinery, equipment, or system at the same time or when two or more people perform one servicing operation on multiple machines, equipment, or systems at the same time.

b. For landside individual lockout systems, LOTP coordination is not required for multiple servicing, if the isolation of a single hazardous energy source completely isolates the machinery, equipment, or system (or section of that machinery, equipment, or system) AND all individuals use their personal lock, AND where one employee‟s action of changing the status of the lockout/tags-plus system would NOT endanger another employee.

c. All multiple servicing performed on vessels and vessel sections require LOTP coordination.

29. Navy Ship‟s Force. The crew of a vessel that is owned or operated by the U.S. Navy, that is under the control of a Commanding

Officer or Master.

30. Normal Production Operations. The use of machinery, equipment, or systems, including, but not limited to, punch presses, bending presses, shears, lathes, keel press rollers, and automated burning machines, to perform a shipyard-employment production process.

31. Personal Lockout/Tags-Plus System.

What an AE uses to personally control the

LOTP System. Examples include: (1) applying LOTP at the hazardous energy-isolating device(s), (2) applying a lock to a group lockbox, or (3) signing the PAE Sign-

In/Sign-Out Log in a group tags-plus.

OSHE CONTROL MANUAL 250 Rev I Sheet 250-7

Appendix G is the PAE Sign-In/Sign-Out

Log.

32. Primary Authorized Employee (PAE).

An authorized employee assigned by the

LOTP Coordinator as the representative for a specific group of AEs involved in a group lockout/tags-plus application.

33. Primary Authorized Employee (PAE)

Log. The log form used to account for the work status of AEs under the responsibility of an assigned PAE. AEs will sign in and out on this form to provide an accurate status of who is working under the group tags-plus system.

34. Safe Exposure Status. Knowledge that all AEs in a servicing group working under a

PAE are protected from hazardous energy.

35. Service Craft. A classification of waterborne craft that comprises generally the waterborne utilitarian craft not classified as ships or boats, designed to operate in coastal and protected waters and provide general support to combatant forces and shore establishments. Service craft are designated by type in reference 250.3.F, and listed in the CBSS and Naval Vessel

Register. Examples of service craft include dive tenders (YDT), radiological repair barges (YRR), floating cranes (YD), and floating dry docks (AFDL, AFDM, ARDM, and YFD). All servicing work performed on service craft will be performed in accordance with this chapter.

36. Servicing. Workplace activities that involve the construction, installation, removal, adjustment, inspection, modification, testing, or repair of machinery, equipment, or systems. Servicing also includes maintaining machines, equipment, or systems when performing these activities would expose the employee to harm from the start-up or energization of the system being serviced or the release of hazardous energy.

37. Single Energy Source. An energy source which requires only one isolation device to control all hazardous energy from the area where the AE will be servicing

38. Tags-Plus System. A system to control hazardous energy that consists of an energy-isolating device with a Hazardous Energy

Control Tag affixed to it, and at least one additional safety measure.

39. Verification of Isolation. The means necessary to detect the presence of hazardous energy, which may involve the use of a test instrument (for example, a voltmeter), and, for other than electric shock protection, a visual inspection, or a deliberate attempt to start-up the machinery, equipment, or system.

40. Vessel. A craft for traveling on or in water, such as a ship or boat.

41. Vessel Section. A subassembly, module, or other component of a vessel being built or repaired.

42. Work Area. A specific area, such as a machine shop, engineering space, or fabrication area, where one or more employees are performing job tasks.

43. Worksite. A general work location where one or more employees are performing work, such as a shipyard, pier, barge, vessel, or vessel section.

B. General Requirements:

1. All Naval Shipyards‟ strict Hazardous

Energy Control Program policy requires that

OSHE CONTROL MANUAL 250 Rev I Sheet 250-8 before any AE performs servicing when energization, startup, or release of hazardous energy may occur, all hazardous energy sources impacting the personnel safety for the work to be performed are identified, isolated, restrained, and dissipated, and the machinery, equipment, or system is rendered inoperative. NOTE: No employee shall attempt to start, open, close, energize, or operate that machinery, equipment, or system, except to verify hazardous energy control isolation. There are four different variations of LOTP.

a. Individual Lockout;

b. Individual Tags-Plus;

c. Group Lockout; and

d. Group Tags-Plus.

2. Only AEs shall perform LOTP applications on machinery, equipment, or

3. Lockout is the primary means of personnel protection for the AE or affected employees while servicing operations are ongoing.

4. When using lockout systems, the AE shall affix each lock in a manner that will hold the energy-isolating device in a safe or off position.

5. When using tags-plus systems, the AE shall affix a tag directly to the energy-isolating device that clearly indicates that the removal of the device from a safe or off position is prohibited. Whenever Tags-Plus is to be used, even when a system can be locked out, prior approval must be obtained by identifying that Tags-Plus is to be used on the Energy Control Procedure (ECP), Appendix F. Approval to use Tags-Plus must also be authorized by Shop

Head/Department Head and C106 OSHE

Director, as will be required by the ECP.

6. When the tag cannot be affixed directly to the energy-isolating device, the AE shall locate it as close as safely possible to the device, in a safe and immediately obvious position.

7. If an AE(s) servicing machinery, equipment, or system is unable to physically or safely install and/or remove his or her personal LOTP system, an ECP shall be developed for this specific application to ensure the AE(s) is provided the same level of protection as he or she would have when installing and/or removing his or her personal LOTP system. This ECP shall require Shop Head/Department Head and

C106 OSHE Director authorization.

8. In the case of an out-of-position or missing LOTP system, NEVER reposition the energy-isolating device without following the proper steps to correct the out-of-position, damaged, or missing LOTP system in a safe manner. For damaged tags, notify your supervisor and the LOTC for resolution. This is a SERIOUS SAFETY

PROBLEM and requires that immediate actions be taken to ensure personnel safety.

Corrective action steps are:

a. Stop work, clear the work area, and warn affected employees there may be a potential safety hazard.

b. Guard the area (or have someone else guard the area) where the out-of-position, damaged, or missing energy isolating device is located. DO NOT reposition the energy-isolating device or let anyone else reposition it.

OSHE CONTROL MANUAL 250 Rev I Sheet 250-9

c. Notify (or have someone notify) your supervisor immediately of the problem.

d. Notify the cognizant shop/code and have them determine the appropriate, immediate corrective actions to place the machine, equipment, or system in a safe condition. After this is accomplished, notify

Code 106‟s Hazardous Energy Control

Program Manager of the unsafe condition.

9. Tags-Plus System.

a. Must provide a level of safety equivalent to that obtained by lockout. This is accomplished by identifying at least one energy-isolating device with a tag affixed to it and at least one additional safety measure.

These additional isolation points will be identified in energy control procedures.

HEC tags may be affixed at the location of the additional safety measure if the authorized employee, primary authorized employee, or Lockout/Tags-Plus coordinator thinks it beneficial in providing additional information on the Tags-Plus system being

b. Requires Shop Head/Department

Head and C106 OSHE Director authorization.

10. The Hazardous Energy Control Decision

Matrix (Appendix B) provides guidance on

LOTP, ECP, PAE, and LOTC requirements and provides examples of servicing activities corresponding to various energy isolation applications. Consult this

Appendix in planning the LOTP requirements for a specific servicing activity. Hazardous Energy Control

Decision Flowcharts (Appendix C) summarizes decision logic embedded in the

Appendix B matrix in two simplified flowcharts.

11. The Hazardous Energy Control tag to be used by the AE in tags-plus applications is depicted in Appendix D (Hazardous Energy

Control Tag).

12. The example logbook form to be used by the LOTC in coordinated lockout/tags-plus applications is depicted in Appendix E

(Lockout/Tags-Plus Coordinator Logbook

Form). The Lockout/Tags-Plus Coordinator

Logbook contents will be determined by each shipyard. An example log is depicted in Appendix E.

13. An example form for developing an energy control procedure is depicted in

Appendix F (Energy Control Procedure

Form).

14. Primary Authorized Employees will use the PAE Sign-In/Sign-Out Log to account for all AEs under their cognizance during group Tags-Plus applications. An example log is depicted in Appendix G.

15. No employee, except for AEs performing verification of a deenergized hazardous energy source, or testing or positioning machinery, equipment, or system (per section 250.4.E), shall attempt to start, open, close, energize, or operate machinery, equipment, or system during servicing.

C. Procedures for Application of

Hazardous Energy Control:

1. The following procedures shall be used when applying LOTP.

2. Preparing for shutdown and isolation.

a. The AE shall have knowledge of:

OSHE CONTROL MANUAL 250 Rev I Sheet 250-10

(1) The source, type, and magnitude of the hazards associated with the machine,

(2) The hazards associated with the

(3) The means to control these hazards.

b. The AE shall notify each affected employee that the machinery, equipment, or system will be shut down and de-energized prior to servicing, and that a lockout/tags-plus system will be implemented.

3. Shutdown and isolation.

a. The AE shall ensure that the machinery, equipment, or system has been shut down.

b. The AE shall relieve, disconnect, restrain, or otherwise render safe all potentially hazardous energy that is connected to the machinery, equipment, or system. Stored, re-accumulating, or residual energy (e.g., capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure) must be dissipated or restrained by methods such as repositioning, blocking, depressurizing, bleeding down, draining, etc.

4. Applying lockout/tags-plus systems.

a. Apply LOTP, per any one of the following applications in its entirety.

(1) Applying Individual Lockout

(per 250.4.H)

(2) Applying Individual Tags-Plus

(per 250.4.I)

(3) Applying Group Lockout (per

250.4.J)

(4) Applying Group Tags-Plus (per

250.4.K)

b. The AE shall ensure that each energy-isolating device that controls energy to the machinery, equipment, or system is effective in isolating the machinery, equipment, or system from all potentially hazardous energy source(s). Stored, re-accumulating, or residual energy (e.g., springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure) must be dissipated or restrained by methods such as repositioning, blocking, depressurizing, bleeding down, draining, etc.

5. Verification of hazardous energy control isolation.

a. Before servicing machinery, equipment, or a system that has a lockout/tags-plus system, the AE, or the

PAE in a group lockout/tags-plus application, shall verify hazardous energy control of the machinery, equipment, or system.

b. The AE, or the PAE in a group lockout/tags-plus application, shall ensure verification of hazardous energy control while servicing the machinery, equipment, or system. This may include attempts to start up or actuate machinery, equipment, or

c. Each AE in a group lockout/tags-plus application who will be servicing the machinery, equipment, or system must be given the option to verify hazardous energy control of the machinery, equipment, or system, even when verification is performed by the PAE. If de-energization verification

OSHE CONTROL MANUAL 250 Rev I Sheet 250-11 by an AE poses a hazardous situation for other AEs (e.g., depressing a start button), the AE must ensure all personnel are clear of machinery, equipment, or system prior to verification of de-energization.

D. Procedure for Shift or Personnel

Change:

1. The following requirements must be complied with for continuation of work during shift changes and PAE assignment changes.

2. When Individual Lockout is used, the following requirements apply:

a. AEs leaving the work area can keep their lock(s) on the hazardous energy-isolating device(s).

b. At least one AE must keep his or her lock(s) on the hazardous energy-isolating device(s) until the machinery, equipment, or system is suitable for safe operation and work is complete. AEs whose lock(s) remain installed must have an understanding of the remaining work and status of the machinery, equipment, or system.

c. On vessels and vessel sections, LOTP Coordination is required when workers perform unrelated servicing at the same time, regardless if on separate or the same machinery, equipment, or system. On landside facilities, LOTP Coordination is required when workers perform unrelated servicing at the same time, on the same machinery, equipment, or system.

(1) LOTC enters the Individual

Lockout information into the LOTC

Logbook.

(2) AE writes date and his or her name in the “Employee Applying” column before starting work.

(3) AE writes date and his or her name in the “Employee Removing” column when the machinery, equipment, or system is suitable for safe operation, work is completed, and Individual Lockout System is removed.

d. For landside individual lockout for multiple servicing, if the isolation of a single hazardous energy source completely isolates the machinery, equipment, or system (or section of that machinery, equipment, or system) AND all individuals use their personal lock, AND where one employee‟s action of changing the status of

3. When Individual Tags-Plus is used, the

a. Tags-Plus must remain in place, including the Additional Safety Measure(s), until the machinery, equipment, or system suitable for safe operation and work is complete.

b. AE responsibilities:

(1) The departing AE writes current date in LOTC Logbook “Employee

Removing” Date column.

(2) The departing AE writes

“Transferred to (NAME OF ON-COMING

AE)” in the “Employee Removing” Name column.

(3) The LOTC re-writes the Tags-

Plus System information in the LOTC

OSHE CONTROL MANUAL 250 Rev I Sheet 250-12

Logbook, as if it were a new entry, but using the same LOTC Logbook serial number.

(4) The on-coming AE writes the date and his or her name in the “Employee

Applying” columns.

c. LOTP Coordination is REQUIRED.

4. When Group Lockout is used, the

a. AEs leaving the work area can keep their locks on the Group Lockbox, but have the option to remove them.

b. The current PAE must have his or her lock on the Group Lockbox during all work, and until the machinery, equipment, or system is suitable for safe operation and work is complete.

c. LOTP Coordination is REQUIRED.

d. PAE designation is REQUIRED.

(1) LOTC designates the PAEs for the work done during a shift, and ensures the

LOTC Logbook is accurate.

(2) Only one PAE will serve on a

Group Lockout at a time.

(3) The transition from one PAE to another is at the discretion of the LOTP

Coordinator.

5. When Group Tags-Plus is used, the

a. A PAE must remain on the LOTC

Logbook for the Group Tags-Plus during work and until the machinery, equipment, or system is suitable for safe operation and work is complete.

b. LOTP Coordination is REQUIRED.

c. PAE designation is REQUIRED.

(1) LOTC designates the PAE for the work done during a shift, and ensures the

LOTC Logbook is accurate.

(2) Only one PAE will serve on a

Group Tags-Plus at a time.

(3) The transition from one PAE to another is at the discretion of the LOTP

Coordinator.

d. PAE responsibilities:

(1) The departing PAE writes current date in LOTP Log "Employee Removing"

Date column.

(2) The departing PAE writes

"Transferred to (NAME OF ON-COMING

PAE)" in the "Employee Removing" Name column.

(3) The LOTC re-writes the Tags-

Plus System information in the LOTP Log, as if it was a new entry, but using the same

LOTP Log serial number.

(4) The on-coming PAE writes the date and his or her name in the "Employee

Applying" columns.

e. AE responsibilities:

(1) All AEs must log out on the departing PAE's PAE Log.

(2) All AEs that will continue working must log in on the on-coming

PAE's PAE Log.

OSHE CONTROL MANUAL 250 Rev I Sheet 250-13

E. Testing or Positioning:

1. In each situation in which a lockout/tags-plus system must be removed temporarily and the machinery, equipment, or system restarted to test it or to position a component, the AE shall perform the following, in sequence:

a. When a LOTC is involved, the AE shall brief the LOTC of the testing/positioning procedures prior to the start of work.

b. Clear tools and materials from the work area.

c. Remove nonessential employees from the work area.

d. Remove each lockout/tags-plus

e. Reenergize the machinery, equipment, or system in accordance with section 250.4.G and then proceed with testing or positioning.

f. If additional work is required before the machinery, equipment, or system can be considered repaired, de-energize the equipment, machinery or system and reapply the LOTP devices.

F. Removal of Lockout and Tags-Plus

Systems:

1. Before removing any lockout/tags-plus system and restoring the machinery, equipment, or system to use, the AE shall perform the following:

a. Notify all other authorized and affected employees in the area that the lockout/tags-plus system will be removed.

b. Ensure that all employees in the work area have been safely positioned or removed.

c. Inspect the work area to ensure that nonessential items have been removed and machinery, equipment, or system components are operationally intact.

2. Ensure that each lock or tags-plus system is removed by the AE who applied it.

3. When the AE who applied the lockout/tags-plus system is not available to remove it, the supervisor can direct removal by another AE, provided the following additional requirements are met:

a. Verify that the AE who applied the lockout/tags-plus system is not in the facility.

b. Make all reasonable efforts to contact the AE to inform him or her that the lockout/tags-plus system will be removed.

c. Ensure that the AE who applied the lock or tags-plus system has knowledge of the removal before the worker resumes work on the affected machinery, equipment, or

d. Obtain concurrence of the LOTC, when involved.

4. When LOTP work is completed, AEs will coordinate with the LOTC to close out their portion in the LOTC Logbook form.

G. Re-Energizing the Machinery, Equipment, or System:

1. The AE shall have knowledge of the source, type, and magnitude of the hazards associated with energizing or start-up and the means to control these hazards.

OSHE CONTROL MANUAL 250 Rev I Sheet 250-14

2. The AE shall ensure that the equipment, machinery, or system is re-energized and started in accordance with established

H. Applying Individual Lockout:

1. Each AE hangs his or her personal lockout system at all hazardous energy-isolating device(s).

2. For landside individual lockout systems, LOTP coordination is not required for multiple servicing, if the isolation of a single hazardous energy source completely isolates the machinery, equipment, or system (or section of that machinery, equipment, or system) AND all individuals use their personal lock, AND where one employee‟s action of changing the status of the lockout/tags-plus system would NOT

3. On vessels and vessel sections, LOTP

Coordination is required when workers perform unrelated servicing at the same time, regardless if on separate or the same machinery, equipment, or system. On landside facilities, LOTP Coordination is required when workers perform unrelated servicing at the same time when ship's force is not in control, on the same machinery, equipment, or system. If coordination is required, comply with the following:

a. LOTC enters the Individual Lockout information into the LOTC Logbook.

b. AE writes date and his or her name in the “Employee Applying” column before starting work.

c. AE writes date and his or her name in the “Employee Removing” column when the machinery, equipment, or system is suitable for safe operation, work is completed, and Individual Lockout System is removed.

4. An ECP is required unless all of the following requirements are met:

a. There is no potential for hazardous energy to be released (or to re-accumulate) after shutting down the machinery,

b. The machinery, equipment, or system has a single energy source that can be readily identified and isolated.

c. The isolation and lockout of that energy source will completely de-energize and deactivate the machinery, equipment, or system, and there is no potential for re-accumulation of energy.

d. The energy source is isolated and secured from the machinery, equipment, or system during servicing.

e. Only one lock is necessary for isolating the energy source.

f. The lock is under the exclusive control of the AE performing the servicing.

g. The servicing does not create a hazard for any other employee.

h. The shipyard, in utilizing this exception, has not had any accidents or incidents involving activation or re-energization of this type of machinery, equipment, or system during servicing for the last four years.

I. Applying Individual Tags-Plus:

1. Each AE hangs his or her personal tags-plus system at the hazardous energy-

OSHE CONTROL MANUAL 250 Rev I Sheet 250-15 isolating device(s) that cannot be locked, per the applicable ECP.

2. Department Head approval and review by Code 106 OSHE Director is required prior to utilizing tags-plus system(s).

3. Each AE coordinates the work with the

LOTC.

a. LOTC enters the Individual Tags-

Plus information into the LOTC Logbook.

b. AE writes date and his or her name in the “Employee Applying” column before starting work.

c. AE writes date and his or her name in the “Employee Removing” column when the machinery, equipment, or system is suitable for safe operation, work is completed, and

Individual Tags-Plus System is removed.

J. Applying Group Lockout:

1. When more than one AE services the same machinery, equipment, or system at the same time, Group Lockout may be used in lieu of individual lockout, per 250.4.H.

2. The LOTC must coordinate the Group

Lockout. The LOTC responsibilities are:

a. Ensure the LOTC Logbook is filled out.

b. Assign the PAE for the work shift.

c. Ensure the PAE understands the requirements of the ECP to be used.

d. Assign and document lock usage on the hazardous energy isolation devices.

3. The PAE must maintain control and knowledge of the LOTP system status. The

PAE responsibilities are:

a. Coordinate and communicate with the LOTC the status of the Group Lockout.

b. Communicate to all working and on-coming AEs the status of the Group

Lockout.

c. Determine the safe exposure status for each AE in the group with regard to the

Group LOTP system.

d. The current PAE must have his or her lock on the Group Lockbox during all work and until the equipment is suitable for safe operation and work is complete.

e. The responsibility of the PAE may be transferred, per the instructions of

250.4.D.

4. The AE responsibilities are:

a. Communicate with the PAE:

(1) His or her intent to work under the protection of the Group Lockout.

(2) Understand his or her safe exposure status.

(3) The disposition of the machinery, equipment, or system that the AE was working on, when taking off his or her personal lock from Group Lockbox.

b. Hang a personal lock on the Group

Lockbox while working.

(1) The AE‟s lock may be left on the

Group Lockbox when leaving the area.

OSHE CONTROL MANUAL 250 Rev I Sheet 250-16

(2) Remove the lock when directed by the PAE, but only if it does not create a hazard for others.

K. Applying Group Tags-Plus:

1. When more than one AE services the same machinery, equipment, or system at the same time, Group Tags-Plus can be

2. The LOTC must coordinate the Group

Tags-Plus. The LOTC responsibilities are:

a. Ensure the planned evolution has

Department Head approval and Code 106

OSHE Director authorization.

b. Ensure the LOTC Logbook is filled out.

c. Assign the PAE for the work shift.

d. Ensure the PAE understands the requirements of the ECP to be used.

3. The PAE must maintain control and knowledge of the LOTP system status. The

PAE responsibilities are:

a. Coordinate and communicate with the LOTC the status of the Group Tags-Plus.

b. Communicate the disposition of the

Group Tags-Plus system to all on-coming

AEs, and have them log in on the PAE Log.

(1) Each PAE maintains his or her own PAE Log.

(2) The PAE Log may be disposed of once all AEs that have logged in have logged out.

c. Establish the Tags-Plus systems on all hazardous energy-isolating device(s) that cannot be locked, per the applicable ECP.

d. Determine the safe exposure status for each AE in the group with regard to the

Group LOTP system.

e. At least one PAE must be signed in on the LOTC Logbook until the machinery, equipment, or system is suitable for safe operation, work is completed, and Group

Tags-Plus system is removed.

f. The responsibility of the PAE may be transferred, per the instructions of

250.4.D.

4. The AE responsibilities are:

a. Communicate with the PAE:

(1) His or her intent to work under the protection of the PAE Lockout / Tags-plus Log.

(2) Understanding of his or her hazardous energy exposure status.

(3) The disposition of the machinery, equipment, or system that the AE was working on, when signing out of the PAE

Lockout / Tags-plus Log.

b. AEs log in on a PAE Log before starting work for the shift.

c. AEs log out on the PAE Log at the completion of work or end of shift.

5. An ECP is required.

L. Interface Work Requirements:

1. Interface Work shall require an ECP, LOTP coordination, and authorization of the

OSHE CONTROL MANUAL 250 Rev I Sheet 250-17 ship via a Work Authorization Form of reference 250.3.G.

M. Energy Control Procedures (ECPs):

1. ECPs prevent energization or startup, or the release of hazardous energy, during the servicing of any machinery, equipment, or system. Energy Control Procedures are specific to machinery, equipment, or systems; however, when similar machines, equipment, or systems are designed the same and have identical hazardous energy-isolating device(s), they can be covered with a single, generic, written energy control procedure. The ECP shall identify the types of equipment to which the isolation of hazardous energy applies. Appendix F provides of an ECP form to be used when developing an ECP, if one has not been created for a specific machine, equipment, or system.

2. Purpose: An ECP establishes the minimum requirements for the lockout/tags-plus application of energy-isolating devices on vessels and vessel sections, and for landside facilities whenever servicing is done on machinery, equipment, or systems in shipyards. ECPs shall be used to ensure that all potentially hazardous energy sources have been isolated and the machinery, equipment, or system to be serviced has been rendered inoperative through the use of lockout or tags-plus procedures before employees perform any servicing when the energization or start-up of the machinery, equipment, or system, or the release of hazardous energy could cause injury.

3. Compliance with ECPs. All employees are required to comply with the restrictions and limitations imposed on them during the use of lockout or tags-plus applications.

AEs are required to perform each lockout or tags-plus application in accordance with this procedure.

4. Energy Control Procedures requirements are detailed in Appendix F. A sample ECP form is provided. An ECP must include the elements listed in Appendix F.

5. An ECP is not required when the following conditions are met:

a. There is no potential for hazardous energy to be released (or to re-accumulate) after shutting down the machinery,

b. The machinery, equipment, or system has a single energy source that can be readily identified and isolated.

c. The isolation and lockout of that energy source will completely de-energize and deactivate the machinery, equipment, or system, and there is no potential for re-accumulation of energy.

d. The energy source is isolated and secured from the machinery, equipment, or

e. Only one lock is necessary for isolating the energy source.

f. The lock and key are under the exclusive control of the AE performing the

g. The servicing does not create a hazard for any other employee.

h. The shop/code using this exception has not had any accidents or incidents involving the activation or reenergization of this type of machinery, equipment, or

OSHE CONTROL MANUAL 250 Rev I Sheet 250-18

N. Program Review:

1. Program Evaluation.

a. Code 106 shall evaluate the program‟s effectiveness on an annual basis.

b. Code 106 shall review compliance provisions of reference 250.3.H, of this chapter, and specific procedures developed as a result of program implementation.

2. Program Audits.

a. Shops and codes using the lockout or tags-plus systems conduct an annual assessment audit of the LOTP program and procedures currently in use to ensure the procedures and the requirements of this instruction are being followed and to identify and correct any deficiencies in accordance with reference 250.3.I and

Paragraph 250.5.A.3.h of this chapter, including the following:

(1) A review of the written lockout/tags-plus program and procedures.

(2) A review of the current LOTC

Logbook.

(3) Verification of the accuracy of the LOTC Logbook.

(4) A review of incident reports since the last audit.

(5) A review conducted between the auditor and AEs regarding the AEs‟ responsibilities under the lockout systems being audited.

(6) A review conducted between the auditor and AFEs and AEs regarding their responsibilities under the tags-plus systems being audited.

b. Within 15 days after…