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Chapter 10.pdf

CHAPTER 10 - TABLE OF CONTENTS
10.0 PURPOSE . 10-1
10.1 REFERENCE SUMMARY . 10-1
10.1.1 OPNAVINST 5100.23 (SERIES) . 10-1
10.1.2 GENERAL INDUSTRY OCCUPATIONAL SAFETY AND HEALTH
STANDARDS (29 CFR Parts 1910.1 to end). 10-1
10.1.3 OPNAVINST 4110.2 (SERIES) . 10-1
10.1.4 NAVSECGRUINST 4110.2 (SERIES) . 10-2
10.1.5 OPNAVINST 5100.19 (SERIES) . 10-2
10.1.6 OPNAVINST 3120.32 (SERIES) . 10-2
10.2 SYNOPSIS OF RELATED INSTRUCTIONS. 10-2
10.2.1 NAVSECGRUINST 11320.1 (SERIES). 10-2
10.2.2 OPNAVINST 11320.23 (SERIES) . 10-2
10.2.3 OPNAVINST 11320.25 (SERIES
) . 10-3
10.2.4 NAVFACINST 11320.22 (SERIES) . 10-3
10.2.5 NAVFAC P-1021 . 10-3
10.2.6 NAVSUPINST 4000.70 (SERIES) . 10-3
10.2.7 SPAWARINST 5100.9 (SERIES) . 10-3
10.3 SAFETY RESPONSIBILITIES . 10-3
10.4 PERSONAL SAFETY PRACTICES . 10-4
10.4.1 GENERAL GUIDELINES . 10-4
10.4.2 ELECTRIC SHOCK . 10-6
10.4.3 ENERGIZED CIRCUITS . 10-8
10.4.4 WORKING NEAR ELECTRICAL EQUIPMENT. 10-9
10.4.5 "AUTHORIZED PERSONNEL ONLY" . 10-9
10.4.6 THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT) . 10-9
10.4.7 SPECIAL PRECAUTIONS FOR DIRECT SUPPORT PERSONNEL . 10-9
10.5 MAKING THE SPACES SAFE . 10-10
10.5.1 DANGER SIGNS . 10-11
10.5.2 WARNING SIGNS AND GUARDS . 10-11
10.6 EMERGENCY PREPAREDNESS . 10-11
10.6.1 EMERGENCY CUTOFF SWITCHES . 10-11
10.6.2 EMERGENCY ELECTRONICS SAFETY BOARD. 10-11
10.6.3 APPROVED WORKBENCHES . 10-14
10.7 SAFETY PRECAUTIONS FOR SPECIFIC SITUATIONS. 10-17
10.7.1 INTERLOCK SWITCHES . 10-17
10.7.2 BLEEDER RESISTORS . 10-17
10.7.3 CURRENT-LIMITING RESISTORS . 10-17
10.7.4 INSULATED CONTROLS . 10-18
10.7.5 USE OF SHORTING/GROUNDING PROBES.10-18
10.8 ELECTRICAL EQUIPMENT AND PORTABLE TOOLS . 10-18
10.8.1 PORTABLE POWER TOOLS . 10-19
10.8.2 EXTENSION CORDS . 10-21
10.8.3 ELECTRON TUBES . 10-22
10.8.4 CATHODE RAY TUBES (CRTs) . 10-22
10.8.5 RADIOACTIVE TUBES . 10-23

10.8.6 CIRCUIT BREAKERS AND FUSES . 10-23
10.8.7 EQUIPMENT MALFUNCTION SIGNALS . 10-23
10.9 HAZARDOUS MATERIALS . 10-24
10.9.1 FLAMMABLE LIQUIDS AND OTHER HAZARDOUS MATERIALS . 10-24
10.9.2 BATTERIES . 10-25
10.9.3 FLUORESCENT LAMPS . 10-25
10.10 WORKING OUTSIDE THE SPACES . 10-26
10.10.1 WORK NEAR TRANSMITTING ANTENNAE. 10-26
10.10.2 GROUNDS MAINTENANCE . 10-28
10.11 ENERGY CONTROL PROGRAM (LOCKOUT/TAGOUT) ASHORE . 10-31
10.11.1 EXCEPTIONS . 10-31
10.11.2 DEFINITIONS . 10-32
10.11.3 FUNCTIONS AND RESPONSIBILITIES. 10-32
10.11.4 GENERAL PROCEDURES . 10-33
10.11.5 ACTIVITY SPECIFIC ENERGY CONTROL PROCEDURES . 10-36
10.11.6 TRAINING AND COMMUNICATION . 10-37
10.12 POWER DISTRIBUTION . 10-38
10.12.1 LABELING OF POWER PANELS . 10-38
10.12.2 BAY/EQUIPMENT . 10-38
10.12.3 SUPPRESSION OF POWER TRANSIENTS. 10-39
10.13 SUMMARY . 10-39

LIST OF FIGURES
10-1 AUTHORIZED WOODEN WORKBENCH . 10-16
10-2 PMS/TOOL TAG . 10-20
10-3 REQUEST FORM FOR DANGEROUS WORK . 10-30

CHAPTER 10
ELECTRONIC SAFETY

REFERENCES
(a) OPNAVINST 5100.23 (series) (e) OPNAVINST 5100.19 (series)
(b) 29 CFR 1910

(f) OPNAVINST 3120.32 (series)
(c) OPNAVINST 4110.2 (series)
(d) NAVSECGRUINST 4110.2 (series)

10.0 PURPOSE. The Safety and Health of personnel is of
paramount concern - more important than security, mission, time
or money. It is Navy policy to provide a safe and healthful
workplace for all personnel. These conditions shall be ensured
through an aggressive and comprehensive Navy Occupational Safety
and Health (NAVOSH) Program fully endorsed by the Secretary of
the Navy and implemented through the chain of command. Safety
cannot be learned through occasional lectures. Whether afloat
or ashore, NAVSECGRU personnel must receive repeated, informed
and pointed instruction in safe practices. The purpose of this
chapter is to focus on only one aspect of this broad topic -
electronic/electrical safety.
10.1 REFERENCE SUMMARY. The following references are important
for NAVSECGRU activities. Since safety requirements are
constantly changing, it is important that the current standards
are followed.
10.1.1 OPNAVINST 5100.23 (series). Navy Occupational Safety and
Health (NAVOSH) Program Manual, covers the Navy policy and
procedures which apply to all Navy civilian and military
personnel and operations except in those areas wherein
responsibility for such a program rests with the Commandant of
the Marine Corps (CMC).
10.1.2 GENERAL INDUSTRY OCCUPATIONAL SAFETY AND HEALTH STANDARDS
(29 CFR Parts 1910.1 to end)
revised as of 1 July (updated
annually). This Code of Federal Regulations (CFR) contains
occupational safety and health standards which are established
Federal law.
10.1.3 OPNAVINST 4110.2 (series). Hazardous Material Control
and Management (HMC&M) establishes uniform policy, guidance, and
requirements for the life-cycle control and Total QualityManagement (TQM) of hazardous material (HM) acquired and used bythe Navy. The instruction applies to all Navy organizations andshore activities involved in the planning, procurement,acquisition, storage, distribution, requisition, use or otherdisposition of HM, including disposal of resultant hazardouswastes (HW).
10.1.4 NAVSECGRUINST 4110.2 (series). Hazardous Material
Control and Management (HMC&M) Program establishes uniform
policy, guidance, requirements, procedures and assigns
responsibilities for the life-cycle control and Total Quality
Management (TQM) of hazardous material (HM) acquired and used by
the Naval Security Group Command (NAVSECGRU).
10.1.5 OPNAVINST 5100.19 (series). Navy Occupational Safety and
Health (NAVOSH) Program Manual For Forces Afloat, applies to all
levels of command which comprise the naval afloat establishment.
10.1.6 OPNAVINST 3120.32 (series). Standard Organization and
Regulations of the U.S. Navy.
10.2 SYNOPSIS OF RELATED INSTRUCTIONS. In addition to the above
instructions, the following paragraphs, while by no means compre-
hensive, describe documents used to determine safety require-
ments. Some additional instructions/publications that are not
specifically reviewed here may also be found in Chapter 1.
10.2.1 NAVSECGRUINST 11320.1 (series). The Fire Protection and
Prevention Program for the Naval Security Group Command provides
guidance for administering a comprehensive fire protection and
prevention program. Specific guidance on fire drills, actual
fire emergencies and monthly fire prevention inspections is
provided.
10.2.2 OPNAVINST 11320.23 (series). The Shore Activities Fire
Protection Program provides policy and responsibilities for fire
protection at Navy-wide shore activities.
10.2.3 OPNAVINST 11320.25 (series). Reporting of Fires and
Related Emergencies at Naval Shore Activities and Marine Corps
Facilities provides specific guidance on reporting fires.
Detailed information for preparing the DOD Fire Incident Report
is provided. A reportable fire is a fire discovered in progress,
discovered following extinguishment, or detected later during an
inspection that results in damage of $1 or more or that causes
loss of life or injury.
10.2.4 NAVFACINST 11320.22 (series). Navy Shore Establishment
Fire Protection/Prevention Program promulgates detailed, Navy-
wide fire protection policy, standards, criteria, and
implementing directions in support of the Navy’s Shore Activities
Fire Protection Program. This instruction also specifies that
commands shall utilize NAVFAC P-1021 in executing their
responsibilities in implementing the policy set forth in
OPNAVINST 11320.23.
10.2.5 NAVFAC P-1021. Navy Shore Establishment Fire
Protection/Prevention Program establishes minimum standards
governing the Fire Protection Program to prevent fires and reduce
loss from fire or personnel, real property, material and
vehicles. It outlines doctrine, provides guidance and authority
to implement fire protection measures and explains how to submit
reports, keep records, conduct technical investigations and
evaluate results of fires.
10.2.6 NAVSUPINST 4000.70 (series). This instruction is
applicable to all military services and covers Special
Measurement Clothing and Footwear, Orthopedic Footwear, Guidons,
Streamers, and Flags. It contains the necessary procedures to
order clothing and footwear sizes that are not available with a
National Stock Number (NSN).
10.2.7 SPAWARINST 5100.9 (series). Navy Shore Electronics
Safety Precautions, provides information applicable to Navy
military and civilian personnel engaged in repair and maintenance
of electronic equipment ashore. There are thirteen separate
chapters on general requirements and precautions; i.e., special
equipment, safety boards, lockout/tagout program, radio frequency
(RF) and microwave hazards, infrared hazards, laser hazards,
ionizing radiation, etc.
10.3 SAFETY RESPONSIBILITIES. Safety is the responsibility of
everyone, from the Commanding Officer through the chain of command
to each individual. Most accidents do not happen because of poor
equipment design but because of unsafe acts or unsafe conditions.
It is the responsibility of each Navy member and employee tounderstand and observe safety standards and regulationsestablished to prevent injury or damage to property and equipment.
Managers and supervisors must always set a good example; youcannot ignore safety regulations and expect others to follow them.
To assist NAVSECGRU activities in fully developing an effectiveand authoritative electronic safety program, many aspects ofelectronic safety are presented in the following sections. Activities should not view the information in this chapter ascomprehensive, but should use the previously cited references tobuild a Command safety program. See chapter 9 of thisinstruction for safety training requirements for maintenancepersonnel. Commanding Officers are responsible for ensuring thatall personnel engaged in electrical or electronic installationsare fully informed of hazards involved.
10.4 PERSONAL SAFETY PRACTICES. All NAVSECGRU maintenance
personnel and civilian employees performing electronic
maintenance work shall be provided proper instruction in personal
accident prevention, CPR and first aid procedures relative to
electronic safety.
10.4.1 GENERAL GUIDELINES. As a minimum, the following specific
safety guidelines should be observed:
• Guard against flying solder, particularly when de-soldering leads. Use safety glasses or goggles.
• Brazing with silver solder containing cadmium produces toxic cadmium oxide fumes. Prolonged exposure to high concentra-tions of these fumes can be fatal. Eliminate this hazard byusing a silver brazing alloy that does not contain cadmium.
• Do not work on electric/electronic equipment when hands and • Do not wear loose, flapping clothing or clothing with exposed metallic zippers or metallic threads when working onelectronic equipment.
• Do not wear watches, rings, bracelets, neck chains or eye glasses with metallic frames while working with electronicgear.
• Whenever possible work should be performed on de-energized electronic circuits. When emergencies arise or work has to beperformed on a live circuit, the following precautions will betaken: - ensure at least one other person is present who is trained and certified in CPR and is familiar with power securingmethods - cover the deck area with the proper insulating materials - familiarize personnel with general first aid methods • Provide insulating barriers to prevent accidental contact with circuits when work is done in the area of exposed electricalcircuits.
• Use dry wooden stools or platforms to prevent contact between • Cover metal tool handles with rubber insulation.
• Securely close fuse boxes unless work is actively being done • Check the resistance between the metal bases and frames of electronic equipment and ground at regular intervals (andespecially after repairs) to ensure that an effective groundis present.
• Do not alter or disconnect safety devices (e.g., interlocks, overload relays and fuses) except for replacement.
• Ensure the shanks of screwdrivers used inside of electronic equipment are insulated with insulating sheaths, leaving 3/16inch exposed. If insulating tape cannot be used forscrewdriver handles, electrical insulation varnish may be used.
• Ensure personnel working on live circuits wear electrical hazard safety shoes. Issue non-conductive shoes to allelectricians, electronic technicians and cryptologictechnicians (maintenance).
• Commanding Officers shall provide at Government expense personal protective clothing appropriate to the worksituation.
• The safety shoe for standard toe protection is the Chukka style shoe (NSN 8430-00-596-5396 series, 8430-01-032-2900series and 8430-01-078-9260 series) for all militarypersonnel; however, this shoe is not a non-conductive shoe.
• Safety shoes, of any type, that become worn or are in a state of disrepair will be replaced with local operating funds.
• When energizing electronic equipment in the work area, do not break energized high-voltage output circuits except whenabsolutely necessary and authorized by a qualified person.
• Be alert to prevent shock, burns or other injuries when transmitting equipment is in use at the same installation orclose by.
• Before touching a capacitor ensure power has been properly secured. Always ensure that the capacitor is completelydischarged. This can be done with an approved insulatedshorting/grounding bar by following the instructions in10.7.5.
• Never work on energized electrical equipment unless work is in accordance with an official technical manual and in thepresence of another person capable of rendering emergency aid; • Always radiate into a dummy load. Ensure RF levels do not • Ensure all hazardous materials are properly labeled and • Ensure sufficient danger and/or warning signs are posted where 10.4.2 ELECTRIC SHOCK. Current, not voltage, is the criterion
of shock intensity. The passage of even a very small current
through a vital part of the human body can cause death. The
voltage necessary to produce the fatal current is dependent on
the resistance of the body, contact conditions and the path
through
the body. Human tissue will not prevent a fatal shock from 115volts or even lower voltage-fatalities from as low as 30 voltshave been recorded. Tests have shown that body resistance underunfavorable conditions may be as low as 300 ohms and possibly aslow as 100 ohms from temple to temple if the skin is broken. Volt for volt, DC potentials normally are not as dangerous as AC,as evidenced from the fact that reasonable safe "let go currents"for 60 hz AC is 9.0 milliamperes for men and 6.0 milliamperes forwomen, while the corresponding values for DC are 62.0milliamperes for men and 41.0 milliamperes for women.
First Aid Procedures. After a severe electrical shock, thevictim could become very pale or "bluish". The pulse isextremely weak or entirely absent, unconsciousness is completeand burns are usually present. Although the victim's body maybecome rigid in a few minutes, this condition can be caused bymuscular reaction to shock and should not necessarily beconsidered as rigor mortis. If the victim is not breathingartificial respiration must be administered immediately,regardless of body stiffness. Recoveries, after stiffness hasappeared, have been reported. Saving electric shock victimsdepends on prompt administration of first aid. As a minimum, allelectrical/electronic rating personnel shall be certified incardio-pulmonary resuscitation (CPR) procedures (see Chapter 9for CPR training requirements). BEFORE TOUCHING A VICTIM OFELECTRIC SHOCK, THE CIRCUIT SHALL BE DE-ENERGIZED OR THE VICTIMFREED FROM THE LINE CONDUCTOR BY THE USE OF SOME SUITABLENONCONDUCTIVE OBJECT SUCH AS A DRY WOODEN STICK OR SAFETY HOOK.
When attempting to administer first aid to a victim, proceed asfollows: Have someone call for advanced medical help (Dial 911 or local If the power cannot be secured, attempt to remove the victim immediately, observing the following precautions: - protect yourself with dry insulating material - insulating rubber gloves within leather glove protectors - use a dry board, belt, dry clothing or other available nonconductive material to free the victim (by pulling, pushing orrolling) from the power source. The proper equipment should bereadily available on an Emergency Safety Board. DO NOT TOUCH THEVICTIM.
After removing the victim from the power source, first aid procedures appropriate to the victim’s condition shall be started immediately, i.e., rescue breathing, CPR, etc.
10.4.3 ENERGIZED CIRCUITS. Careless work habits cause most
shock-related deaths in the Navy; most are preventable. The
following rules shall be strictly observed:
• Take the time to be safe by studying the schematics of the wiring diagrams before attempting to service a system.
• Never work alone. Always guard high potential portions of electronic gear when power is applied. Never work alone onelectronic gear in which live circuits are present. When doorinterlock circuits require bridging to facilitate repair, postone person trained in CPR to operate the main disconnectbreaker in case of a failure.
• Do Not Attempt to discharge high voltage capacitors.
• Ground any test equipment having a metal case to the equipment • In testing high-voltage electronic circuits, use only one hand if possible. Otherwise, use test probes with retractableprongs.
• Eliminate RF hazards when working with transmitters. The threshold for adverse biological effects is recognized to be 4watts per kilogram (W/kg), and with a safety factor of 10added, the accepted threshold level is 0.4 W/kg for the wholebody, averaged over any 6-minute period. Technicalassistance, advise and documented RFR hazard surveys areavailable from NEHC, NAVSEA and NISEEAST. Consult Chapter 22of reference (a) for additional information.
• DO NOT ATTEMPT to solder any energized circuit, wire or 10.4.4 WORKING NEAR ELECTRICAL EQUIPMENT. When work must be
performed in the immediate vicinity of electrical equipment,
check with the senior maintenance technician on duty (ashore) or
with the duty electrician (shipboard) to avoid any potential
hazards of which you may not be immediately aware.
10.4.5 "AUTHORIZED PERSONNEL ONLY." Because of the danger of
fire damage to equipment and injury to personnel, all maintenance
work on electrical equipment shall be performed only by
authorized maintenance personnel. Work should not be performed
on any equipment you have not been specifically authorized to
work on. In particular, stay clear of electrical equipment open
for inspection, test or servicing.
10.4.6 THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT).
Reference (b), section 147 covers the servicing and maintenance
of machines and equipment in which the unexpected energization or
start up of the machines or equipment, or release of stored
energy could cause injury to employees. This standard
establishes minimum performance requirements for the control of
such hazardous energy. Lockout devices that utilize positive
means such as a lock, either key or combination type, to hold an
energy isolating device in a safe position and prevent the
energizing of a machine or equipment must be used at shore
facilities. If an energy isolation device is not capable of
being locked out, the activity’s energy control program shall
utilize a tagout procedure that provides full employee protection
equivalent to that of a lockout procedure. Electronic
maintenance activities must comply with the host’s lockout/tagout
program. Additional guidance is contained in Chapter 24 of
reference (a).
Work on cord and plug-connected electrical equipment whereexposure to the hazards of unexpected start-up of the equipmentis controlled by unplugging the equipment, and the plug is underthe exclusive control of the worker performing the servicing ormaintenance are exempt from shore facility lockout requirements.
Activity specific maintenance procedures should be followed.
10.4.7 SPECIAL PRECAUTIONS FOR DIRECT SUPPORT PERSONNEL. Direct
Support personnel, however experienced, must realize that
electrical/electronic safety procedures vary from ship to ship.
It is a wise policy for installation supervisors to check with
the duty engineer/electrician to determine any unique
requirements. Don't assume one ship is like the last. NAVSECGRU
activities with Direct Support work centers shall provide formal
general JQR
training for all CTM personnel working aboard ships and documentcompletion of the JQR in accordance with chapter 9 of thisinstruction.
The danger of shock from the 450-volt AC ship's service system iswell recognized by afloat personnel. Relatively few reports ofserious shock are received from this voltage despite itswidespread use. On the other hand, a number of shipboardfatalities have been reported because of contact with 115-voltcircuits. Despite a fairly widespread but totally unfoundedpopular belief to the contrary, low voltage (114 volts and below)circuits are very dangerous and can cause death where theresistance of the body is lowered by moisture and especially whencurrent passes through the chest. Aboard ship, the body islikely to contact the metal structure, and body resistance toelectric current may be low because of perspiration or dampclothing. Therefore, extra care and awareness of this hazard isneeded.
Short circuits can be caused by accidentally placing or droppinga metal tool, rule, flashlight case or other conducting articleacross an energized line. The arc and fire that results on evenrelatively low voltage circuits may cause extensive damage toequipment and serious injury to personnel.
Ship service power distribution systems are designed to beungrounded. Many persons believe it is safe to touch oneconductor since no electrical current would flow. This is nottrue. If one conductor of an ungrounded system is touched whilethe body is in contact with the hull or other metal equipmentenclosure, a fatal electric current can pass through the body. All live electric circuits shall be treated as potential hazardsat all times.
Lastly, remember that ship's company electricians "hand-over-hand"the ship's entire electrical system before qualifying for watchesunderway. Don't make the mistake of assuming you've learned it allonce you've made a couple of installations or deployments. Itmight be your last - or someone else's because of you.
10.5 MAKING THE SPACES SAFE. Safety in the electronic
maintenance and operation spaces must become standard operating
procedure. Each person must be aware of the potential hazards
these spaces contain. Responsibility for safety starts with each
employee with the final responsibility resting with the
Commanding Officer. Regular and frequent zone and safety
inspections of the
spaces by the Commanding Officer and senior personnel shall beroutine. See Chapter 11.
10.5.1 DANGER SIGNS. Danger signs shall be used where
appropriate to warn personnel of hazards involved in servicing
electronic material. Some safety signs are available through the
supply system and others may be obtained through open purchase.
10.5.2 WARNING SIGNS AND GUARDS. Warning signs and suitable
guards shall be provided to prevent personnel from contact with
dangerous voltages, for warning personnel of possible presence of
explosive vapors, for warning Direct Support personnel (working
aloft) of poisonous effects of stack gases, etc. HEED ALL
WARNING SIGNS. They have been installed for your protection.
To disregard them is to invite personal injury as well aspossible damage to equipment.
CAUTION and DANGER signs are to be used in cases where a warningis needed to prevent inadvertent equipment damage. Such signsshould also be used where potential personnel hazards exist.
These are specifically intended for applications which arepermanent and instructional or precautionary in nature, and arenot intended to circumvent normal lock-out/tag-out requirements
.
10.6 EMERGENCY PREPAREDNESS. All NAVSECGRU activities will
provide either emergency cutoff switches or emergency safety
boards. The preferred method is to provide emergency cutoff
switches that secure all power to the electronics workbenches in
an emergency.
10.6.1 EMERGENCY CUTOFF SWITCHES. The primary means of
providing emergency protection to employees working on energized
equipment will be power cutoff switches that neutralize all power
being supplied to the electronics workbenches. NAVSECGRU
activities shall install emergency cutoff (kill) switches in all
electronics maintenance shops that are clearly marked and
accessible to all employees. There shall be a minimum of 36
inches of clearance in front of each emergency cutoff switch.
10.6.2 EMERGENCY ELECTRONICS SAFETY BOARD. NAVSECGRU activities
that cannot or have not installed emergency cutoff switches
shall place emergency safety boards in their electronicmaintenance shops. A safety board is simply a board used to keepreadily available various items that may be needed in the eventof an emergency, including a first aid kit (where authorized),personal protection devices, emergency phone numbers and otheritems.
10.6.2.1 INVENTORY OF EMERGENCY SAFETY BOARDS. The activity
safety manager and electronics maintenance officer will determine
the inventory of the emergency safety board based on the types of
systems, equipment, operations, location and number of personnel
involved. Once an inventory for each location is determined, an
inventory of approved items will be posted on each board.
Emergency safety boards may contain the following items as
appropriate to the operation:
• Resuscitation and Cardiopulmonary Resuscitation (CPR) instructions, (1I 0177-LF-226-3400 for resuscitation and 0I0510-LP-097-0022 for CPR) • First Aid Kit (NSN 9L 6545-00-116-1410) fully stocked, less the meclizine hydrochloride tablets USP (United StatesPharmacopoeia) NSN 9L 6505-00-926-2111, and sealed with thecontents listed next to the kit (this is the only NAVSECGRUauthorized kit) Note: If a 24 hour operational military or civilian infirmary,
clinic or hospital is not more than 10 minutes away from your
work place a first aid kit is not authorized.
• Unvarnished wooden cane (9L 6515-00-774-0000) • Rope (15 ft by 5/8 inches, hemp preferred composition; nylon and similar materials have low flammability/softening pointand should not be used) (9G 4020-00-289-8616) • Insulated rubber gloves certified before issue and every six months thereafter (reference (b) section 137, Table I-5.) • Flashlight (non-metallic) marked with luminescent tape for easy location (flashlight: 9Q 6230-00-270-5418, tape: 9390-00-282-7867) • Wool blanket (not pictured) (9D 7210-00-082-5668) • Insulating rubber blanket or a 6-foot roll of approved rubber • Any personal protective equipment that might be needed in the area in an emergency, i.e., CPR mask, medical gloves, etc.
• Emergency phone numbers and the location of the nearest phone • Current Fire Bill (NAVFAC Form 3-1132019: IH 105-LF-001-6001) • Red DANGER tags and lockout devices (no more than 3 or 4) • Side cutting pliers with insulated handles (dikes) 10.6.2.2 LOCATION OF EMERGENCY SAFETY BOARDS. Emergency Safety
Boards are intended to provide a ready source for safety
equipment and safety items in an emergency. Their numbers and
locations at an activity will be determined by the activity
safety manager and the electronics maintenance officer based on
the needs of the activity. Keep in mind that several boards may
be needed for a single space if ready access to a board is
restricted because of security requirements.
10.6.2.3 EMERGENCY SAFETY BOARD MAINTENANCE. Inventory will be
accomplished quarterly using the posted inventory list to ensure
all required contents are present. Material must also be checked
for wear and replaced as required. To ensure standardized
inventory procedures and scheduling, it is recommended that
safety board inventories fall under a locally developed PMS.
Locks and danger tags for safety boards are for life threatening
(or potentially life threatening) emergency uses only. If use is
required, logging must be accomplished in accordance with the
local activity lock-out/tag-out procedures.

Safety Board Locks and Danger Tags will be accounted for duringquarterly safety board inventories. The posted inventory listshould indicate the exact quantity of locks/tags normally present(i.e., QTY - 3). To ensure lock-out/tag-out log transactionsreflect actual Danger/Caution requirements, Safety Board Locksand Danger Tags will not be pre-serialized. The contents of thefirstaid kits need only be inventoried if the seal is found broken orshows signs of tampering.
10.6.2.4 TRAINING. When personal protective equipment is
provided in the workplace, it is assumed that each employee that
works in that space is expected to use that equipment in an
emergency. Therefore, in accordance with reference (b) section
132, training shall be provided to each employee who may be
required to use the safety equipment and/or Personal Protective
Equipment located on the emergency safety board. Training shall
include, at a minimum: when use of the equipment is necessary and
appropriate, how to properly use the equipment, what the
equipment’s limitations are and the proper, care, maintenance and
disposal of the equipment. The employer shall verify that each
affected employee has received and understood the training by
keeping a roster that contains the name of each employee, the
date of training and the subject. Training should be held
annually.
10.6.3 APPROVED WORKBENCHES. NAVSECGRU activities will use the
following guidance:
Workbenches used for repair/maintenance work on energizedequipment must have nonconductive work surfaces. Ordinarysoldering, work on unenergized equipment, and other similar workdoes not require a specialized electronic workbench. Also,designated ESD work-stations are not authorized to be used forenergized equipment maintenance. A prudent solution is todesignate certain areas in workcenters for work on energizedequipment, and use one of the following: a. An existing workbench modified so that all worksurfacesare nonconductive b. Make or have made an entirely wooden workbench similar tothe drawing in Figure 10-1. This workbench is not in the supplysystem and must be made locally. (Note: The requirement for acopper pan/plate has been deleted.) “Electrical Shock Damage - Do Not Touch Energized Circuits”warning signs shall be mounted above all electronic workbenchesused for repair/maintenance of energized equipment. Specificgrounding criteria are discussed later in this chapter. Activities requiring additional workbenches or having unsafeworkbenches shall use activity funds, or if not available, submita request for funds to COMNAVSECGRU. Questions regarding designor possible alternatives should be addressed to COMNAVSECGRU N4.
10.6.3.1 GROUNDING OF WORKBENCHES. A grounding bus with
suitable attachment cables shall be provided to ground equipment
serviced at workbenches. The grounding bus shall be connected
to the (green insulated) grounding conductor only by the main
bonding jumper at the service entrance. Exposed metal parts of
the workbench which could become energized by contact with live
equipment shall be similarly grounded by connection with the
grounding bus. Equipment grounding straps connected to the
grounding bus shall be provided every four feet along the
workbench surface and shall be equipped with free ends with a 50
ampere power clip (type PC).
The impedance between the ground neutral and the green wiregrounding conductor when measured with a ground impedance testershall be less than 0.5 ohms. The impedance between the groundingbus and the grounding conductor shall be less than 0.1 ohms.
10.6.3.2 RUBBER INSULATING MATTING. The deck in front of
electronic workbenches must be covered with insulating rubber
matting meeting MilSpec MIL-M-15-562F (NAVY). One continuous run
or strip 36 inches wide of Type III (Raised Diamond Basic
Configuration with an Antiskid Surface) must continue beyond the
work-bench for at least 24 inches on each side. NSNs
7220-01-057-1897 and 7220-01-056-1944 apply. Type II electrical
matting will not be ordered, but may be used until unserviceable.
10.6.3.3 WORKBENCH LIGHTING. The lighting in workbench areas
shall be no less than 100 footcandles.
NOTE 1: THE RECEPTACLE STRIP MUST CONTAIN THREE WIRES - ONE
DEDICATED GROUND WIRE WHICH IS PHYSICALLY CONNECTED TO ALL
RECEPTACLES.

NOTE 2: REFER TO PARAGRAPH 10.6.3.1 FOR GROUNDING REQUIREMENTS
FIGURE 10-1
AUTHORIZED WOODEN WORKBENCH
10.7 SAFETY PRECAUTIONS FOR SPECIFIC SITUATIONS. This section
describes safety considerations for specific equipment or
situations.
10.7.1 INTERLOCK SWITCHES. Interlock switches may be of the
following types:
• wired in series with the coil or a relay that de-energizes to open contacts in series with the powerline leads to theelectric power supply unit • installed on the lid or door of the enclosure so as to break the circuit when the lid or door is opened • multiple interlock switches connected in series that may be • complex interlock systems that may be provided when several separate circuits must be opened for safety 10.7.2 BLEEDER RESISTORS. Bleeder resistors will normally be
connected across the output terminals of high voltage DC power
supplies (installed by the equipment manufacturer). They are
used to bleed the dangerous charges of the filter capacitors
because a high-grade filter capacitor can maintain its charge for
a long time. When bleeder resistors are used, discharge high
voltage capacitors with an approved shorting/grounding bar before
working on the high-voltage circuit. Additionally, filter
capacitors should be discharged as a matter of routine when
repair work is to be done. Ensure the equipment is de-energized,
including INPUT power for power supplies, before attempting
discharge.
10.7.3 CURRENT-LIMITING RESISTORS. Use current-limiting
resistors connected in series with the output lead of a high-
voltage power supply circuit to limit the current to a safe value
when a short circuit or an accidental contact causes excessive
loading. This prevents equipment damage. Exercise extreme
caution at all times when working on live circuits because
current-limiting resistors will not limit currents to safety
values if personal contact is made.
10.7.4 INSULATED CONTROLS. Insulated controls should be used on
all electronic equipment when practicable. Remember:
use only approved power cords in good conditionprotect power cords with insulated grommets at the point where they pass through the chassis or panel 10.7.5 USE OF SHORTING/GROUNDING PROBES. When using the safety
shorting probe, always be sure to connect the grounding clip to a
good ground connection (if necessary, scrape the paint of the
grounding metal to make good contact). Then, while holding the
safety probe by the handle behind the protective shield, touch
the end of the metal rod to the point to be shorted-out. Touch
each point to be shorted-out several times to make sure that the
circuit is completely discharged. Always verify that the
capacitor is fully discharged by connecting a DC voltmeter to
both terminals. If the reading is anything other than zero
volts, the capacitor is not fully discharged.
10.8 ELECTRICAL EQUIPMENT AND PORTABLE TOOLS. In order to
minimize the potential shock hazard present with portable tools,
Navy specifications require electric cords for such tools be
provided with a distinctively marked ground in addition to the
conductors for supplying power to the tool. The end of the
ground wire within the tool should be connected to the tool's
metal housing. The other end of the ground wire should be
connected to a positive ground. Portable tools and electric
equipment shall have a three conductor cord and a dead front
constructed ground-type plug. The ground wire is connected to a
positive station ground or shipboard ground. Underwriters
Laboratories (UL) listed double-insulated tools are exempt from
these requirements. Cord length on portable tools shall not
exceed 25 feet. The metallic equipment cases of all installed
electronic equipment should be grounded by an approved
groundstrap to a positive station ground
or shipboard ground. Ungrounded electronic equipment cases
create unnecessary shock hazards and frequently produce
electronic interference as well.
In accordance with 29 CFR 1926.404, quarterly PMS inspections andtesting must be made to certify the electrical safety of all cord and plug connected construction type equipment, i.e., drills,saws, etc.
The test record shall identify the piece of equipment and thelast date it was tested. The test record can be kept by means oflogs, color coding or any other effective means. The PMS/ToolTag shown in Figure 10-2 is a recommended form for NAVSECGRU usewith local miscellaneous shore electrical equipment and MIP 4911.
Tags must be fully annotated (front and back) and personnelshould be familiar with their use and intent. Any item whichrequires a check and is overdue shall not be used until therequired PMS can be accomplished to verify it is safe to operate.
In accordance with reference (b), Section 334, all other cord andplug connected equipment and flexible cord sets (extension cords/detachable cords) shall be visually inspected before use for ULlisting, external defects (such as loose parts, deformed ormissing pins or damage to outer jacket or insulation) and forevidence of possible internal damage (such as pinched or crushedcord sets which remain connected once they are put in place andare not exposed to damage need not be visually inspected inaccordance with this paragraph. Calibration labs that do notrequire MIP 4911/001 S1-R (R2) may delete this requirement perthe MIP scheduling aid. If there is a defect or evidence ofdamage that might expose an employee to injury, the defective ordamaged item shall be removed from service, and no employee mayuse it until repairs and tests necessary to render the equipmentsafe have been made.
10.8.1 PORTABLE POWER TOOLS. Before using a power tool, care-
fully examine it to ensure that cord, plug and switch are all in
good operating condition, that the tool is properly grounded, and
the PMS/Tool Tag in Figure 10-2 or other PMS tag authorized by
local instruction is properly attached and current. Do not use
portable power tools that are grounded incorrectly or have
defective cords, plugs, switches or electrical connections. If
defects are noted, deliver it to an electrical shop or other
appropriate work center for proper repairs. A Danger/Caution Tag
should be attached, as appropriate, until repairs can be
accomplished. When using portable power tools the following
guidelines shall be observed:
• Ensure PMS Safety Check Tag is current prior to use.
• Do not use portable power saws, grinders and other tools that are normally equipped with guards without them.
• Do not use portable power tools in the vicinity of flammable • Do not use power tools near flammable or toxic solvents. If compressed air must be used for cleaning, ensure the airpressure is under 30 pounds per square inch. Always wearsafety glasses or other appropriate personal protectiveequipment.
• Avoid excessive oiling of the tool to prevent deterioration of • Before accessories on a portable power tool are changed, disconnect the cord to make sure power is off.
• Never hang cords over nails or sharp edges or string them along surfaces where they may be damaged by vehicles, personsor materials passing over them.
• Damaged power cords shall be replaced. They will not be SEE REVERSE SIDE
DO NOT USE THIS
EQUIPMENT IF MORE THAN :

(CHECK ONE) ONE WEEK
ONE MONTH ONE YEAR
OTHER_____ HAS ELAPSED
SINCE LAST SAFETY CHECK.

NAVSEA 5100/5 (E-82) FRONT
S/N 0115-LF-051-0025

NAVSEA 5100/5 BACK
FIGURE 10-2
PMS/Tool Tag
• Do not use cords in such a way as to cause a trip hazard.
• Do not carry portable power tools by the cord.
• Do not use power tools while wearing long neckties, loose clothing, large rings or other items that might get caught inmoving machine parts. Be aware that identification badges canbe a hazard when operating power tools and may need to besecured during power tool operation.
• Wear goggles over the eyes when using a portable grinder, buffer, sander or any other power tool that may cause dust,grit or chips to fly.
• Tools shall be stored in a clean, dry place where the power cord may be loosely coiled. Both the tool and cord must beprotected from damage or abuse.
10.8.2 EXTENSION CORDS. Only single-ended, three-conductor
extension cords that have three-prong plugs and three slot
receptacles shall be used (metal wall outlet boxes are not
authorized). Extension cords should be no longer than 100 feet
in length, and will not be connected together for use. When
using extension cords the following guidelines shall be observed:
• Ensure the initial safety visual inspection is completed.
• Never hang extension cords over nails or sharp edges. They should not be allowed to kink or be strung along surfaceswhere they may be damaged by vehicles, persons or materialspassing over them. If they must be temporarily (less than oneworkshift) run through a doorway or hatch, extension cordsmust be protected to guard against accidental closing of thedoor/hatch.
• Extension cords used in wet or damp areas should be GFCI • Extension cords must not come in contact with oil, grease, hot • Do not use extension cords in such a way as to cause a trip hazard or strain the plug/receptacles.
• Damaged extension cords shall be replaced. They will not be • Extension cords are only authorized to be used with portable tools and not with items such as typewriters, word processors,etc. If desired, in-line surge protector may be used withmicrocomputers. They will not, however, be used solely toprovide multiple outlets or to circumvent proper facilitiesdesign/planning. • Extension cords shall be stored in a clean, dry place where they can be loosely coiled and protected from damage.
10.8.3 ELECTRON TUBES. Various types of electron tubes are used
in the variety of electronic equipment maintenance personnel
encounter daily. Most require no special handling. However, a
small number require special attention, handling and/or
disposition. Cathode ray tubes (CRTs) and radioactive tubes are
two examples.
10.8.4 CATHODE RAY TUBES (CRTs). These are tubes used in
televisions, oscilloscopes, video monitors and video displays.
The use of large CRTs increases the danger of implosion, flying
glass and injury from high voltage. The following safety
precautions must be observed when handling CRTs:
• wear protective clothing to prevent exposure to glass • exercise extreme care to avoid bumping, scratching or dropping • ensure CRTs are properly stored/ protected in original When energized, CRTs carry extremely high voltage. Do not workon energized CRTs.
Before a CRT is discarded, it should be made harmless by breakingthe vacuum glass seal. To accomplish this, place the tube to bediscarded in an empty carton (face down) and carefully break offthe locating pin from its base. The CRT then can be disposed ofin accordance with local instructions.
10.8.5 RADIOACTIVE TUBES. These tubes are found in certain
transmitters, test equipment, power supplies, smoke/gas detectors
and time standards. Several types of electron tubes contain
radioactive materials in their construction. These require
special marking, handling and storage as follows:

• clearly mark all radioactive electronic tubes • handle them with extreme caution to prevent breakage • store them only in approved containers • dispose of them in accordance with rules regulating disposal 10.8.6 CIRCUIT BREAKERS AND FUSES. Unauthorized operation of
circuit breakers and insertion or removal of fuses may endanger
personnel as well as damage equipment. Keep Covers Closed.
Covers for all fuse boxes, junction boxes, switch boxes and
wiring accessories shall be kept closed. Any cover that is not
closed or is missing shall be reported to the maintenance shop
duty electrician/maintenance technician.
This includes reinstallation of tabs or similar protection when acircuit breaker is removed. Use of electrical tape or similarmaterial is not acceptable. Broken or malfunctioning circuitbreakers must also be replaced. Failure to do so may result inpersonnel injury or damage to equipment in the event accidentalcontact is made to exposed live parts.
10.8.7 EQUIPMENT MALFUNCTION SIGNALS. Be on the alert for any
signal of malfunction of equipment; the senses of sight, hearing,
smell and touch all serve to make one aware of possible
electrical malfunctions. Examples of such signs are:
• An unusual sound, fire, smoke, sparks or arcing from an • Receptacles, plugs and cords that feel warm to the touch • Slight shocks felt while handling electrical equipment • Odor of burning or overheated insulation • Electrical equipment that either fails to operate or operates • Electrical equipment that produces excessive vibration If any of the above signs are noted, they shall be reportedimmediately to the Work Center Supervisor or the activity SafetyOfficer. Do not delay. Do not operate suspect equipment orattempt to make any repairs yourself. Stand clear of anysuspected hazard (and instruct others to do likewise) securepower and lock-out/tag-out immediately.
10.9 HAZARDOUS MATERIALS
10.9.1 FLAMMABLE LIQUIDS AND OTHER HAZARDOUS MATERIALS. When
working with flammables (including flammable aerosols) such as
insulating varnish, paint, lacquer, turpentine, kerosene and
other materials producing flammable vapors, always provide ample
ventilation to prevent accumulation of fumes.
Flammable cleaning fluids must never be used on or near energizedelectrical apparatus.
When working with hazardous materials, solvents and gases such astrichloroethane, freon, sulfur hexafluoride, nitrogen or carbondioxide, provide adequate ventilation and follow precautions inreference (a). Gas-free engineering requirements aboard shipshall be followed before entering confined spaces. Eye and skinprotection shall be used when working around high pressure suchas refrigerant lines and water cooling systems. Dispose ofhazardous materials in the manner prescribed in references (c)and (d) and local instructions.
Flammable liquids at NAVSECGRU activities shall be stowed inapproved flammable storage lockers (such as "SE-CUR-ALL" ModelA331 37" x 36" x 24"). Typically, a two shelf flammable storagelocker will also be provided in each work center for storage ofimmediate maintenance materials. Command Hazardous Material (HM)inventories and Command Authorized Use List must be used andmaintained in accordance with reference (c). A Manufacturer'sMaterial Safety Data Sheet (MSDS) must be maintained in the workcenter for each item authorized/used.
Special attention must be paid to ensure incompatible hazardousmaterials. In particular, corrosives and flammables must not bestored together. Corrosive storage lockers must also be plainlyidentified.
10.9.2 BATTERIES. Wet cell batteries generate highly explosive
hydrogen gas while being charged. Flames and sparks of all kinds
must be kept away from batteries. Be sure to ventilate battery
spaces that may have been sealed before entering the space,
turning on any lights, starting engines or equipment, making or
breaking any electrical connections or doing any work in a
battery storage or charging space. When using tools near a
battery, be careful not to short circuit the battery terminals.
Never store conducting materials on or above a battery where they
could fall and short circuit the battery terminals. Batteries
should be charged only in accordance with approved procedures.
Charging rates (especially for nickel cadmium batteries) are
critical in preventing explosions.
Mercury batteries shall not be used in nuclear submarines withoutspecial approval of NAVSEA. Lithium batteries shall not be usedwithout special approval in accordance with NAVSEAINST 9310.1A. Primary batteries (especially mercury and lithium batteries)shall never be punctured, incinerated or recharged. Dispose ofmercury and lithium batteries properly as hazardous waste, inaccordance with reference (c). Mercury cell batteries shall bedisposed of as soon as possible. Remove batteries from equipmentbefore shipment or storage. Cover terminals of batteries with aninsulating material to prevent short circuits. Store batteriesin an adequately ventilated and cool fireproof area. Appropriateeye and skin protection should be used when working with wetbatteries. Personnel must ensure the battery switch is turnedoff when equipment is not in use or after the battery fails tooperate the equipment.
10.9.3 FLUORESCENT LAMPS. Fluorescent lamps contain poisonous
mercury vapor and beryllium dust.
No danger arises from unbroken
lamps, whether in use or not, because the vapor and dust are
sealed inside. However, injury could result from broken glass,
from breathing the mercury vapor or from dust liberated when
lamps are broken. Ashore, the discarded lamps should be placed
in the shipping container as new lamps are takenout. When full
of used lamps, the container should be disposed of in accordance
with local instructions
. To prevent injury and contamination,
fluorescent lamps shall not be discarded at sea. Store them in
the original shipping containers until they can be off-loaded and
disposed of ashore.
10.10 WORKING OUTSIDE THE SPACES. When working aloft or on the
grounds of activities ashore, the guidelines in the following
sections apply.
10.10.1 WORK NEAR TRANSMITTING ANTENNAE. The business of main-
taining large antenna "farms" is so hazardous that specific
safety precautions must be observed. Just "being careful" is not
enough - nothing must be left to chance. Although dangerous, the
work must be done, and this section discusses potential hazards
and describes procedures and devices to minimize risk. Although
this section addresses work on transmitting antennae, many of the
points in the discussion are applicable to receiving antennae as
well. Procedures differ greatly ashore and afloat; the procedure
discussed here is for a shore station.
Individual ship's bills should be reviewed before working on ornear antennae afloat. Check first with the duty electrician,duty radioman and CDO to be sure of the proper procedures.
Personnel must always remember that the removal of a unit or partfrom the normal location within an assembly and the energizing ofthe unit or part, while it is outside the normal enclosure,removes the protective features such as interlocks, grounds andenclosures. Since these safety features then no longer exist,special precautions and safety measures must be taken. Thechassis and frame of all power supplies and high voltage unitsremoved for servicing shall be grounded, and all circuitsnormally grounded in operation shall be grounded whenever poweris applied to the unit.
10.10.1.1 MAINTENANCE PROCEDURES FOR SHORE PERSONNEL. Each and
every time maintenance is to be performed on an antenna, the
following steps must be taken:
• Request permission from the Senior Operations or Communications Watch Officer on duty and the CDO to take theantenna out of service. This shall be done in writing usingthe form shown in Figure 10-3. The CDO shall retain the formuntil the work is completed and the antenna returned toservice or lock-out/tag-out is in place.
• Remove the antenna patch at the matrix and lock/tag it out of service with a lock or red "DANGER" tag in accordance with alocally implemented lock-out/tag-out bill and the proceduresin this chapter. If a Delta switching matrix is used, aspecial, locally fabricated "lockout bar" should be used. This device, painted red, fits over the knobs on the matrix toprevent a transmitter from being connected inadvertently tothe antenna.
• If antenna multicouplers are installed, it will be necessary to disconnect the antenna at the multicoupler and lock/tag itout of service also.
• At the antenna, connect a grounding strap or wire from the antenna feed point or center conductor of the transmissionline to the ground mat.
• With an RF voltmeter, check for dangerous potentials between the antenna feed point or center conductor and the ground mat.
• Begin maintenance on the antenna.
10.10.1.2 CLIMBING. The most dangerous part of antenna
maintenance is climbing the structure and working aloft. This
should be done only by trained, experienced riggers. Before
climbing, observe the following precautions:
• Obtain permission from the activity (or ship) CDO to work aloft. This shall be done in writing ashore, using the form inFigure 10-3. Individual ship's bills apply when afloat.
• DON'T CLIMB ALONE. At least two qualified riggers must be present even if only one is required to go aloft. • DON'T CLIMB IN ADVERSE WEATHER CONDITIONS. If weather conditions threaten rain, snow or fog, postpone the climb.
• WEAR PERSONAL PROTECTIVE EQUIPMENT. Ensure an approved safety harness (effective 01 Jan 98, body belts are mpt acceptable as
part of a personal fall arrest system) safety straps are
available at the climbing site and that the rigger going aloft
is trained in their proper use. All climbing ropes and straps
used in lanyards, lifelines and strenth components of body
harnesses shall be made from synthetic fibers. They shall be
inspected before each use for damage. Equipment with visible
damage shall be permanently removed from service. Tower
rescue procedures must be practiced at least semi-annually.

Ensure all antenna maintenance/rigger personnel are trained
and certified in CPR and first aid procedures.
• If the structure is fitted with a safety rail, it must be • Test the two-way radio, sound power phone, bullhorn or other communication device that will be used to communicate with therigger going aloft.
• Don't rely on safety devices without first checking them. Check belts, block and tackle, and tools that are to be used.
• Check the antenna structure itself and the guy wires to ensure they are safe before beginning to work aloft.
• Before placing weight on pole steps, inspect them for • Ensure an appropriate first aid kit (NSN 9L 6545-00-116-1410) is available at the climbing site. Know where the nearestphone or radio is for contacting emergency services ifnecessary.
• When finished working aloft, obtain the CDO's signature and then notify the senior watch section supervisor that climbingis secured.
10.10.2 GROUNDS MAINTENANCE. Safety precautions are frequently
overlooked in the process of clearing vegetation from antenna
fields. It is important that personnel wear adequate personal
protective gear, including gloves and boots, when cutting heavy
vegetation either by machine or by machete. Note that the use of
herbicides to clear vegetation must only be applied by a properly
trained and NAVFACENGCOM certified individual. Special
instructions should be given about poisonous plants, reptiles,
biting insects or weather conditions that may be found in that
particular area. Keep stray animals and children away from
antennae. This is most important not only because of high
voltages present, but also because it may present an attractive
climbing playground for youngsters. High voltage warning signs
should be posted repeatedly along the isolation fencing around
the antenna itself, particularly in the case of transmitting
antennae.
FIGURE 10-3
REQUEST FORM FOR DANGEROUS WORK
NAVSECGRU FORM 4000.11. REQUEST FOR AUTHORITY FOR DANGEROUS WORK
1. DESCRIPTION OF WORK TO BE PERFORMED. (Include tower and/or antenna and transmission lines concerned.) ________________________________________ _______________________________________________________________________ 2. Lock-out/tag-out, Aloft Commencement Time1 _____________________________ Expected Completion Time _____________________________ Actual Tag-in Descent Time _____________________________ 3. WORK CREW. (Enter names of all members of crew.) A. ________________ C. ________________ E. _________________ B. ________________ D. ________________ F. _________________ 4. I, supervisor of the above listed work crew, certify that all members ofthis work crew, including myself, understand all safety precautions requiredfor this operation and that appropriate safety measures have been or will betaken.
___________________________ Signature - Date - Time 5. I, the Senior Watch Supervisor of Building ______(building number), certifythat all switches are open and locked or tagged, except tower lightingswitches, and all transmission lines are grounded which may apply or transmitelectrical power to the components described in paragraph 1 of this report.
Lock/Tag Numbers __________________________ __________________________ ___________________________ Signature - Date - Time 6. CDO Approval2 ___________________________ Signature - Date - Time 7. I, supervisor of the above listed work crew, certify that all personnel areclear of the above described work and all components involved. WatchSupervisor of Building ____ (building number) has been informed.
___________________________ Signature - Date - Time 8. CDO Clear Signature ___________________________ Signature - Date - Time 1It is mandatory that climbing instructions be provided formally by local PQS/JQR (see Ch 9) before allowing personnel to work aloft.
2CDO approval may be via telephone call if designated in the Activity Safety Bill by the Commanding Officer.
10.11 ENERGY CONTROL PROGRAM (LOCKOUT/TAGOUT) ASHORE. Each
activity shall ensure that, before any employee performs any
servicing or maintenance on a machine or equipment where the
unexpected energizing, start up, or release of stored energy
could occur and cause injury, the machine or equipment is
isolated and rendered inoperative through the use of a lockout
device whenever the machinery or equipment is capable of being
locked out.
If an energy isolating device is not capable of being locked out,a tagout procedure that provides full employee protectionequivalent to that of a lockout procedure shall be utilized. Lockout/tagout applies to the control of energy during servicingand maintenance of machinery and equipment at shore facilities. These requirements apply only when the unexpected energization ormovement of machinery or equipment or the release of energyduring the maintenance or servicing of such equipment/machinerycould cause injury to personnel and/or property damage. 10.11.1 EXCEPTIONS. The requirements of this chapter do not
apply to the following:
a. Shipboard operations which are covered under reference(e) and (f) NOTE: Direct support personnel working aboard ship should review
the individual Ship’s tagout bill prior to beginning direct
support work.
b. Equipment under the exclusive control of electricalutilization installations for the purpose of power generation,transmission and distribution, including related equipment forcommunication or metering.
c. Exposure to electrical hazards from work on, near, orwith conductors or equipment in electrical utilizationinstallations.
d. Work on cord and plug-connected electrical/electronicequipment where exposure to the hazards of unexpected start-up ofthe equipment is controlled by unplugging the equipment, and theplug is under the exclusive control of the worker performing theservicing or maintenance.
e. Hot tap operations involving transmission anddistribution systems for substances such as gas, steam, water orpetroleum products performed on pressurized pipelines if: (2) shutdown of the system is impractical; and/or (3) documented procedures are followed and special 10.11.2 DEFINITIONS. As used in this instruction, the following
definitions apply.
10.11.2.1 AUTHORIZED EMPLOYEE. The person who applies the locks
and/or tags or other energy-isolating devices to the machine,
equipment or system in order to perform servicing or maintenance.
Authorized employees shall be designated by their line
supervisors and trained in accordance with section 10.11.6.
10.11.2.2 AFFECTED EMPLOYEE. Any person whose job requires
him/her to operate or use a machine, equipment or system on which
servicing or maintenance is being performed under lockout or
tagout, or a person whose job requires him/her to work in an area
in which such servicing or maintenance is being performed where
the unexpected startup of a machine or equipment or
reenergization of a system could be hazardous.
10.11.3 FUNCTIONS AND RESPONSIBILITIES
10.11.3.1 Commanders, Commanding Officers and Officers in Charge
shall:
a. Develop and implement written plans and procedures for alockout/tagout program that meet the specific needs of theactivity and comply with chapter 24 of reference (a).
b. Initiate actions to identify and resolve deficiencies inthe lockout/tagout budget and allocation of resources to bringabout effective local program implementation.
c. Ensure lockout/tagout programs are revised and updated asnecessary.
d. Ensure a current roster of trained and qualifiedemployees who are authorized to work on hazardous energy systemsand equipment is maintained.
10.11.3.2 Activity OSH Offices shall:
a. Approve the equipment or applications where tagout may beused in place of lockout (and maintain a list of approvals)unless this responsibility is delegated, in writing, to someoneelse by the Commanding Officer.
b. Annually review the compliance with the provisions of chapter 24 of reference (a) and any activity specific proceduresdeveloped as a result.
NOTE: A list shall be maintained by type of equipment and
applications where tagout may be used. The official authorizing
tagout will ensure compliance with the requirements of this
chapter for use of tagouts to achieve protection equivalent to
lockout systems.
10.11.4 GENERAL PROCEDURES. The application of energy controls
(implementation of lockout or tagout procedures) shall require
all of the following elements and actions to be taken in the
following sequence:
• Before an authorized employee deenergizes a machine, piece of equipment, or system, the authorized employee shall haveknowledge of the type and magnitude of the energy involved,the hazards of the energy to be controlled and the method ormeans to control the energy.
• The machine, piece of equipment or system shall be turned off or shut down using procedures which are consistent with thischapter. An orderly shutdown must be utilized to avoid anyadditional or increased hazard(s) to employees as a result ofequipment deenergization.
• All energy isolating devices that are needed to control the energy to the machine or equipment shall be physicallylocated and operated in such a manner as to isolate themachine or equipment from the energy source(s).
• Appropriate lockout or tagout devices shall be applied. As stated in the general policy, lockout devices shall be usedwhenever feasible. Tagout devices shall only be used inaccordance with the procedures approved by the activityCommanding Officer, and only for equipment types specified inthose procedures for which lockout cannot be used.
- Lockout or tagout devices shall be affixed to each energyisolating device by authorized employees only. Use of grouplockout-tagout methods are discussed in chapter 24 of reference(a).
- Lockout devices, where used, shall be affixed in a manner that will hold the energy-isolating devices in the “safe” or“off” position.
- Tagout devices, where used, shall clearly indicate theoperation or movement of energy-isolating devices from the “safe”or “off” position is prohibited.
1) Whenever possible, tagout devices shall be affixed to 2) Where a tag cannot be affixed directly to the energy-isolating device, the tag shall be located as close as safelypossible to the device, in a position that will be immediatelyobvious to anyone attempting to operate the device.
3) Activities shall demonstrate that the tagout program achieves protection equivalent to the lockout program. Activities are also encouraged to implement more than one of thefollowing additional safety measures: - Removal of an isolating circuit element (e.g., fuse orcircuit breaker) 2) Opening of an additional disconnecting or relief 3) Removal of a valve handle to reduce the likelihood of • Stored energy shall be controlled under the following a. Following the application of lockout or tagout devices toenergy-isolating devices, all potentially hazardous stored orresidual energy shall be relieved, disconnected, restrained andotherwise rendered safe.
b. If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall becontinued until the servicing or maintenance is completed oruntil the possibility of such accumulation no longer exists.
• Prior to starting work on machines or equipment that have been locked-out or tagged-out, the authorized employee shallverify that isolation and deenergization of the machine orequipment have been accomplished. The authorized employeeshall verify that all affected employees are not in an areathat could be dangerous during equipment energization. Theauthorized employee shall verify the system or equipment isdeenergized by testing with an appropriate instrument or byattempting to energize the system or equipment.
• In situations that require lockout or tagout devices to be temporarily removed from the energy-isolating device to testor position the machine, equipment or a component thereof,the following sequence of actions shall be followed: 1) Clear the machine equipment or system of tools and materials 2) Ensure that the machine, equipment or system components areoperationally intact 3) Remove all employees not required for the test orpositioning from the machine or equipment area.
4) Verify all affected employees are in a safe location.
5) Remove the lockout or tagout devices.
6) Energize and proceed with testing or positioning.
7) De-energize all systems and reapply energy control measuresand lockout/tagout devices to continue the servicing and/ormaintenance.
Before lockout or tagout devices are to be removed permanentlyand energy is restored to the machine or equipment, proceduresshall be followed and actions taken by the authorized employee(s)to ensure the following: 1) The work area shall be checked to ensure that non-essentialitems have been removed and to ensure that machine or equipmentcomponents are operationally intact.
- The work area shall be checked to ensure that all employeeshave been safely positioned or removed.
- Before lockout or tagout devices are removed and beforemachines or equipment are energized, affected employees shall benotified that the lockout or tagout devices are being removed.
- Lockout and/or tagout devices shall be removed from eachenergy-isolating device by the authorized employee who appliedthe device. When the authorized employee who applied the lockoutor tagout device is not available to remove it, that device maybe removed under the direction of the authorized employee’ssupervisor, provided the facility-specific procedures andtraining for such removal have been developed, documented andincorporated into the activity’s energy control program. Theactivity shall demonstrate that the specific procedure provides alevel of safety equivalent to only allowing removal of the deviceby the authorized employee who applied it. The specificprocedure shall include at least the following elements: 1) Provision to make a reasonable effort to contact theauthorized employee in order to verify that the authorizedemployee who applied the device is not at the activity.
2) Provisions to ensure that the authorized employee has thisknowledge before he/she resumes work at that activity (e.g., byacknowledging lockout/tagout removal in a logbook).
10.11.5 ACTIVITY SPECIFIC ENERGY CONTROL PROCEDURES. Each
activity shall develop and use specific written procedures to
control potentially hazardous energy during servicing ormaintenance actions. Similar machines and/or equipment (such asthose using the same type and magnitude of energy and the same orsimilar types of controls) can be covered with a single writtenprocedure. For example, floor-mounted, electrically-operated,shop equipment with a single source of power and a single on/offswitch and no potential for stored energy could be covered by asingle generic procedure. Each procedure shall list the types ofequipment to which it applies.
10.11.6 TRAINING AND COMMUNICATION. Each activity shall provide
training to ensure that the purpose and function of the energy
control program are understood by employees and that the
knowledge and skills required for the safe application, usage and
removal of energy controls are acquired by employees. Activities
shall keep
such training up-to-date and shall document all training provided
per chapter 6 of reference (a).
10.11.6.1 MINIMUM TRAINING REQUIREMENTS. Lockout/tagout
training shall be provided to naval personnel as follows:
Each authorized employee shall receive training on therecognition of applicable hazardous energy sources, the type andmagnitude of the energy available in the workplace, and themethods and means necessary for energy isolation and control. All training shall be specific to the activity and need notinclude instruction on energy sources or means of isolation thatare not applicable to the activity.
Each affected employee shall be instructed in the requirements ofchapter 24 of reference (a).
All other employees whose work operations are or may be in anarea where energy control procedures may be utilized, shall beinstructed about the prohibition relating to attempts to restartor reenergize machines, equipment or systems which are locked-outor tagged-out.
10.11.6.2 ADDITIONAL TAGOUT TRAINING. At facilities where
tagout systems are used, training shall include the following
limitations of tags:
Tags are essentially warning devices affixed to energy-isolatingdevices and do not provide the physical restraint on thosedevices that is provided by a lock.
When a tag is attached to an energy-isolating means, it is not tobe removed without permission of the authorized personresponsible for it, and it is never to be bypassed, ignored orotherwise defeated.
Tags must be legible and understandable by all authorizedemployees, affected employees and all other employees whose workoperations are or may be in the area, in order to be effective.
Tags must be made of materials which will withstand theenvironmental conditions encountered in the workplace. Tagoutdevice attachment shall be of a non-reusable type, attached byhand, self-locking and non-releasable with a minimum lockingstrength of no less than 50 pounds and having the general designTags may evoke a false sense of security and their meaning needsto be understood as part of the overall energy control program.
Tags must be securely attached to the energy-isolating devices sothat they cannot be inadvertently or accidentally detached duringuse.
10.12 POWER DISTRIBUTION
10.12.1 LABELING OF POWER PANELS. All electrical power panels
should be fully identified and properly labeled. This includes
both circuit breaker listings on the inside of the power panel
doors and external labeling of the power panel itself. Circuit
breakers should be numbered as if all breakers were installed or
used. External designators shall be readily discernible at a
distance of 15 feet. The labeling of electrical power panels
should be completed by the host activity public works department.
10.12.2 BAY/EQUIPMENT. To facilitate rapid identification of
electronic equipment power sources, each equipment bay or floor
mounted unit will normally be provided with an engraved, hard
plastic (or similar) label. Such labels should be legible at a
distance of 8 to 10 feet and include not only bay or position
number, but the associated power panel and circuit breaker
designators. This form of cross-reference will also prove useful
when validating current power panel circuit breaker listings or
when equipment/power lock-out/tagout is required. Deployable
equipment (FES/DIRSUP) is exempt from this requirement, unless
installed as part of a permanent test position, etc.
10.12.3 SUPPRESSION OF POWER TRANSIENTS. Suppression of power
transients is considered essential to protection of electronic
equipment. Reference provided installation guidance for MOVs to
assist in this effort. Requests for further guidance should be
referred to COMNAVSECGRU N4 for resolution.
10.13 SUMMARY. The following points summarize the electronic
safety requirements for NAVSECGRU activities ashore:
• Personal safety depends on repeated, pointed and informed • NAVSECGRU activities shall make maintenance and operations - Installing power cutoff switches for emergency use - Using workbenches with non-conductive worksurfaces - Installing safety boards, if unable to provide cutoffswitches - Posting danger and/or other warning signs - Using approved rubber matting where necessary - Using approved personal protective equipment, when appropriate - Properly storing, marking, inventorying, and disposing of hazardous material/waste • NAVSECGRU activities shall promulgate via local instruction procedures for working aloft/near transmitters andlockout/tagout procedures.

Source: http://study.schleppingsquid.net/Files/Pubs/NSGINST-4000.1D/Chapter10.PDF

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