NAVY SAFETY AND OCCUPATIONAL HEALTH PROGRAM MANUAL FOR FORCES AFLOAT

OPNAVINST 5100.19F 5 May 2019

C1-1 SECTION C. SURFACE SHIP SAFETY STANDARDS

CHAPTER 1

BASIC SAFETY

Ref: (a) OPNAVINST 3500.39D, Operational Risk Management

1. Discussion

a. Shipboard life is one of the more hazardous working and living environments that exist. The existence of HAZMATs and equipment, in addition to the fact that a ship is a constantly moving platform subject to conditions such as weather, collision, and grounding contribute to a potentially hazardous environment. Any chain of mishaps could lead to a major catastrophe. It is for this reason, practical safety must be followed and the prescribed safety regulations strictly followed to prevent personal injury and illness.

b. As a risk control measure, and a consideration when using ORM to plan an evolution, consider assigning a safety observer whose only responsibility is safety during any evolution that could injure personnel or damage equipment. This safety observer should be knowledgeable in the proper performance of the evolution and have the ability to identify safety related concerns or procedural violations. Reference (a) contains additional guidance on ORM.

c. The general safety standards in the following paragraph 2 are applicable to all shipboard operations and spaces. These standards have been adopted from requirements from the NAVSEASYSCOM, OSHA, USCG, SOLAS, ANSI, and previous OPNAV directives. The standards provided in this chapter may not be all inclusive for every possible evolution on board ship, and the lack of a specific standard does not imply that a practice is safe just because it is not mentioned. Use ORM to determine the safety requirements for unique evolutions and operations.

2. General Safety Standards

a. Ladders and Egress

(1) Be familiar with all exits and egress routes from working and living spaces.

(2) Always move up or down a ladder with one hand on the railing. Never slide down inclined ladder rails. Do not carry loads up or down ladders that obstruct movement or sight (use additional personnel to support the load and a spotter when required).

(3) Always ensure exits are not locked or blocked with equipment or any other type of interference.

OPNAVINST 5100.19F 5 May 2019

C1-2 (4) Do not run onboard except for designated exercise locations.

(5) Always be cautious when nearing a "blind" corner or when opening doors.

(6) Never lock escape scuttles or other accesses so they cannot be opened from the inside.

(7) Never dismantle or remove any inclined or vertical ladder without permission of the commanding officer. Secure such areas with temporary lifelines and post with a warning sign on every deck affected.

(8) After opening and prior to passing through a watertight hatch, scuttle, or manhole cover, ensure hatch brace pins, safety pawls, scuttle and manhole covers are positively locked. Properly secure watertight door, hatch, scuttle, or manhole cover when access is complete.

(9) Provide temporary barriers using guardrails, line, or chains, suitably supported by stanchions or pads, when opening accesses in bulkheads or decks that are normally closed.

(10) Ensure that low overheads above inclined ladders (less than 72 inches in height), ladder grab bars, passageways (less than 75 inches in height) and obstructions in passageways (less than 72 inches in height), are padded or protected to prevent head injury if struck.

b. Non-Skid Decking Material. Ensure non-skid decking material, non-skid paint or 3 adhesive non-skid strips (no space in between strips) are installed at the locations listed in subparagraphs 2b(1) through 2b(6).

(1) At the top and bottom of each ladder.

(2) On both sides of doors and arches with sills or coaming higher than 4 inches.

(3) On both sides of doors to mess room, galley, and sanitary spaces (may be on exit side only if non-skid tiles are installed in messing spaces).

(4) Outside of refrigerated stores spaces.

(5) On the passage side of doors from spaces which may have wet decks such as CHT rooms.

(6) In the machinery operators’ work areas.

OPNAVINST 5100.19F 5 May 2019

C1-3 c. Damage Control

(1) Know the location and operation of life preservers, EEBDs, and other emergency equipment in or near working and living spaces.

(2) Know the location of all fire stations and other firefighting equipment in or near the living and working spaces frequented.

(3) If passing through a watertight door, hatch, or scuttle designated to be closed during normal operations, be certain to properly close and dog it.

(4) Never tamper with any damage control fittings or equipment.

(5) Never open a tank or void without permission of the gas free engineer. When working in a tank or void ensure a gas free certificate is properly posted. Personnel entering the tank or void must wear a harness with attached safety line, wear proper protective equipment, and have a second person tending the safety line outside the tank or void.

d. Stowage and HAZMATs

(1) Make sure that all movable objects in spaces are secured for sea using appropriate materials. Whenever feasible, provide permanent secure-for-sea mountings with metal bands, bolts, or other securing devices.

(2) Ensure all HAZMATs, including cleaners and paints, are properly labeled, safely used, and returned after use; see chapter B3.

e. Machinery

(1) Wear short sleeves or roll up sleeves when operating rotating industrial machinery. See chapter B12 for specific protective clothing requirements.

(2) Know the emergency shutdown procedures for all equipment used.

(3) Do not wear rings, watches, key rings, bracelets, cell phones, pagers, and other items that may become entangled or caught on projections, or may be a shock hazard when working with electrical or electronic equipment.

(4) Always wear approved safety shoes when required.

(5) Do not operate machinery and tools without proper training and authorization.

OPNAVINST 5100.19F 5 May 2019

C1-4 (6) Keep decks free of obstacles and materials causing slippery conditions, particularly in work areas. Post warning signs in areas that are slippery.

(7) Never operate machinery or equipment with defective or missing safety devices.

(8) Ensure hazard boundaries around machinery are established and marked with appropriate deck markings

(9) Never tamper with or render ineffective any safety device, interlock, ground strap or similar device intended to protect operators or the equipment without specific approval of the commanding officer.

(10) Only open or close electrical switches, breakers, and pipe valves when authorized to do so.

f. Ventilation. Always ensure ventilation ducts are free of blockage. Never alter ducts or diffusers without permission. Know where ventilation controllers are located for work and living areas.

g. General Space Safety

(1) Keep constantly familiar with the whereabouts of crewmembers in the space where one is working, especially if they are working in tanks, voids or other restricted movement areas.

(2) Observe and enforce all PPE requirements.

(3) Promptly report all unsafe conditions discovered.

(4) Never straddle or step over lines, wire, and chains under tension.

(5) Never hesitate to stop a shipmate from doing something that may be hazardous or unsafe, and never leave a worksite in an unsafe condition.

(6) Use of personal earphones and headphones is not authorized except in the berthing spaces, in recreation and study areas, or in other authorized ship spaces.

(7) Ensure spaces containing flammable liquids are marked with red danger signs to warn personnel.

OPNAVINST 5100.19F 5 May 2019

C1-5 h. Topside

(1) Appropriate sunglasses may be worn when topside. Sunglasses will not be worn as a substitute for impact safety glasses, sun and wind goggles, flight deck goggles, or as protective equipment for operations such as fire watch or welding.

(2) Know where all life rings, dye markers, and flares are located for man overboard emergencies.

(3) Do not lean against lifelines. Never dismantle or remove any lifeline, or hang or secure any weight or line to any lifeline except as authorized by the commanding officer. When no lifeline is available, temporary lifelines must be used.

(4) Wear an inherently buoyant life preserver (IBLP) or auto-inflatable utility life preserver topside where the potential exists of falling, slipping, being thrown, or carried into the water.

(5) Never dismantle any permanent lifeline system without permission of the commanding officer and without providing temporary lifelines.

(6) Know the location of all lifeboat and life raft stations. Be familiar with access routes to the stations from the living and working spaces frequented.

3. Safety Color Code and Signs for Marking Physical Hazards

a. Danger. Red is the basic color for the identification of dangerous equipment or situations:

(1) Safety cans or other approved portable containers of flammable liquids. These metal cans must be painted red with some additional clearly visible identification either in the form of a yellow band around the can or the name of the contents conspicuously stenciled or painted on the can in yellow.

(2) Danger signs are red with black and white lettering, to indicate a hazardous situation, equipment, area, or condition, which has a high probability of death or severe injury.

(3) Emergency stop bars on hazardous machines, such as rubber mills, wire blocks, or flat work ironers. Stop buttons or electrical switches, on which letters or other markings appear and are used for emergency stopping of machinery, must be red.

(4) Guards or barriers enclosing rotating shafts, belts, pinch points or moving parts on machinery or elevators which could cause death or severe injury, if removed.

OPNAVINST 5100.19F 5 May 2019

C1-6 (5) Red danger tape is used to indicate an immediate hazard or area and excludes any unauthorized personnel from entering the area.

b. Caution. Yellow is the basic color to denote caution.

(1) Yellow is the basic color for designating caution and for marking physical hazards such as: striking against, stumbling, falling, tripping, and "caught in between." Solid yellow, yellow and black stripes with suitable contrasting color should be used interchangeably, choosing the combination which will attract the most attention in a given environment. Overhead obstructions (less than 72 inches in height), monorails and turntables are painted solid yellow.

(2) Yellow and black are the colors of caution signs used to indicate a hazardous situation, which may result in minor or moderate injury. Caution signs are yellow with black lettering, and are used for eye hazard and noise hazard signs.

(3) Use yellow and black striping or checkerboard designs, painted or tape, to indicate industrial eye hazardous areas, trip hazard areas, or other areas where caution should be exercised.

(4) Yellow caution tape is used to indicate a potential hazard or area and only authorized personnel with knowledge of the hazard may be allowed to work in the area.

c. Safety Information. Green is the color of general safety information and instructional signs, such as the location of emergency eye wash stations and safety precaution placards.

d. Workshop Deck Markings. Deck markings are used around permanently installed workshop machinery to alert personnel nearby of potential hazards. Markings may be applied using commercially available safety tape or painted onto surfaces. Markings are to be applied around each machine. Avoid marking an entire space as hazardous by applying deck markings only at a doorway or entrance. Operator and eye hazard areas may overlap if machines are installed close together.

(1) Operator Work Areas. The area at the machine where the operator normally stands while using the machine is marked to alert personnel not to enter that operator area. The operator should be provided enough room to safely operate the equipment without being bumped by transiting personnel. An operator area is marked by painting the entire operator area as a solid yellow block. The operator area must also have non-skid decking to prevent slipping on oily decks and falling into the machines. The non-skid may be non-skid paint or adhesive non- skid strips with no spaces between the strips. Non-skid should not be painted yellow. The operator area around the non-skid strips must be painted yellow or for non-skid painted areas a boarder outlining the operator area must be painted yellow.

OPNAVINST 5100.19F 5 May 2019

C1-7 (2) Eye Hazardous Areas. Any area around a machine determined to pose an eye hazard must have those boundaries outlined in black and yellow strips or checkerboard paint or tape. To determine the extent of the eye hazard, note areas where chips or debris are thrown or materials splashed during operation. That area or machine must also be labeled with a "Caution – Eye Hazard" sign in yellow and black (see chapter B5 for details).

(3) Safe Passage and Caution Areas. If space permits, lanes used for normal traffic through a machine shop or around industrial machinery should be outlined using solid white (safe) or yellow (caution) lines.

OPNAVINST 5100.19F 5 May 2019

C2-1 SECTION C

CHAPTER 2

DRY CARGO OPERATIONS, STORES HANDLING, AND RIGGING

Ref: (a) OPNAVINST 3500.39D, Operational Risk Management (b) NSTM 589, Cranes (c) NSTM 077, Personnel Protection Equipment (d) NAVSUP MHE538, Management of Materials Handling Equipment and Shipboard Mobile Support Equipment (e) NAVSEA SW023-AH-WHM-010, Handling of Ammunition and Explosives with Industrial Material Handling Equipment (f) NWP 4-01-4, Replenishment Underway (g) NSTM 572, Shipboard Stores and Provision Handling

1. Discussion

a. Dry cargo and stores are any material that are carried in their own containers and are not in bulk form, such as fuel. Examples of dry cargo are stores, equipment and machinery that are carried in a ship for its own or another vessel's use.

b. This chapter does not discuss underway replenishment (UNREP) operations or refueling at sea operations except fuel used in drums or other approved containers. UNREP and refueling at sea operations are covered in other chapters.

c. Dry cargo and stores handling evolutions are extremely dangerous, even though they appear routine. Cargo and stores being handled can fall or shift, causing injury to personnel and damage to the ship. Additionally, damaged HAZMAT cargo may cause illness or death from resulting spills in extreme conditions. Cargo and stores handling gear can fail, causing not only cargo damage, but additionally the failed cargo handling gear can itself maim and even kill, as well as cause physical damage. It is for these reasons that extreme care must be used during cargo and stores handling operations.

d. Working parties and personnel moving stores throughout a ship result in numerous injuries. Handlers may need hand and foot protection, back injury prevention training, and supervision to prevent injuries.

e. Complete an ORM review, per reference (a), before the evolution and mitigate risks as feasible.

OPNAVINST 5100.19F 5 May 2019

C2-2 2. Precautions – Working Parties Moving Stores. The precautions below in subparagraphs 2a through 2g are for personnel assigned to temporarily assembled or routine working parties, and their supervisors, when handling and moving stores through a ship.

a. Ensure the path throughout the ship where stores will be moved is clear of obstructions and traffic through those areas restricted during stores movement.

b. Wear hand protection (when handling wire rope or banded material), and steel-toed safety shoes.

c. Ensure there are sufficient personnel assigned to allow passing of boxes or material and that all members are fit to handle the anticipated weight.

d. Arrange sufficient numbers of personnel in the working party to minimize twisting or exertion while passing the material. Never toss or throw boxes, cases, or materials from one person to the next.

e. Prior to each handling evolution, review proper handling techniques to avoid back injury (lift with legs, do not bend at waist to lift, get help with heavier loads, get a firm grip before releasing to next person, and stop and report any strains immediately).

f. Ensure slides at inclined ladders are firmly in place and do not have sharp edges or protrusions.

g. Review spill response procedures if handling HAZMATs.

3. Precautions - Cargo Handling for Supervisors. The precautions in the following subparagraphs 3a through 3x are for cargo handling supervisors. Supervisors must initiate these precautions as well as those in reference (b) before beginning any cargo handling operations.

a. Ensure open hatches in use are cleared of adjacent loose equipment that might fall into the hold and injure personnel below.

b. Restrict traffic about hatches to the side away from where cargo is being worked. Rope off areas to traffic over which loads are traveling.

c. Secure or remove hatch beams or other structures in the way of hatches where cargo is being worked. Personnel engaged in moving hatch beams must wear a safety harness with associated safety lines, which must be tended at all times.

d. Ensure that all personnel handling cargo gear are familiar with the use of their equipment and limitations on load capacity and outreach and are PQS qualified.

OPNAVINST 5100.19F 5 May 2019

C2-3 e. Ensure that trained and qualified signalmen are designated and posted during crane or boom operations. The following crane crew personnel will be qualified, per reference (b), tagline handler, rigger, signalman, crane operator, crane safety observer, and crane maintenance technician. Where applicable, NAVEDTRA PQSs are available and should be used to supplement the reference (b) qualification requirements.

f. Verify that all designated cargo handlers are wearing the required PPE, including hand protection (when handling wire rope or banded material), head protection (hard hats), and steel- toed safety shoes. Ensure all other personnel immediately involved in the cargo handling operations (e.g., safety observer, rig captain, signalmen, winch operator, and winch checker), including personnel observing for training, wear head protection (a hard hat) with the chin strap in place under the chin.

g. Ensure that all cargo holds to be used are open and hatch covers properly stowed. Ensure all hinged or folding cargo hatches, normally stowed in an upright position are secured with hatch securing pawls and safety preventer chains engaged.

h. Visually verify that all pallets and containers are of the correct type and safe for the intended use. If a pallet appears unsafe, discard or repair it prior to use.

i. Inspect the cargo handling area and ensure that dunnage is properly stowed clear of all proposed cargo handling activity.

j. Visually check and ensure that all required cargo handling warning signs are properly posted near personnel transit areas.

k. Ensure that all required trim and stability calculations have been completed before the cargo is loaded or off-loaded.

l. Visually check and verify that all cargo boom preventer guys, straps, and whips are rigged correctly.

m. If handling ordnance, ensure that all applicable safety standards are followed and enforced. Chapter C14 provides additional guidance.

n. Use caution when using dock or mobile cranes. Rotary cranes, booms and structures can strike and damage the ship's superstructure.

o. Ensure that all suspected unsafe cargo handling gear is tagged out of commission, removed, and repaired or replaced, and tested prior to re-issue.

p. Ensure that all holds and levels being utilized have the required safety barriers (e.g., rope, chains, and nets) installed.

OPNAVINST 5100.19F 5 May 2019

C2-4 q. Verify that all required cargo (save-all) nets are in place.

r. Ensure there are no oily or slick decks where cargo is to be handled.

s. Ensure adequate lighting is provided at the boom heads, cargo holds, and draft areas when conducting nighttime cargo operations.

t. Do not operate any cargo handling system with inoperative safety devices or guards without the specific approval of the commanding officer.

u. Rig suspended baskets and buckets per reference (b). Personnel in the basket or bucket must wear a safety harness with safety line attached. Leave the safety lanyard disconnected when the basket or bucket is positioned over water. When conducting work that will suspend personnel over water, personnel must wear approved life preservers in conjunction with fall protection per reference (c).

v. Use correct and well-maintained blocks and sheaves for safe load handling operations.

w. Conduct an informal safety brief for all participants prior to the start of cargo.

x. Ensure that safety observers are not involved in any other aspects of cargo handling operations except observing safe procedures.

4. Precautions During Cargo Operations. All personnel handling cargo should follow the precautions listed below is subparagraphs 4a through 4ae during cargo handling operations.

a. Always know where the cargo is during a transfer.

b. Wear a hard hat with chinstrap in place under chin, gloves (when handling wire rope or banded material), and steel-toed safety shoes.

c. When transiting a cargo operations area, walk only in the designated transit areas that are located on the side of the ship opposite the cargo handling operations.

d. Never look into a hold when cargo is being handled or cargo gear is in use unless controlling the movement of the cargo.

e. Never walk under suspended cargo or tensioned highline.

f. Do not ride on pallets, containers, or hooks. Do not ride on conveyors.

g. Know the firefighting and safety equipment locations.

OPNAVINST 5100.19F 5 May 2019

C2-5 h. Do not walk backward.

i. Always listen to equipment. Abnormal sounds usually mean trouble.

j. Never allow cargo to swing or remain suspended for a period longer than necessary.

k. When cargo is being lowered, keep feet and hands clear. Never put hands under cargo during transfer.

l. Never allow unsecured cargo gear or equipment to go unattended.

m. Never throw anything down a hold or onto a dock.

n. Never step into bights of line.

o. Never grab or hold onto cargo lines.

p. Know the location of all exits from holds.

q. Know the location and use of emergency cut-off switches.

r. Do not oil or lubricate equipment while it is in use.

s. Check cargo-handling equipment for damage and proper operation if struck by cargo being handled.

t. Ensure cargo never exceeds cargo handling equipment's listed safe working load limit at the outreach being used.

u. Avoid making side pulls.

v. Never climb up or down exposed ladders when cargo is being handled within the immediate area.

w. Do not smoke.

x. Inform supervisors of unsafe or damaged equipment or conditions.

y. Do not use personnel-only elevators for cargo.

z. Always lift loads evenly.

OPNAVINST 5100.19F 5 May 2019

C2-6 aa. When suspending a load, only do so over the deck, not the hatch.

ab. Wear eye, face and hand protection when removing steel strapping. Stand to one side and out of the path of the strapping as strapping will recoil when cut.

ac. Do not overload hand and fork trucks. Ensure trucks are below handlers when going up or down an incline.

ad. Remove, repair, or replace defective or broken strapping on cargo.

ae. Provide tag lines to loads requiring continuous manual guidance while in motion.

5. Precautions – Material Handling Equipment (MHE) During Cargo Operations. All MHE operators should the precautions listed in the following subparagraphs 5a through 5h during cargo handling operations.

a. Be trained and licensed, where appropriate, and follow the requirements in references (d) and (e).

b. Use a ground guide in congested areas and areas with limit clearance and vision.

c. Operate MHE at a speed that will permit it to be brought to a stop in a safe manner.

d. Ascend or descend grades slowly. On all grades, the forks must be tilted back and raised only as far as necessary to clear the floor, deck or road surface. Do not turn on an incline. When traveling up or down a grade in excess of 5 percent (3 degrees) with a loaded forklift truck, keep the load upgrade to maintain control.

e. Do not travel two MHE abreast unless approved by the commanding officer.

f. Maintain a safe distance from the edge of elevators, ramps, platforms, and safety nets. Be aware of “tail swing” motion on rear-steering MHE to avoid driving off the edge of elevators, ramps, and platforms.

g. Sound the horn at intersections, congested areas and other locations where vision is obstructed. Also, sound the horn before proceeding around corners or into elevators when the view is obstructed. Operators must sound the horn before moving rearward if the MHE does not have an audible backing warning system.

h. Wear seatbelts at all times.

OPNAVINST 5100.19F 5 May 2019

C2-7 6. Stowage Precautions

a. Before handling vehicles as cargo, inspect and ensure that all fuel has been emptied from the vehicle's tanks with the exception of combat loaded military vehicles.

b. Stow vehicles fore and aft, chock wheels, use approved or installed tie downs or wire rope lashings.

c. Always brace, shore, and lash cargo that may shift.

d. Always pre-plan the location of material to be stowed so that heavier items are stowed below lighter ones.

e. Use dunnage only when necessary.

f. For specific tie down information, see the appropriate transportability guidance technical manual.

7. Nets

a. Use cargo nets when loading or unloading packages, bundled and bagged materials, or other objects that might roll or shift, creating an unsafe condition if lifted on a sling.

b. When cargo nets are used to discharge cargo onto trucks, land the load slowly to prevent damage to the truck and possible injury to personnel. Carefully disconnect the net from the sling and leave the net in the truck with its load.

c. Inspect nets prior to and during use for wear and damage. Remove worn or damaged nets from service until repaired or replaced.

d. Refer to reference (f) for additional precautions associated with vertical replenishment (VERTREP).

8. Pallets

a. Palletizing speeds up the handling of cargo, prevents damage to easily crushed items, and increases the amount of cargo that can be stacked in a pile. For these reasons, pallets are used extensively in cargo handling operations.

b. When loading a pallet, stack the cargo so that no possibility of cargo spilling exists, and the pallet will be stable and level when lifted. When loading a pallet with cases of uneven size, place the highest and strongest cases at each end of the pallet with the smaller and more fragile cases in the center. In this manner, when piling one pallet on top of another, a stronger and more

OPNAVINST 5100.19F 5 May 2019

C2-8 level surface is offered. This will result in safer stowage of the pallets. Do not lift pallets on which items are loose or broken and which cannot be properly reloaded in cargo nets.

c. Palletize round commodities, such as cylinders, by using specially constructed chocks, made up and spaced to fit the particular cargo. For safe handling, tie the chocks together by 2 narrow strips that lie in the space between the chocks and are flush with the top of the pallet's platform. Lay the second tier in the cantlines of the first.

d. Use pallet bridles and bars whenever possible and especially when loading or unloading pallets containing even-sized cases or cartons.

e. Do not lift a load on damaged pallets. A damaged, palletized load may be lifted if a sound pallet is placed under the damaged pallet or if the load is placed into a cargo net. Otherwise, repalletize the load.

f. Refer to reference (f) for additional precautions associated with VERTREP.

9. Conveyors

a. When using a power conveyor, run the device slowly enough that personnel at the end of the conveyor can handle the packages without rushing.

b. Do not ride a moving conveyor. Signs must be posted on all conveyors to this effect. Do not walk on idle conveyors, except as required for maintenance.

c. Never leave a powered conveyor unattended while it is in operation. When operating a dual-control conveyor from one control station, use the station affording the best view of the entire conveying operation. For elevated conveyors, this usually means the elevated end. Control stations must be placarded with operating instructions and precautions.

d. Do not convey materials having an unstable load distribution.

e. Examine all conveyors frequently for sharp edges, dents, worn liners, or any other conditions that could cause injury to personnel or damage to conveyed materials. Inspect power conveyors for loose or broken parts.

f. Do not lubricate, adjust, or repair any part of the conveyor while the machine is in operation. Tag-out and remove conveyor from service before performing maintenance, inspection, or adjustments.

g. Wear steel-toed safety shoes when loading or unloading conveyors. Wear hand protection if the materials have metal bands or sharp edges.

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C2-9 h To avoid personnel injury from falling cargo, do not go underneath the conveyor or inside the specified safe distance from its sides and ends.

i. Always use the two-man rule when operating conveyors per reference (g).

j. Always maintain positive communication between the control stations at each level of operation.

k. Ensure there is adequate lighting and firm footing (including non-slip) for personnel loading conveyors.

l. Ensure all platform-locking bars, interlocks, and audible alarms are working prior to using the conveyor.

m. Ensure that all conveyor operators and maintenance personnel are PQS qualified.

10. Chainfalls and Come-A-Longs

a. Do not exceed weight for which the equipment was designed.

b. Never kink, twist, or knot chains or slings, as these are among the greatest causes of failures.

c. Never splice or shorten chains by bolting, wiring, or knotting.

d. Clearly mark chain falls and come-a-longs to show the capacity. Do not exceed marked capacity.

e. Do not use chain, whether new, repaired, or to which hooks or rings have been added, without thoroughly inspecting or weight testing, if required. Tag defective chains or slings or immediately cut up and properly dispose of them.

f. Do not subject chains to sudden shock while in use. Jerky movements put severe strains on the chain.

g. Keep chains free from grit and dirt. Do not drag chains or drop them on hard materials.

h. Use attachments or fittings for chains of the type, grade, and size suitable for service with the size of chain used.

i. Keep brakes free from grease, oil, and rust. Adjust for wear as required.

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C2-10 j. Do not operate unless the ratchet and pawl mechanism is engaged.

k. Keep the equipment dry and rust-free. Lubricate only the load chain.

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C3-1 SECTION C

CHAPTER 3

UNDERWAY REPLENISHMENT (UNREP)

Ref: (a) NWP 4-01-4, Underway Replenishment (b) OPNAVINST 3500.39D, Operational Risk Management (c) NSTM 077, Personnel Protection Equipment

1. Discussion

a. All precautions listed for handling cargo in chapter C2 must be followed during UNREP operations. However, several operations involved with UNREP are unique and require special attention and safety. VERTREP operations are covered in chapter C7, Helicopter Safety. Reference (a) contains additional procedures, requirements, safety precautions, and warnings associated with UNREP planning, ship handling, personnel, rigs, and transfer operations.

b. Fueling at sea and replenishment at sea involve the transfer of cargo, personnel, and fuel between two or more ships while underway. This involves not only the dangers normally found with cargo transfers but also adds the problem of heavy weather, motion, streaming operations, and the possibility of collisions. For these extra threats, special precautions and practices must exist.

c. Complete an ORM assessment before the evolution. Reference (b) provides additional guidance on ORM. Mitigate risks as feasible.

2. Precautions to Be Observed Prior to UNREP Operations. The senior personnel in charge of UNREP operations must take the precautions in the following subparagraphs 2a through 2v.

a. Ensure all UNREP equipment and breakaway equipment is in place and operational.

b. Ensure all assigned crew members know their duties, are qualified where applicable, and are aware of their responsibilities.

c. Test and ensure that proper communications equipment is being used and is operational.

d. Ensure that communications (including back-up systems) are established with the UNREP vessel.

e. Ensure UNREP stations have non-slip deck treads or non-skid paint.

f. Ensure all permanent lifelines and temporary lifelines are in place.

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C3-2 g. Ensure that all UNREP personnel have removed all watches, bracelets, etc., and are wearing life preservers, head protection (hard hats) with chin straps, hand protection (when handling wire rope or banded material), steel-toed safety shoes and non-vented safety goggles. Ensure that personnel assigned to work stations are carrying an appropriate knife for routine or emergency use.

h. When fueling, ensure all firefighting stations are properly equipped to combat a casualty.

i. Ensure life rings, buoys, and markers are within easy access for UNREP team members, and station lookouts on the fantail for each engaged side.

j. Ensure that all UNREP team members are thoroughly familiar with emergency breakaway procedures. Station-to-station phone talkers and rig captains should discuss emergency breakaway procedures as soon as sound powered phone communications are established. Phone talkers should never fasten the phone strap around their necks. Emergency breakaway procedures must be issued by the delivery ship, but can be initiated by either ship.

k. Ensure that all cargo handling equipment, including padeyes, are not overloaded.

l. Post UNREP warnings at designated personnel transit areas.

m. Only allow essential personnel at UNREP stations.

n. Ensure that all UNREP personnel wear snug fitting clothes.

o. In cold climates, make sure all ice and snow is removed from UNREP station and the UNREP area deck is properly sanded.

p. During night UNREP operations, ensure that all lights are operating.

q. During personnel transfers:

(1) make sure transferring personnel wear head protection (hard hats) with chin straps and authorized life preservers per reference (c) and are equipped with whistles and personal marker lights;

(2) ensure that transferring personnel know how to get out of the transfer chair in an emergency;

(3) inspect transfer rig before using. In particular, inspect the manila or synthetic highline, as applicable, for evidence of rot, broken strands, cuts, or other signs of weakened condition.

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C3-3 (4) use only manila or synthetic highlines and messenger lines. Hand tend messenger lines and personnel highlines; and

(5) additional information on personnel transfers can be found in chapter 8, paragraph 8.6, of reference (a).

r. Ensure that a ready lifeboat is manned and ready in case of an emergency.

s. Clear area of dunnage.

t. Ensure padding is in place for ordnance.

u. Assign a PQS qualified safety observer to every UNREP station during all UNREP evolutions. Ensure that the safety observer's only function is to watch for hazardous conditions. The safety observer should know the locations of all nearby eye wash stations and be familiar with emergency measures in the event of accidental eye splashing.

v. Ensure a safety brief is held for all participants prior to all UNREP evolutions using the principles of ORM.

3. Precautions During UNREP Operations. All personnel must comply with the following in subparagraphs 3a through 3aa.

a. Wear head protection (hard hat) with chin straps, hand protection (when handling wire rope or banding material), life preserver, and steel toed safety shoes.

b. Wear snug fitting clothing appropriate for the weather conditions. Remove rings, watches, key rings, cell phone, pager, and other personal gear, which may become entangled in loads or lines.

c. Know the location of lifesaving equipment and firefighting stations.

d. Be aware and exercise caution when line throwing gun or bolo are in use.

e. Stand clear of the bights of lines.

f. Transit the UNREP station area in the designated transit area on the side opposite the UNREP operations station.

g. Never turn away on incoming cargo or rigs.

h. Stand clear of suspended or incoming cargo.

OPNAVINST 5100.19F 5 May 2019

C3-4 i. Do not stand between incoming cargo and a fixed object.

j. Secure cargo immediately.

k. Never step on or in cargo nets attached to a cargo hook.

l. Know all emergency procedures, especially emergency breakaway.

m. Do not smoke.

n. Ensure supervisors are immediately informed of all damaged or broken equipment, including the conditions of lines.

o. Ensure station-to-station phone talkers do not fasten phone straps around the neck.

p. When passing lines:

(1) when possible, use a line-throwing gun for initial line transfer, and ensure that a bolo line is available at each transfer station as a backup;

(2) CVNs, LPDs, LHAs, LHDs, and ships configured for multiple air operations must provide the shot line;

(3) send the bolo or shot line across only after being advised that the station on the receiving ship is ready;

(4) do not aim line-throwing guns and bolo lines to areas on the other ship that are under cover or where activities are obscured;

(5) direct all station personnel to take cover before indicating ready to receive the bolo line or the shot line; and

(6) apecified personnel must retrieve the bolo or shot line only upon the order of the petty officer in charge of the station.

q. Neatly fake or coil down all lines to avoid a tripping hazard.

r. Stay clear of all lines, especially bights, unless directly engaged in their handling. Line handlers UNREP personnel should always remain inboard and forward of all rigs, space permitting.

s. Space permitting, keep at least 6 feet from any block or cleat through which lines pass.

OPNAVINST 5100.19F 5 May 2019

C3-5 t. Use tag lines to control a load during hoisting and lowering.

u. Secure cargo to prevent shifting.

v. Ensure that all transfers of empty hooks are treated as full load transfers with the proper catenary maintained.

w. Keep working areas clear of all dunnage and items that create a tripping hazard.

x. When handling ammunition and guided missiles, use padding on decks, bulkheads, and gun mounts in the vicinity of the station.

y. Raise loads only as high as necessary to clear obstructions.

z. Do not overload hoist rigs.

aa. Keep the bridge informed of any change affecting the readiness of the station to transfer. Before reporting all lines clear, ensure that all lines are clear of the receiving ship. When reporting all lines on deck, ensure that no lines are trailing in the water but are in fact on board and clear of the ship's sides.

OPNAVINST 5100.19F 5 May 2019

C4-1 SECTION C

CHAPTER 4

SMALL BOAT SAFETY

Ref: (a) OPNAVINST 3500.39D, Operational Risk Management (b) NSTM 077, Personnel Protection Equipment (c) NSTM 583, Boats and Small Craft

1. Discussion

a. The Navy uses several types of small boats. All can be used for emergency evacuation.

b. Launching and recovery are the most dangerous operations involving small boats. It is during these critical evolutions that human error and mechanical failure of boat davits and launching and retrieval machinery can occur, and when weather and sea state often worsen the effects. Sea state can also have an adverse effect while approaching accommodation ladders, pilot boarding stations or side port doors, and gates and ramps at sea. Therefore, inherently buoyant (kapok type) life preservers will be worn at all at-sea or at-anchor small boat evolutions to include entering and exiting well decks of L class ships by navy operated amphibious crafts (except landing craft air cushion (LCAC) and amphibious vehicles).

c. Unsafe contracted liberty boats (water taxis) have contributed to the death and injury of Navy personnel. To reduce the hazards associated with these operations, contracts for these services must specify a minimum level of safety and seaworthiness. In addition, commanding officers must ensure that a knowledgeable officer inspects water taxis prior to their being placed in service and at least daily thereafter. Paragraph 5 provides guidance on these safety inspections.

d. Complete an ORM assessment before the evolution and mitigate risks as feasible. Reference (a) provides additional guidance on ORM.

2. Precautions for Launching and Retrieval. Observe the precautions in the following subparagraphs 2a through 2r.

a. Never engage a crank when hoisting motor is energized.

b. Inspect all equipment before use, especially the condition of the boat falls, the machinery, and the boat itself.

OPNAVINST 5100.19F 5 May 2019

C4-2 c. Conduct a safety brief prior to all evolutions. Ensure people riding the boat wear an inherently buoyant (kapok type) life preserver and a safety helmet with the chinstrap fastened under the chin following section 2 of reference (b). Personnel assigned to the boat handling station will dress out the same including wearing a safety helmet with the chinstrap fastened under the chin following section 2 of reference (b).

d. Conduct a boat inspection. Inventory equipment; install bilge plug; remove ropes from bags; and check hoisting hook, rings, slings, and bales.

e. Keep non-essential personnel away from the davit area. Do not stand under the boat during lowering or raising.

f. When preparing davit to raise or lower the boat, post a davit winch watcher to monitor the spooling of the wire rope falls.

g. If the ready life boat is rigged for use, the sea painter connection will be checked during the morning boat report and before any launching evolution.

h. Obtain permission from the bridge; then raise or lower the boat slowly when cleared.

i. Permit only required personnel to be in the boat during lowering or hoisting operations. Personnel must wear IBLPs. The boat crew will be loaded when the boat is alongside the rail and after permission has been granted by the bridge through the petty officer in charge of the evolution. These personnel must hold on to the manropes when provided. Manropes must be positioned to the outboard side of the boat.

j. The small boat’s engine will be engaged prior to the small boat entering the water and disengaged after being recovered out of the water.

k. Release the stern hook first when launching from a double-hoisting wire davit.

l. The safety lines will be released in the following order after the small boat has been launched: aft steadying line, forward steadying line, sea painter. The safety lines will be reattached in the following order when recovering the small boat: sea painter, forward steadying line, aft steadying line.

m. Do not launch a boat when own ship's speed is greater than 5 knots.

n. Do not hoist boats aboard ship or lower with water in the bilge in excess of that which the installed bilge pumps would normally remove.

o. Properly secure lifting hook bails before a boat is raised or lowered.

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C4-3 p. Be alert for any possible malfunctioning and act quickly if it occurs. Do not lower or raise the davit arms into the davit arm stops at full speed. Do not use limit switches as stop switches.

q. When hoisting a rigid inflatable boat or other ship's boat with survivors embarked, only three crewmembers are required to be aboard: bowhook, sternhook, and coxswain. Other crewmembers should disembark by alternate means in deference to survivors prior to hoisting the boat. Although undesirable, when human life is in jeopardy and depending on operating conditions, the rigid inflatable boat or other ship's boat's limit on the number of people may be exceeded. The boat and boat davit safety factors are sufficient to permit hoisting the boat to the rail or deck edge when carrying the full capacity (see reference (c), section 5 for detailed guidance). However, under no circumstances must the boat be swung in or out when carrying more than five people.

r. Before raising or lowering a boat, ensure all slings, bale shackles, and pins are seated and seized.

3. Fueling

a. If possible, fuel a boat in the daytime and while it is in the water with its engine stopped. Fueling a boat at night requires the permission of the OOD.

b. If it is necessary to fuel a boat in its shipboard stowage, provide adequate spill control and firefighting equipment at the scene. Ensure all electrical equipment in use during refueling on or in the immediate are of the boat is approved for hazardous atmospheres.

c. Do not fuel boats with passengers on board.

d. Prior to fueling, make a grounding and bonding connection between the fuel delivery pump and the fuel tank for gasoline propelled boats.

e. Always keep gas cap in place when not fueling.

f. Only personnel specifically authorized by the ship's fueling instruction will fuel small boats.

g. Smoking or use of non-explosion-proof lights are not permitted near small boats during fueling operations.

h. Before starting the engine, inspect compartments and bilges, clean, and ventilate as necessary.

OPNAVINST 5100.19F 5 May 2019

C4-4 i. Ensure gasoline is stowed only in approved fuel containers, and returned to approved storage location upon completion of the fueling operation.

j. Report to the OOD any fuel or oil spills into navigable waters. Do not rinse, bail, or discharge anything from the small boat into navigable waters without the OOD's permission.

k. Always use non-vented safety goggles when handling fuels.

l. See reference (c) for additional requirements for small boat fueling at the boat stowage location.

4. Operations

a. Know and obey the "Rules of the Road." Especially important to boat coxswains is the "Rule of Good Seamanship," which requires that boats give way to ships and seaplanes. Boats should turn away from ships or seaplanes early and radically or show clearly their intentions so as not to embarrass the larger and less maneuverable vessels.

b. Always post a bow lookout while underway.

c. Do not maneuver close to ships anchored, moored or pass close around the corner of a pier, except when such a procedure cannot be avoided. Coxswains must transit slowly until there is no danger of collision with any boat or vessel that may be obscured.

d. Boat capacity

(1) Be familiar with and never exceed the designated personnel carrying capacity. Be able to calculate the load and regulate the number of personnel accordingly. While carrying stores, the load in pounds, including personnel and stores, must never exceed the maximum allowable cargo load.

(2) Do not carry passengers, stores, or baggage topside on motorboats. If it is necessary to carry stores or baggage, reduce the maximum number of passengers accordingly. Refer to reference (c) for detailed guidance.

(3) Installation of flotation material must not relieve operating personnel from exercising prudence in the loading of boats or providing of life preservers when conditions warrant.

(4) In choppy seas, reduce capacity. The rated capacity designated on the label plate is the maximum capacity under normal weather conditions in calm waters. Always reduce capacity under less than optimum weather conditions or on the open sea.

e. Do not use gasoline to clean the engine or its parts.

OPNAVINST 5100.19F 5 May 2019

C4-5 f. Keep bilges and sumps dry.

g. Prohibit smoking or open flames.

h. Never start the engine if excessive vapors are present. Check for leaks, damaged piping, and loose connections. Correct deficiencies. If a leak is observed during engine operation, stop the engine and correct the cause of the leak.

i. Use PQS qualified boat officers in foul weather, reduced visibility, long duration transits, first boat transit in foreign or unfamiliar ports, and when returning large liberty parties after sunset.

j. Do not operate the boat with a defective bilge pump.

k. Never open the bow ramp of a landing craft while underway.

l. Ensure boats carry proper fog signaling equipment (refer to reference (c), section 6) and two 18-inch life rings, one forward and one aft. Life rings must be secured in such a manner that they are easily broken out.

m. For precautions on charging small boat batteries, see chapter C9, paragraph 4.

n. Ensure boat crewmembers wear authorized life preservers following section 2 of reference (b), under adverse weather conditions, including reduced visibility.

o. Run boats dead slow when passing other boats that are alongside ships or landings, in narrow or crowded waters, and when passing deeply laden boats.

p. Ensure that authorized life preservers according to section 2 of reference (b), are readily accessible in boats for all members of the crew and all passengers. Never allow the number of personnel in the boat to exceed the number of life preservers available.

q. Do not operate boats with enclosed engine rooms without the engineer being on board and on station, and then only when proper ventilation is assured.

r. Ensure that boat fire extinguishers are in place and charged.

s. Ensure that life preservers are always kept dry while in storage.

t. Inspect the electrical system for loose connections and worn insulation before operating a boat and whenever damage to these systems is suspected. Do not operate the boat until corrective action is completed.

OPNAVINST 5100.19F 5 May 2019

C4-6 u. Display running lights per the “Rules of the Road” when underway between sunset and sunrise or in reduced visibility. (Refer to section 6 of reference (c) for guidance.)

v. Ensure shackles and pins are used with anchors. Ensure hoisting slings or bales and steering cables are seized and cotter pins are in place.

w. Boat handling system

(1) Be sure winch and davit safety and operating placards, lubrication charts, and test label plates are posted. Ensure winch controls, brake, clutch, and pawl handles are labeled to show function and direction of movement.

(2) Always check the wire rope on the winch drum before operation to ensure the wire is properly spooled on the drum.

(3) Except in an emergency, check limit switches for operability.

(4) Ensure all turnbuckles used on boat gripes are marked to show the limit of tensioning.

x. Ensure that only qualified (class II or above) swimmers are assigned as boat crew members.

5. Contract Liberty Boat Safety

a. Commanding officers must ensure that husbanding agents and contractors provide contract liberty boats that are always manned with a minimum of one operator (coxswain) and two line handlers, operated safely, and secured to the pier or landing with a minimum of two mooring lines during embarkation and debarkation of passengers. Prior to being placed into service, a knowledgeable officer, acting for the commanding officer, must inspect and approve all contract liberty boats (water taxis) for operational safety.

(1) Ensure the navigation lights, lighted compass, distress signals, and a fog signal device are present and in working condition, and that the area charts are available and current.

(2) Ensure that fire extinguishers are present in sufficient number for the size of the boat.

(3) Verify that there is a working radio aboard, with backup battery, capable of bridge-to- bridge communications.

(4) Inspect the anchor, anchor chain, and mooring lines for adequacy given the size of the vessel.

OPNAVINST 5100.19F 5 May 2019

C4-7 (5) Verify that the weather deck drains are free from obstructions and drain overboard, not into the bilge.

(6) Check engineering spaces and compartments for fire or flooding hazards.

(7) Conduct a visual inspection topside for conditions which may be hazardous to passengers, to:

(a) ensure that the vessel is equipped with a sufficient number of clean and serviceable life preservers for the maximum capacity of the vessel, and ensure the life preservers are stowed in a readily accessible place marked clearly in English;

(b) verify that decks, railings, doors and seats are structurally sound, latched, and tightened as appropriate;

(c) ensure that no bare or exposed electrical wires or connections are located in the passenger area;

(d)Validate that a sufficient number of unobstructed exits are present and marked in English; and

(e) verify that no loose gear, potential projectile hazards, or trip hazards exist.

(8) Ensure the operator understands that the boat must be properly secured to the pier or landing with a minimum of two mooring lines before allowing passengers to embark or debark.

b. It is impractical to establish detailed specifications for every inspection item. Inspectors must use their judgment and experience when advising the commanding officer of the overall safety of the contract water taxi.

c. Any item missing that is critical to safety may be provided by the commanding officer for the duration of the contract boat services. Ensure that the contracted boat crew return any such items prior to the expiration of the contract. In all cases where Government furnished property is provided due to contractor's failure to meet the terms of the contract or the contractor's vessel is unsafe for use, the commanding officer must immediately notify the contracting officer of the circumstances surrounding the deficiency(ies). If the contracting officer is not on site, notification must be by message.

d. Assign boat officers to the contract water taxis during hours of darkness, or low visibility, and heavy weather. Boat officers must be PQS qualified by the ship and responsible for maintaining good order and discipline of personnel onboard.

OPNAVINST 5100.19F 5 May 2019

C4-8 e. When boat officers are assigned to contract water taxis, they have the authority to not allow boarding when the water taxi's crew performance and navigation are unsatisfactory. Boat officers must ensure boats are securely moored to the pier or landing with a minimum of two mooring lines before allowing passengers to embark or debark. When weather conditions are determined to be unsafe, the boat officer has the authority to refuse to get underway.

OPNAVINST 5100.19F 5 May 2019

C5-1 SECTION C

CHAPTER 5

WIRE AND FIBER ROPE

Ref: (a) OPNAVINST 3500.39D, Operational Risk Management (b) NSTM 613, Wire and Fiber

1. Discussion

a. Ropes come in a multitude of types, quality, and sizes, each with its own characteristics. In general, there are two types of rope: fiber (natural and synthetic) and wire. When removed from a coil or reel, fiber ropes are generally referred to as lines. Wire is referred to as "wire rope" or "wire," but not "cable." Additionally, there is a fiber and wire hybrid known as "spring lay" rope. Spring lay rope is composed of six main strands laid around a fiber core. Each main strand consists of three preformed wire strands and three fiber strands laid alternatively around a fiber center. Each of these ropes has been developed to satisfy a specific requirement. They can be safely used, but must be properly maintained.

b. Complete an ORM review before any line handling evolution, and mitigate risks as feasible. Reference (a) contains additional guidance on ORM.

2. General Precautions

a. Always inspect wires, ropes, and lines before use. Look for deterioration, broken wires or fibers, visible signs of rot, chafing, and variations in color, crushing, or the other signs of damage. Refer to reference (b) for additional information on use, maintenance, and material requirements for ropes.

b. Wear steel-toed safety shoes with skid-proof soles before handling lines. When handling lines, do not wear rings, watches, cell phones, pagers, key rings, and other items that may become entangled.

c. Check all rollers, capstans, gypsy heads, and windlasses, to ensure they are operating satisfactorily.

d. Avoid getting hands, feet, or clothing caught in bights formed by wires, ropes, or lines.

e. Do not stand directly in line with the point where wires, ropes, or lines change direction (e.g., around a bitt, capstan, or through a block).

OPNAVINST 5100.19F 5 May 2019

C5-2 f. Do not straddle or stand on chains, wires, ropes, or lines, whether under tension or not. Never step over chains, wires, ropes or lines under tension.

g. Avoid placing wires, ropes, or lines on rough or sharp surfaces that can cause chafing or cutting. Use chafing gear.

h. Do not place objects on wires, ropes, or lines.

i. Ensure all kinks are out of wires, ropes, or lines before use.

j. Check sheaves and blocks being used for proper size and strength. Do not use sheaves or blocks that are too small for the wire, rope, or line used.

k. Listen to wires, ropes, and lines under tension. Any unusual popping or tearing noises may mean that the wire, rope, or line is in danger of parting.

l. Always place hands above lines fairlead into gypsy heads, capstans, or bitts.

m. Do not lubricate lines.

n. Do not apply loads suddenly.

o. Never leave wires, ropes, or lines under strain on gypsy heads or capstans.

p. Do not use sheaves or drums with corrugated grooves.

q. Remove the loose ends of splices.

r. Seize all bitter ends.

s. Use the same type of material for stoppers as the hawser being held (e.g., synthetic stopper for synthetic line). Chain must be used for stoppers on wire rope.

t. Do not use manila, wire, spring-lay rope, or synthetic line together on the same chock, bitt, or reel.

u. Carefully make up lines not in use.

v. Do not permit rat guards and sharp edges to wear mooring lines. Use chafing gear and lash well.

w. Change boat falls, highlines, and mooring lines following PMS procedures. Failure to make such changes can result in serious injury.

OPNAVINST 5100.19F 5 May 2019

C5-3 x. Make up wires, ropes, and lines not in use and stow clear of walkways and passages.

y. Ensure wires, ropes, lines, and rigging are not subject to overload.

z. Use steadying or frapping lines on boat falls and large lifts to prevent uncontrolled swinging or twisting.

aa. Refer to reference (b) for additional information on use, maintenance, and material requirements for wires, ropes, and lines.

3. Natural Lines. In addition to the precautions stated in paragraph 2, also follow the following precautions in subparagraphs 3a through 3l.

a. Do not use natural lines in sheaves and blocks built for wire rope service.

b. Never use manila lines 5 or more years old.

c. Do not continue to use natural fiber line in which any of the conditions in the following subparagraphs 3c(1) through 3c(7) are present.

(1) Ruptured fibers and powdering between the strands.

(2) Dark red, brown, or black spots between the strands, and a sour, musty or acidic odor.

(3) Thirty percent of the yarns in the cross-section have been worn through.

(4) Long jawed and distorted strand areas.

(5) Salt incrustation and swollen areas.

(6) A harsh, dry, dead feel in manila or sisal lines.

(7) Evidence of gritty material between the strands.

d. Store lines in cool, dry spaces.

e. Fake lines down after use to dry out.

f. Always thaw frozen lines before use.

g. Do not allow lines to come into contact with chemicals, acid, alkalis, paints, soaps, rust, or vegetable oils.

OPNAVINST 5100.19F 5 May 2019

C5-4 h. Do not drag lines over sand, grit areas, or non-skid decks.

i. Do not let line wear become localized; rotate lines.

j. Use chafing gear if necessary.

k. Only use undamaged lines. Always remove damaged lines from use and repair or discard immediately.

l. Do not use chain or wire stoppers on fiber lines.

4. Synthetic Lines. In addition to the precautions in paragraph 2, the following precautions in the below subparagraphs 4a through 4g must be observed.

a. Do not expose lines unnecessarily to heat, sunlight, excessive cold, or chemicals.

b. Store nylon and polyester lines under cover or tightly wound on reels or on cleats during excessive cold.

c. Always thaw frozen lines before use.

d. Install tattletale lines to gauge how far lines are stretching. Tattletales cannot be used on aramid fiber ropes, due to their low stretch. The load should be carefully controlled on aramid lines to avoid excessive tension of the line. This is best accomplished by having line handlers ″check the line″ frequently until they have a feel for the load. Checking means allowing only enough line to render around the bitts to prevent the line from parting. It is never prudent seamanship to hold a line while a ship has movement. Remember, a parted line serves no useful purpose and is definitely a safety hazard. Regardless of the safety features of aramid lines, they must be treated with the same respect afforded to other lines under tension.

e. Payout lines on cleats, bitts, or capstans slowly. Exercise extreme care when easing out synthetic lines under heavy load. Because of their high extendibility under load, their rapid recovery, and their low coefficient of friction, these ropes may slip suddenly on easing out, thereby causing injury to line handlers. For control in easing out or surging, take two round turns on the bitts and then apply one or two figure eight bends. No more than two figure eight bends will be used. Because these bends tend to lock under surge, use of more than two figure eight bends will cause difficulty in easing out operations.

f. Double up lines under excessive strain.

g. Stand clear of lines under strain. (The videotape, "Synthetic Line Snapback," PIN 82971 ,should be viewed for an appreciation of this phenomenon.)

OPNAVINST 5100.19F 5 May 2019

C5-5 5. Wire and Spring Lay Rope. In addition to paragraph 2, the precautions listed below in subparagraphs 5a through 5k must be observed.

a. Always wear heavy-duty hand protection when handling wire and spring lay rope.

b. Always wear eye protection while splicing.

c. Seize wire ends to prevent unlaying.

d. Store wire and spring lay rope away from weather, acid, and chemicals.

e. Inspect wire and spring lay rope per PMS procedures.

f. When using U-bolt clamps to form an eye, always put the U-bolt itself over the bitter end. Tighten clamps only after putting line under stress.

g. Only operate winches with more than 2 turns of wire on the drum.

h. Do not use sheaves or blocks designed for use with fiber rope with wire rope.

i. Inspect end fittings, such as sockets, connectors, and wire rope clips prior to use to determine if there is an area of break adjacent to the fitting. Tighten clips after the first hour of running and at PMS specified intervals thereafter. Remove clips after long use and examine rope for broken wires. Remove the damaged part, if broken wires are found, and make a new attachment.

j. Inspect the bitter end of a wire on a drum to ensure it is properly attached.

k. Because spring lay is a combination of wire and fiber, rules for the care of both wire and fiber rope apply.

6. Cable Cleaner and Lubricator. Many ships are now using the pollution prevention cable cleaner and lubricator to clean and grease wire rope. User instructions are provided with the equipment, and the precautions in the following subparagraphs 6a through 6i must be observed.

a. Do not exceed the pressure rating of any of the system components.

b. Check the hoses for damage and ensure connections and fittings are secure prior to operation.

c. Release all system pressure before any service or disassembly of the unit.

OPNAVINST 5100.19F 5 May 2019

C5-6 d. Ensure chains or slings used are weight-tested or rated to withstand an initial line pull of 600 pounds.

e. Ensure personnel are clear of the exit end of the lubrication collar during the lubrication process.

f. Ensure that all shackles and fittings are tightened prior to operation.

g. Do not run the system unless the airline lubricator has oil in it.

h. Ensure personnel wear steel-toed shoes, eye and hand protection when handling the wire rope during the cleaning and lubricating.

i. Dispose of any greasy rags or debris following the ship’s local HAZMAT instructions (e.g., turn in to the ship’s HAZMINCEN).

OPNAVINST 5100.19F 5 May 2019

C6-1 SECTION C

CHAPTER 6

GROUND TACKLE AND TOWING

Ref: (a) SL 740-AA-MAN-010, U.S. Navy Towing Manual (NOTAL) (b) OPNAVINST 3500.39D, Operational Risk Management (c) NSTM 581, Anchors and Anchoring

1. Discussion

a. Ground tackle is a general term used to refer to the anchor, anchor chain, the anchor windlass, and auxiliary equipment. Although this chapter discusses the gypsy head, additional information is provided under general line handling precautions in chapter C5.

b. Personnel injury may result if any part of the anchor or its handling system fails when under strain. Precautions must be observed to avoid personnel injury or system damage resulting from excessive strain.

c. Towing is an evolution, which is seldom accomplished except in an emergency or for training. Due to the large inertia associated with the ships involved in the evolution, it can be extremely hazardous, particularly if excessive strain is placed on the towline and its parts. Refer to the ship’s towing bill, reference (a), and ORM policy in reference (b).

d. Complete an ORM review before anchor handling or towing evolutions, and mitigate risks as feasible. Reference (b) contains additional guidance on ORM.

2. Ground Tackle Precautions

a. All personnel must wear snug fitting clothing, hand, eye and head protection, and steel toed safety shoes.

b. Check equipment to ensure it is in proper operating condition.

c. Ensure all equipment is lubricated and fluid levels are adequate.

d. Keep hands or feet off moving anchor chains.

e. Beware of oily areas or ice on decks during cold weather. Clean up oil and spread salt or sand or both for ice. Keep decks clear of obstructions that may impede quick escape.

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C6-2 f. Ensure proper communications to the bridge and the machinery spaces have been established prior to any evolution.

g. Only enter the chain locker when no anchor operations are planned and only with OOD permission. Chain lockers should be entered only when the ship is in port. Space must be certified as gas free before entry (see chapter B8).

h. Check that the chain locker is clear and free for running before using the anchor.

i. Allow only the anchor and line detail in the ground tackle area during operations.

j. Set brake on windlass immediately when yellow painted chain link is visible.

k. Never allow the chain to run free without braking. Excessive payout speed can cause loss of the anchor, or injury to personnel.

l. Ensure anchor chain is securely fastened to the padeye in the chain locker when reinstalling the chain after painting.

m. If using chain stoppers, set and clear the immediate area before strain is put on the chain.

n. Always keep the hawser deck bolster pipe cover in place when not hoisting or letting go the anchor.

o. When first red chain link appears on deck and the brake fails to hold, clear the immediate area.

p. House anchor in hawse-pipe shell bolster at the lowest possible speed.

q. Operate windlass at a low speed whenever the chain out exceeds 60 fathoms.

r. If the chain tends around the stem, report the situation to the bridge. The chain must be allowed to run free or the sharp bend may damage links. Detachable links are particularly susceptible.

s. Replace anchor chain if corrosion has reduced the mean diameter to less than the criteria in reference (c).

t. Personnel assigned to work over the side of the ship to hose down the anchor after hoisting must be in proper fall protection equipment; see chapter B13.

OPNAVINST 5100.19F 5 May 2019

C6-3 u. Windlasses

(1) When at anchor, nothing must interfere with the readiness to run, slip, or heave in the chain, or let go the spare anchor.

(2) When using the gypsy head, observe the following safety precautions:

(a)Never make a line fast to the gypsy head, but only to fittings provided for that purpose, such as cleats or bitts.

(b) Disengage the wildcat shaft locking head and hold the wildcat by the brake.

(3) When using the capstan, observe the following procedures and safety precautions:

(a) Keep capstan heads free of gouges, paint, any and all petroleum based products, and rust.

(b) When using the capstan for heaving, ensure turns are taken in the right direction for heaving.

(c) Never make lines fast to capstans, but only to fittings provided for that purpose, such as cleats or bitts.

(d) When handling lines on the capstan, when possible, position line handlers perpendicular to the line of pull.

(4) Ensure operating, safety, lubrication label placards, and test label plates are posted on or in the vicinity of windlasses or capstans.

(5) Ensure controls, brakes, and clutch levers are labeled properly.

(6) Never place any part of the body into moving machinery.

(7) Do not wear jewelry, neckties, cell phone, pagers, or loose fitting clothing while operating equipment.

(8) Wear proper protective clothing, eye and hearing protection, and equipment suited to the operation being performed.

3. Towing Precautions. Personnel involved in towing operations must be thoroughly trained, disciplined, and equipped not only to perform routine duties, but also to react appropriately to

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C6-4 unusual or non-routine situations. The officers and crew of vessels involved in towing operations routinely should conduct safety indoctrination lectures and exercises aimed at reducing unsafe conditions or practices and at reacting appropriately to unusual circumstances through professional knowledge of their duties and towing procedures. Consult reference (a) for detailed precautions based on the type of towing evolution.

OPNAVINST 5100.19F 5 May 2019

C7-1 SECTION C

CHAPTER 7

HELICOPTER AND TILTROTOR SAFETY

Ref: (a) NAVAIR 00-80T-122, Helicopter Operating Procedures for Air Capable Ships NATOPS Manual (b) NTTP 3-50.1, Navy Search and Rescue Manual (c) OPNAVINST 3500.39D, Operational Risk Management (d) NAVSEA OP 3565/NAVAIR 16-1-529/NAVELEX 0967-LP-624-6010, Electromagnetic Radiation Hazards (Hazards to Personnel, Fuel, and Other Flammable Material)

1. Discussion

a. Helicopters and tiltrotors are used for various operations at sea, including anti-submarine warfare, VERTREP, and search and rescue. Helicopters create special hazards. Catastrophic mishaps can severely damage the ship, aircraft, and cause injury or death to personnel.

b. Helicopter or tiltrotor mishaps can happen at any time and result in varying degrees of damage, injury, and loss of aircraft and crew. Examples of mishaps include a crash on takeoff or landing, injury to ship’s personnel from static electricity discharge during hoisting evolutions, inadvertent external cargo release during VERTREP operations, or injury from debris blowing about by rotor wash.

c. These standards are written for all ships that are air-capable.

d. Consult references (a) and (b) for further details concerning specific procedures and related safety procedures.

e. Complete an ORM review before any flight operations, and mitigate risks as feasible. Reference (c) provides additional guidance on ORM.

2. General Precautions

a. Avoid approaching within 50 feet of a helicopter or tiltrotor when the rotor blades are turning, unless necessary. Whenever required to approach or leave a helicopter or tiltrotor that has its blades rotating, remain in full view of the landing signalman enlisted and pilot and keep in a crouched position. Unless authorized, do not work in the area of the cockpit or cabin rearward while blades are rotating. Do not attempt to leave or approach a helicopter or tiltrotor that is

OPNAVINST 5100.19F 5 May 2019

C7-2 engaging or disengaging rotors. A crouched position with one side to the helicopter or tiltrotor lowers the risk of being blown down or overboard by rotorwash.

b. Always wear complete flight deck PPE, including cranials with double hearing protection, goggles, and float coats when required during flight quarters. Long sleeve shirts must be worn with sleeves rolled down at all times during flight operations. Personnel involved in flight deck operations including maintenance and refueling must wear steel toed leather safety shoes or boots with non-slip oil and fuel resistant soles.

c. Remove soft hats topside during helicopter or tiltrotor landing or take-off.

d. Know the location and use of firefighting and lifesaving equipment.

e. Prohibit the dumping of trash during helicopter or tiltrotor operations.

f. Prohibit blowing tubes when a helicopter or tiltrotor is on or in close proximity to the flight deck.

g. Conduct a foreign object damage (FOD) walkdown on the weather decks and flight deck prior to flight operations. FOD is defined as any article or object which may be disturbed by the wind across the flight deck or rotor wash and may cause damage to personnel, aircraft, or equipment. FOD prevention is the responsibility of all-hands. Take only necessary tools and material to the flight deck, and account for all tools brought to the flight deck before leaving. Report any missing items immediately.

h. Secure all hatches that open into the helicopter or tiltrotor operating area. Scuttles and hatches that open into the aircraft operating area will be posted with the following notice:

CAUTION

DO NOT OPEN DURING FLIGHT QUARTERS EXCEPT FOR

EMERGENCY EXIT. NOISE HAZARD AREA – HEARING

PROTECTION REQUIRED.

i. During flight operations, permit only authorized personnel on the flight deck or weather areas adjacent to the flight deck. Personnel will not stand in or otherwise block entrances to flight deck weather areas.

j. Utilizing flash producing equipment on the flight deck during launch, recovery, or taxi evolutions, especially at night, requires the approval of the flight deck officer.

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C7-3 k. Night flight operations, from 30 minutes prior to sunset to 30 minutes after sunrise, are always more hazardous for both pilots and flight deck crews. The tempo of night flight operations should be reduced in both volume and intensity when compared to day operations.

l. Flight operations and top side motor gasoline fueling operations must not be conducted within 50 feet.

m. Follow approved HERO emission control procedures per reference (d).

OPNAVINST 5100.19F 5 May 2019

C8-1 SECTION C

CHAPTER 8

WORKING OVER THE SIDE OR ALOFT; VERTICAL TRUNKS; AERIAL WORK PLATFORMS; DRY DOCK SAFETY

Ref: (a) NAVFAC P-307, Management of Weight Handling Equipment (b) NSTM S0570-AC-CCM-010/8010, Industrial Ship Safety Manual for Fire Prevention and Response (c) NSTM 772, Cargo and Weapons Elevators

1. Discussion

a. Since many areas on the exterior of a ship are inaccessible to the crew from decks or built-in work platforms, it becomes necessary to work "over the side" or "aloft" to reach these areas. "Over the side" is defined as anywhere outboard of the lifeline system and above water. The key hazard for working over the side is asphyxiation by drowning. "Aloft" is defined as being located outside the hull or superstructure in an area where specific emission hazards exist such as non-ionizing radiation from radars and antennas, radiation-induced electrical shock, inhalation of stack exhausts, and proximity to operation of a ship’s whistle. The term aloft does not include the potential for fall hazards from working at height. Fall hazards, fall protection requirements and equipment utilized while working over the side, aloft, and in vertical trunks are covered in chapter B13.

Note: Access trunks, escape trunks, elevator trunks, dumbwaiter trunks, and vertical pallet and package conveyor trunks are all vertical trunks where the potential for a fall exists, but are not locations where personnel are considered aloft because they are located inside a ship’s hull or superstructure.

Note: It is important to understand the mutually exclusive distinctions between the terms “over the side,” “aloft,” and “at height.” A person working outboard of a lifeline system and above a lower deck would not be working over the side. However, that person could be working “at height” if there is a possibility of a fall from 5 feet or more to a lower level; or, where there is a possibility of a fall from any height onto dangerous equipment, or onto an impalement hazard. A person aloft can also be working at height; whereas, a person working at height is not necessarily aloft. It is entirely possible for a person to be working in any combination of over the side, aloft, or at height because of the different hazards associated with each term.

b. When a ship is in dry dock, many of the precautions associated with working over the side or aloft must be followed. This chapter will discuss the hazards and precautions associated with this unique evolution.

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C8-2 c. Personnel suspended in a man basket over the side by a crane are subject to electrical shock and burn hazards from voltage induced in the hoist wire from transmitting antenna and radar. When personnel are suspended over the side by a crane, all precautions listed in this chapter must be taken.

d. As a risk control measure, assign and position a safety observer near the work being performed, whose only responsibility is safety, during any deck or seamanship evolution that could injure personnel or damage equipment. This safety observer must be knowledgeable in the proper performance of the evolution. Examples of deck evolutions include: operation of boat davits, rigging pilot and accommodation ladders, and handling lines.

2. General Precautions

a. An appropriate check sheet must be routed to the OOD or CDO for permission to work either over the side (OPNAV 5100/24 Working Over the Side Check Sheet) or aloft (OPNAV 5100/23 Working Aloft Check Sheet).

b. When exposed to falls of 5 feet or more to a lower level, or, where there is a possibility of a fall from any height onto dangerous equipment, or onto an impalement hazard wear appropriate fall protection equipment per chapter B13.

c. When performing hot work, replace personal safety and staging boatswain (bosun) chair fiber lines with wire rope. Personal safety lines must be corrosion resistant steel wire rope.

d. Attach safety lanyards to all tools, if practicable. Never carry tools up and down ladders. Rig a line and raise or lower tools in a bucket.

e. Stop work when the ship begins to roll in excess of 10 degrees, or the ship begins to pitch in excess of 5 degrees, or wind speed is greater than 30 knots, or in an ice storm or when lightning threatens.

f. Ensure appropriate signal flags are hoisted. (Kilo for personnel working aloft; Kilo One is for personnel working over the side; Kilo Three is for personnel working aloft and over the side.)

g. When underway or when working near stacks or exhausts that are actively discharging gases, the commanding officer's permission is required to work aloft or over the side.

h. An experienced senior person must check the rigging of the bosun chair or staging prior to use. Never rig lines over sharp edges. Inspect lines for damage, rot, and wear.

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C8-3 i. The petty officer in charge must mark off an area and keep unnecessary personnel clear. He or she must also maintain a sharp lookout for anything that would cause an increase in ship's motion or drastic change in direction. Personnel must not work over the side during maneuvers with other ships because of the unpredictable nature of these evolutions.

j. Read and comply with any safety placards (e.g., radio-frequency radiation warning signs) posted in the area prior to commencing work.

k. Cranes used to suspend personnel over the side must be certified, per reference (a), and work platforms or man baskets must be approved by COMNAVSEASYSCOM as safe for manned handling. Comply with the caution plates attached to the inside and outside of the man basket gate. Personnel suspended over the side by a crane are subject to radiation burn hazards from voltage induced in the hoist wire from transmitting antenna and precautions must be taken.

3. Procedures for Working Over the Side. Complete OPNAV 5100/24 prior to commencing work over the side.

a. Personnel working over or near water, where the danger of drowning exists, must wear a NAVSEASYSCOM-approved IBLP.

b. Where water directly abuts the ship and the distance from walking and working surface to the water is 25 feet or more, fall protection is required; IBLPs are not required.

c. Where the distance from the walking or working surface to the water surface is less than 25 feet and the water depth is less than 10 feet, or hazards (machinery, barges, camels, or other structures fastened to and directly abutting ship) are present, fall protection is required. IBLPs are not required.

d. When using both IBLP and fall protection, the harness must be worn under the IBLP.

4. Procedures for Personnel Working Aloft. Complete OPNAV 5100/23 prior to commencing work aloft.

a. Do not go aloft on masts, macks, stacks, or kingposts or be suspended over the side by a crane without first obtaining written permission from the OOD in the form of a working aloft checklist as described in paragraph 2.

b. Wear respiratory protection designated by the RPPM when working near stacks or exhausts that are actively discharging gases.

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C8-4 c. Wear appropriate fall protection equipment per chapter B13, if a fall hazard exists

d. Prior to commencement of work, and every 15 minutes thereafter, pass a verbal warning over the one multi-channel: "Do not rotate antennas, energize, or radiate any electrical or electronic equipment while personnel are working aloft." If personnel aloft are in the vicinity of the stacks add: "Do not blow tubes or lift safety valves while personnel are working aloft."

e. Inform ships in the vicinity that personnel will be working aloft to ensure they take appropriate action on operation of electrical or electronic equipment.

f. Departments concerned must ensure that all radio transmitters and radars that pose RADHAZs are placed in the “STANDBY” position and a sign placed on the equipment that reads:

"SECURED. PERSONNEL ALOFT. DATE_______ TIME_______ INITIALS________."

g. Position a safety observer on deck near the work being performed. Outfit the safety observer with appropriate fall protection and rescue equipment per chapter B13 to permit rapid emergency assistance, if required. The safety observer must keep the deck area beneath the work aloft free of unnecessary personnel.

5. Dry Dock Safety Precautions

a. Personnel working at heights while in dry dock must comply with the precautions indicated in this chapter. Personnel working at heights in dry dock will normally be in a man basket with full body safety harness and safety lanyard worn. On temporary elevated work areas (e.g., staging, scaffolding, etc.) with properly constructed guard rails, a safety harness is not required.

b. Ensure all temporary elevated work areas (e.g., staging, scaffolding, etc.) are properly constructed and supported per chapter B13.

c. Only enter the dock with a hard hat that meets ANSI/International Safety Equipment Association (ISEA) Z89 standards, steel-toed safety shoes that meets ANSI/ISEA Z41 standards, and eye protection that meets ANSI/ISEA Z87 standards. PPE that meets ANSI/ISEA standards will be labeled, stamped, or embossed with the standard.

d. Shift no weights within the ship while in dry dock without the permission of the docking officer.

e. Ensure the ship is adequately grounded at all times.

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C8-5 f. Drain all lines subject to freezing, in freezing weather. If frequent service is required, maintain a small flow through the line to prevent freezing.

g. Ensure adequate topside lighting is provided by either installed dock lights or by temporary lighting, particularly in areas where normal passage is obstructed or disrupted by service lines or work in progress.

h. Ensure that any equipment that projects through the hull is only operated with the permission of the commanding officer and then with a safety observer outside the hull.

i. Do not throw anything over the side into the dock, including debris from cleaning or preservation.

j. When carrying fuel of any kind in dry dock, do not allow fuel to drain into the dock. Should it be necessary to remove fuel from tanks or receptacles while in dry dock, take precautions that will prevent any of the fuel from reaching the floor of the dock.

k. Gangways

(1) Provide one gangway located at the ship’s quarterdeck.

(2) Per reference (b), provide one additional gangway for ships less than 600 feet in length. Provide two additional gangways for ships 600 feet or over in length. The additional gangways are required to provide a separate means of egress; therefore, additional gangways are not allowed to be placed in the same fire zone as the quarterdeck gangway without concurrence from the cognizant shore safety office and fire department. Gangways and landing platforms must be a minimum of 3 feet in width and be designed and constructed to support a minimum load of 75 pounds per square foot. The entire length of gangways and adjacent areas must be illuminated with weather-tight lights, and shielded to prevent temporary blinding of personnel. Safety nets must be installed under gangways and platforms that are not fitted with both side rails having a vertical height of 42 inches nominal and metallic meshing or similar material with small openings (approximately 2-1/2 inch) between the top of the rail and the gangway platform deck. Safety nets, when used, must extend 6 feet beyond each side of gangways and platforms. Gangways must be maintained free of debris, ice, snow, and foreign matter.

(3) Do not permit horseplay, leaning on lifelines, or other negligent practices leading to falling over the side.

6. Operating Aerial Work Platforms

a. Aerial work platforms include aerial lift equipment (i.e., vehicle-mounted rotating and elevating aerial devices, or boom-supported elevating work platforms), scissor lifts, and mobile scaffolds.

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C8-6 b. Before an aerial work platform operation begins, the operator must:

(1) be qualified and licensed according to local instructions;

(2) read and understand the operating instructions and safety rules for the equipment being used;

(3) understand all decals, warnings, and instructions displayed on the work platform;

(4) send the OOD and commanding officer the OPNAV 5100/23 and the OPNAV 5100/24 to request permission to work either over the side or aloft;

(5) inspect the equipment for defects that would affect its safe operation, and be alert for cracked welds or other structural defects, leaks in the hydraulics, damaged control cables, loose wires, and bad tires; and

(6) test the operating controls to make sure they work; and check the operating condition of the brakes, lights and other automotive-operating accessories, such as the horn and warning devices. Test all limit switches.

c. Equipment operators must observe these rules when working on, around, or over water.

(1) Wear a NAVSEASYSCOM-approved IBLP over the full-body safety harness. Attach the safety lanyard to a staple or pad-eye designated for fall arrest inside the man basket. Do not attach safety harnesses or lanyards to the aerial work platform railing. Do not attach lanyards while over water.

(2) Ensure a paint punt is in the water near the aerial work platform operations (for rescue purposes).

(3) When using an aerial work platform on a barge, secure it to the barge with wire or tie- down so that it cannot move.

(4) Do not alter or disable safety devices or interlocks.

(5) Make sure a supervisor watches aerial work platform operations from the pier.

(6) When personnel are working on a ship's sides, the supervisor must ensure the deck above the aerial work platform is free from hazards, especially falling objects.

(7) Wear hard hats with chin straps.

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C8-7 d. Before each elevation, the aerial work platform operator must:

(1) check for overhead obstructions and high-voltage conductors;

(2) elevate the work platform on only a firm, level surface;

(3) make sure the load and its distribution on the platform follows the manufacturer's rated capacity, and never exceed the manufacturer's rated workload;

(4) use the outriggers or stabilizers, if required, following the manufacturer's instruction;

(5) make sure guardrails on the platform are installed correctly and the gates or openings are closed; and

(6) check all occupants' safety harnesses and lanyards, making sure they are attached properly to a staple or pad eye inside the man basket; do not attach lanyards to objects outside the basket.

e. Before and while driving with the aerial work platform elevated, the operator must:

(1) look in the direction of, and keep a clear view of the path of travel, and make sure the path is firm and level;

(2) maintain a safe distance from obstacles (ahead, behind, below, and above), debris, drop-offs, holes, depressions, ramps, and other hazards; and

(3) set the brakes and chock the wheels once stopped.

f. While using the aerial work platform, the operator must not:

(1) use ladders or makeshift devices on the platform to obtain greater height; such practices are prohibited;

(2) climb up or down extendible arms;

(3) sit on or climb on the edge of the basket;

(4) delay reporting any defects or malfunctions to the supervisor; and

(5) engage in stunt driving or horseplay.

7. Procedures for Working in Vertical Trunks. Complete OPNAV 5100/25 Working in Vertical Trunk Check Sheet, prior to commencing work in an elevator, dumbwaiter, or conveyor trunk.

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C8-8 a. Personnel working in vertical trunks must comply with the precautions indicated in this chapter with the exception that life preservers are not required. On scaffolding with guardrails a safety harness is not required.

b. Ensure all staging is correctly constructed and supported chapter B13.

c. When replacing access trunk safety nets and staging has not been installed, work from below the net.

d. Where elevator or dumbwaiter guardrails are not installed or available, safety lanyards must be attached to the platform tie down fitting farthest away from the side of the trunk where work is being performed.

e. Per reference (c), personnel are prohibited from riding on the platform of cargo and weapons elevators in motion unless permission is obtained from the commanding officer, or his or her designee. If movement of an elevator platform cannot be avoided during maintenance, the precautions in the following subparagraphs 7e(1) through 7e(4) must be taken.

(1) Establish effective communication between all personnel before any platform movement.

(2) The preferred method of moving the platform is with the hoist motor de-energized and tagged out, manually releasing the brake.

(3) If releasing the brake will not allow proper positioning of the platform, jogging the platform in only the down direction is the next preferred alternative.

(4) If jogging down will not permit proper positioning of the platform, only as a last resort, the platform may be jogged in the up direction. This movement puts personnel at the greatest risk and should be avoided if at all possible.

OPNAVINST 5100.19F 5 May 2019

C9-1 SECTION C

CHAPTER 9

ELECTRICAL SAFETY, ELECTRONIC SAFETY, AND TAG-OUT PRECAUTIONS

Ref: (a) NSTM 300, Rev 9, Electrical Plant – General (b) NAVSEA S0400-AD-URM-010, Tag-Out Users’ Manual (TUM) (c) NAVSEA S9310-AQ-SAF-010, Technical Manual for Batteries, Navy Lithium Battery Safety Program Responsibilities and Procedures (d) OPNAVINST 5090.1D, Environmental Readiness Program (e) NSTM 555, Volume 1, Surface Ship Firefighting (f) NAVSEA SE 000-00-EIM-100, Electronics Installation and Maintenance Book (EIMB), General Handbook (g) NSTM 634, Deck Coverings

1. Discussion

a. Practically every piece of equipment on board ship requires electrical power. Radars, communication equipment, as well as lighting, portable tools, and personal equipment all use power from the ship.

b. The fact that electrical equipment and tools are so commonplace means that hazards involved with electricity are often taken for granted. This occurs despite the fact that the hazards of electrical shock are commonplace ashore where the extra shipboard hazards of high-powered equipment, unstable work spaces, and saltwater are usually non-existent. Compared to other environments, the potential for electrical shock aboard ship is far greater. Because ships' electrical and electronic systems are ungrounded, personnel and equipment may easily become a path to ground in cases of faulty wiring, resulting in injury, death or damage to equipment.

c. Reference (a) is the primary technical reference for shipboard electrical safety.

2. Definitions

a. "Electrical equipment" includes generators, electrically powered machinery and mechanisms, power cables, controllers, transformers, and associated equipment.

b. "Electronic equipment" includes radars, sonars, radios, power amplifiers, antennas, electronic warfare equipment, computers, and associated controls and peripherals.

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C9-2 3. Electrical Precautions

a. Portable electrical equipment is any device that is hand-held, may be plugged into the ship’s electrical power, and is generally used in a variety of different locations throughout the ship (drills, grinders, vacuums, etc.). All personnel using portable electrical tools will:

(1) wear electrical safety gloves when using electric portable tools in hazardous conditions, such as wet decks or bilge areas;

(2) wear leather gloves over electrical safety gloves when the work being done could damage the rubber gloves;

(3) conduct the required PMS on electrical safety gloves before issue and use, inspect electrical safety gloves prior to storage and store them so they are protected from damage, and not use electrical safety gloves for cleaning, painting, or any purpose other than electrical work;

(4) wear required eye protection when working where particles may strike the eyes;

(5) wear hearing protection (earplugs or circumaural muffs or both) when working with noise hazardous tools or in the area where such work is being conducted;

(6) not use spliced cables on tool cords or extension cords;

(7) not use any portable equipment that has a frayed cord or broken or damaged plug;

(8) make sure that the on and off switch is in the "off" position prior to inserting or removing the plug from the energized receptacle;

(9) always connect the cord of portable electrical equipment into the extension cord before the extension cord is inserted into an energized receptacle;

(10) always unplug the extension cord from an energized receptacle before the cord of the portable electrical equipment is unplugged from the extension cord;

(11) arrange the cords so that they will not create a trip hazard;

(12) never pick up the tool by the electrical cord;

(13) when drilling or cutting through bulkheads, check the opposite side for cables and pipes;

(14) only use electric equipment in explosive atmospheres including gasoline hazard areas if the equipment is approved for such use (explosion proof or intrinsically safe);

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C9-3 (15) not allow cords to run through hatches, chemicals, scuttles, or watertight doors or over sharp objects or hot surfaces;

(16) not join more than two 25-foot extension cords together;

(17) protect the cord to guard against accidental closing of the door or hatch when it is necessary to run electrical leads through doors or hatches, and install chafing gear;

(18) return portable electrical power tools, drop cords, and extension cords to the proper location at the end of the operation or workday to prevent damage to the equipment unless permission is granted to retain overnight;

(19) visually inspect portable cables for any signs of an unsatisfactory condition, such as tears, chafing, exposed insulated conductors, and damaged plugs and receptacles, and cables must be of the proper length and cross-sectional area; and

(20) only use COMNAVSEASYSCOM-authorized extension or trouble lights for shipboard use to eliminate or drastically reduce the many hazards associated with the use of unauthorized commercial grade lights. These lights are intended for temporary use and should not be mounted in any manner. The approved lights most frequently used aboard ships are:

(a) a caged, 100-watt incandescent bulb equipped with 50-foot, three conductor cable for use as a general multi-purpose extension light, NSN 9G 6230-00-701-2947; and

(b) a small 4-watt fluorescent tube for servicing electronic equipment. This light is of all plastic construction with no outside conductive surfaces. It is intended for use in open electronic equipment areas only. It is not explosion-proof and is not acceptable for use in hazardous atmospheres.

b. Do not touch a conductor until it is properly tagged out of service and tested, to be sure it is de-energized or discharged.

c. Obey all warning signs; read equipment warning labels before use.

d. Never work on live (energized) electrical equipment unless in strict adherence with reference (a).

e. Always de-energize and "tag-out" installed electrical equipment before starting any maintenance or repair unless directed by higher authority (Engineering Operational Sequencing System (EOSS), PMS, technical manuals, etc.). Test for energized circuits prior to performing work per reference (a).

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C9-4 f. Do not energize any electrical equipment that is tagged-out. Clear the tag first following reference (b). If a caution tag is installed, ensure compliance with amplifying instructions prior to energizing equipment.

g. Only use authorized equipment to perform maintenance on electrical equipment. Ground all metal-cased electrical equipment, except power tools verified to be double-insulated on the label and by electrical safety check.

h. Close all fuse boxes, junction boxes, switch boxes, and wiring accessories.

i. Use the one-hand rule when turning on electrical equipment. Never operate a switch with the other hand on a metal surface, which would provide a path to ground through the body.

j. Never use outlets that appear to be burnt or damaged. Do not use equipment with worn or damaged cords, or crushed or damaged plugs. They are not to be patched with electrical tape. Turn in such items immediately to electrical tool issue, informing them of the problem.

k. Ensure that "dead-man" switches work properly when installed.

l. Use an authorized voltage indicator to test whether equipment or circuits are energized.

m. Never remove overload relays except for corrective or preventive maintenance.

n. Follow all safety precautions in reference (a) when working on energized circuits or equipment.

o. Never remove overload relays except for corrective or preventive maintenance.

p. Visually inspect portable cables, such as shore power "pigtails," for any sign of an unsatisfactory condition, such as tears, chafing, exposed insulated conductors, and damaged plugs and receptacles. Cables must be of the proper length and cross-sectional area. Do not use spliced portable cables except in emergency conditions, as outlined in reference (a).

q. Only install fuses of the rating specified on a fuse box or panel. Do not over-fuse.

r. Do not use aluminum or metal portable ladders when working on electrical equipment.

s. Use only Navy-approved power strips for computer equipment, printers, and peripherals per reference (a). Never use power strips in series (connected one to another and “daisy- chained”).

t. Wear skin and eye protection when changing out battle lantern batteries.

OPNAVINST 5100.19F 5 May 2019

C9-5 4. Wet Cell Batteries

a. The charging of wet cell batteries will produce hydrogen gas that may be ignited causing fire and explosion. Verify that wet cell battery compartments, which have been sealed, are first opened and well ventilated before entering, turning on any lights, making or breaking any electrical connections, or doing any work in the compartment. Verify that the ventilating apparatus of a wet cell battery compartment is running properly before starting to charge wet cell batteries, and that the exhaust ventilation interlock with the charger is operable. Keep the wet cell battery storage area or compartment well-ventilated during charging. Ensure that battery charging circuit ventilation fans are interlocked so that if power is lost to the fans, the battery charger turns off.

b. While wet cell battery charging is in progress, post a warning placard at the access to the wet cell battery storage area or compartment that reads:

CAUTION

WET CELL BATTERY CHARGING IN PROGRESS

c. Prohibit smoking in the charging area.

d. Prevent open flames, sparks, or electric arcs in wet cell battery charging areas.

e. Keep uninsulated tools and other metallic objects away from the top of uncovered wet cell batteries. When using tools around a wet cell battery, do not allow tools to bridge the wet cell battery terminals or short circuit any part of the wet cell battery. Only tools with insulated handles will be used on the wet cell battery.

f. During normal use, keep cell service openings closed except when they must be opened to take readings or add water. When charging wet cell batteries, completely unscrew the wet cell battery cap, but leave the cap in place on top of the service opening. This will allow hydrogen gas, which is formed during the charging process, to escape but will minimize the release of acid or alkaline mist into the shop atmosphere. Note: This is not applicable to maintenance-free, sealed batteries.

g. Keep cell tops clean.

h. Never stow loose gear in the wet cell battery compartment. Gear such as cleaning rags, hydrometer boxes, pieces of wire, and tools must be removed immediately after use.

i. Charge a wet cell battery only at the rate stated on its nameplate. Never charge a wet cell battery at a higher finishing rate than that stated on its nameplate.

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C9-6 j. When charging several wet cell batteries at once, ensure the voltage of the charging line exceeds the total voltage of all the wet cell batteries being charged, but that the charging rate in amperes does not exceed the maximum charging rate of the wet cell battery in the line having the lowest ampere-hour capacity.

k. Do not operate wet cell batteries above 52 degrees Celsius (126 degree Fahrenheit). When charging wet cell batteries, lower the charging rate immediately if wet cell battery reaches 52 degrees Celsius (126 degrees Fahrenheit) or emits gas.

l. When charging wet cell batteries, keep compartment temperature below 36 degrees Celsius (97 degrees Fahrenheit), if possible.

m. While current is flowing in the charging line, do not attempt to repair the connections of any wet cell battery or connect or disconnect wet cell batteries from the line. Turn current off before attempting any of these procedures.

n. For lead acid batteries (not applicable to maintenance-free or sealed batteries):

(1) Do not add acid of specific gravity greater than 1.350 to a wet cell battery.

(2) Water added to a wet cell battery must be pure distilled water. Never add salt water to a wet cell battery or use salt water to wash out wet cell battery components. Salt water added to a wet cell battery will evolve extremely toxic chlorine gas.

(3) Do not pour water into concentrated sulfuric acid. The heat generated will cause a violent reaction. Sulfuric acid is highly corrosive. Wash up spillage with water and sodium bicarbonate. When handling acid or electrolyte, always wear PPE consisting of a rubber apron, rubber boots, rubber gloves, chemical splash goggles, and a face shield. Store and dispose of battery acid following local hazardous material (HAZMAT) procedures.

o. Do not connect or disconnect batteries in compartments that may contain gasoline vapors. In any use of wet cell batteries, verify that all connections are tight to prevent loose connections that may cause sparks.

p. When wet cell batteries are used with one terminal grounded, always disconnect the grounded terminal first when replacing wet cell battery.

5. Lithium and Mercury Batteries

a. Lithium batteries will not be used aboard ship without specific approval of COMNAVSEASYSCOM, and following reference (c).

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C9-7 b. Primary batteries, especially mercury and lithium batteries, must never be punctured, incinerated or recharged.

c. Dispose of mercury and lithium batteries per reference (d) and local HAZMAT disposal procedures.

d. Turn the battery switch off when battery-driven equipment is not in use or battery charge becomes insufficient to operate equipment. Remove batteries from any equipment that is to be stored or shipped. Cover removed battery terminals with insulating material to prevent short circuits. In the case of equipment powered by dry batteries, remove batteries if equipment is to remain idle for 2 weeks or more. These batteries should be scrapped or stored.

e. Store batteries in an adequately ventilated and cool fireproof area.

f. Ensure alkaline batteries and equipment are segregated from lead acid batteries and equipment.

g. The B section of the Navy type 19026 battery can deliver an extremely serious or fatal shock. Avoid contacting the terminals of this high voltage battery.

6. Electrical Fires

a. For electrical firefighting procedures, see reference (e).

b. Battery fires

(1) A battery fire is nearly always preceded by an explosion. Great care is required fighting such a fire to avoid creating another explosion.

(2) The safest and most effective method for fighting a battery compartment fire is through oxygen starvation. Secure the compartment and stop all ventilation within, including agitation air, to deprive flames of oxygen.

WARNING

Never attempt to extinguish a battery fire by pouring water on the battery. The hydrogen and oxygen generated by electrolysis could produce a violent explosion.

c. Electrical fire prevention

(1) Keep electric motors and generators clean.

OPNAVINST 5100.19F 5 May 2019

C9-8 (2) Ensure proper maintenance is performed on electrical equipment (e.g., motors, generators, bearings, and filters).

(3) Report overheating or arcing electrical equipment.

(4) Keep air filters clean.

(5) Do not overfuse.

7. First Aid for Electrical Shock

a. Fundamentally, electrical current rather than 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 upon the resistance of the body, contact conditions, the path through the body, etc.

b. It is imperative to recognize that the resistance of the human body cannot be relied upon to prevent a fatal shock from 115 volts or even lower voltage; fatalities from as low as 30 volts have been recorded. Tests have shown that body resistance under unfavorable conditions may be as low as 300 ohms and possibly as low as 100 ohms from temple to temple if the skin is broken.

(1) Electrical Shock Symptoms. In the event of severe electrical shock, the victim could become very pale or "bluish." His or her pulse is extremely weak or entirely absent, unconsciousness, and burns are usually present. The victim's body may become rigid or stiff within a few minutes. This condition can be caused by muscular reaction to shock, and it should not be considered as rigor mortis. Therefore, artificial respiration must be administered immediately, regardless of body stiffness, as recovery from such a state has been reported. Consequently, the appearance of rigor mortis will not be accepted as a positive sign of death.

(2) Victim Rescue. The rescue of electrical shock victims is dependent upon prompt administration of first aid.

CAUTION

Do not attempt to administer first aid or come in physical contact with an electrical shock victim before the power is shut off, or, if the power cannot be shut off immediately, before the victim has been removed from the live conductor.

(3) First Aid. When attempting to administer first aid to an electrical shock victim, first proceed as per subparagraphs 7b(3)(a) and 7b(3)(b), then proceed to subparagraphs 7b(3)(c) and 7b(3)(d).

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C9-9 (a) Shut off the power.

(b) If the power cannot be deactivated, per step (a), remove the victim immediately, observing the following precautions.

1. Protect oneself with dry insulating material.

2. Use a dry board, belt, dry clothing, or other available non-conductive material to free the victim (by pulling, pushing, or rolling) from the power-carrying object. Do not touch the victim.

(c) Immediately after removal of the victim from the power-carrying object call for emergency medical assistance team and automated external defibrillator and administer CPR.

(d) When providing first aid measures, take into account any possible spinal injuries or fractures.

8. Electronic Precautions

a. Definitions

(1) Repair. The removal or replacement, by any method, of any component, subassembly, module, circuit card, or conductor to bring malfunctioning equipment back to an operational status.

(2) Corrective Maintenance. The alignment, adjustment, tuning, or trouble shooting of malfunctioning equipment per published maintenance or technical manual procedure.

(3) Preventive Maintenance. The alignment, adjustment, tuning, or testing of operational equipment to ensure performance within published MRC or technical manual procedures.

b. Repair of electronic equipment is normally accomplished with the circuit de-energized. Every effort should be made to avoid making repairs to energized equipment. Do not repair energized electronic equipment unless using approved procedures from technical manuals or the commanding officer has granted permission to perform such repair. In such an emergency, trained personnel must accomplish the repair of energized circuits and an experienced technician or officer must supervise. Electronic repair personnel should observe the safety precautions in references (a) and (f).

c. Corrective maintenance on energized electronic equipment is authorized when done according to published maintenance or technical manual procedures. Freelance corrective maintenance (e.g., without a published procedure) on energized electronic equipment must be

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C9-10 performed only with the specific permission of the commanding officer. Refer to reference (a) for specific safety instructions when performing work on energized equipment.

d. Preventive maintenance on energized electronic equipment is authorized when it follows a published MRC or technical manual procedures. Refer to reference (a) for specific safety instructions when performing work on energized equipment.

e. Perform preventive or corrective maintenance on energized electronic equipment only when authorized by higher authority and trained on that type of equipment. Refer to reference (a) for specific safety instructions when performing work on energized equipment.

f. Whenever work on energized electronic equipment exposes the technician to 30 volts or greater, adhere to the precautions in the following subparagraphs 8f(1) through 8f (11).

(1) Study the applicable schematic and wiring diagrams before servicing.

(2) Research into or enter energized electronic equipment enclosure for the purpose of servicing or adjusting only when prescribed by applicable technical manuals, MRC, or other approved documentation.

(3) Obtain the commanding officer's permission whenever work on energized electronic equipment deviates from published corrective or preventive maintenance procedures.

(4) Station a safety observer capable of securing power and rendering adequate aid in the event of an emergency.

(5) Provide warning signs and suitable guards to prevent personnel from coming in accidental contact with dangerous voltage.

(6) Obey all warning signs and heed all equipment warning labels.

(7) Insulate the work from ground with approved electrical grade rubber matting. Installation requirements for electrical grade matting are contained in reference (g).

(8) Remove or snugly secure any loose clothing. Remove all jewelry.

(9) Insulate all metal tools.

(10) Use only one hand, if practical, in accomplishing the work.

(11) Wear electrical safety gloves on both hands, if possible. If the nature of the work is too cumbersome to wear gloves on both hands, then a glove must be worn on the non-working hand.

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C9-11 g. Reaching into de-energized equipment also requires special care and precaution.

(1) Study the applicable schematic and wiring diagrams before servicing.

(2) Ensure familiarity with all circuits that must be de-energized and all voltage storing and high voltage components.

(3) Discharge all voltage storing components with an approved shorting probe and applicable PPE.

(4) Do not touch a conductor or electronic component unless it has been proven to be de- energized by using a known good voltage tester.

h. Removal of a unit or part from the normal location within an assembly and the energizing of the unit or part, while it is outside the normal enclosure, removes the protective features such as interlocks, grounded, and enclosures. These safety features may then no longer function as designed. Ground the chassis and frame of all units removed for servicing and ground all circuits normally grounded in operation whenever power is applied to the unit.

i. Do not energize any equipment that is tagged-out. Clear the tag-out first. If a caution tag is installed, ensure compliance with the amplifying instructions prior to energizing equipment.

j. Never defeat an interlock or built-in safety device. Modify such safeguard circuits only as authorized by the cognizant system command.

k. Refer to references (a) and (f) for additional precautions regarding electric systems.

9. Electrically and Electronically Safe Work Benches. Electrical and electronic work benches must be constructed and maintained per appendix H of reference (a).

10. Tag-Out. Tagging-out of electrical or electronic energy sources must be conducted per reference (b).

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C10-1 SECTION C

CHAPTER 10

SHIPBOARD FUELS

Ref: (a) NSTM 541, Ship Fuel and Fuel Systems (b) NSTM 542, Gasoline and JP-5 Fuel Systems (c) OPNAVINST 3500.39D, Operational Risk Management

1. Discussion

a. Fuels are used to power the ship, emergency auxiliary equipment, aircraft, vehicles, small boats, and a multitude of smaller pieces of machinery. There are several types of fuels in use, each with its own characteristics and traits. It is impossible to cover all the scenarios that can occur with shipboard fuels; however, this chapter will cover the main points. See references (a) and (b) for additional information concerning fuels.

b. The biggest hazard with shipboard fuels is explosion and fire. Fuels can cause asphyxiation, body burns, eye and respiratory difficulties, and environmental contamination. Due to the incredible impact a shipboard explosion and fire would have, the possibility that a catastrophe could occur should constantly be in the minds of all personnel, especially those involved in fuel storage and transfer operations.

c. Complete an ORM review before refueling operations and mitigate risks, as feasible. Reference (c) contains additional guidance on ORM.

2. Definitions

a. Hazardous areas are locations where hazardous vapors (whether physical or health hazard) could accumulate.

b. Gasoline hazard areas are those areas where gasoline vapors may be present in quantities sufficient to produce explosive or ignitable mixtures. This includes gasoline stowage, handling, and transfer areas, gasoline pump rooms, spaces connected to gasoline hazard area by common ventilation, and up to 15 feet away horizontally from an open gasoline hazard area.

c. Class I flammable liquids are fuels and other liquids with a flashpoint of 100 degrees Fahrenheit (38 degrees Celsius). Class I flammable liquids in contact with air will release flammable vapors under most typical shipboard conditions.

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C10-2 3. General Precautions

a. Never smoke in fuel storage or transfer areas, during maintenance, fueling, or venting operations.

b. Prohibit any open flames, hot work, or the use of non-explosion-proof fixtures or equipment near fuel storage or transfer areas. Fluorescent fixtures are permitted in areas in which JP-5 or F-76 fuel is handled.

c. When working in motor gasoline tanks, the following are prohibited: shoes with steel clips, metal key chains, metal belt buckles, pagers, cell phones, buttons made out of spark producing material, or clothes made of static generating material such as wool, silk, nylon, or Nomex ®.

d. Always ventilate fuel tanks (see chapter A4, subparagraph 3b(2) note) and obtain gas free engineer's certification before entering. Ship’s gas free engineer may certify only for ship’s force entry.

e. Never enter a tank to aid an unconscious crewmember without proper emergency breathing apparatus, such as an SCBA, and a back-up person standing by. The back-up person must also be equipped with the proper emergency breathing apparatus.

f. Detect leaks and make immediate repairs in all fuel systems. Report and clean up pools of leaked or spilled fuel immediately using appropriate HAZMAT or oil spill cleanup equipment and procedures. Dispose of fuel contaminated rags and materials as directed by the HAZMAT coordinator.

g. Inspect tanks, piping, cargo hoses, pumps, and communication equipment before transferring fuel. Ensure a drip pan is under all transfer hose connections and that gaskets are in place in hose joints and couplings.

h. Store oily wastes and rags in an approved container and empty it daily following local HAZMAT procedures.

i. Do not discharge fuel or oily wastes over the side. Do not allow spilled fuel or oily wastes to go over the side. Use rags or absorbent materials to stop fuel from running over the side and report the spill immediately to the supervisor.

j. Avoid physical contact with fuel(s). Remove fuel soaked clothing and thoroughly wash exposed skin after incidental contact. Personnel who suspect that they have ingested or inhaled fuel, or are having a skin reaction to fuel contact, should immediately seek medical attention.

k. Wear eye protection and use respiratory protection if required by the RPPM.

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C10-3 l. When in canisters or drums, flammable fuels must be placed on the weather deck if no flammable storeroom is provided. Gasoline storage must be in remotely jettisonable racks on the weather decks. Do not store near heat sources or near ventilation intakes.

m. Close hatches, doors, and ports in vicinity of tank vents while transferring fuel.

n. During refueling, close and secure all portholes on the engaged side of the ship. Place oil or fuel absorbent materials at deck edge openings and scuppers to prevent spills from running over the side.

o. Ensure exhaust ventilation and gas detection systems are operational in enclosed spaces used for storage, use or handling of low flashpoint liquids prior to entering. Any work in these spaces must include a dedicated fire watch equipped with a charged potassium bicarbonate dry powder portable fire extinguisher or equivalent.

p. Ignition sources are prohibited in hazardous areas containing class I flammable liquids and flammable gases. This includes smoking, open flames, spark producing tools, hot work, electrostatic discharges, and non-approved (i.e., explosion-proof or intrinsically safe) electrical equipment and components.

OPNAVINST 5100.19F 5 May 2019

C11-1 SECTION C

CHAPTER 11

WELDING, CUTTING, BRAZING, AND HOT WORK

Ref: (a) NSTM 074 (Volume 1), S09086-CH-STM-010, Welding and Allied Processes (b) NAVSEA OP-4, Ammunition and Explosives Safety Afloat (c) NSTM 555 (Volume 1), S9086-S3-STM-010/CH-555, Surface Ship Firefighting (d) OPNAVINST 8020.14A, Department of the Navy Explosive Safety Management Policy

1. Discussion

a. The convenience of metal arc and gas welding and cutting lies largely in the fact that the equipment can be taken to the job. This convenience leads to the performance of construction or repair jobs in locations that have not been designed for such concentrated heat, or mixtures of toxic or explosive gases. The failure to take proper precautions, during welding or cutting operations in such spaces, presents a serious fire, explosion, electric shock, and health hazard.

b. Health hazards common to welding, cutting, and brazing are numerous. In addition to electric shock, burns to the eyes and skin can be caused by sparks, molten metal, and ultraviolet and infrared radiation. Fumes and gases generated by welding can produce ozone and oxides of nitrogen which are poisonous. Lead, zinc, chromium, and cadmium in alloys (strips or wire in coils or rods) produce toxic fumes. Paints and coatings may produce toxic gases when heated by the flames of the welding torch. Additionally, some metal fumes are capable of producing metal-fume fever. Local exhaust ventilation is a must to remove excessive concentrations of air contaminants. Welding in closed, unventilated spaces can result in respiratory irritation or poisoning of personnel. Follow chapter A4, subparagraph 3b note, when using portable exhaust ventilation inside the ship.

c. Hot work includes:

(1) flame heating, welding, torch cutting, brazing, or carbon arc gouging; and

(2) any operation which produces temperatures of 400 degrees Fahrenheit or higher.

Note: Operations not producing hot sparks or flames such as spark-producing or arc producing tools or equipment, static discharge, friction, open flames or embers, impact, and non-explosion-proof equipment such as lights, fixtures, or motors are not considered hot work unless occurring in the presence of flammable liquids or in a flammable atmosphere.

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C11-2 d. Hot work is divided into two classes where only class alpha materials, such as ordinary combustibles (wood, cloth, paper, rubber, and many plastics) are exposed. These classes are as per the following subparagraphs 1d(1) and 1d(2).

(1) Class I. These processes produce either high energy sparks or slag that can be thrown or dropped at the work site or produce heat that can be transferred through the deck, overhead, bulkhead, or structure to a location not visible to the hot work operator. This class includes:

(a) flame cutting,

(b) welding,

(c) plasma cutting,

(d) arcing and gouging,

(e) electric arc welding,

(f) thermal spraying, and

(g) other hot spark or flame producing process not included in class II.

(2) Class II. These processes produce flames or minimal energy sparks or slag that is generally localized to the immediate work area. This class includes:

(a) stud welding with an electric stud gun,

(b) gas-tungsten-arc welding,

(c) torch brazing, and

(d) ferrous metal grinding with abrasive disks.

2. General Precautions

a. Clothing and Protective Equipment

(1) Use the appropriately shaded welder’s goggles, welding face shield, or welder’s helmet as required by reference (a) and the IH survey. A respirator may be required if indicated by the RPPM.

(2) Remove lighters from pockets during hot work.

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C11-3 (3) Do not wear synthetic-fiber clothing.

(4) Do not roll up sleeves, cuffs, or have open pockets.

(5) Always wear a welder's jacket or sleeves, apron or leggings, and flameproof boots while welding. Helmets and face shields must be fitted with the proper filter and cover lenses.

(6) Always wear electrical safety gloves with leather outer gloves when removing or replacing electrodes, or handling energized holders, layout tables, or equipment. The gloves must be dry and in good condition.

(7) Consult with the RPPM for specific guidance regarding respirator needs or selection. Cartridge respirators, when properly selected, will protect against metal fumes generated during welding. They do not provide oxygen, which may be necessary when working in a confined space. Metal inert gas and tungsten inert gas welding generate hazardous gases and require adequate ventilation or the use of a supplied air respirator. Follow chapter A4, subparagraph 3b(2) note, when using portable exhaust ventilation inside the ship.

(8) To protect passers-by from ultraviolet arc flash and combustible materials from sparks, use NAVSEASYSCOM-approved welding curtains or panels, as specified in reference (a).

b. Space Precautions

(1) Observe the precautions in the below subparagraphs 2(1)(a) through 2(1)(k) during the performance of hot work.

(a) Do not perform hot work when flammable liquids or flammable atmospheres are present without specific instructions of the gas free engineer.

(b) Inspect the other side of the bulkhead, deck, overhead, or other structure to ensure that hot work will not damage materials or equipment that may be on the other side of the hot work operation.

(c) Remove explosive materials and flammable liquids or vapors and take suitable precautions against the re-accumulation of such materials. For welding in magazines or adjacent to magazines, refer to reference (b).

(d) Where practicable, relocate all combustibles at least 35 feet from the work site. Where relocation is impracticable, protect combustibles with metal guards or curtains constructed of MIL-C-24576 material. Tighten edges of covers at the deck to prevent sparks from going underneath the covers. This precaution is also important at overlaps where several covers are used to protect a large pile of combustibles.

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C11-4 (e) Protect intricate and vulnerable machinery and equipment from falling sparks or other potential sources of fire with metal guards or curtains constructed of MIL-C-24576 material. Secure the protection in-place before commencing hot work.

(f) For hot work processes that generate slag, weld splatter, or sparks, cover openings in decks, bulkheads, or overheads within 35 feet which can be a path to prevent ignition sources from passing into adjacent compartments, spaces, or decks below. A complete containment system as described in reference (a), section 10 meets this requirement. If openings cannot be covered, post a fire watch on the far side.

(g) Blank off ducts and conveyor systems that might carry sparks to distant combustibles or otherwise suitably protect.

(h) When hot work is done near decks, bulkheads, partitions, or overheads of combustible construction, take precautions to prevent ignition.

(i) Do not undertake hot work on pipes or other metal in contact with insulation or combustible decks, bulkheads, partitions, or overheads if the work is close enough to cause ignition by heat conduction.

(j) Do not start hot work in areas other than those specifically designated for hot work, such as welding shops, without approval of the commanding officer or his or her designated representative. Abrasive disk grinding with a small wheel (typically 3-inch diameter or less) does not require notification or approval.

(k) De-energize electrical equipment exposed to the hot work.

(2) Ensure that a gas free engineer's survey has been completed before working in tanks, voids, or other confined spaces, including adjacent spaces (especially if those tanks contained flammable liquids or vapors) if these spaces are identified as a confined space per reference (a).

(3) Notify the DCA or fire marshal before starting hot work.

(4) Conduct hot work in or on fuel tanks, in spaces in which fuel tank vents terminate, or in other confined spaces known to contain flammable fuel, only with the commanding officer's approval.

(5) Set fire watches as per the following subparagraphs 2b(5)(a) through 2b(5)(i).

(a) In confined or enclosed spaces, machinery rooms, catapult rooms, bilges, and other locations proximate to flammable atmospheres (e.g., near fuel tank vents and sounding tubes), post fire watches at the worksite when hot work is undertaken. After completion of the

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C11-5 hot work operation, fire watches must remain on station for a minimum of 30 minutes, ensure the area is cool to the touch, and no smoldering embers remain.

(b) For class I hot work, post fire watches when hot work is undertaken. The fire watches must stand watch for fire for 30 minutes after hot work is completed, or until hot work area is cool to the touch.

(c) For class II hot work, the DCA, fire marshal, or individual designated in writing by the DCA will determine the need for a fire watch in addition to the hot worker based on his or her assessment of the worksite prior to undertaking hot work. When posted, the fire watch(s) must stand watch for 30 minutes after hot work is completed, or until hot work area is cool to the touch.

Note: Abrasive disk grinding on a ferrous material with a large wheel (larger than 3 inches in diameter) typically throws large sparks long distances. A fire watch is recommended for large wheel grinding when class alpha materials (ordinary combustibles) are exposed. The DCA or fire marshal will determine the need for a fire watch.

(d) When a fire watch is not required for class II hot work, the hot worker must have the appropriate fire extinguishing equipment available. The hot worker may leave the site after hot work is completed and after he or she has conducted a thorough survey of the area to check for smoldering fires. When grinding a ferrous material with a large abrasive disk wheel (larger than 3 inches in diameter), the hot worker must stand watch for 30 minutes after the hot work ends, or until hot work area is cool to the touch.

(e) When any type of hot work is being performed on bulkheads, decks, or overheads where sparks or heat transfer may ignite combustibles on the opposite, accessible side, set a fire watch on the far side.

(f) The hot worker and the hot worker’s supervisor are responsible for ensuring fire watches are in place prior to starting work.

(g) Train fire watches per reference (c), section 10.

(h) Equip fire watches with PPE as required for the operation being conducted and anticipated hazards.

(i) When more than one fire watch is required, establish a communication means between fire watches.

(6) Ensure fire extinguishing equipment is available in immediate area. The types of fire extinguishing equipment fire watches must use are specified in reference (c), section 10.

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C11-6 (7) Provide ventilation (see chapter A4, subparagraph 3b(2) note) as specified in reference (a), IH survey, gas free chit, or hot work chit.

(8) Personnel in areas adjacent to welding areas exposed to arc-produced ultraviolet radiation must be protected by providing screens, appropriate eye protection or other approved means.

(9) Never weld near a source of halocarbons, such as chlorinated solvents (e.g., trichloroethane) or refrigerant gases. Phosgene gas can be produced when halocarbons are exposed to high temperatures.

(10) Do not perform hot work during fueling or ammunition transfer operations. Submarine tenders are exempted from this requirement, but must comply with the requirements of reference (d) while performing hot work or ammunition handling.

c. Practices

(1) Never use oxygen to operate pneumatic tools, on oil preheating burners, start internal combustion engines, blow out pipe lines, blow dust from clothing or work areas, create pressure, or for ventilation purposes.

(2) Do not carry oxygen, acetylene, or other fuel gas cylinders into confined spaces. Use leads of an appropriate length to reach the work area while properly securing gas cylinders away from the confined space point of entry.

(3) Always return cylinders to the storage racks when work is completed and ensure cylinders are secured in place by metal retaining collars.

(4) Ground and bond all electrical welding equipment before use.

(5) Stand on a dry surface or insulating material if surface is not completely dry to avoid electric shock.

(6) Never permit the metal part of the electrode or the electrode holder to touch the bare skin or any damp clothing, which the operator may be wearing. Do not loop the welding cable over a shoulder or other parts of the body. Operators have been dragged off staging or scaffolds when the welding cables were fouled by other workmen or moving equipment.

(7) When stopping work for a significant time (lunch or overnight), remove the electrode from the electrode holder, de-energize the equipment and disconnect the welding supply cable from the welding machine.

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C11-7 (8) When using portable machines, ensure the primary supply cables are separately laid out and do not become entangled with welding supply cables.

(9) Inspect work and electrode lead cables regularly for wear and damage. Replace cables with damaged insulation or exposed conductors. Use connecting devices specifically intended for the purpose when joining lengths of supply and electrode cables. Adequately insulate the connecting devices for the proposed service conditions.

(10) Keep welding cables dry and free from grease and oil, wherever practical, to prevent premature breakdown of the insulation which could cause serious short circuits.

(11) Suitably support cables overhead when necessary to run them some distance from the welding machine. If this cannot be done, and cables are laid on deck, protect them in such a manner that they will not be damaged or interfere with safe passage of personnel. Take special care to see that welding supply cables are not close to power supply cables, lighting circuits, or any equipment that utilizes magnetic tapes or depends upon a magnetic principle for operation. Block hatches and doors to prevent damage to welding cables.

(12) Protect welding equipment used in the open from weather conditions (e.g., rain, sleet, snow, spray, etc.) to prevent short circuiting.

(13) Do not smoke cigarettes or use other forms of tobacco while welding or brazing.

d. Cylinder Safety

(1) Store individual cylinders securely fastened in the upright position (valve end up) by metal collars, with each cylinder independently fastened, and ensure that the cylinder valve protection caps are in place.

(2) Store flammable and explosive gases securely on the weather decks protected from direct exposure to the sun or in flammable compressed gas cylinder storerooms.

(3) Never store flammable gases with oxidizing gases. Typical oxidizing gases are oxygen and chlorine. Compressed gases such as helium, CO 2, nitrogen, and argon can be stored with all gases except acetylene, oxidizing or flammable gases. Ensure inert gases are segregated and readily identifiable.

(4) Do not lift cylinders by valve-protection caps. Bars must not be used under valves or valve-protection caps to pry cylinders loose when frozen in place or otherwise fixed. Use warm (not boiling) water to defrost.

(5) Close valves of empty cylinders.

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C11-8 (6) Place cylinders a safe distance away from the actual welding or cutting operation so that sparks, hot slag, or flame will not reach them. Use fire-resistant shields.

(7) Do not place cylinders where they might become part of an electric circuit. Contact with energized equipment must be avoided. Cylinders must be kept away from radiators, piping systems, or layout tables that may be used for grounding electric circuits, such as for arc welding machines. Any practice, such as the tapping of an electrode against a cylinder to strike an arc, is prohibited.

(8) Never use cylinders as rollers or supports, whether full or empty.

(9) Do not change or alter the numbers and markings stamped into cylinders.

(10) Never attempt to mix gases in a cylinder. Unauthorized personnel should never refill a cylinder.

(11) Unless connected to a manifold, do not use oxygen from a cylinder without first attaching an oxygen regulator to the cylinder valve. Before connecting the regulator to the cylinder valve, open the valve slightly for an instant and then close valve. Always stand away and to one side of the outlet when opening the cylinder valve.

(12) Do not use hammers or wrenches to open cylinder valves. If valves cannot be opened by hand, the cylinder should be returned to supply.

(13) Do not tamper with, or attempt to repair, cylinder valves. If trouble is experienced, remove from service, tag as defective, and notify the supplier, indicating the character of the trouble and the cylinder's serial number. Follow supplier's instructions as to its disposition.

(14) Do not remove the stem from a diaphragm-type cylinder valve.

(15) Always place the fuel-gas cylinders with valve end up. Store and ship liquefied gases with the valve end up. Prior to use, store acetylene cylinders in a vertical position for a minimum of 2 hours to stabilize the gas.

(16) Handle cylinders carefully. Rough handling, knocks, or falls are liable to damage the cylinder, valve, or safety devices and cause leakage.

(17) Close the cylinder valve and release the gas from the regulator before the regulator is removed from a cylinder valve.

(18) Do not place anything on top of an acetylene cylinder which may damage the safety device or interfere with the quick closing of the valve.

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C11-9 (19) Never use fuel gas from cylinders through torches or other devices equipped with shutoff valves without reducing the pressure through a regulator attached to the cylinder valve or manifold.

(20) Do not use copper tubing with acetylene gas cylinders due to the potential of an explosive chemical reaction to take place.

3. Extra Precautions for Work in Restricted Access Spaces

a. For the purpose of this paragraph, a restricted space is defined as:

(1) a space with only one exit, and

(2) a space where equipment or structural barriers prevent easy exit or entrance.

b. Ensure proper ventilation (see chapter A4, subparagraph 3b(2) note) is available to permit work in restricted access spaces. When sufficient ventilation cannot be obtained without blocking the means of access, personnel in the confined space must be protected by supplied air respirators. Ensure space has been certified gas free, if the space is unmanned and ventilation is non-existent or the space is used to store HAZMAT.

c. Leave gas cylinders and heavy welding or cutting equipment outside the restricted access space.

d. Station an attendant outside with instructions to observe the welding operator at all times, and in case of emergency, immediately shut off the gas or welding machine and render such help as the occasion warrants.

e. If entering a restricted access space through a manhole or other small opening, provide means for quick personnel removal in case of an emergency. When safety belts and lifelines are used for this purpose, they must be so attached to the body that the body cannot be jammed in a small exit opening.

f. If the access fitting to a restricted access space is remotely controlled, ensure measures are taken to secure and danger tag-out remote-control equipment to avoid accidental closing of doors.

g. If work in a restricted access space is suspended for any substantial period of time, remove electrodes from the holders of arc welding equipment. One of the three precautions in the following subparagraphs 3g(1) through 3g(3) must be taken.

(1) Remove all arc welding equipment from the restricted access spaces.

OPNAVINST 5100.19F 5 May 2019

C11-10 (2) Disconnect all such equipment from the source of power. This must always be done if the equipment is to be left overnight.

(3) Positively insulate all such equipment, including the electrode holder, so that no accidental contacts can be made even if the equipment is moved during this period.

h. In the case of gas welding equipment, always close the torch valves and the gas supply to the torch, when not actually in use, to eliminate the possibility of gas escaping through leaks or improperly closed valves. The gas supply to the torch must be able to be positively secured from outside the space. Torches must remain in restricted-access spaces only for the period necessary to perform the required hot work. Overnight and at the change of shifts, the torch and hose must be immediately removed from confined spaces when they are disconnected from the torch or other gas consuming device.

OPNAVINST 5100.19F 5 May 2019

C12-1 SECTION C

CHAPTER 12

SHIPBOARD AIRCRAFT SAFETY

Ref: (a) NSTM, Chapter 670, Stowage, Handling, and Disposal of Hazardous General Use Consumables (b) NAVSEA OP 3565/NAVAIR 16-1-529/NAVELEX 0967-LP-624-6010, Electromagnetic Radiation Hazards (Hazards to Personnel, Fuel, and other Flammable Material)

1. Discussion

a. This chapter applies to fixed-wing and rotary wing operations on ships that have full flight and hangar decks (CVNs, LHAs, LHDs, LPD 17 class, CGs, DDGs, and LCS).

b. Flight decks are hazardous and the danger to personnel goes beyond the possibility of crashes. Air intakes on jet engines can actually suck personnel off the deck and into the engine. Jet engine exhaust can propel personnel into other objects or over the side of the ship. Propellers and rotor blades can maim or kill. Aircraft carry ordnance and fuel that can cause fires and explosions. Moving aircraft can hit personnel. The ship itself is pitching and rolling. For these reasons, personnel whose job requires them to work on the flight deck must be constantly alert to many hazards to avoid injury or death.

2. General Fire Precautions

a. Smoking

(1) Do not smoke or permit open flames on flight decks, hangar decks, sponsons, and weather decks.

(2) Only smoke in designated smoking areas.

b. Open Flames and Ignition Sources

(1) Do not permit open flames or any other ignition source in the vicinity of flammable liquids, gases, or explosive ordnance.

(2) Provide continuous fresh air or properly designed exhaust systems where flammable vapors are present.

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C12-2 c. Heating Units

(1) Use caution when using approved element space heaters in any part of a hangar deck or in any ship space where a fire hazard exists.

(2) In no case permit such heaters in locations where ignitable concentrations of flammable gases or vapors are likely to exist, or where flammable or explosive substances in the form of gas, vapor, mist, dust or fibers are present.

d. Shoes. Personnel must wear non-sparking, protective steel toed leather safety shoes with non-slip oil and fuel resistant soles in the vicinity of flammable gases and vapors.

e. Stowage of Combustible Rags. Correctly labeled, metal receptacles with metal covers will be provided for the holding of oily rags, solvent soaked waste, and other combustible waste materials for disposal. Receptacles will be emptied daily per local HAZMAT turn-in procedures.

f. Stowage of Combustibles. Approved flammable storage lockers are required for storing combustible materials. See chapter B3 and reference (a) for details.

3. Housekeeping

a. Clean work areas and keep them clean, during and after maintenance evolutions.

b. Keep decks free from oil, grease, and FOD.

c. Properly store compressed air tanks, tools, and equipment after use.

d. Spills

(1) Immediately clean up oil, grease, fuels, and other flammable liquids or slippery substances to prevent injury or fire.

(2) Use drip pans in the hangar during maintenance evolutions to prevent drips and leaks from becoming fire or slip hazards, particularly under aircraft engines.

e. Place hoses, power cords, and similar equipment in their designed stowage areas to alleviate trip hazards. This will also reduce excessive wear and damage to the cords and hoses from traffic and deck abrasion.

4. FOD

a. Prohibit dumping of trash and garbage during launch or recovery operations. Only dump trash from the fantail or designated sponsons.

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C12-3 b. Only use approved flight deck uniforms, cranial headgear and sound attenuators per appropriate Naval Air Training Operating Procedures Standardization during flight operations. Do not wear ball caps, white hats, watch caps, garrison hats, bridge caps, or hard hats on the flight deck, catwalks, or gallery decks during flight operations.

c. Remove any loose objects and jewelry from person prior to entering the flight deck area.

d. Be careful, aircraft jet engines suck up loose objects from the deck or the area immediately adjacent to the intake, including in some cases, personnel who venture too close. Ingestion of articles into engines can cause costly damage, loss of the engine, and injury and death to personnel. Aircraft Naval Air Training Operating Procedures Standardization manuals depict intake and exhaust danger zones.

5. Liquid Oxygen (LOX)

a. LOX. LOX is a pale blue fluid which flows like water. It boils into gaseous oxygen at minus 297 degrees Fahrenheit (-183 degrees Celsius); therefore, it is capable of immediately freezing any object that comes in contact with it. When warmed to ambient temperature, LOX expands as a gas to about 860 times its liquid volume. Therefore, if a volume of the liquid were confined and allowed to warm, it would exert extremely high pressure (up to 12,000 psi). Because of these properties, extra safety precautions must be observed when working with LOX.

b. Fire Protection

(1) Keep the work area and equipment free of oil, grease, or any readily combustible material.

(2) Keep tools and clothing free of oil and grease.

(3) Ensure that the aircraft or the LOX converter when removed from the aircraft and the LOX servicing trailer are grounded and bonded. The grounding conductor must be connected to the frame of the trailer and all metal parts must be bonded together.

(4) Prohibit smoking, open flames, or sparks within 50 feet of liquid or gaseous oxygen servicing trailers that are transferring or storing oxygen. Any combustion in an oxygen-rich atmosphere may be violent.

(5) Mark oxygen generation and storage spaces with a sign reading:

OXYGEN - NO SMOKING - NO OPEN FLAMES -DO NOT BLOCK LOX JETTISON RAMPS, or an equivalent.

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C12-4 (6) Ensure that adequate ventilation is present or supplemental ventilation (see chapterA4, subparagraph 3b(2) note) is provided when transferring LOX to avoid an oxygen-rich atmosphere.

(7) Do not spill LOX on deck areas. In case of accidental spillage, the area should be thoroughly ventilated and all unnecessary personnel must evacuate the area.

(8) Ensure that a fully operational fire extinguisher is immediately available in the LOX handling space.

(9) Ensure that only approved non-sparking tools are used when working on LOX equipment.

c. Freezing Precautions

(1) The extreme cold of LOX will instantly produce burns if LOX comes into direct contact with the skin.

(2) Frostbite or freezing will occur if the skin comes into contact with surfaces that have been cooled by LOX.

d. Protective Clothing. The possibility of exposure from accidental spillage of LOX exists; therefore, wear the following protective clothing listed in subparagraphs 5d(1) through 5d(4).

(1) Face and eye protection.

(2) White cuff-less coveralls.

(3) Hand protection made of leather.

(4) Molder's (style, slip on) safety shoes.

Note: Ensure that all protective clothing worn is clean and free of oil, grease, and FOD.

e. Handling Precautions

(1) Wear clean, dry leather gloves offering insulation to cold, when handling parts of equipment that have been cooled by LOX. In the event rubber or neoprene gloves are used, wear a covering glove or an interlining glove in conjunction with the molded glove.

(2) Only handle the tubing or fittings through which the LOX is flowing when necessary, wearing insulated gloves or other devices for protection against freezing.

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C12-5 (3) Do not permit LOX to flow onto any part of the body, clothes, pockets, or cuffs where it might be trapped.

(4) In the event the LOX is spilled on clothing, remove the clothing immediately and thoroughly air to allow dilution of the oxygen concentration.

(5) When an un-insulated container of LOX is touched, or when there is any reason to suspect some part of the body has been frozen or chilled through contact with LOX, thoroughly wash the area with clean water and immediately seek medical treatment.

(6) Ensure that at least two persons conduct LOX operations.

(7) Protect LOX storage containers, piping, valves, regulating equipment and other accessories against physical damage and tampering.

6. Arresting Gear and Barricades

a. Unauthorized personnel must remain clear of the walkways, arresting gear machinery, spaces, and equipment.

b. During arresting gear maintenance evolutions, all personnel must remain clear of the bight of the wire. Only authorized personnel will work on arresting gear.

7. HERO. Follow approved HERO omission control procedures per reference (b).

OPNAVINST 5100.19F 5 May 2019

C13-1 SECTION C

CHAPTER 13

MACHINERY

1. Discussion

a. Machinery is located everywhere in the ship, from the more obvious examples of propulsion equipment in the engine room, to the less than obvious example of galley equipment. This chapter defines precautions for all types of machinery. Chapter C9 covers electrical safety precautions. Galley equipment is described in chapter C19.

b. All machinery has moving parts. The fact that moving parts are present means that the possibility of personnel injury is also present. While personnel injury is one aspect of machinery injury, the fact that a person has interrupted the machinery process can lead to even more disastrous mishaps.

c. Except in emergencies, and then only when no qualified operator is present, no person will operate, repair, adjust, or otherwise tamper with any machinery unless assigned by a competent authority, (for example, OOD, CDO, or engineering duty officer), to perform a specific function on such machinery. No person will be assigned to operate or adjust machinery unless he or she has demonstrated a practical knowledge of its operations and repair and all applicable safety precautions, and then, only when qualified by the department head having cognizance over such machinery. Unqualified personnel will operate machinery only under the supervision of qualified personnel.

2. General Precautions. Personnel must observe the following safety precautions and adhere to the SOPs for individual machine or ship system operations.

a. Never place any part of the body into moving machinery.

b. Never attempt to ride machinery that is not designed for transport, such as vertical package conveyors or weapons elevators.

c. Do not wear jewelry (e.g. rings, watches, necklaces, bracelets, loose fitted clothing, cell phones or other electronic devices while operating machinery).

d. Wear proper protective clothing and equipment suited to the operation being performed as required by technical manual or current IH survey (e.g., hearing protection, eye, hand and foot protection, respirators), or if indicated by the RPPM.

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C13-2 e. Observe manufacturer's safety precautions on the SDS and warning labels when handling flammable or toxic liquids; in particular, ensure that ventilation is adequate, and wear appropriate PPE. Wear proper personnel protective equipment such as goggles, gloves and respirators, as recommended in the current IH survey or if indicated by the RPPM.

f. Use only hand tools and work lights that are in good material condition. Electrical tools and lights must be used only if inspected and approved. Special non-sparking and explosion- proof electrical equipment may be required in the presence of flammable solvents and fuels.

g. Use electrical tools and lights only if inspected and approved. The DCA may require non-sparking and explosion-proof electrical equipment.

h. Ensure that equipment is de-energized, depressurized and properly tagged out of service before attempting to perform repairs or preventive maintenance.

i. Ensure machinery, hand tools, and electrical equipment are properly grounded prior to operation.

j. When working near electrical equipment or electrical cables, be alert to the presence of dangerous voltages and avoid striking such equipment with tools of any kind. Should such damage inadvertently occur, report it immediately to the chain-of-command and ship's electrical officer.

k. Do not use compressed air to clean personnel, clothing, or to perform general housekeeping in lieu of vacuuming or sweeping. Compressed air may be used to clean machinery parts that have been properly disassembled provided that the supply air pressure does not exceed 30 psi or the nozzle is equipped with a 30 psi limiter. Wear safety goggles when using compressed air for approved cleaning.

l. Do not store in-use quantities of paints, solvents, acids, or corrosives in unapproved containers or cabinets. Ensure material compatibility and proper labeling. Follow HAZMAT policies established for the ship.

m. Return closed, authorized containers of flammable consumables to approved storage lockers, the ship’s HAZMINCEN, or to the flammable liquid storeroom or paint locker at the end of each working day.

n. Keep containers of flammable, volatile fluids and adhesives tightly closed when not in use.

o. Supervisors must ensure that anyone who incurs any type of injury or who experiences any adverse health effect during or immediately following work activities receives prompt medical attention.

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C13-3 p. Promptly reinstall shaft guards, coupling guards, deck plates, handrails, flange shields, and other protective devices removed as interference immediately after completion of maintenance on machinery, piping, valves, or other system components.

q. Do not use LP air to unclog flammable fluid piping systems unless a specific directive or approved procedure requires its use.

3. Maintenance

a. Ensure that all installed safety devices, alarms, and sensors are inspected and tested per scheduled PMS and other TYCOM requirements.

(1) Assign the repair of defective safety devices a high priority.

(2) Correct oil leaks at their source. Wipe up spills of any kind immediately and store the wiping rags in fire safe containers. Dispose of oily rags daily per the ship’s HAZMAT turn-in procedures.

(3) Avoid trip hazards by maintaining proper stowage.

(4) Do not allow fire hazards to accumulate.

(5) Ensure that all firefighting equipment is kept in a maximum state of readiness at all times.

(6) Ensure repair lockers are properly outfitted and restored after each use.

(7) Continually monitor fire and flooding alarm panels. No alarm or flag must be allowed to go uninvestigated. Alarm panels known to give false or spurious indications must either be labeled and repaired or replaced as soon as possible.

(8) Piping systems that have been opened for maintenance (after having been properly isolated and tagged-out of service) must not be left open overnight. Install appropriate metal blank flanges if a section of piping has to remain open overnight or for any extended period of time. Add such temporary openings to the list of items to be checked by the below decks, shutdown roving watch, or space watch for the duration of the maintenance period.

(9) Open all drains and vents to all drums and headers before loosening manhole or handhold plates. Stand clear of such fittings when initially opening them after service.

b. When maintenance exceeds boundaries of PMS, appropriate supervisors must ensure the quality assurance documentation and procedures are followed.

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C13-4 4. Industrial Equipment

a. General Industrial Equipment Operation and Repair Safety

(1) Read manufacturer's instruction books for essential details of readying machines and equipment for operation, cleaning, lubricating, and general care and maintenance. These instruction books, supplemented by technical handbooks, provide comprehensive instructions on all phases of shop practice.

(2) Inspect before operating industrial equipment (fixed or portable) to ensure that the equipment is in good working condition and that all installed or attached safety features (such as guards, limit switches, interlocks, and speed limiting controls) are in place and in good working order.

(3) Unplug or disconnect from power source and affix a red tag (DANGER - DO NOT OPERATE) on all fixed or portable industrial equipment requiring repairs.

(4) Unplug or disconnect from power source when changing industrial equipment parts such as faceplates or chucks on lathes, drill bits in electric drills, or saw blades. Open and Danger tag the power source circuit breakers of fixed industrial equipment that are “hard wired.”

(5) Block up ram where applicable and open the switches and red tag (DANGER - DO NOT OPERATE) on power shears, drills, punches, and presses when it becomes necessary to place any part of the body under or within the equipment.

(6) Replace machine guards and safety devices after repairing, oiling or greasing, or after inspections or PMS have been completed before the machine is started or operated.

(7) Remove all industrial tools or test equipment used in making repairs, adjustments to machinery, or other shipboard equipment or systems so that all working parts of the machinery, equipment, or system will be free to operate without damage.

(8) Take care that no one is in a position to be injured when the machinery, equipment, or system is again set in operation.

(9) Be sure all personnel are clear before starting any industrial tools or equipment.

(10) Do not permit anyone to operate electrical or mechanical equipment or machines in any space when alone.

(11) Make sure there is plenty of light to work by before operating a machine.

(12) See that tools and work are properly clamped before starting a machine.

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C13-5 (13) Place or mount a saw, cutter head, grinding wheel, or tool collar on a machine arbor only when the tool is the proper size to fit the arbor.

(14) Ensure each powered machine has a means of cutting off power which can be safely reached and operated from the operator's normal position, without reaching through the point of operation or other hazardous areas.

(15) On machines where injury to personnel might result if motors were to restart after power failures, check that provisions have been made to prevent machines from automatically restarting upon restoration of power.

(16) Make sure that operating controls, including treadles, are protected by recessing, guarding, location, or other effective means against unexpected or accidental activation of the machine.

(17) The point-of-operation is the area of a machine where the work is actually performed upon the material being processed. Check that the point-of-operation is guarded so that personnel cannot be injured by contact with the machine or by flying objects propelled from the machine. Methods of point-of-operation guarding include barriers, shields, interlocks, automatic feed and removal, and two-hand activation devices. The best guarding device is usually one designed and attached by the manufacturer as an integral part of the machine. The selection and design of guards other than those provided by the manufacturer must be adequate to protect personnel and not present a hazard in themselves.

(18) Power transmission devices include belts, chains, pulleys, shafting, fly wheels, gears, sprockets, and any other moving parts of a machine other than the point-of-operation. Ensure that power transmission devices are enclosed within the machine or otherwise guarded or so located that it is not possible for personnel to contact the moving parts. Power transmission devices over 7 feet above the deck or other standing or walking surface need not be guarded.

(19) Ensure all warning and caution signs, for eye hazards, noise hazards, pinch points, etc., and machine safety precautions are posted within sight of the machine operator. Machine safety precautions may be posted using standard stock placards or excerpts from technical manuals. Ensure caution areas and eye hazard areas around the machine are marked as defined in chapter C1.

b. Housekeeping

(1) Keep areas around machines clear of obstructions and in a non-slippery condition. Clean up all spilled oil or grease immediately.

(2) Keep machines clean.

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C13-6 (3) Do not clean chips from the surface of machines with compressed air or with hands; use a brush or hook and wear leather gloves.

(4) Do not use compressed air to clean clothing or to blow dust off the body or to assist in the cleanup of dust, debris, or other particulate matter.

(5) Do not place hand tools on lathes or other machines. Keep them in their assigned location.

(6) Turn off all power to the equipment before removing chips and other debris.

(7) Ensure all portable tools (electrical or pneumatic) have been tested prior to initial use and periodically, as prescribed by PMS or other data.

(8) Ensure that all machine guards and other safety devices are in place prior to equipment operation.

c. Portable Power Tools

(1) Ensure all portable electric power tools have a current safety inspection by the electrical tool issue room prior to use.

(2) Ensure that portable circular saws, electric or pneumatic chain saws, and percussion tools without positive accessory holding (e.g., equipped with a constant pressure switch that will shut off the power when the pressure is released) are equipped with an operable "dead-man" switch.

(3) Keep portable power tools clean, lubricated, and in good repair.

(4) Keep all electrical cords clear of moving parts when using portable electrical equipment around machine tools.

(5) Wear and use the required PPE, such as hearing or sight protection, for those tools and equipment requiring PPE.

d. Operating Precautions – General

(1) Remove chuck keys, wrenches, or other devices used to attach accessories to industrial machines before operating.

(2) Do not attempt to adjust a tool or feel the edge to be cut while the equipment or tool is in motion.

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C13-7 (3) Never attempt to stop or grab by hand or apply a wrench or tool to moving work or to moving industrial-equipment parts.

(4) Do not use hangers to knock cutters into positions.

(5) Never lean against a machine that is running.

(6) Never leave moving machinery unattended.

(7) Do not distract the attention of a machine operator.

(8) Remove cutting tools from machines when not in use.

(9) Avoid excessive cutting speeds, feeds, and depth of cut. Keep hands clear of moving parts. Use a separate block to feed stock into cutting blades.

(10) Never operate equipment without all guards in place.

e. Securing for Sea. When securing for sea, take all precautions to ensure that components of industrial equipment or tools, including accessories, will not sway or shift with the motion of the ship. These precautions should include, but are not limited to, the following in subparagraphs 4e(1) through 4e(8).

(1) Lower the arm of top-heavy equipment, such as a radial drill press, to rest on the table or base of the machine and then clamp and block securely.

(2) Secure chain falls, trolleys, overhead cranes, and other suspended equipment, such as counterweights on boring mills and drill presses.

(3) Secure tailstocks of lathes.

(4) Secure spindles of horizontal boring mills.

(5) Protect and secure tools stowed in cabinets or drawers. Secure drawers and cabinet doors. Where possible, install metal bands or fixtures vice using line to temporarily secure equipment. Secure all bar and sheet-metal stock and use caution when handling or moving while underway.

(6) Inspect foundation bolts of heavy equipment per PMS to ensure tightness.

(7) While underway or while at anchor in high sea states, do not operate shop machines whose components are subject to shifting or swaying with the motion of the ship, so as to present a hazard to operators, without permission of the commanding officer.

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C13-8 (8) Do not perform operations such as the melting and pouring of metal or similarly dangerous evolutions while the ship is underway.

f. Posted Safety Precautions and Deck Markings

(1) Post operating instructions and safety precautions tailored to the specific equipment at each piece of industrial plant equipment. Install warning plates, located to ensure visibility, wherever necessary to minimize possible injury. Also, include instructions to never allow machines to run unattended and not to distract the operator while the machine is in operation. Posting may be accomplished using standard stock placards or excerpts from technical manuals.

(2) Clearly establish and mark equipment hazard areas or zones per chapter B5 ship's plans and specifications, and IH survey.

g. Safety Precautions for Specific Types of Equipment

(1) Pneumatic Tools – General

(a) Wear and use necessary personnel protective devices, especially eye and hearing protection.

(b) Do not connect or drive pneumatic tools by air pressure in excess of that for which the tools are designed.

(c) Only authorized and trained personnel will operate pneumatic tools.

(d) Lay pneumatic tools down in such a manner that no harm can be done if the switch is accidentally tripped. Do not leave idle tools in a standing position.

(e) Keep pneumatic tools in good operating condition and thoroughly inspect them at regular intervals with particular attention given to on-off control valve trigger guard (if installed), hose connections, guide clips on hammers, and the chucks of reamers and drills.

(f) Pneumatic tools and airlines may be fitted with quick disconnect fittings which incorporate automatic excess flow shut-off valves, which shuts off the air at the airlines before changing grinding wheels, needles, chisels, or other cutting or drilling bits.

(g) Only use air hoses suitable to withstand the pressure required for the tool. Remove leaking or defective hoses from service.

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C13-9 (h) Do not lay hoses over ladders, steps, scaffolds, or walkways in such a manner as to create a trip hazard. Where a hose is run through doorways, protect the hose against damage by the door edge. Preferably, elevate air hose over walkways or working surfaces in a manner to permit clear passage and prevent damage to the hose.

(i) Connect a tool retainer on each piece of equipment that, without such a retainer, may eject the tool.

(j) Ensure that all portable pneumatic grinders and reciprocating saws are equipped with a safety lock-off device. The lock-off device must automatically and positively lock the throttle in the off position when the throttle is released.

(k) Pneumatic tool air hose fittings must not be interchangeable with the hose fittings designated for airline respirators.

(l) Ensure that air hoses are equipped with "quick disconnect" fittings at all hatches, doors, or scuttles.

(2) Pneumatic Hammers

(a) Do not point any pneumatic hammer at other personnel. Operate hammers in a careful and safe manner at all times.

(b) Ensure that all hammers are equipped with a device for holding the tool bit in the hammer. Inspect safety tool holders at frequent intervals per PMS.

(c) Do not restrict the air exhaust in any fashion.

(d) Ensure that all pneumatic hammers are equipped with a handgrip safety switch (dead-man switch).

(e) Use pneumatic hammers only for those purposes for which designed.

(f) When operating a power hammer, wear necessary eye, face, ear, and body protection, including gloves.

(3) Power Saws. In addition to the general precautions for portable electric and pneumatic tools contained in this instruction, observe the precautions in the following subparagraphs 4g(3)(a) through 4g(3)(x) for electric and pneumatic saws.

(a) Provide all circular power saws with guards that fully encompass the unused portion of the blades.

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C13-10 (b) Ensure that qualified personnel install circular saw blades.

(c) Only use portable electric or pneumatic saws that have handgrip "dead-man" switches installed.

(d) Grasp portable power saws with both hands and hold firmly against the work. Take care that the saw does not break away, thereby causing injury.

(e) Disconnect the power supply and inspect the blade at frequent intervals or immediately after it has locked, pinched, or burned.

(f) Inspect and remove potential obstacles from the material to be cut before using a saw.

(g) Immediately remove dull, badly set, improperly filed, or improperly tensioned saws from service before they can begin to cause the material to stick, jam, or kickback when it is fed to the saw at normal speed.

(h) Immediately clean saws when gum or pitch has adhered to the sides. Disconnect power before cleaning.

(i) Keep bearings well lubricated.

(j) Keep arbors of all circular saws free from play.

(k) Only trained and designated personnel will sharpen or tension saw blades or cutters.

(l) Maintain cleanliness around woodworking machinery, particularly as regards the effective functioning of guards and the prevention of fire hazards in switch enclosures, bearings, and motors.

(m) Remove all cracked saws from service.

(n) Do not permit the practice of inserting wedges between the saw disk and the collar to form what is commonly known as a "wobble saw.”

(o) Provide push sticks or push blocks at the work place in the several sizes and types suitable for the work to be done. Push sticks, blocks, or other special hand tools are not substitutes for guards. Keep all required guards in place and operable when push sticks or blocks are used.

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C13-11 (p) On band saws, ensure all portions of the blade are enclosed or guarded, except for the working portion of the blade between the bottom of the guide rolls and the table. The portion of the guard between the upper-saw-wheel guard and the guide rolls must guard the front and outer side of the blade and must be adjustable to move with the guide as it is raised and lowered. When the band saw is in use, position the adjustable guard to maintain the minimum clearance between the guide rolls and the material consistent with free movement of the material being cut.

(q) To avoid vibration, welded joints in band saws must be the same thickness as the saw blade.

(r) Ensure that each circular table saw is guarded by a hood that completely encloses the portion of the saw above the table and above the material being cut. Mount the hood so that it will automatically adjust itself to the thickness of, and remain in contact with, the material being cut. An approved clear plastic guard cantilevered over the saw table may be used as an alternative to the enclosing hood. The plastic guard must be large enough and set low enough to prevent the hands of personnel from contacting the blade.

(s) Make sure that each hand-fed rip saw has a spreader mounted in a position 1/2 inch from the back of the largest saw which may be mounted on the machine. The spreader prevents material from squeezing the saw and being thrown back on the operator. The spreader must be thinner than the saw kerf and rigid enough to resist side thrust and bending. The spreader is not required for grooving, dadoing, or rabbeting but must be replaced immediately upon completion of such operations.

(t) Check that each ripsaw, including hand-fed rip saws with spreaders, is provided with non-kickback fingers or dogs to prevent material from being thrown toward the operator.

(u) Ensure that self-feed circular saws have a hood or guard that will prevent the operator's hands from contacting the nip point of the feed rolls.

(v) Verify that radial saws are guarded, as required by the following in subparagraphs 4g(3)(v)1 through 4g(3)(v)4.

1. The upper portion of the blade, including the arbor, must be completely enclosed by a hood. The sides of the lower portion of the blade must be guarded to the full diameter of the blade by a guard that will automatically adjust to the thickness of the material being cut.

2. The work surface must be wide enough, or a stop must be provided, to prevent the cutting head from traveling to a point where the blade extends beyond the outer edge of the table.

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C13-12 3. The unit must be tilted back or counterweights must be provided so that the cutting head will return to the starting position when released.

4. Ripping and ploughing with a radial saw must be against the direction that the saw rotates. The direction of rotation must be conspicuously marked on the hood. A label must be affixed to the rear of the hood reading, "DANGER: Do not rip or plough from this end." Non-kickback fingers must be provided for ripping and ploughing operations.

(w) Inspect saw blades by non-destructive, PMS test methods for surface cracks and defects.

(x) Ensure sawdust collectors are properly attached prior to use of wood saws and are in serviceable condition. Empty sawdust from the collector bags per the manufacturer’s instructions.

(4) Sanding Machines

(a) Carefully inspect all sanders before use. Do not use sanding discs or belts if they are frayed or cracked.

(b) Use eye protection during sanding operations and while cleaning up. Consult the IH survey and the RPPM about the need for respirators while sanding or cleaning dust collectors. Operate dust-collecting systems for sanders, if installed, when sanding is in progress.

(c) Keep hands or other parts of the body from coming into contact with the abrasive surface of the sander.

(d) Grasp portable hand-held sanders with both hands and hold firmly against the work. Take care that the sander does not break away, thereby causing injury or damage.

(e) When permanently mounted sanders are used, grasp the work firmly and hold it to the sanding surface carefully to avoid finger contact with the sanding belt or disc. Sand small pieces of work that would bring the fingers within 1 inch of the belt or disc surface by hand, rather than on powered sanders.

(f) For portable sanders and fixed sanders having electric plugs, pull the electric plug before sanding belts or discs are changed or before repairs or adjustments are made to the sander. Open and danger tag the power source circuit breaker of fixed sanders that are "hard wired" before making repairs or adjustments or changing belts or discs.

(g) Ensure each belt sanding machine has both belt pulleys enclosed in such manner as to guard the points where the sanding belt runs onto the pulleys. Enclose the unused run of the sanding belt. Adjust belt type sanders to the proper tension.

OPNAVINST 5100.19F 5 May 2019

C13-13 (h) Ensure coast down brakes, where installed by the manufacturer, are in good working condition before commencement of sanding and use them to stop belt or disc motion after the power is secured.

(5) Buffers, Grinders, and Cut-Off Wheels – General

(a) Check the spindle speed of the machine before mounting of the wheel to be certain that it does not exceed the maximum operating speed marked on the wheel.

(b) Gently tap wheels with a light non-metallic implement, such as the handle of a screwdriver for light wheels, or a wooden mallet for heavier wheels, immediately before mounting. Do not use if they sound cracked (dead). This is known as the "ring test." It should also be noted that organic bonded wheels do not emit the same clear metallic ring as do vitrified and silicate wheels.

(c) Wheels must be dry and free from sawdust when applying the "ring test," otherwise the sound will be deadened.

(d) Dress or replace wheels that are chipped, have imbedded non-ferrous material, are rounded, or worn out of round prior to using the grinder.

(e) Replace fabric buffer wheels that are frayed or worn out of round.

(f) Replace wire buffer wheels that are badly worn or loose at the hub.

(g) Permanently mounted buffers and grinders must have a shatterproof safety shield in place between the operator's eyes and the work at all times while buffing and grinding. Wear eye and hearing protection (if posted as noise hazardous) when operating either portable or permanently mounted buffers or grinders.

(h) Clean the flange surface of grinding and buffing wheels, normally placed between washers and the spindle hole, before mounting the wheel so that clamping pressure will be evenly distributed.

(i) Ensure that the hole in the buffer or grinding wheel is of the proper size for spindle (neither too small nor too large).

(j) Use compression washers as large as the flanges in diameter for buffer and grinding wheels.

(k) Tighten spindle nuts just enough to keep the buffer or grinding wheel from moving out of position between the washers.

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C13-14 (l) Mount tool or work rests on firm supports and space not more than 1/8 of an inch from the surface of grinding wheel. Ensure any dust collection bags, of non-flammable material, are in place and emptied regularly.

(m) Ensure the hood around grinding wheels is constructed so its periphery can be adjusted to the constantly decreasing diameter of the wheel by means of an adjustable tongue or equivalent. Maintain the distance between the wheel periphery and the tongue or end of the periphery band at approximately 1/4 of an inch.

(n) Ensure that the upper point of opening in the grinding wheel hood facing the operator is not less than 25 degrees and not more than 65 degrees from a vertical line drawn through the spindle center.

(o) Ensure that the maximum exposure of a grinding or cut-off wheel periphery or circumference for hoods on a swing frame machine does not exceed 180 degrees and the top half of the wheel is protected at all times.

(p) Ensure that the maximum exposure of the wheel periphery or circumference on bench or floor stands does not exceed 90 degrees.

(q) Protect cup type wheels used for external grinding by either a movable cup guard or a band type guard. Provide all other portable abrasive wheels used for external grinding with safety guards (protection hoods), except as follows:

1. When the work location makes it impractical, use a wheel equipped with safety flanges.

2. When using wheels 2 inches or less in diameter, securely mount the wheel on the end of a steel mandrel.

(r) When safety flanges are required, use them only with wheels designed to fit the flanges. Use only safety flanges of a type and design and properly assembled as to ensure that the pieces of the wheel will be retained in case of accidental breakage.

(s) Ensure portable abrasive wheels used for internal grinding are provided with safety flanges (protection flanges), with the exceptions in the following subparagraphs 4g(5)(s)1 and 4g(5)(s)2.

1. When wheels are 2 inches or less in diameter, securely mount on the end of a steel mandrel.

2. If the wheel is entirely within the work area being ground.

OPNAVINST 5100.19F 5 May 2019

C13-15 (t) Ensure that all deck or bench mounted abrasive wheels have a work rest. Keep the work rest adjusted to within 1/8 inch of the wheel periphery to prevent the work from being jammed between the rest and the wheel.

(6) Operating Grinding, Buffing, and Cut-off Wheels

(a) Stand to one side of the wheel when first applying power.

(b) Take care that the hands are not drawn into contact with buffing, grinding, and cut-off wheels.

(c) Never operate stationary grinding wheels unless protective eye guards and hooks are in their place and the tool rest is correctly adjusted. Wear eye and face protection.

(d) Never operate portable pneumatic or electric grinding machines using wheels and wire brushes without a hood.

(e) Before the power is turned on, check to ascertain that the wheel runs true, is not out of balance, and does not strike or rub against housing, hood, safety shield, or tool rest. Dress wheels as necessary.

(f) Never use a grinding wheel on nonferrous materials. Nonferrous materials could build up on the wheel causing an imbalance condition, over-heating, or possible debris hazard. Dress grinding wheels that have excessive imbedded non-ferrous material.

(7) Industrial Slotted Hoods. Dip tanks, and varnish tanks may be equipped with local exhaust ventilation, usually in the form of slotted hoods, based on the hazardous chemical gas, vapor or mist that is expected to be generated during the operation or released when the tank is opened. A slotted hood removes gas, vapor or mist at the point of generation before the contaminant reaches the user’s breathing zone.

(a) Ensure that local exhaust ventilation is operational prior to using. Know where the controllers are for local exhaust systems. If the system is not working properly, notify the supervisor.

(b) Ensure the slots on the hood area are not obstructed.

(c) Follow the posted operating instructions and safety precautions for the dip tank or washer and never put other than approved chemicals or cleaners into the tank.

OPNAVINST 5100.19F 5 May 2019

C13-16 (8) Drill Presses. Stationary, mounted drill presses must be equipped with guards to prevent injury from shattering drill bits or chips of material. Telescoping drill bit guards, which cover the drill bit as it is lowered and raised during use, are required for all drill presses.

(9) Parts Washers and Pollution Prevention Equipment. Enclosed parts washers, ultrasonic cleaners, degreasers, and other pollution prevention devices used in workshops will be provided with local exhaust ventilation and must have posted safety precautions. For top loading aqueous parts washers located in well ventilated areas, additional local exhaust ventilation will not be required since the equipment only emits a small amount of water vapor.

OPNAVINST 5100.19F 5 May 2019

C14-1 SECTION C

CHAPTER 14

ORDNANCE

Ref: (a) NAVSEA OP 4, Ammunition and Explosives Safety Afloat (b) NAVSEA OP 3565/NAVAIR 16-1-529, Volume 2, Electromagnetic Radiation Hazards (U) (Hazards to Ordnance) (U) (c) SW394-AF-MMO-090, Vertical Launching System MK 41 MODS 0/2/7/15/31 (d) C14-4. SW393-C0-MMM-A10, Decoy Launching System MK 53 MODS 3, 4, 5, 6, 7 and 8 (e) S6340-AA-MMA-010, Technical Manual for OTTO Fuel II (f) SW300-BC-SAF-010, Clearing Live Ammunition from Guns (g) SW323-F2-MMO-010, 5-Inch 54 Caliber Gun Mount MK 45 Mod 2

1. Discussion

a. All ships that support the United States Navy carry ordnance that can be used offensively, defensively, or to provide safe for sea capability. Ordnance is identified by family groups which include aircraft egress systems, air missiles, bombs, bulk explosives material, cartridges, cluster bombs, containerized explosives, demolition material, expendable countermeasures, fire bombs, fixed gun ammunition, grenades, landing force operation reserve material, mines, paraflares, practice bombs, precision guided munitions, projectiles, propelling charges, pyrotechnics, rockets, small arms ammunition, sonobuoys, underwater sound signals, sub-surface missiles, surface missiles, tactical air launched decoy vehicles, targets and torpedoes.

b. The greatest danger from ordnance is an explosion. Loss of life can be expected and propagation may result in progressive flooding of shipboard compartments leading to a catastrophic event. There is a great deal of safety built into weapon design that can include thermal coating to protect from fire, electrical, and mechanical safety interlocks to prevent premature arming and as a result of shipboard ordnance accidents occurring in the decade of the 1960’s, the Navy has established a program to reduce the sensitivity of explosives and related material through development of insensitive munitions technologies and subsequent incorporation of those technologies into munitions. The major safety factor in preventing an ordnance catastrophe is using only qualified and certified personnel who have gone through a great deal of training and are under constant supervision that understands ordnance safety. A proactive explosives safety culture that resonates down from the commanding officer to junior ordnance handler is a must.

2. General Ordnance Precautions

a. No smoking, matches, lighters or open flames.

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C14-2 b. Per reference (a), no hot work to the space or boundaries with ordnance present unless the hot work procedures are followed.

c. No eating or drinking.

d. Do not sit or stand on any ordnance.

e. Competition with other handling parties is prohibited.

f. Horseplay is prohibited.

g. No unauthorized equipment will be used.

h. Any unusual conditions of the ordnance such as leaks, moisture damage, odors or shifting in stowage must be reported to supervisory personnel immediately.

i. Handling of ordnance must be kept to a minimum.

j. All ordnance must be secured against ship’s movement.

3. General Safety Regulations for Ordnance, Weapons Systems, and Launchers

a. Per reference (a), ammunition and explosives operations on flight decks, exposed weather decks and other locations directly exposed to the weather must be halted when electrical storms are within a 5 nm radius of the ship.

b. Per reference (a), prompt first aid treatment of personnel hit by white phosphorus is required. First aid must consist of flushing with large amounts of water. Remove obvious large particles of white phosphorus from the skin by brushing with a knife, tool or stick, and cover with a wet dressing. The most effective treatment is neutralization of any phosphoric acid with a 5 percent bicarbonate solution (1 cup sodium bicarbonate dissolved in a gallon of water). Irrigation should be continued for 10 to 15 minutes. Do not use grease or ointments on white phosphorus burns.

c. Per reference (a), do not stand in danger circles around power-driven systems, such as gun mounts, turrets, gun and missile directors and missile launchers.

d. Per reference (a), adhere to all missile blast area danger signs.

e. Per reference (b), set HERO emission control following the ship’s HERO bill prior to handling ordnance.

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C14-3 f. Per reference (c), be very careful when working in areas containing lethal voltages. Under some conditions, dangerous potentials may exist in electronic circuits after power is shut off. Do not perform work in a lethal voltage area under any circumstances without the presence of a second person who can give aid in the event of electric shock.

g. Per reference (c), be very careful when working with equipment that may reach high temperatures. Hatch covers, power supplies, and certain components (such as motors and lamps) can develop temperatures that can cause injury.

h. Per reference (c), do not perform any maintenance on the deluge or sprinkler systems until fire main water pressure is turned off. Do not disassemble any part of either system until all pressure in lines has been released.

i. Per reference (c), use protective devices (including hard hat, safety shoes, insulated gloves, ear plugs, facial mask, and personnel grounding devices, as applicable) when performing strike down and maintenance procedures on the Vertical Launching System (VLS) equipment. Use safety observer’s safety switch and sound--powered telephones when performing any strike down or hatch operation. Always use hatch restraint tool or some other method to secure hatch open when performing maintenance on elevator hatch or uptake hatch. Use some other method, if possible, to secure cell hatch open when performing maintenance on cell hatch. Unless permanent carbon monoxide (CO) monitor is installed in launcher (ORDALT 16147), always use individual toxic gas sensor when working inside launcher.

j. Per reference (c), when a missile is fired from the VLS, the missile blast residue that remains can contain several heavy metals, including copper, nickel, lead, arsenic, chromium, and cadmium. Some of these chemicals can cause cancer and other adverse health effects if they are inhaled, ingested, or absorbed into the body. During missile launch, hydrogen chloride gas is formed, which can combine with water to form hydrochloric acid. Because the gases being created as the missile is launched are very hot (over 2,000 degrees Fahrenheit), there will be no water left in its liquid form inside the canister or launcher immediately after launch. Hydrochloric acid will not be present in the solid missile blast residue once any trapped gases remaining after the launch are dissipated, typically less than 2 hours. Personnel first opening the hatch immediately after a launch should inspect it for evidence of condensation on the inside. Absence of condensation ensures no water is present and hydrochloric acid was not formed. Personnel engaged in cleaning missile blast residue from the plenum, sills, or adapters are required to wear appropriate PPE and to practice good personal hygiene after completing work. The amount of missile blast residue remaining after cleaning is done is minimal, and PPE is not required when entering the VLS space to perform maintenance other than cleaning. However, anyone entering VLS launcher spaces should practice good personal hygiene upon launcher exit and wash their hands and face before eating, drinking, smoking, or applying cosmetics and emollient creams.

OPNAVINST 5100.19F 5 May 2019

C14-4 k. Per reference (c), do not work with or near high voltages unless familiar with methods of CPR.

l. Per reference (c), do not reach into any equipment or enter the launcher to service or adjust components except in the presence of someone who can give aid.

m. Per reference (c), personnel must remain clear of equipment that is in motion. Should equipment require adjustment while in motion, a safety watch must be posted. The safety watch should have full view of operation being performed and immediate access to controls capable of stopping equipment motion.

n. Per reference (d), chaff fibers are classified as a health hazard (irritant). Personnel must wear protective eye wear, dust mask, rubber gloves, and protective clothing, i.e., coveralls, smock, laboratory style coat, apron, etc., when chaff being blown back onto the ship is a possibility or when chaff particles that fall on the ship are being cleaned up. The protective clothing should be decontaminated or disposed of to prevent the chaff dipoles from being transported to living quarters.

o. Per reference (e), all operating personnel must be familiar with the nature and characteristics of OTTO fuel II.

p. Per reference (e), safety showers, eyewash fountain, emergency breathing air, and PPE must be available, and they must be inspected periodically prior to operations involving OTTO fuel II.

q. Per reference (e), remove personnel overexposed to OTTO fuel II from contaminated area into fresh air. If symptoms persist, obtain medical aid.

r. Per reference (f), all personnel working on a jammed gun must wear protective gear (i.e., flak jackets, battle helmets, and eye and ear protection). If loose propellant or powder is evident due to damaged cartridges, neutralize the exposed propellant with water to minimize the chance of ignition. Exposed propellant presents a risk of ignition that is best minimized by wetting the propellant with water.

s. Per reference (f), do not walk or stand in front of gun while live rounds remain in gun.

t. Per reference (g), personnel assigned to operate or maintain, 5-inch 54-caliber gun mount MK 45 MOD 2 must be familiar with naval safety precautions for ammunition and explosives handling and gun mount operation. In addition, these personnel must receive a thorough indoctrination in the safety precautions applicable to the gun mount.

u. Do not leave exposed ordnance unattended. Do not leave open magazines or lockers unattended.

OPNAVINST 5100.19F 5 May 2019

C15-1 SECTION C

CHAPTER 15

SANITATION (SEWAGE) SYSTEMS

Ref: (a) OPNAVINST 5090.1D, Environmental Readiness Program (b) NAVSEAINST 9593.1C, Certification Program for Marine Sanitation Devices (MSDs) Installed on Surface Ships, Craft and Boats in the U.S. Navy (c) NSTM 593, NAVSEA S9086-T8-STM-000/CW 593R, Pollution Control (d) NMCPHC TM OM-6260, Medical Surveillance Procedures Manual and Medical Matrix (Edition 12), August 2015 (e) BUMEDINST 6230.15B, Immunizations and Chemoprophylaxis for the Prevention of Infectious Diseases (f) NSTM 074, NAVSEA S9086-CH-STM-030/CH-074-VOL3, Gas Free Engineering

1. Discussion

a. All naval ships have a marine sanitation device (MSD) designed and operated to prevent the overboard discharge of untreated or inadequately treated sewage into navigable waters of the United States or other countries.

b. MSDs either hold raw sewage until it can be discharged overboard or to a pier connection, or treat sewage in certified treatment-based MSDs.

c. All naval ship MSDs must be certified by NAVSEASYSCOM per references (a) and (b) to ensure the MSDs meet performance and safety and health requirements. Navy certification of shipboard MSDs is a one-time requirement – there is no time-based recertification requirement for shipboard MSDs. The need to recertify an existing MSD based on modifications by a ship change is determined by NAVSEASYCOM and the appropriate ship program manager or TYCOM.

2. Sanitary, Hygienic, and Safety Procedures

a. Hygienic Procedures. The following basic hygienic procedures are applicable to all MSDs (e.g., CHT systems, vacuum CHT systems, and treatment based MSDs. Detailed information is contained in reference (c)).

(1) Wear appropriate PPE (e.g., rubber gloves, rubber boots, chemical splash goggles, face shield, and disposable coveralls), while connecting or disconnecting sewage hoses, while performing maintenance requiring disassembly of MSD equipment, or when contact with sewage is possible.

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C15-2 (2) Ensure that personnel exposed to sewage or who work on MSDs or graywater systems are placed in medical surveillance and maintain their basic immunizations as required by references (d) and (e).

b. Leak or Spill Clean-up Procedures

(1) In the event spaces become contaminated with sewage as a result of leaks, spills, or sewage system backflow, evacuate the space immediately and notify the OOD, DCA, and MDR of the spill.

(2) Secure the spill area from traffic.

(3) See reference (c) for information on spill cleanup and sanitation of the space.

(4) EEBDs are to be mounted in all MSD pump rooms and equipment spaces, and kept available in MSD work areas for emergency exiting. A minimum of two EEBDs must be mounted in each pump room and equipment space.

3. Gas Free Engineering for MSD Systems. MSD tanks and sewage collection and transfer piping systems (piping, valves, pumps, etc.) are considered IDLH. Do not open or enter an MSD tank, pump, pipe, or valve. Do not remove a component which will leave an opening to the tank unless approval is granted by the commanding officer and the system is inspected and certified gas free per references (c) and (f).

4. Control of Toxic Gas Hazards in Sewage MSD Systems. To minimize the potential hazards resulting from the release of toxic gases from the MSD system, observe the precautions in the following subparagraphs 4a through 4e.

a. Always assume that the MSD tank and piping system contains sewage and toxic gases, and have an oxygen deficient atmosphere. Of particular concern is hydrogen sulfide (H 2S), a gas with a rotten egg smell at low concentrations. This odor is not reliable as a warning signal because H2S deadens the sense of smell. As H2S concentration increases, the degree of danger increases.

b. If H 2S is detected by smell when working in the MSD pump room, MSD space, comminutor space, or any space containing sewage piping, evacuate the space immediately. If the space is equipped with a H2S alarm, evacuate the space immediately when the alarm sounds.

c. Contact a gas free engineer immediately. A space in which the H 2S odor has been detected or an H2S alarm sounds should only be re-entered by personnel who have been properly trained and are wearing the proper IDLH respiratory protection equipment.

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C15-3 d. In any space where a sewage spill has occurred, do not conduct any work or maintenance other than work required to clean up the spill, until gas levels are below acceptable limits, as determined by a gas free engineer, and all sewage wastes, including solids, have been removed from the space and the space washed down.

e. Ensure all H 2S alarms and ventilation low flow indicators are properly maintained and operable at all times. In spaces where the ventilation low flow indicator reads zero or the low flow alarm has sounded, ensure the atmosphere is tested prior to entry.

5. Graywater Collection, Transfer Systems, and Graywater Collection Tanks. The sanitary, hygienic, and safety procedures, gas free engineering requirements, and requirements related to the control of toxic gas hazards provided herein also apply to dedicated graywater collection and transfer systems and graywater collection tanks where installed. See reference (c) for additional information.

6. Discharge Requirements and Additional Guidance. Refer to reference (a) prior to any discharge of sewage overboard.

OPNAVINST 5100.19F 5 May 2019

C16-1 SECTION C

CHAPTER 16

HEAVY WEATHER

Ref: (a) OPNAVINST 3500.39D, Operational Risk Management

1. Discussion

a. Heavy weather is defined as any weather condition that results in high winds, extreme sea states, heavy rain, heavy snow or hail.

b. There are multitudes of hazards present in heavy weather. Objects can slide or fall on personnel causing injury. Personnel can fall into machinery or equipment. Heavy weather is as dangerous now as it was during the days of sail, and all personnel must be aware of potential hazards and safety requirements.

2. Lifelines

a. Keep lifelines or rails rigged at all times along all boundaries. Keep permanent lifelines in good repair.

b. Keep unguarded openings adjacent liferail or lifeline sections or an end section and adjacent structures to a minimum and in no case greater than 5 inches.

3. Tie-Downs

a. Use approved tie-downs or lashing to secure moveable shipboard items, such as aircraft, vehicles and cargo, against the motion of the ship and exposed areas against the forces of wind and waves.

b. Seize or tie-down shackles, hooks, turnbuckles, release devices to prevent working loose. Check them for security more frequently in heavy weather.

4. Safety Precautions Under Heavy Weather Conditions

a. Be aware of stowage locations of all equipment necessary for rigging heavy weather lifelines.

b. Inspect tie-down equipment such as cables, turnbuckles, deck pads and bolts, at frequent intervals to ensure their security.

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C16-2 c. Only use the fittings provided on the aircraft, vehicle, and equipment to be transported to secure the item to the ship.

d. Do not use excessive force to place a tie-down onto a fitting.

e. Ensure that the arrangement of individual tie-down assemblies is in strict conformance with design requirements.

f. Ensure that when lashing and tie-down equipment is not in use, it is stowed in its proper location.

g. Take special precautions in dealing with equipment which may have broken loose during heavy weather conditions. Conduct an ORM assessment (see reference (a)) to evaluate the hazards to personnel and to the ship and identify and implement controls prior to attempting to secure equipment, vehicles, or aircraft.

h. Refrain from the use of machinery, tools, moving heavy stores, or other non-essential evolutions that may have an increased risk due to the ship’s movement during heavy weather.

i. Supervisors must take into account the physical condition (sea sickness) of crew members during heavy ship movement before assigning critical or hazardous tasks.

j. In cold weather situations where crew members are assigned to remove snow or ice from topside areas, ensure personnel are properly outfitted with cold weather gear and gloves.

k. Avoid any mast or topside work, and secure personnel from exterior areas when thunderstorms threaten, whether or not lightning is sighted.

OPNAVINST 5100.19F 5 May 2019

C17-1 SECTION C

CHAPTER 17

ABANDONING SHIP

Ref: (a) NSTM 077, Personnel Protection Equipment

1. Safety Precautions During Abandoning Ship

a. Wear a full set of clothing including long sleeve shirt, shoes and a soft cap or head covering as protection from exposure. Do not wear a helmet (e.g., Kevlar®) or plastic hard hat when going over the side. If ordered to abandon a sinking ship, don the abandon-ship inflatable life preserver by removing the life preserver from the pouch, unrolling it, pass head through the life preserver collar, and ensure that the lower end of the preserver is out of the pouch. Do not abandon a ship surrounded by flames with the MK-1 inflatable life vest or an inherently buoyant preserver. These life preservers will not permit the wearer to swim underwater, below the flames.

b. The abandon ship inflatable life preserver is USCG approved and provides 33 pounds of buoyancy. It consists of a waist belt, a pouch for stowing the buoyancy chamber and the manual inflation assembly with a CO 2 cylinder and a pocket stowing the distress marker light, whistle, and toggle line. Life preservers authorized by reference (a) must be securely fastened to the person.

c. Go over the sides by means of a line, ladder, or debarkation net if time permits.

d. If it is necessary to jump, look before jumping into the water to be sure that water below is clear of personnel, floating gear, or wreckage. Know the direction of the wind and go to the windward side of the ship if possible, to avoid flames, oil, and the drift of ship.

e. Do not dive into the water. Always jump feet first, with feet and legs together, and arms crossed over the chest holding onto the life preserver. If necessary to jump into burning water, place one hand over mouth with palm under the chin and fingers split over the nose. The other hand is placed on the inflatable life preserver collar to keep it from riding up.

f. The abandon ship inflatable life preserver must not be inflated until the wearer is in the water and clear of flames or other danger. The life preserver must be manually inflated by pulling down on the inflator lanyard or through the oral inflation tube.

g. When in the water, concentrate on staying calm and avoiding panic. Obey the rules in the below subparagraphs 1g(1) through 1g(6).

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C17-2 (1) Swim away from the ship. If there is debris and oil in the water, use the breast stroke to clear a path. If space is available, climb into a lifeboat or life raft. If there is no room in the rafts of boats, use a safety line or the life preserver toggle line to attach life preserver to a raft, boat, or other personnel in the water wearing life preservers.

(2) After arriving at a safe distance from the ship, attach the distress marker light to the velcro patch on the buoyancy chamber, to conserve energy by moving as little as possible.

(3) If possible, keep clear of oil slicks. If not possible to avoid oil slicks, protect eyes, mouth and nose by keeping head high or swimming underwater. If swimming underwater, prior to surfacing, put hands above head and splash the water surface to disperse oil, debris, or flames.

(4) If there is danger of underwater explosion, float or swim on the back as near to the water surface as possible.

(5) Remain with other personnel in the water to reduce danger of sharks and facilitate rescue attempts. In cold water, forming close circles with others will preserve heat. Conserve energy by moving as little as possible.

(6) If ship is sinking rapidly, promptly swim clear and tow injured persons clear to avoid suction effect.

h. Follow all other procedures and precautions as delineated in the ship's abandon ship bill.

OPNAVINST 5100.19F 5 May 2019

C18-1 SECTION C

CHAPTER 18

PAINTING AND PRESERVATION

Ref: (a) NSTM 631, NAVSEA S9086-VD-STM-010/Volume 3 Painting and Preservation of Ships (b) OPNAVINST 5090.1D, Environmental Readiness Program

1. Discussion

a. For precautions for application and removal procedures of lead-based paint, see chapter B10. This chapter deals exclusively with the application and removal of paint not containing lead or other toxic metals such as cadmium and chromium. Prior to paint removal, submit paint samples to a certified IH lab to verify absence of toxic metals.

b. Many paints, varnishes, lacquers, cleaners, solvents, and other finishing materials contain flammable solvents and, therefore, present a fire hazard. In addition, these same products may give off toxic vapors which can be harmful to health and the environment. It is therefore necessary that personnel take proper precautions in handling and using these products. Appendix C18-A provides a list of best practices that should be followed, if at all possible, to reduce the environmental impact of paint vapors and debris. Reference (a) provides detailed procedures for paint application. The shipboard marine coating use section of reference (b) contains information on volatile organic compounds and environmental recording that may be required.

c. Paint removal operations can produce extremely high personnel exposures to toxic substances found in paints, depending on the method of removal. Chipping causes scale to be dislodged, presenting possibility of eye or facial injury. It is therefore necessary that personnel take proper precautions in handling and using these products. Follow administrative and protective measures to reduce the amount of dust from sanding, grinding, and chipping paints and from fumes generated during hot work on painted surfaces.

2. Safety Precautions for Paint Removal

a. Ship’s force must not perform routine shipboard paint removal for cosmetic reasons or due to excessive coating thickness. Ship’s force should only remove paint when required to accomplish preservation of corroded surfaces, incidental to hot work, welding, or when bare metal is necessary for an inspection.

b. Wear eye protection, and a long sleeve shirt or coveralls with sleeves rolled down. Consult the RPPM about any respirator requirements for the operation.

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C18-2 c. For paint removal, keep mechanical grinding and sanding to the absolute minimum with primary reliance on manual removal methods, impact tools and authorized chemical paint strippers.

d. Use only pneumatic, not electric powered, wire brushes and chipping tools over the side. Tie all tools off by small stuff (line), to prevent tools from falling on someone below.

e. When working over the side or aloft, see chapter B13 and chapter C8 for additional precautions.

f. Wear protective gloves when handling cleaning compounds or chemical removers.

g. Wear electrical safety gloves when using portable, electric-powered tools. See chapter C9 for additional precautions when using electrical power tools.

h. Many paint removal tools are noise hazardous equipment. If equipment is labeled as noise hazardous, ensure that proper hearing protective equipment is worn. See chapter B4 for additional information.

i. Assume all paint contains substances, such as lead and chromate, which are hazardous to health if ingested or inhaled in small amounts, unless proven otherwise by sample analysis.

j. Treat all paint debris as environmentally HAZMAT and control and dispose of accordingly. When working topside, set up barriers to prevent paint debris from entering surrounding waters.

k. Provide local exhaust ventilation as needed during painting operations to remove airborne particles and vapors. Reference (b) should be consulted for environmental requirements that may apply to exhaust ventilation of airborne particles and vapors. If IH surveys identify that respirators are required to provide additional protection, follow the recommendations of the RPPM and the requirements of chapter B6 regarding the use and care of respirators.

l. Secure and cover all deck drains and installed ventilation systems and openings in the paint removal work area to control dust. Isolate the work area to the maximum extent possible with drop cloths or plastic.

m. Personnel must minimize the use of water as dust control or clean-up in the paint removal process, since any used in the operation must be treated as HAZMAT.

n. Tools and surfaces in the work area must be wiped down with a damp cloth or tack cloth after completion of the task to remove dust.

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C18-3 o. Ensure that paint debris, wipe down rags, and other disposable materials are separated from reusable coveralls, gloves, and boots. Place disposable materials into plastic bags and turn them in to the ship’s HAZMINCEN or HAZMAT coordinator.

3. Safety Precautions for Surface Preparation and Painting Operations

a. Wear eye and face protection and long sleeve shirts or coveralls with sleeves rolled down and all buttons buttoned at all times while chipping or operating power brushes, chipping, or scaling tools. Consult the RPPM about any respirator requirements for the operation. If lead- containing paint or paint containing other toxic metals is to be removed, an industrial hygienist should evaluate the operation and recommend proper respiratory protection and other personal protective clothing per chapter B10.

b. Do not paint in any area where welding or other hot work is being performed.

c. Wear respirators for painting operations if directed by the RPPM.

d. Return paint in closed, authorized containers, to the paint locker or ship’s HAZMINCEN at the end of each day.

e. Store paint, brushes, and stirring sticks in closed metal containers. Do not place or store paint and paint wastes on the pier for extended periods of time. Do not place used paint containers in pier dumpsters after use. Turn in all paint waste to the ship’s HAZMINCEN or designated area for disposal.

f. Ensure local exhaust ventilation system is switched on and operational in closed areas when painting.

g. Wear protective gloves when handling cleaning compounds, thinners, paints, removers, or other irritants. Do not use electrical safety gloves for paint work.

h. De-energize all equipment in areas being painted if using highly flammable paints.

i. Do not allow eating, drinking, or using tobacco products in the paint area. Ensure that when handling painting materials, take care to wash hands prior to eating, drinking, using tobacco products, or using the head.

j. When working over the side or aloft, see chapter B13 for additional precautions.

k. Use explosion-proof lighting during spray painting operations if using highly flammable paints.

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C18-4 l. All paints, paint cleaners, solvents and brush cleaners are HAZMAT. Return all containers of paints and thinners to the paint locker or ship’s HAZMINCEN upon completion of the job, at the end of the workday, or when taking a lengthy break.

m. Only perform paint mixing in the paint locker or ship’s HAZMINCEN if adequately ventilated. If not adequately ventilated, only mix paints on the weather decks. Provide posted barricades to ensure smoking, open flames, or hot work does not occur in the vicinity of the paint mixing area.

n. Avoid prolonged skin contact with paints and thinners and do not use paint thinners or mineral spirits to clean paint off of skin. Use an approved industrial skin cleaner to remove paint from skin. Never use bare hands to mix paints.

o. Use approved painting pollution prevention equipment according to the safety precautions provided.

(1) Wear eye and skin protection when dispensing paint, maintaining dispensers and brush holders, and cleaning paint brushes.

(2) Paint dispensing systems and paint brush holders are to be operated and maintained only by authorized personnel.

(3) Approved paint brush holders, provided for storage of paint brushes in mineral spirits, will be kept closed to avoid evaporation and release of vapors into the air.

OPNAVINST 5100.19F 5 May 2019

C18-A-1 Appendix A of Section C, Chapter 18 APPENDIX C18-A BEST MANAGEMENT PRACTICES (BMP) FOR REMOVAL AND APPLICATION OF PAINT, FINISHING, AND COATING MATERIALS

1. Surface preparation and the application of paints, finishes and coatings to ships can be sources of pollutants. Potential pollutants include organic compounds, oils and greases, heavy metals, and suspended solids. It is important both on ships and on the pier that painting and sanding operations be covered and contained and that good housekeeping and preventive maintenance practices are applied to prevent the contamination of storm water with paint over sprays and grit from sanding, chipping and needle gunning. The following subparagraphs 1a through 1p contain BMPs that should be applied if at all possible to minimize both water contamination and air emissions.

a. If using JLG Industries, Inc. aerial lifts, etc.:

(1) put tarps in floor of basket and get basket as close to the side of the ship where painting is occurring such that any drips of paint will be into the tarped basket,

(2) use smallest possible cans or drums of paint to reduce potential spillage, and

(3) ensure can is secured (tabs down) when not actively transferring paint.

b. If using paint floats or other floating platforms:

(1) pull the float as close to the hull as possible such that any drips will be captured on the float,

(2) use shrouds, tarps, or other protective devices between the float and the hull (can be secured by magnets) to protect any drips from entering the water,

(3) use smallest possible cans or drums of paint to reduce potential spillage, and

(4) ensure can is secured (tabs down) when not actively transferring paint.

c. When working pier side, whether in a JLG or just standing on the pier:

(1) a tarp should be placed above the water surface underneath the work area between vessel and pier or shore to prevent spillage into the water, when feasible, and the bottom edges of tarps and plastic sheeting need to be weighted to keep them in place;

(2) shrouds should be cleaned frequently to prevent material from being blown into the water;

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C18-A-2 Appendix A of Section C, Chapter 18 (3) if a tarp cannot be secured between the ship and shore, use extreme caution to eliminate drips of paint into the water; and

(4) ensure cans are secured (tabs down) when not actively transferring paint.

d. When painting onboard ship or pier side, minimize air emissions:

(1) do not thin paint used on vessels or components;

(2) take care when transferring material to avoid spills, and clean up and properly containerize all spill residues immediately; and

(3) do not soak paint-related items such as stir rods in open thinner containers. Paint and solvent containers must remain closed at all times when material is not being added or removed.

e. Use drop cloths, cardboard, tarpaulins or other protective devices in staging area on pier where paint buckets, brushes, rollers, etc. are stored and paint transfer between containers is performed to keep any spills from reaching the pier or water or both.

f. Use minimal amount of paint on rollers and brushes so no drips are evident when removing from the staging and work area.

g. Use a roller pan to apply paint to roller and remove excess paint prior to extending the roller over the water. Use of 5 gallon buckets as dip pans is not acceptable for this purpose.

h. When not transferring paint, paint cans must be covered and sealed (tabs secured) to reduce the chance of spillage.

i. Collect and contain any debris generated from surface preparation work. Complete recovery of blasting material and paint chips is required.

(1) Use vacuum sanders that have dust-containment bags to remove paint from hulls and collect paint dust.

(2) Use plywood or plastic sheeting or both to cover open areas between decks when sandblasting (scuppers, railings, freeing ports, ladders, and doorways).

(3) Plug scuppers to contain dust and debris.

(4) Wipe down small amounts of sanding dust with a damp rag and vacuum or sweep paved surfaces regularly if debris has reached them. Never hose down areas that have spilled paint or debris. Properly dispose of debris.

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C18-A-3 Appendix A of Section C, Chapter 18 j. Do not conduct spraying, blasting, or sanding activities in windy conditions such that containment measures are rendered ineffective.

k. Have absorbent and other cleanup items readily available for immediate cleanup of spills. Wipe up spills immediately.

l. Use a storm drain cover, filter fabric, or similarly effective runoff control device if dust, grit, paint, or other pollutants may escape the work area and enter a catch basin or pier drain. The containment device(s) must be in place at the beginning of the workday.

m. Use a ground cloth, pail, drum, drip pan, tarpaulin, or other protective device for activities such as brush cleaning outside or where spills can contaminate stormwater.

n. Inspect the condition of all protective devices at minimum before each work shift and repair and reposition as needed.

o. Store paint or tools with residual paint under cover during precipitation events and when not in use to prevent contact with stormwater.

p. Rags contaminated with solvent must be bagged and turned in for proper disposal. Do not allow to air dry. Never keep rags contaminated with solvent in work areas or other non-fire protected spaces as rags could self combust.

2. It is important to note that these are just some of the BMPs that can be used. Not all are applicable for every application. Judgment must be used to determine which can be used with the ultimate goal of keeping the paint and debris from reaching the pier and water. If there is a method for containing paint and debris that is not listed above and the applicability is uncertain, contact the local base environmental office for assistance.

OPNAVINST 5100.19F 5 May 2019

C19-1 SECTION C

CHAPTER 19

FOOD SERVICE AND SOLID WASTE DISPOSAL EQUIPMENT

Ref: (a) NAVMED P-5010, Manual of Preventive Medicine, Chapter 1 (b) NSTM 555, Surface Ship Firefighting

1. Discussion

a. A basic necessity for any ship is a galley. The crew must be fed and personnel must prepare food for consumption. The food preparation required to feed a large body of people means that machinery and equipment must be used. The use of this machinery introduces hazards unique to the galley and food preparation areas.

b. Every Navy ship is equipped with solid waste and garbage processing machinery, frequently under the purview of the supply department. This equipment includes pulpers, trash compactors, incinerators, plastic waste processors (PWP), and garbage disposers. Use of this machinery has unique hazards as well as environmental pollution ramifications.

2. General Precautions. Before attempting to operate machinery, observe the general precautions contained in the following subparagraphs 2a through 2x.

a. Check for and determine the location of emergency equipment, such as fire extinguishers, cut-off switches, and first aid boxes, to ensure their availability should an accident occur. Ensure machinery, hand tools and electrical equipment is properly grounded prior to operation. Report any deficiencies or malfunctioning equipment to the supervisor.

b. Ensure that the work area around the equipment is clear of obstructions and thoroughly dry. Clean up all spills immediately to ensure a clean, dry, non-slippery walking surface.

c. Ensure the installed lighting in the work area is operating properly and provides sufficient light.

d. Read, observe, and follow posted operating instructions and safety precautions.

e. If there is any doubt about operating procedures or safety precautions, ask the supervisor.

f. Only qualified personnel will attempt to operate equipment.

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C19-2 g. Ensure no loose gear is in the vicinity of moving parts of machinery. Make sure all safety guards, screens, and devices are in place before turning on machinery.

h. When operating a machine, maintain a safe distance from all moving parts. Never use hands or the body to stop moving blades and parts even if power has been secured.

i. Never lean against a machine while it is operating.

j. If ship movement is severe, exercise caution in operating machines; if severe movement continues, secure nonessential machines.

k. Use eye and hand protection, and safety equipment such as dip baskets while handling chemicals or hot water. Personnel at the deep sink must wear protective gloves with elbow- length or longer sleeves and apron to prevent hot water burns.

l. Keep hands, the body, and clothing away from operating machine parts.

m. Never leave operating machinery unattended.

n. Do not distract the attention of personnel who are operating machinery.

o. Do not attempt to clean or service machinery while it is in operation. Before cleaning, adjusting, oiling or greasing equipment, be sure power is secured and equipment is danger tagged. Follow tag-out procedure when servicing or cleaning equipment. If in doubt about the requirement to tag out any equipment, consult with the supervisor.

p. Ensure only qualified personnel make all repairs and service machines.

q. Make sure safety devices such as safety interlocks on galley equipment, such as the covers of garbage grinders, vegetable peelers and bread slicer, are maintained in proper working condition at all times. If removed for any reason, replace such devices before the machine is returned to operation.

r. Remove rings and watches, pagers, cell phones, and eliminate any loose clothing such as rolled-up sleeve cuffs, oversized gloves, and ill-fitting coats and jackets.

s. Ensure that permanently-mounted equipment is hardwired (extension cords are not permitted). Know where the cut-off switches for hard-wired equipment are located. Obey all tag-out tags on switches.

t. When cleaning, look before reaching into enclosed spaces or under grills or griddles for loose wires or sharp obstructions.

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C19-3 u. Use caution when applying conductive cleaning fluids or water in the vicinity of electrical devices to mitigate shock hazards and damage to electrical equipment.

v. Avoid touching sharp metal edges of opened cans and lids.

w. Report any injuries, such as burns, cuts or open wounds, to the MDR.

x. Additional precautions may be found in reference (a). Personnel assigned to permanent and temporary work in food service areas must be given a copy of these precautions prior to beginning their assignment.

3. Cooking Utensils

a. Secure all coffee pots and urns to prevent dislodging and splashing.

b. Exercise extreme caution and care when handling hot oils, water, and other liquids or when operating steam valves and equipment. In heavy or moderate sea states, do not transfer hot liquids.

c. Never leave operating hot plates, pots, griddles, steam kettles, or fryers unattended.

d. Be careful not to place meat, vegetables, or other foods on a knife or other sharp instrument. The food may conceal the cutting edge.

e. Do not place knives in the wash water until ready to wash them. Lay them in plain view beside the sink.

f. Keep the free hand away from the sharp edge of the cleaver when chopping foods.

g. Use a protective glove (e.g., metal fiber or Kevlar) when boning meat.

h. Keep the surfaces of meat blocks level.

i. Store utensils in their proper places.

j. Do not allow pot or pan handles to extend beyond the edge of the range or counter. They can be bumped and serious burns to personnel resulting from spilled food or liquid.

k. Before removing foods from hot ranges and ovens, be sure there is a clear place on which to set them and clear the path to that place.

l. Use only the proper implements for opening cans and other containers.

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C19-4 m. Hold knives firmly. Ensure knife handles are dry or free of grease before handling them.

n. Knives should be stored in National Sanitation Foundation racks.

o. Magnetic knife racks are prohibited due to knife magnetism picking up foreign material.

p. Keep knives sharp at all times.

q. Never handle a knife while carrying another object.

r. Ensure hot pads are clean and dry.

s. Keep all tools clean and dry.

4. Food Preparation

a. Practice good personal hygiene at all times, and report all illnesses and injuries to the supervisor.

b. Keep hands clean and thoroughly wash hands with soap and water after using the head, touching the mouth or nose, or handling any food.

c. Keep fingernails short.

d. Wear appropriate hair covering at all times in food-handling areas.

e. Do not touch food with bare hands. Use appropriate implements for handling food or wear plastic food handling gloves when working with ready to eat foods.

f. Never handle food with an open wound or infection of any kind on the hands or arms. Sore throats, colds, intestinal disturbances, or symptoms of other general diseases must be reported to the MDR at once.

g. Clean up spilled food immediately.

h. Do not use leftovers held over 24 hours. Ensure all leftovers are marked with the date and time they were placed in storage.

i. Ensure that distant-reading dial thermometers and, when required, electronic temperature-monitoring units are installed, calibrated and operating. Verify thermometer accuracy monthly. Ensure the emergency door-release mechanism required in "walk-in" refrigerators and freezers is installed and properly operating.

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C19-5 j. Discard protein foods that have remained at temperature between 41 degrees Fahrenheit and 135 degrees Fahrenheit longer than 4 hours.

k. Observe safety precautions around all electrical equipment to avoid injury from shock. Do not reach into areas for cleaning around griddles and ovens that have exposed wiring unless the equipment has been tagged out.

l. Wear eye and hand protection when using oven cleaners or other strong cleaning materials. Do not dispense bulk cleaners into spray bottles without properly labeling the spray bottle with the new contents; see chapter B3 for details on labeling HAZMATs.

5. Safe Operation of Food Service Equipment

a. General precautions. Observe all posted operating procedures or manufacturers operating instructions for each piece of food service equipment prior to operating. Additionally, inspect all electrical equipment (range, griddle hotplate, and disposals) for exposed, chafed or frayed wiring.

(1) Ensure all power switches are functional.

(2) Ensure all required guards are in place.

(3) Ensure rubber boots over switches in wet areas are in good condition.

(4) Ensure all personnel operating equipment or performing food service functions are trained and properly supervised.

b. Deep Fat Fryer

(1) Beware, this is high voltage equipment.

(2) Extinguish a fire in the deep fat fryer per reference (b).

(3) Never leave fryer unattended when in use.

(4) Ensure heating coils are completely covered with cooking oil before turning on the equipment.

(5) Never exceed the maximum temperature noted by manufacturer.

(6) Monitor cooking oil temperature with a proper thermometer whenever the deep fat fryer is in use. Ensure backup safety thermostat is installed and operational.

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C19-6 (7) Install cover when fryer is not in use.

(8) Secure deep fat fryer following posted instructions when not in use.

(9) Ensure that grease spills are cleaned up promptly.

(10) Wash and change grease filters in range hoods as often as necessary per PMS, but not less than weekly, to avoid the danger of fire.

c. Dough Mixing Machine

(1) Never attempt to cut dough while the agitator is revolving.

(2) Never attempt to knead or feel consistency of dough product while machine is in operation.

(3) Never attempt to clean out a bowl in the tilt position by reaching in unit while the agitator is revolving.

(4) Check safety switch to lid cover for proper functioning per PMS requirements.

d. Food Mixing Machine

(1) Use proper machine speed for the specific operation.

(2) Never place hands into the bowl while machine is in operation.

e. Vegetable Cutting and Slicing Machine

(1) Always use plunger when applying pressure on vegetables being fed into the hopper.

(2) Do not use loose-fitting gloves when operating the machine.

f. Meat Slicing Machine

(1) Never operate the machine unless the blade guard is secured in place.

(2) Do not use hands to press down food.

(3) Never touch the blade when it is running or exposed for slicing.

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C19-7 (4) Set index at zero and secure power at the distribution box or by pulling the plug when cleaning blade.

(5) Ensure slicing machines are provided with a toggle -switch finger-guard that is oriented in the proper direction for protection.

(6) Always disconnect power cord prior to cleaning and reconnect only when ready to use.

(7) Ensure meat slicers are de-energized at the power source, not just turned off with a local switch, prior to dismantling and reassembling for cleaning. Ensure any switches on meat slicers are guarded to prevent then being turned on unintentionally.

(8) Once de-energized, clean the blade with a clean, detergent-soaked cloth wrapped around a cook's fork or other extension utensil. Rinse the blades following a similar procedure and sanitize them with an approved disinfectant.

(9) Reassemble machine after cleaning.

(10) Meat slicers that are hardwired must have an interlocking switch installed. Tag-out procedures must be followed prior to blade removal.

g. Direct Steam Kettle

(1) Each day this equipment is used, test the safety relief-valve while under operating pressure by pulling the chain attached to the safety relief valve arm.

(2) Do not tamper with the safety-valve or tie it closed. It is there to prevent the kettle from exploding.

(3) Do not apply steam to an empty kettle; never put water into a hot, dry kettle.

(4) Ensure safety relief-valve levers are equipped with an 18-inch chain to allow activation from a safe distance. Chains must be mounted in such a way that the need to reach over or between or behind hot kettles is eliminated.

(5) Ensure relief valves are hydrostatically tested as required by applicable PMS.

(6) Piping from relief valves must extend to just inside the deck coaming.

(7) Lagging under steam kettle must be removed and replaced with perforated steel or aluminum with approximately 1/2-inch standoff.

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C19-8 h. Electric Steam Kettle

(1) If required, check water level as necessary and fill when the kettle is cool.

(2) Prior to kettle maintenance, ensure the kettle is cool with power secured. Follow tag- out procedures before completing kettle maintenance.

(3) Relief valves should only be lifted when the kettle has been laid up and is cold per MIP 6520. An 18-inch pull chain is not required for electric kettles.

(4) Ensure relief valves are hydrostatically tested as required by applicable PMS.

(5) Piping from relief valves must extend to just inside the deck coaming.

i. Electric Griddle

(1) Keep griddle turned off when not in use.

(2) Keep cooking surface and grease gutter scraped and wiped clean at all times.

(3) Remove, empty, and clean grease drawer after each use. Do not reach into the drawer area for cleaning unless the griddle is tagged out.

(4) Use griddle guards to keep food from sliding off the cooking surface.

(5) Never use water to clean a griddle surface. Wipe the surface with clean, dry paper towels when the griddle is cold. Use pumice stone block to clean hard-to-remove burn spots.

j. Coffee Urn

(1) Do not introduce water too quickly into the boiler.

(2) Do not overfill boiler. Be sure water has stopped rising in the gauge glass after the water-inlet valve is closed. Do not turn on activating switch until water-level gauge reads full or the pressure control dial reads 36 ounces.

(3) Do not open urn cover while siphon valve is open. Do not agitate coffee while cover is open. Do not remove leacher from the urn body until it is completely drained.

(4) Do not obstruct safety-valve outlet. Keep equipment clean. Clean the urn immediately after use to prevent development of rancid taste.

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C19-9 k. Ranges and Ovens

(1) Do not allow grease to collect in oven.

(2) Do not clean oven while it is hot.

(3) Clean oven thoroughly once a week in addition to normal daily cleaning.

(4) Turn off surface units when not in use.

(5) Keep range drip-pan and grease trough clean. Never allow grease to accumulate since it is a serious fire hazard.

(6) Observe the electrical wiring under the range griddle and hot plate to see if wiring is secured in place and not chafed or in contact with the grease drip-pan. Tag-out the power source prior to cleaning under the range, griddle, or hot plate. Do not attempt to correct faulty wiring. Report electrical hazards to the supervisor.

l. Combi-Ovens

(1) Do not use chemicals intended for oven cleaning these may be harmful to the interior and exterior oven surfaces.

(2) Cool oven to 140 degrees Fahrenheit before cleaning. If idle, operate in steam mode 3 to 4 minutes before cleaning.

(3) Prior to oven maintenance ensure the oven is cool with power secured. Follow tag- out procedures before completing any oven maintenance.

m. Proofer

(1) Only authorized personnel are permitted to operate this equipment.

(2) Clean the proofer after each use.

n. Dishwashing Machine. Observe operating instructions and safety precautions.

(1) Ensure rubber protectors over switches are in good condition (no cracks or tears).

(2) Wear protective equipment when changing out cleaner dispensers.

(3) General ventilation in the space and local exhaust ventilation to remove steam from the machine must be operational.

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C19-10 (4) Do not reach into the dishwashing machine while operating - secure power before trying to clear the conveyor.

o. Steam Table

(1) Use the proper implements, such as pot holders and tongs, for handling the containers.

(2) Tilt containers away from oneself when inserting them into the wells.

(3) Carry hot liquids in covered containers with the covers securely in place and use heat protective hand protection.

(4) Promptly mop up grease which is spilled on the deck. Greasy decks are doubly hazardous. They can cause fires as well as falls.

p. Gaylord Exhaust Hoods

(1) The fire extinguisher control box contains a live electrical circuit. Prevent water or other cleaning fluids from entering this box.

(2) The baffle blades and interior of hood should be cleaned at least once a day to prevent fires from accumulation of grease.

(3) Keep the access doors closed during the wash and rinse cycles to prevent hot water from splashing personnel.

(4) Keep hood drains clear at all times.

q. Meat Chopping Machine

(1) Never feed this equipment by hand. Use a pestle (stomper).

(2) Never attempt to remove anything from these machines while they are operating.

(3) Always disconnect the machines before cleaning them.

r. Potato Peeler

(1) Make sure water is running before operating this equipment.

(2) Never put hands in this machine while it is operating.

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C19-11 (3) Ensure power is properly secured prior to cleaning the machine. Remove the internal bottom with two round rods and clean with hot soapy water; rinse before reinstalling bottom.

s. Microwave Ovens

(1) Keep the inside of the oven door and cabinet surfaces clean at all times. Do not use tools or abrasives on door closing surfaces.

(2) Do not allow oven door to be closed on any object including rags, towels, etc.

(3) Do not attempt to defeat the oven door safety interlocks.

(4) Do not operate the oven with an empty cavity and keep all metal utensils out of the oven cavity at all times.

(5) Do not obstruct cooling vents in the oven housing.

(6) Keep the oven door closed when the oven is not in use.

6. Solid Waste Processing Equipment

a. Garbage Disposers

(1) Do not put hands into disposers when in operation.

(2) Ensure guards, safety cutoffs, and other safety features provided with the unit are installed and functional prior to use.

(3) Start disposers and turn on water before feeding waste.

(4) Feed food waste gradually.

(5) Do not feed metal, wood, paper products, cloth, rubber, plastics, rice, or corn husks into the disposer. If such material is fed accidentally, secure power to the disposer. Notify the supervisor to see if tag-out procedures are needed to safely remove the object. Do not feed bones larger than 1/4 inch in diameter for the 400-pound per hour model or larger than 1 inch in diameter for the 1,600-pound per hour model into the disposer.

b. PWPs

(1) Only authorized personnel may operate the PWP.

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C19-12 (2) Hazards with the PWP include hot surfaces, electrical hazards when cleaning, and slippery decks.

(3) Follow operating instructions provided with the PWP.

(4) Wear the proper PPE including heavy-duty gloves, safety glasses, and leather apron while operating the PWP.

c. Incinerator

(1) Only authorized personnel may operate the incinerator.

(2) Hazards with the incinerator include hot surfaces.

(3) Follow operating instructions provided with the incinerator.

(4) Wear the proper PPE including fire retardant coveralls, heavy-duty gloves, face shield, and apron while operating the incinerator.

(5) Ensure guards, safety cutoffs, and other safety features provided with the unit are installed and functional prior to use.

(6) During ash removal, wear the proper PPE including heavy-duty gloves, face shield, apron, and respirator with P100 filter.

(7) Do not process feminine hygiene products or pilot urine bags through the shredder.

(8) Do not batch load any waste material, other than feminine hygiene products or pilot urine bags, directly into the combustion chamber.

(9) Due to explosion or health hazards, do not incinerate any HAZMATs including:

(a) flammable liquid or explosive material,

(b) aerosol cans,

(c) medical and dental waste,

(d) batteries,

(e) butane lighters,

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C19-13 (f) heavily soaked oily rags (lightly soaked oily rags may be burned in Golar incinerators), and

(g) CO2 cartridges.

(10) Incinerate no more than 25 percent of load volume or greater than 50 pounds per hour of plastics and textiles (e.g., packing material, foams, shrink wrap, pilot maps).

d. Pulper

(1) Do not put hands into pulper when in operation.

(2) Only authorized personnel may operate the pulper.

(3) Hazards with the pulper include electrical hazards when cleaning and slippery decks.

(4) Follow operating instructions provided with the pulper.

(5) Wear the proper personnel protective equipment including rubber gloves, face shield, and apron while operating the pulper.

e. Solid Waste Shredder

(1) Do not put hands into shredder when in operation.

(2) Only authorized personnel may operate the solid waste shredder.

(3) Hazards with the shredder include electrical hazards when cleaning and slippery decks.

(4) Follow operating instructions provided with the shredder.

(5) Wear the proper personnel protective equipment including heavy-duty gloves, safety glasses, and leather apron while operating the shredder.

OPNAVINST 5100.19F 5 May 2019

C20-1 SECTION C

CHAPTER 20

LAUNDRY

Ref: (a) NSTM 670, Stowage, Handling, and Disposal of Hazardous General Use Consumables (b) NSTM 300, Electrical Plant Safety (c) NAVSEA S0400-AD-URM-010, Tag-Out User’s Manual (TUM), Revision 7 (d) NSTM 655, Laundry and Dry Cleaning

1. Discussion. Hazards in laundries include mechanical equipment, toxic chemicals, electric power, noise, and heat stress. General safety precautions to be followed in these areas are provided in this chapter. Ships must provide a copy of these precautions to personnel assigned to work with laundry equipment prior to beginning their assignment.

2. Laundry Precautions

a. General Precautions

(1) See reference (a) concerning handling and stowage requirements for HAZMATs used in laundries.

(2) Personnel must use protective equipment listed in reference (a), SDS, or the current IH survey as required.

(3) Do not disable two-hand safety switches on any of the presses and ensure personnel using presses are trained in their safety precautions.

(4) Ensure ventilation systems and spot coolers are functioning in laundry and press areas, and that presses are provided with local exhaust ventilation.

(5) Ensure automated detergent dispensers are properly maintained and electrically grounded per reference (b) and PMS requirements.

b. Washer Extractor

(1) Thoroughly examine all clothing before cleaning; remove all foreign materials such as lighters, ink pens, and metallic objects.

(2) Ensure that the inner pocket door is firmly latched before operating the machine.

OPNAVINST 5100.19F 5 May 2019

C20-2 (3) Do not exceed the prescribed loading capacity of the cylinder; doing so may damage the machine or prove hazardous to personnel.

(4) Ensure the machine is entirely disconnected from the circuit before cleaning or servicing. Use safety tag-out procedures as required by reference (c) and PMS requirements.

(5) Ensure safety devices are maintained in proper working condition at all times. If removed or out of order for any reason, replace safety devices before the machine is put into operation.

(6) Use only approved detergents in recommended quantities. Ensure a neutralizer is used in the wash as residual detergent may cause skin irritation.

(7) Ensure safety precautions and operating procedures are posted.

c. Tumbler Dryer

(1) Never overload the machine.

(2) Never open the door while the tumbler is in motion.

(3) Before servicing or cleaning, be sure the power to the tumbler dryer is entirely disconnected. Use safety tag-out procedures as required by reference (c) and PMS.

(4) Maintain safety devices in proper working order at all times. If removed for any reason, replace safety devices before machine is put into motion.

(5) Ensure that the primary lint screen is checked and cleaned as required prior to use and after every drying cycle and at the end of the workday. Ensure the secondary lint filter (40- mesh) is cleaned after every 8 hours of operation and at the end of the workday.

(6) Ensure the laundry is manned and equipment is monitored while in operation.

(7) Ensure NAVSEA 1995/93 Preventing Laundry Dryer Fires are posted (S/N 0118-LF- 981-6600).

(8) Never allow the thermostatic control switch on the type 1 steam operated dryer to exceed 160 to 185 degrees Fahrenheit, plus or minus 10 degrees Fahrenheit, per reference (d).

d. Self-Service Laundries

(1) Ensure self-service laundry equipment is installed only in authorized areas, where dryer ventilation, drainage, and electrical service are provided.

OPNAVINST 5100.19F 5 May 2019

C20-3 (2) Post NAVSEA 1995/93 at each unit.

(3) Clean dryer primary lint filters after each use. Ensure the secondary lint filter (40- mesh) is cleaned after every 8 hours of operation.

(4) Dryer vents must be directed into an approved overboard exhaust, never to water filter units within the space.

OPNAVINST 5100.19F 5 May 2019

C21-1 SECTION C

CHAPTER 21

MEDICAL AND DENTAL FACILITIES

Ref: (a) BUMEDINST 6250.12D, Pesticide Applicator Training and Certification for Medical Personnel (b) NAVMED P-117, Manual of the Medical Department, Chapter 21, Pharmacy Operation and Drug Control (c) NSTM 670, Stowage, Handling, and Disposal of Hazardous General Use Consumables (d) OPNAV P-45-113-3-99, Afloat Medical Waste Management Guide

1. Discussion. This chapter contains basic safety precautions that medical and dental personnel must observe to protect themselves and their patients from harm. Consult operating manuals and PMS cards for complete safety precautions related to specific equipment.

2. Safety Precautions for Medical and Dental Facilities

a. Special Precautions

(1) Dispose of disposable needles and syringes in "sharps" containers as an entire unit.

(2) Keep all liquid pesticides under lock and key. Keep bulk amounts in a flammable liquid storeroom.

(3) Ensure that only medical department personnel who are certified as shipboard pest management specialists use pesticides per reference (a).

(4) Keep all poisons under lock and key.

(5) Double lock the pharmacy when not in use, with keys made available only to authorized personnel.

(6) Do not stow, use, or dispense methyl alcohol in the pharmacy.

(7) Account for methyl alcohol in same manner as ethyl alcohol and narcotics. Attach a prominent label to each container of methyl alcohol with clear warning of its dangerous qualities.

OPNAVINST 5100.19F 5 May 2019

C21-2 (8) Stow acids and bases in NAVSEASYSCOM-approved corrosive lockers segregated as required by references (b) and (c). Corrosive lockers may be stored in the medical storeroom or other spaces as required by reference (c). Contact the HAZMAT coordinator for assistance in determining proper storage locations.

(9) Stow a minimum working stock of flammable materials (e.g., alcohol and acetone) in a NAVSEASYSCOM-approved flammable locker in medical department spaces. Keep bulk stock in the flammable liquid storeroom.

(10) Ensure only medical department personnel handle bacteriological specimens.

(11) Due to a large number of extremely hazardous shipboard jobs requiring full attention at all times, label all medications affecting awareness.

(12) When handling and disposing of medical waste follow the guidelines in reference (d).

b. General Safety Precautions

(1) Do not permit any smoking, including use of e-cigarettes or vapes, in areas where oxygen is being administered.

(2) Secure all medical equipment having wheels when not in use. Use wheel blocks or securing straps for this purpose.

(3) Do not plug non-medical or personal electronic equipment into electrical outlets designated “for medical equipment use only.”

OPNAVINST 5100.19F 5 May 2019

C22-1 SECTION C

CHAPTER 22

CO2 FIXED FLOODING SYSTEMS

Ref: (a) NSTM, NAVSEA S9086-CH-STM-030/CH-074 V3, Gas Free Engineering

1. Discussion

a. This chapter contains basic safety precautions that personnel must observe to protect themselves from harm from carbon dioxide (CO 2) fixed flooding systems. Consult operating manuals and PMS MRCs for complete safety precautions related to specific items of equipment.

b. Follow the procedures and precautions in this chapter whenever performing corrective or preventive maintenance work inside or outside a space protected by a CO 2 fixed flooding system. This includes work on the CO2 fixed flooding system and in the immediate area of manual or electrical controls for the system.

c. This chapter discusses the health hazards of CO 2, general safety precautions, and procedures for disabling CO2 fixed flooding systems, for general maintenance and for rescue personnel.

d. CO 2 is a colorless, odorless gas that is naturally present in the atmosphere at an average concentration of 0.03 percent. It extinguishes fires at high concentrations by reducing the concentration of oxygen to the point that combustion stops. Concentrations of CO 2 in the range of 30 to 70 percent are needed to extinguish fires.

e. CO 2 for firefighting is stored as a liquid at high pressures. Upon discharge into a protected space, most of the liquid flashes to vapor and the rest forms fine, dry ice particles.

2. Health Hazards of CO2

a. CO 2 is 1.5 times heavier than air, and will collect at low points. Unless forced ventilation is provided, CO2 will remain in the protected space and may migrate to adjacent spaces, especially if they are lower than the protected space. Ship's personnel should be aware of this whenever they approach a room in which the CO 2 has discharged.

b. If CO 2 concentrations are greater than 30 percent, loss of consciousness will occur within half a minute. As the concentration increases further, cardiac arrest, brain damage due to lack of oxygen and even death might occur. The body reacts to concentrations less than 10 percent by rapid and deeper breathing, headaches, and vomiting.

OPNAVINST 5100.19F 5 May 2019

C22-2 c. Tests have shown that within 2 seconds of actuation of a CO2 fixed flooding system within a protected space, visibility is obstructed and within 3 seconds enough pressure has built up to prevent opening inward swinging doors.

3. Safety Precautions

a. Personnel performing work inside CO 2-protected spaces without a CO2 system time delay must ensure that inward swinging access doors are blocked open by a positive means, such as a C-clamp rigidly attached to the frame or door, to provide a minimum opening of 6 inches.

b. Ensure that the safety precautions in the below subparagraphs 3b(1) through 3b(9) are followed when working on the CO 2 system inside a CO2-protected space with the CO2 system functional.

(1) Do not begin work on a CO 2 fixed-flooding system until a safety briefing has been given to all personnel involved in the maintenance work, the assigned rescue personnel, and persons in areas susceptible to CO2 leakage.

(2) Verify that CO 2-protected space ventilation is in operation.

(3) Evacuate all personnel from the CO 2-protected space except those directly associated with the maintenance work. Evacuate all non-essential personnel from areas susceptible to CO2 leakage.

(4) Identify and be familiar with an escape path from the protected space and areas susceptible to leakage of CO 2 to a safe haven not susceptible to CO2 leakage.

(5) Verify that doors or hatches to the CO 2-protected space and from areas susceptible to CO2 leakage are blocked open and hatches or doors on the way to a well-ventilated space or to the weather are blocked open.

(6) Post temporary danger signs to warn personnel of the hazard and temporary warning signs to limit access to the CO 2-protected space and spaces susceptible to leakage of CO2. These signs should have lettering of at least 1 inch high. Danger signs must include the words, "DANGER - CARBON DIOXIDE GAS - WHEN ALARM SOUNDS - VACATE IMMEDIATELY." Post signs inside and at accesses to CO 2-protected spaces and inside all spaces susceptible to CO2 leakage.

(7) Ensure all personnel inside CO 2-protected spaces wear operating SCBA.

(8) Verify that all personnel in spaces susceptible to leakage of CO 2 have EEBDs immediately available.

OPNAVINST 5100.19F 5 May 2019

C22-3 (9) Ensure rescue personnel are assigned, equipped, and located per paragraph 6. Rescue personnel must maintain a count of personnel inside the CO2-protected space.

c. Ensure that the following safety precautions are followed when working on the CO2 system outside a CO2-protected space with the CO2 system functional. Follow the procedures listed in subparagraph 3b for work done inside the CO2-protected space with the exception of the following escape path procedures in subparagraphs 3c(1) and 3c(2).

(1) Verify that the doors and hatches to the CO 2-protected space are closed.

(2) Verify that the doors or hatches in the escape path are blocked open.

d. Test the alarm systems within the guidelines provided by the PMS cards.

e. Be aware that any movement of the cylinder or the pull cable can actuate the pull-cable actuation systems.

f. Be aware that the seawater sprinkling system controls look similar to components of the CO 2 fixed-flooding systems.

g. Be aware that CO 2 can be discharged from CO2 bottles if they are dropped and their discharge heads become damaged.

h. Take precautions not to accidentally rotate the CO2 cylinder in its brackets, thereby putting tension on the actuation cable.

i. Follow PMS procedures carefully during the process of removing and installing discharge and control heads to avoid accidental discharge of CO2.

4. General Procedures During Maintenance Work

a. Ensure that the DCA, the EOOW, cognizant department head, and the OOD, when underway, or the CDO, engineering department duty officer, cognizant department head, the OOD, and damage control central, when in-port, are notified and requested to be ready to respond immediately in case of an emergency before the work starts.

b. Ensure that all personnel directly involved follow tag-out procedures, including tag-out of all locations from which CO 2 discharge can be actuated.

c. The cognizant division officer must verify that all ship maintenance personnel involved in maintenance on CO 2 fixed-flooding systems meet the applicable personnel qualification standards and that knowledgeable, qualified supervision is assigned.

OPNAVINST 5100.19F 5 May 2019

C22-4 d. Ensure that any actuation of a CO2 discharge alarm, either audible or visual, is investigated. An alarm that continues longer than one minute is abnormal and should be immediately investigated.

e. When corrective or preventive maintenance work is being done on the CO 2 system, do not permit normal space functions and other maintenance work in the CO2-protected space.

5. Disabling Procedures

a. Always disable CO 2 fixed-flooding systems by removal of the discharge heads and removal of the CO2 cylinder control head, when installed.

b. Ensure that the period of time that a CO 2 fixed-flooding system is disabled is limited whenever flammable material is in the CO2 protected space.

c. Establish backup flammable liquid firefighting capabilities (such as an aqueous film forming foam hose or a seawater hose with a 5-gallon can of aqueous film forming foam concentrate and a portable educator) during the period the CO 2 system is disabled.

d. Establish fire watches during the period that the CO2 system is disabled.

6. Rescue Personnel Procedures

a. Ensure that a minimum of two rescue personnel are assigned. Assign additional personnel when more than four maintenance personnel are present using a ratio of one rescue person for each two maintenance personnel.

b. Locate rescue personnel at or near the access to the CO 2-protected space in which the maintenance work is being performed or in the area in which the work is being done outside the CO 2-protected space. Position rescue personnel so that they can monitor maintenance personnel, as well as space and area conditions.

c. One rescue person must have communications, such as a sound-powered phone, with a manned location such as damage control central, main control, the quarterdeck, or the bridge.

d. Equip assigned, qualified rescue personnel with SCBA and ensure they are capable of providing CPR.

e. Once accidental discharge of CO 2 has occurred; rescue personnel should do the following contained in subparagraphs 6e(1) through 6e(9).

(1) Inform DC central, main control, and the quarterdeck (when in port) or the bridge (when underway) of the emergency and request assistance, including medical assistance.

OPNAVINST 5100.19F 5 May 2019

C22-5 (2) Help maintenance personnel escape.

(3) Count personnel leaving area to assure all personnel have departed.

(4) Search for personnel who have not departed and assist them to escape.

(5) Verify that space in which CO 2 is dumped is free of personnel and then close the access door or hatch to reduce spread of CO2 to other areas of the ship or space.

(6) Proceed to a safe haven.

(7) Perform CPR on any personnel that require help until assistance arrives.

(8) Report status of escape to operating station.

(9) Start ventilation to space.

f. Rescue personnel must wear PPE (e.g., SCBA) appropriate for entry into IDLH atmospheres (refer to reference (a)).