USCG safety alert: Hot work and lockout/tagout compliance

The United States Coast Guard issued a Safety Alert in response to a recent marine casualty involving a fire and severe injuries to two crewmembers. The incident occurred due to the combination of hot work being performed in a hazardous area, the use of Liquefied Natural Gas (LNG) as a fuel source, and a failure to properly implement lockout/tagout procedures.

The accident involved a tri-fueled vessel (powered by LNG, diesel, and battery) where two crewmembers were conducting hot work on the air castle deck. Unknowingly, they were performing work in an area where LNG was being used as the active fuel source. Had the crew known that LNG was in use at the time, they would have avoided this hazardous area. The situation was made worse by a malfunctioning actuator for the engine’s purge valve, which caused methane vapors to escape into the hot work area. Believing the area was gas-free, the crewmembers struck a lighter, igniting the methane and resulting in a fire and severe burns to the two individuals.

The Coast Guard’s investigation highlights the critical need for vessels using LNG as a fuel to implement proper safety protocols. The International Code of Safety For Ships Using Gases or Other Low-Flashpoint Fuels (IGF Code) requires that hot work near fuel tanks, fuel piping, and insulation systems—particularly in areas where flammable gases or hydrocarbons may be present—should only be conducted after the area is proven to be safe. Although the IGF Code was not directly applicable to this specific vessel, the USCG strongly recommends that this guideline be followed on all vessels operating with LNG.

The Coast Guard urges vessel owners, operators, and stakeholders to take several key actions to prevent similar incidents:

Review and Implement Lockout/Tagout Procedures: Ensure that all LNG systems are properly tagged out before beginning any hot work in or near hazardous areas. Crewmembers must verify the lockout/tagout status of these systems to confirm they are de-energized and safe to work on.
Develop Multi-Fuel System Procedures: Establish comprehensive procedures that ensure all crewmembers are aware of the specific hazards associated with multi-fuel systems. This includes clear guidelines on what work can be performed based on the active fuel type (e.g., LNG, diesel, or battery).

Marine inspectors, investigators, and surveyors are also encouraged to remain vigilant and take corrective actions when necessary to address potential safety concerns on vessels.

This Safety Alert serves as an informational resource and is not intended to relieve any domestic or international safety, operational, or material requirements. The alert was developed by Marine Safety Unit Houma and distributed by the Office of Investigations and Casualty Analysis. For further inquiries, stakeholders can contact the USCG at HQS-SMB-CG-INV@uscg.mil.