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OVERCOMING THE CHALLENGES OF IMPLEMENTING A LOCKOUT PROGRAM

CSA Z460-13 BEST PRACTICES for CANADA

Master Lock Safety Solutions

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■  CSA Z460 Background and information sources

■  Lockout Program Requirements

■  Process for Lockout and re-energization

■  Applying Lockout - challenges and resolutions –  Written procedure development –  Authorized and Affected personnel training –  Periodic Auditing –  Working with Contractors –  Outside personnel and shift changes

■  Questions and Comments

Agenda

Your Questions and Comments are always Welcome

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Lockout is the process of controlling hazardous energy during the service and maintenance of machinery and equipment

What is Lockout?

■  Specific work safety procedures and practices that safeguard employees from: –  The unexpected powering or start up of machinery or

equipment –  The release of hazardous energy during service or

maintenance activities

■  Hazardous energy sources are isolated and inoperative before any service procedure is started

■  Facilities are responsible for developing a Lockout program which clearly outlines the process for isolating hazardous energy –  How to Lockout each piece of equipment –  Who is authorized to complete Lockout –  Use of padlocks and devices

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CSA Z460 Lockout Standard

The CSA Z460 Lockout Standard ■  Control of Hazardous Energy—Lockout and other Methods

(Updated in 2013) Originated by the CSA in 2005 in it’s first release ■  Industry consensus standard, not law unless cited in Canadian

Provincial or Territorial regulations ■  Establishes best practices and details specific methods/examples of

how to implement ■  Based on U.S. OSHA regulatory requirements found in 29

CFR1910.147 (Lockout / Tagout for General Industry) ■  Based on the American National Standards Institute ANSI Z244.1

Standard (recently updated in 2008)

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Canada – Labour Program Human Resources and Skills Development Canada Alberta – Workplace Health and Safety British Columbia – WorkSafeBC Manitoba – SAFE Manitoba New Brunswick – WorkSafeNB Newfoundland and Labrador – Occupational Health and Safety Branch; Service NL Northwest Territories and Nunavut – Workers’ Safety and Compensation Commission of the Northwest Territories and Nunavut Nova Scotia – Occupational Health & Safety Division; Nova Scotia Labour and Advanced Education Ontario – Occupational Health and Safety Branch; Ministry of Labour Prince Edward Island – Safe Workplaces; Workers’ Compensation Board Quebec – Commission de la santé et de la sécurité du travail du Québec Saskatchewan – Occupational Health and Safety; Ministry of Labour Relations and Workplace Safety Yukon – Yukon Worker’s Compensation, Health and Safety Board; Occupational Health and Safety Branch

CSA Standards are provided to support existing regulations and legislation enforced across Canada by Provincial and Territorial Government Agencies and are recognized to be Best Practice Guidelines

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■  An employee must either remove or bypass machine guards or other safety devices, resulting in exposure to hazards at the point of operation;

■  An employee is required to place any part of his/her body in contact with the point of operation of the operational machine or piece of equipment;

■  or the employee is required to place any part of his or her body into a danger zone associated with a machine operating cycle.

When does Lockout need to be used?

Generally, normal production operations are not covered by the standard. But they are covered whenever . . .

According to the standard, servicing and maintenance are defined to include the following:

■  erecting, installing, constructing, repairing, adjusting, inspecting, unjamming, setting up, troubleshooting, testing, cleaning, dismantling, servicing, and maintaining machines, equipment, or processes.

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Top 5 contributing factors to fatalities resulting from failure to implement Lockout

Factors Contributing to Deaths and Serious Injuries

■  Failure to stop equipment

■  Failure to disconnect equipment from power source

■  Failure to dissipate stored/residual energy

■  Accidental restarting of equipment

■  Failure to clear work area before restarting equipment

–  Hundreds of Fatalities and thousands of serious injuries are caused annually by the failure to effectively Lockout equipment to prevent unexpected startup.

–  Lockout related injury claims and deficiency concerns are among the most commonly

listed actionable items by insurance company loss prevention and risk evaluation experts and negatively impact insurance premiums.

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Lockout Involves the placement of a secured Lockout device on an energy isolating device such as a valve, breaker or disconnect switch, in accordance with an established procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the Lockout device is removed.

■  CSA Z460 requires that if an energy isolating device is capable of being locked out, a lock must be used to secure the device, unless it can be clearly demonstrated that the utilization of a system will provide equivalent full employee protection.

An alternative measure considered by CSA Z460 called Tagout is allowed in the U.S. It involves the placement of prominent warning tags on energy isolating devices with a secure means of single use attachment, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tag and control device is removed. A high level of communication and understanding of tagout limitations is required among all personnel where this technique is used.

In addition – at least one other method of protecting personnel must also be utilized such as;

•  removing and isolating a circuit element •  blocking a controlling switch •  opening an extra disconnecting device; •  removing a valve handle.

How is Lockout different from Tagout ?

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Minor tool changes, servicing activities and adjustments do not require Lockout to be applied so long as they are “routine, repetitive, and integral to the use of the equipment” for production--as long as the work is performed using alternative measures of effective protection.

■  Alternative measures must assure that the worker wont be harmed during these exceptions because a safe distance or an adequate temporary shielding method is used to protect them against accidental movement or energization.

■  Interlocked guards or emergency stops are not considered effective protection by themselves because they only affect control circuitry and not the actual energy sources that could cause harm.

Lockout Application Exception

Limited allowances are made for:

BEST  PRACTICE:    Be  conserva+ve  when  determining  if  this  allowance  applies  to  a  produc+on  task.  If  you  are  not  ac+vely  suppor+ng  a  produc+ve  process  (i.e.  not  fixing  a  problem)  and  someone  could  get  hurt,  this  excep+on  clearly  does  not  apply.  

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To be considered integral to production, tasks shall exhibit most of the following characteristics:

■  be of short duration;

■  relatively minor in nature;

■  occurring frequently during the shift or production day;

■  usually performed by operators, set-up persons, and maintenance personnel;

■  represent predetermined cyclical activities;

■  minimally interrupt the operation of the production process;

■  exist even when optimal operating levels are achieved; and

■  require task-specific personnel training.

Integral to Production – An Exception to Lockout

According to CSA Z460-13

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All tasks associated with the intended use and reasonably foreseeable misuse of machines, equipment, and processes shall be identified. Task identification should take into account (but not be limited to) the following categories:

CSA Z460 Task Hazard Assessment

THA is an essential first step in developing a machine specific Lockout procedure

§  machine/process set-up;  §  teaching and programming;  §  tryout and start-up;  §  all modes of operation;  §  product feeding into machine/process;  §  product takeoff from machine/process;  §  process/tool changeover;  §  normal stoppages and restart;  

§  unscheduled stoppages (control failure or jam) and restart;

§  emergency stoppages and restart; §  unexpected start-up; §  fault-finding and troubleshooting; §  cleaning and housekeeping; §  planned maintenance and repair; §  unplanned maintenance and repair.

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Example:

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HIRAC Risk Matrix

Note: A frequency rating of “Rarely” does not qualify for OSHA’s description of “routine, and repetitive repetitive, and integral to the use of the equipment for production”

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Type of Energy

Electrical Mechanical Hydraulic Pneu matic Chemical Thermal Gravity

Example of Sources

Electrical work

Rotating machinery

Lines, pumps and cylinders

Compressed air system

Chemical dispensing

Refrigeration/ heating

units

Shifting or falling

objects

Residual Energy

Capacitors and

secondary or backup circuits

Spin down time, torque

release, load shift

movement

Captured pressure in

lines or equipment

Captured pressure in

lines or equipment

Toxic or flammable

liquid or gas residue

Warm up or cool down

period

Release of power or linkage causes

movement

Potential Dangers

Burns, electrocution,

shock, equipment damage

Amputations, lacerations, fractures, crushing injuries

Similar trauma from movement, hydraulic oil

injection injuries

Similar trauma from movement, embolic air

injection injuries

Skin and, eye injuries, inhalation injuries, organ

damage

Heat burns, heat

exhaustion frostbite,

hypothermia

Amputations, lacerations, fractures, crushing injuries

w/trapping

Hazardous Energy Sources

Hazardous energy comes in many different forms, all of which are potentially harmful to workers

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CSA Z460 Requirements: Lockout Program

Minimum program requirements for CSA Z460 Compliant Lockout / Program Element Description Benefit

Written Program and Machine specific Lockout

procedures

Details of methods and responsibilities. Clear instructions

ensure authorized workers know the process for locking out equipment

Lockout training for authorized and affected and “other”

employees

Employees are prepared to recognize their duties under their

employer’s Lockout program

Adequate supply of appropriate Lockout devices and padlocks

Hazardous energy sources can be securely and safely locked out

Annual auditing of written procedures and authorized

personnel

Verifies that procedures are accurate and updated to reflect current

equipment

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According to CSA Z460-13 a lockout program shall consist of the following elements to effectively protect personnel:

Written Hazardous Energy Control Program

■  identification of the hazardous energy covered by the program;

■  identification of the types of energy-isolating devices;

■  identification of the types of de-energizing devices (permanently installed or portable);

■  selection and procurement of protective materials and hardware;

■  assignment of duties and responsibilities;

■  determination of shutdown, de-energization, energization, and start-up sequences;

■  documented lockout procedures for machines, equipment, and processes;

■  training of personnel; and

■  auditing of program elements.

BEST  PRACTICE:    Write  your  program  to  be  a  user  friendly  guide  and  teaching  tool  to  allow  the  use  of  the  applicable  sec+ons  of  your  program  verba+m  in  your  Authorized  and  Affected  personnel  training  and  retraining.      

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Visual Lockout procedures identify the steps required for locking out hazardous energy sources

Lockout Procedures

■  A machine specific Lockout procedure is required for any equipment with: –  More than one energy source –  Unique power connections –  A particular sequence of steps required to shut

down the equipment

■  A common method of hazard assessment includes: –  Identifying the Machine Type –  Serial number and/or identification –  Itemize all energy source(s) –  Identify the isolation method/device –  Identify residual hazards or other conditions that may

create exposures

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Lockout procedures outline the appropriate steps that an authorized employee must complete to adequately Lockout equipment

Lockout Procedures

■  Includes the rules, regulations, and various techniques that can be employed in the control of hazardous energy, such as: –  Procedural steps for shutting down, isolating,

blocking and securing machines or equipment to control hazardous energy

–  Procedural steps for the placement, removal and transfer of Lockout devices or

–  Instructions for testing a machine or equipment to verify the effectiveness of Lockout devices, devices, and to the energy control measures

BEST  PRACTICE:    Provide  quick  access  to  the  procedures  that  are  used  oGen  by  pos+ng  them  near  the  point  of  use.    A  user  friendly  format  makes  them  easy  to  apply.  Be  sure  to  write  up  a  new  procedure  following  a  checklist  approach  prior  to  working  on  an  undocumented  machine.      

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Employee Training and Communication

■  According to the CSA Z460 standard, employers are responsible for providing the following: –  effective initial training –  certification that training has been given to all

employees covered by the standard. –  periodic retraining as necessary

■  Amount and kind of training that each employee receives is based upon: –  The relationship of that employee’s job to the

machine or equipment being locked or tagged out –  the degree of knowledge relevant to hazardous

energy that he/she must possess - need to know

Employees must be trained so they understand the purpose and function of their facility’s Lockout program

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There are TWO types of employees involved in a Lockout program

Employee Training and Communication

■  Authorized employees must receive training on: –  The ability to recognize applicable hazardous energy sources –  The details about the type and magnitude of the hazardous

energy sources present in the workplace –  The methods & means necessary to isolate and control those

energy sources –  Any additional responsibilities under their employer’s Lockout

program

BEST  PRACTICE:    Realis+cally  op+mize  the  number  of  your  Authorized  personnel  so  those  who  will  have  to  come   in  contact  with  machine  ac+on  areas  are  properly   trained  and  equipped.  Most  companies  do  not  train  enough  Authorized  personnel    and  rely  on  maintenance  personnel  or  crew  leaders  to  be  called  in  to  help.    Take  a  real  world  look  at  who  is  opening  guarded  areas  without  protec+on  and  either  train  them   to   be   Authorized   to   Lockout   make   them   aware   of   the   consequences   if   they   do   not   wait   for  assistance.  

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Employee Training and Communication

■  Affected employees must receive training on the purpose of the energy control procedures and to stay away while Lockout has been applied in their work area.

–  They are prohibited from performing servicing, repairs or maintenance where machine guards must be removed or opened, or contact is required with the equipment where the unexpected release of energy or movement would expose them to a hazard.

–  Whenever there is a Lockout device in place on an energy-isolating device, the “affected” or “other” employee must leave it alone and not attempt to energize or operate the equipment.

–  They must understand the purpose, function, and restrictions of the Lockout Program and be able to recognize applied energy control devices

BEST  PRACTICE:  Peripheral  personnel  basically  need   to  know     that   the  Lockout  program  exists  and  how  to  recognize  locked  out    equipment  in  the  workplace  and  can  oGen  be  training  in  a  brief  session  that   shows   them   the   types   of   Lockout   equipment   used   in   the   facility.   This   can   also   be   posted  informa+on  or  a  distributed  handout.    Documenta+on  of  who  received  this  training  is  required.  

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■  supervision or inspections indicate that the individual is not complying with a hazardous energy control program;

■  changed or new technology, equipment, job assignment, or procedures necessitate the use of a hazardous energy control program that is different from that the individual would normally use; or

■  the individual needs to employ a hazardous energy control program that is not normally used during regular job duties.

Employee Retraining

According to CSA Z460, periodic re-training is required at intervals not to exceed 3 years to maintain an appropriate level of understanding. The content of this refresher training shall be based on known hazards and risk assessment for the planned work activities and working conditions and must receive additional training if:

BEST  PRACTICE:    Document  deficiencies  in  the  form  of  a  spontaneous  Lockout  audit  that  specifies  retraining  as  a  correc+ve  ac+on.    This  gets  the  problems  noted  on  the  record,  helps  you  to  priori+ze  correc+ve  ac+on,  and  makes  your  audi+ng  program  very  +mely  and  demonstrates  it’s  effec+veness  

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■  A measurement system that is capable of providing qualitative and quantitative feedback on hazardous energy control performance should be established.

■  Emphasis should be placed on both operational and maintenance personnel who are directly involved in hazardous energy control application.

■  Criteria that provide a basis for repetitive measurement should be established.

■  Management should compare results and determine whether there is a positive or negative change in any program element.

■  A summary should include trends, variances, rates of compliance, key findings and observations, and recommendations for program improvement.

■  A continual auditing plan must be established for specific hazardous energy control procedures that will provide current information on maintenance of application effectiveness. The user shall be responsible for executing the auditing plan to verify that complete compliance is occurring.

Program monitoring, measuring, and assessing components should be included in the program review.

Inspections/Audits

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■  Auditing shall be conducted at least annually and documentation shall be maintained for at least three years. The user should determine the frequency of monitoring (e.g., monthly) and an appropriate specific hazardous energy control procedure application sample size.

■  The application effectiveness audits should be random and address all shifts, days of operation, groups, non-standard work situations, and individual personnel. Knowledgeable personnel should conduct visual observations of authorized individuals performing specific hazardous energy control tasks. These observations should include feedback to the authorized individuals and documentation of the findings and any recommended improvements.

■  Performance feedback: The user shall establish a system for providing both positive and negative feedback on the hazardous energy control program to supervisors and other appropriate personnel.

■  Where deficiencies are found, corrective action shall be taken and the appropriate individuals informed of the required improvements.

Inspections/Audits

Application of specific procedures:

BEST  PRACTICE:    Audi+ng  is  best  done  progressively  throughout  the  course  of  the  year.  Break  down  the  number  of  authorized  personnel  to  be  audited  and  divide  over  9  months.    That  leaves  3  months  to  catch  the  ones  you  missed.    Be  aPen+ve  to  what  equipment  is  being  locked  out  so  you  can  audit  the  wriPen  procedure  when  it  is  ac+vely  being  used.    Use  the  9  mo./3  mo.  strategy  to  have  plenty  of  +me  to  meet  CSA  Z460  Lockout  procedure  audit  requirements  

7 STEP PROCESS FOR LOCKOUT

& SAFE RE-ENERGIZATION

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■  Step 1: Prepare for shutdown –  get all required tools Lockout gear and repair materials ready

■  Step 2: Notify Affected workers –  the machine is being locked out

■  Step 3: Shutdown the equipment –  Use normal shut down procedure

■  Step 4: Isolate the equipment –  Find all energy sources and turn them off or physically secure them to prevent movement

■  Step 5: Apply Lockout devices and padlocks –  One lock per energy source for each Authorized worker

■  Step 6: Release stored energy –  Bleed, purge or ground systems – see Lockout procedure for details

■  Step 7: Verification of a Zero Energy Condition –  Test controls for any remaining operational energy sources and return controls to the “off” position

The Lockout Process

This seven step process that should be followed in order to safely Lockout equipment and machinery

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Lockout Verification

■  As an important precautionary measure, the authorized employee must check to confirm that:

–  The equipment is properly shut down

–  The energy sources have been isolated

–  Lockout and devices are in place

–  Residual energy sources have been neutralized

–  The equipment is disconnected from the energy source(s) by first checking that no personnel are exposed, then verify the isolation of the equipment by trying to make the machine function using the normal operating control(s) to make certain the equipment will not operate

–  Metered testing of electrical circuits by qualified personnel may also be required for certain tasks

■  Once a zero energy condition is verified, return all tested controls to their “off” position

BEST  PRACTICE:    Electrical  Safe  Work  Prac+ces  requires  meter  tes+ng  of  electrical  circuits  to  verify  zero  energy  if  a  contact  shock/burn    hazard  could  exist.    Be  sure  personnel  who  do  this  tes+ng  are  qualified  to  perform  this  skill  when  working  around  open  conductors.  

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■  Step 1: Clear the machine of all personnel, tools and extra repair materials –  Replace and secure all guards that were removed for the task –  Scan carefully to be sure everyone is clear

■  Step 2: Be sure that locks and Lockout devices are removed ONLY by those authorized employees who placed them

■  Step 3: Restore energy to the machine according to the written Lockout procedure

■  Step 4: Notify all Affected employees that the Lockout has been removed and the machine has been energized and they will be notified again when it is safe to return to work

■  Step 5: Verify proper operation and ready to run conditions

■  Testing or positioning of a machine –  CSA Z460 allows the temporary removal of locks or tags and re energization of the machine or equipment ONLY when

power is needed for the testing or positioning of machines or components. If additional work is needed following testing, repeat the notification of affected workers, isolate the machine or equipment from the energy source, and reapply Lockout devices according to the Lockout procedure before resuming repairs. Repeat until ready to run.

■  Step 6: Notify Affected employees they may resume their normal assignments.

Removal of Lockout equipment and Safe Return to Service

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Whenever Contractors are hired to perform work in facilities involving activities covered by the Lockout standard, the following must take place:

Working with Contractors

■  The hosting employer and the contractor must inform each other of their respective Lockout procedures. –  Determine whose energy control program will be applied to the contracted work to be performed –  Provide existing Lockout written procedure to contractors for the equipment they will be working on. –  Assure that new procedures are prepared for all undocumented equipment to be serviced or newly

installed before workers are exposed to potentially hazardous conditions.

■  The host employer shall ensure their employees understand and comply with the restrictions and prohibitions of the contractor’s energy control program –  (if it is chosen as the applicable program for the work to be performed)

■  The host employer should be sufficiently aware of the contractor activities to recognize if procedures are being followed and precautions are adequate to prevent accidents.

■  Contractors should be prepared and equipped to perform all required lockout procedures Their preparation should have provided for all the necessary Lockout equipment to perform the contracted work safely.

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Specific procedures shall be utilized during shift or personnel changes to ensure the continuity of Lockout protection

Shift or Personnel Changes

■  This includes providing for the orderly transfer of Lockout device protection between outgoing and incoming employees, to minimize exposure to hazards from the unexpected energization or start-up of the machine or equipment, or the release of stored energy.

■  Shift or Personnel Changes –  Changes in task must be coordinated and details communicated –  Locks/devices changed together to assure continuity of Lockout and avoid overlooking Lockout

devices that may have to be removed by the emergency procedure if the off-going employee is unavailable

■  Be sure to notify incoming Affected Employees that Lockout is in place

■  Be sure to re-test all operating controls to verify energy is truly neutralized –  don’t count on the last crew to verify your safety –  Replace controls in off/neutral position

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1.  Notify the person’s supervisor. 2.  Ensure that the person is not on the premises.

3.  Attempt to contact him/her at home.

4.  Management authorizes the removal of the lock/tags according to the emergency removal procedure.

5.  Document the removal activity.

6.  Notify the Authorized Employee prior to his/her returning to work.

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Emergency Removal Requirements

Locks/Tags should only be removed by the Authorized Employee who affixed the lock/tag. Employers are required to have an Emergency Removal Procedure

If it becomes necessary to remove a lock/tag that has inadvertently been left by an employee, the following steps must be followed:

QUESTIONS OR COMMENTS?

OVERCOMING THE CHALLENGES OF IMPLEMENTING A LOCKOUT PROGRAM

CSA Z460-13 BEST PRACTICES for CANADA

Master Lock Safety Solutions

Sponsored by