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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.
:
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