CSA Z460

1
CSA Z460 Control of Hazardous Energy- Lockout and
Other Methods Presented by Len Cicero
2
CSA Z460 Control of Hazardous Energy- Lockout and
Other Methods
A Brief History
3
CSAs new Z460 Standard- Control of Hazardous
Energy- Lockout and Other Methods was developed
due to a lack of understanding and measurable
consistency in the field regarding lockout
principles, and also by the rapidly changing
technology and automation related complex
industrial machinery
4
Who Will Z460 Apply to?

• Manufacturing facilities
• Machine Shops
• Robotics
• Refineries
• Print Shops
• Electrical Generation and Distribution
• Industrial Installation Contractors
• Maintenance

5
Control of Hazardous Energy

• Legislation (Ontario)
• Section 75, 76, 78 (1)
• Servicing and/ or maintenance/ repair where
• the unexpected energization, start up or release
  of stored energy could cause injury to a worker

6
Control of Hazardous Energy

• Other Legislation (Ontario)
• Section 42 requires
• Written procedures lockout and tagging of
  electrical equipment before any work is done
• Section 68 requires
• Lockout of mechanical equipment prior to the
  entry into a confined space

7
CSA Z460

• Fills gaps found in existing OHS Regulations
• Provides details for an effective Lockout
  Program
• Lockout Devices and Associated Hardware
• Definitions
• Group Lockout
• Change of Shift
• Lockout and tag removal when worker absent

8
Important Elements of an EffectiveLockout Program
Written Policy Procedures
Hardware (devices)
Training Communication
9
Hazardous Energy Control Program

• User Responsibilities (Clause 7.1)
• Program
• The User shall establish a written program for
  hazardous energy control. The purpose of the such
  programs is to ensure that risk of exposure to
  the hazards identified will be eliminated or
  minimized before any authorized individual
  performs any activity on a machine, equipment, or
  process where the inadvertent energizing, startup
  or release of stored energy could occur and cause
  injury.
• Annex D Sample Written Program/ Policy

10
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Hazardous Energy Control Procedures (7.3.2.2)
• Each unique machine, piece of equipment, system
  or process shall have detailed lockout procedures
  developed and documented for the control of
  hazardous energy for any servicing or maintenance
  activities.
• These Lockout procedures shall be posted or
  otherwise readily available for the authorized
  individuals to review and use.

11
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Where a plant or facility has two or more
  pieces of similar equipment or two or more
  identical machines or process lines, a single
  lockout procedure may be applied.
• Sample Lockout Procedures (Placards) Annex E

12
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Energy Isolating Device Identification (7.3.2.6)
• All energy isolation devices shall be labeled or
  marked using a standardized nomenclature and
  format to indicate their function. The
  information shall include the following
• machine, equipment or process supplied
• energy type and magnitude
• The marking shall be of sufficient durability to
  withstand the anticipated environment

13
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Energy Isolating Device Identification (7.3.2.6)

14
CSA Requirements

• Communication and Training (Clause 7.5)
• Communication (Clause 7.5.1)
• Users shall be responsible for informing all
  personnel about the provisions of the hazardous
  energy control program to an appropriate level.
  Users shall also be responsible for informing
  appropriate authorized individuals about aspects
  of the hazardous energy control program such as
  changes in the program, incident experiences,
  progress against the plan to achieve adequate
  risk reduction, performance data, and auditing
  results.

15
CSA Z460 Requirements

• Communication and Training (Clause 7.5)
• Training (Clause 7.5.2)
• The user shall provide the initial training that
  will ensure that all authorized individuals
  understand the purpose and function of the
  control program to an extent appropriate for the
  level of hazard exposure they will encounter. The
  training program shall comply with the following
  requirements
• Individual training shall be carried out prior to
  authorized individuals performing service and
  maintenance tasks or being potentially exposed to
  hazardous energy
• Training shall be specific to the users program
• The training program shall be developed using
  applicable manufacturers documentation, industry
  best practices, regulatory requirements, and
  input from the authorized individuals

16
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Lockout Devices and Associated Hardware (7.3.2.5)
• All protective materials and hardware required
  for effective isolation of energy shall be
  provided by the user. All lockout devices
  (including all tags used with lockout devices)
  shall be
• Uniquely identified
• The only devices used for controlling hazardous
  energy
• Used for lockout purposes only
• Capable of withstanding the environment to which
  they are exposed

17
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Lockout Devices and Associated Hardware (7.3.2.5)
  
• standardized within the facility in at least one
  of the following criteria
• colour
• shape
• Size
• or specific markings
• substantial enough to prevent the operation of
  the energy isolating device without the use of
  excessive force, unusual measures, or destructive
  techniques- such as the use of bolt cutters or
  other metal- cutting tools

18
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Lockout Devices and Associated Hardware (7.3.2.5)
• An information tag shall be used with each
  lockout device unless the lockout device itself
  the required information attached

19
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Lockout Devices and Associated Hardware (7.3.2.5)
• Each lockout device, and tag if used, shall
  indicate the identity of the authorized
  individual who applied the device(s), and may
  include the date and the reason for the lockout.
  The information shall remain legible for the
  maximum period of time that exposure is expected.
  

20
CSA Z460

• Lockout (CSA Z460 References)
• For Servicing or maintenance/ repair activities-
• - Individual Lockout (7.3.7.1 of CSA Z460)
• - Group Lockout (7.3.7.2 of CSA Z460)
• - Single Lock box, master/ satellite lock box
• - Job locks on master lock boxes for various
• groups.
• - Complex Group Lockout (7.3.7.3 of CSA Z460)
• approval from regulatory authority
  having jurisdiction
• required

21
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Individual Lockout (7.3.7.1)
• Designed to cover maintenance of a very basic
  nature, Individual Lockout requires each and
  every worker involved in activities requiring
  lockout to be knowledgeable of the hazards
  associated with the work and the isolation
  required to eliminate those hazards and to apply
  their own worker locks to the devices needed for
  their protection. They must each then ensure
  before work begins that they verify the machine,
  equipment or process is de-energized.

22
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Group Lockout (7.3.7.2)
• Designed to cover instances where there will be a
  number of workers associated with the activities
  requiring isolation, each energy isolating
  device is secured by using a single lockout with
  the keys placed into a Lock Box or other lockable
  device. The workers involved then assess the
  adequacy of the isolation and when satisfied
  place their own lock on the Lockable device to
  control the keys. They must then verify the
  machine, equipment or process is de-energized
  before allowing work to begin.

23
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Complex Group Lockout (7.3.7.3)
• Complex Group Lockout should be considered for
  those situations where it is not practical for a
  workplace to directly comply with the Individual
  Lockout or Group Lockout approach to Hazardous
  Energy Control because of one or more of the
  following
• The physical extent of the equipment or process
  being serviced
• The relative inaccessibility of the
  energy-isolating devices
• The number of individuals performing the service
  and maintenance activities

24
CSA Z460 Requirements

• Lockout Program (Clause 7.3)
• Complex Group Lockout (7.3.7.3)
• e) The number of energy-isolating devices to be
  isolated
• f) The length of time the equipment or process
  will be isolated
• g) The number of authorized individuals involved
  or
• h) The interdependence and interrelationship of
  the components in the system or between different
  systems.

25
CSA Z460 Requirements

• Other Topics Include
• a) Lock and Tag removals (worker absent)
• b) Shift or Personnel Changes
• c) Outside Service or Contractor Personnel
• d) Definitions
• e) Manufacturer, Integrator, Modifier, Re-
  Manufacturer

26
CSA Z460 Requirements

• Allows provisions for operation tasks (non
  maintenance repair tasks)
• Lockout is recognized as the primary method of
  Hazardous Energy Control.

27
CSA Z460 Requirements

• Other Hazardous Energy Control Methods (Clause
  7.4)
• General (Clause 7.4.1)
• Traditional Lockout to a full zero energy state
  is not practicable in all situations. When
  lockout affects tasks that are integral to the
  production process by design, or traditional
  lockout prohibits the completion of specific
  tasks, other hazardous energy control methods
  shall be used.

28
Hazardous Energy Control Program

• Other Control Methods (Clause 7.4)
• Appropriate Tasks for Other Control Methods
  (Clause 7.4.2.1)
• To be considered integral to production,
  designed tasks shall exhibit most of the
  following characteristics
• Of short duration
• Relatively minor in nature
• Occurring frequently during the shift or
  production day
• Usually performed by operators or others
  functioning as operators
• 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.

29
CSA Z460 Requirements

• Selection of Other Control Methods (Clause 7.4.3)
• The user shall select other control methods that
  are designed so that adequate risk reduction has
  been achieved. The RISK ASSESSMENT shall take
  into consideration the fact that it is possible
  that existing safeguards provided with the
  machine, equipment, or process will need to be
  removed or modified to perform a given task. The
  Other Control Method selected shall have detailed
  procedures developed and documented for the
  control of hazardous energy.

30
CSA Z460 Requirements

Decision Logic for Selecting Method of Hazardous
Energy Control
31
(No Transcript)