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1. Sponsored by
OVERCOMING THE CHALLENGES OF
IMPLEMENTING A LOCKOUT PROGRAM
CSA Z460-13 BEST PRACTICES
for CANADA
Master Lock Safety Solutions

2. 2
■ 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

3. 3
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

4. 4
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)

5. 5
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

6. 6
■ 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.

7. 7
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.

8. 8
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 ?

9. 9
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.

10. 10
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

11. 11
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.

12. 12
Example:

13. 13
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”

14. 14
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

15. 15
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

16. 16
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.

17. 17
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

18. 18
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.

19. 19
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

20. 20
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.

21. 21
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.

22. 22
■ 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

23. 23
■ 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

24. 24
■ 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

25. 7 STEP PROCESS FOR
LOCKOUT
& SAFE RE-ENERGIZATION

26. 26
■ 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

27. 27
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.

28. 28
■ 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

29. 29
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.

30. 30
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

31. 31
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:

32. QUESTIONS OR COMMENTS?
OVERCOMING THE CHALLENGES OF
IMPLEMENTING A LOCKOUT PROGRAM
CSA Z460-13 BEST PRACTICES
for CANADA
Master Lock Safety Solutions
Sponsored by