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River East Transcona School Division
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Lockout Program

 Safe Operating Procedure



 Abstract





 Document Control

A. System
RETSD Quality Management System
B. System ID
​QMS-000043
C. Sector
​Workplace Safety and Health Management System
D. Sector ID
​WSHMS-02B-SOP-013-02
E. Domain
​Public
F. Repository
​Divisional SharePoint Website
G. Audience
​All Staff
H. Status
​Current
I. Title:
Lockout Program
J. Format
​HTML
K. Type
​Safe Operating Procedure
L. Tags

M. Origin
​2010-08-31
N. Reviewed

O. Revised
P. Owner
​Manager, Workplace Safety and Health and Administrative Services
Q. Owner Email
​safetyofficer@retsd.mb.ca
R. Primary Approval
​Divisional  Workplace Safety and Health Committee
S. Department Approval
​Director of Human Resources
T. Senior Administration  Approval
​Assistant Superintendent - Human Resources 
U. Board Approval
​GBG Workplace Safety and Health
V. Notes

W. Scheduled Review

X. File Address
Y. User Defined 1

Z. User Defined 2



 Safe Operating Procedure Controlled Document

WSHMS-02B-SOP-013-02

PURPOSE

 

To establish divisional expectations and standards regarding a lockout program at River East Transcona School Division (RETSD) that meets or exceeds all municipal, federal and provincial legislated workplace safety and health program requirements.

 

A lockout program must be defined and documented for compliance as part of Element 2, identify and control hazards and emergencies, for the effective development and implementation of a workplace safety and health program under Manitoba legislation.

 

SCOPE

 

This safe operating procedure and associated documents establish a procedure for a lockout program for all workers at RETSD. The best practices apply to all RETSD worksites.

 

RESPONSIBILITY

 

RESTD

 

RETSD is responsible to ensure that all equipment, facilities and procedures are established for the control of hazardous energy in all RETSD workplaces.

 

Workers

 

Workers are responsible to comply with all lock out program provisions.

 

Contractors

 

Contractors are expected to follow all lockout program regulations.

 

LOCK OUT PROGRAM GENERAL REQUIREMENTS

 

Locking Out - Safety Precautions

 

When a machine is serviced, repaired, tested, cleaned, maintained or adjusted, River East Transcona School Division shall ensure that no worker performs work on the machine until it has come to a complete stop and the worker performing work on the machine has:

 

(a)locked out the machine and removed and rendered safe any hazardous condition; or

 

(b)otherwise rendered the machine inoperative in a manner that prevents reactivation and provides protection that is equal to, or greater than, the protection provided by clause (a).

 

River East Transcona School Division shall ensure that a worker does not perform work on a machine that is to be serviced, repaired, tested, cleaned, maintained or adjusted until

 

(a)the machine is tested to ensure that it is inoperative; and

 

(b)the worker is assured that it is inoperative.

 

River East Transcona School Division shall develop and implement safe work procedures for the service, repair, testing, cleaning, maintenance or adjustment of a machine when:

 

(a)the manufacturer's specifications require the machine to remain operative when it is serviced, repaired, tested, cleaned, maintained or adjusted; or

 

(b)there are no manufacturer's specifications and it is not reasonably practicable to lockout the machinery when it is serviced, repaired, tested, cleaned, maintained or adjusted.

 

When it is not reasonably practicable to lockout the machinery when it is serviced, repaired, tested, cleaned, maintained or adjusted, River East Transcona School Division shall ensure that the safe work procedures developed offer protection to a worker that is equal to or greater than the protection provided by a lockout procedure.

 

Removing a Lock

 

No person may remove a lock from locked out machinery unless the person is the worker who installed the lock.

 

Notwithstanding the above statement, a competent person designated by the employer may remove the lock in an emergency or when the worker who installed the lock is not available.

 

River East Transcona School Division shall ensure that no worker returns a machine to operation after it has been locked out or rendered inoperable until the worker determines that no other person may be endangered by the operation of the machine.

 

Lock and Key Process

 

When the lockout procedure uses a lock and key, River East Transcona School Division shall:

 

(a)issue to each worker who is required or permitted to work on a machine a lock that is operable only by that worker's key or a duplicate key;

 

(b)designate a worker to keep the key;

 

(c)ensure that the duplicate key is accessible only to the designated worker;

 

(d)ensure that the lock used has a unique mark or identification tag on it that identifies the worker to whom the lock is assigned; and

 

(e)ensure that a logbook is kept to record the use of the duplicate key.

 

Where it is not reasonably practicable to use a worker's key to remove a lock, the employer may permit the designated worker to remove the lock if the designated worker has determined that:

 

(a)the key used to lock the lock is not available; and

 

(b)it is safe to remove the lock and activate the machine.

 

When the lock has been removed, River East Transcona School Division shall try to contact the worker who locked out the machine to inform them of the removal of the lock.

Control of More than One Machine

 

When a central automated system controls more than one machine, River East Transcona School Division shall ensure that any machine to be serviced, repaired, tested, cleaned, maintained or adjusted is isolated from the central system before the lockout procedures are implemented.

 

Tag Out Not Sufficient without Lock Out Procedures in Force

 

Tagging is not considered a lock out.

 

Compliance Expectations

 

All employees are required to comply with the restrictions and limitations imposed on them during the use of lockout to ensure personal safety as well as the safety of others.  Authorized employees are required to perform the lockout in accordance with this procedure.

 

In the event that lockout procedures are violated, an investigation will take place to determine scope of non-compliance. Disciplinary measures up to and including termination of employment will occur if the investigation determines that willful violation of lockout procedures occurred.

 

Definitions

                       

Affected Employee - An employee whose job requires him/her to operate or use a machine or works in an area in which servicing or maintenance is being performed under a lockout (i.e.: production employees who do not typically perform lockout and who are not assigned locks). When maintenance activities are being performed where full lockout is required, affected employees shall work under the lockout device of the authorized employee.

 

Authorized Employee - An individual possessing the training, responsibility and authority to implement lockout on machines / equipment.

 

Disconnect – The valves, electric switches, and mechanical devices used to stop the flow of energy.   Control circuit devices, push buttons, E-stop buttons, selector switches and interlocks may not be used as the sole means for de-energizing and locking out circuits or equipment.

 

Energy Sources – All types of energy that can power a machine (i.e.) electric, hydraulic, pneumatic, mechanical, fluid, chemical, gravitational, and other.

 

Energy Isolating Device – Lockout equipment specifically designed to be attached to the disconnects by a lock & tag to prevent the disconnects and/or energy from accidentally being turned "on", plugged in, or released.

           

Electrically Interlocked Equipment - Equipment that is wired so that when one piece of equipment is down, the other adjoined (electrically interlocked) equipment automatically shuts down. 

            

Group Lockout - If more than one authorized employee will be working on the machine/equipment while it is locked out, each will be required to place their personal lock and tag on the energy isolating device and verify lockout sequence was followed.  When an energy- isolating device is not equipped to accept multiple locks and tags, a multiple lockout device (hasp) may be used.

 

Lockout - Placement of lock, tag, & isolating device on a disconnect in accordance with an established procedure which ensures the machinery or equipment cannot be powered during work.

 

Lockout Tag - An approved tag used in conjunction with the safety lock to identify the employee using the lock, and the reason for the lockout.  The lockout tag is candy striped red and white border and its legend states "DANGER - DO NOT OPERATE", "EQUIPMENT LOCKED OUT BY", and "DATE".

 

Potential Energy – Energy left in the system after the power has been disconnected which must be drained, blocked, vented or released.

 

Hasp - A multi–holed interlocking device which is used at each lockout point when more than one authorized employee is working on the machine or equipment.

 

Work – Generic term in this procedure encompassing the performance of any maintenance, repair, adjustment, un-jamming, diagnostic trouble shooting, installation, modification, servicing, cleaning, lubricating, building of any machinery or equipment where the potential exists for injury due to unintended release of energy.

 

Zero Energy State - A state in which every energy source has been locked out, blocked and/or drained to prevent the unexpected release or transmission of energy.

 

Maintenance Personnel: An authorized employee or contractor possessing the training, responsibility and authority to implement lockout on machines / equipment.

 

Training

 

All employees with exposure to equipment must be trained in the elements of lock, block, and tag.  Employees are classified as "AUTHORIZED," or "AFFECTED" according to the level of exposure to equipment.  Training documentation shall be kept on file with the Maintenance Department.

                       

Training will be provided and documented for:

 

  1. New or transferred employees;

  2. When there is a change in machines, equipment, or processes that present a new potential hazard due to the unexpected release or transmission of equipment/process energy;

  3. When there is a change in the energy control procedures;

  4. Whenever periodic inspections or other information indicates potentially inadequate employee knowledge of the procedure(s).

           

Other Safe Work Procedures

                       

These procedures identify machine safety (guarding) and lockout requirements for each piece of equipment or machinery that may require lockout.

 

Instructions identifying the types of energy involved, lockout equipment needed, and energy isolating locations will be posted electronically at each computer workstation with access to the Intranet to provide direction on how to perform lockout on that unit.

 

Note: certain equipment/jobs may require additional steps, as with work in confined spaces.

 

Situations Requiring Lockouts

 

  1. Installation of Equipment – Including commissioning activities

  2. Operations by Operator or Helper (Equipment jam removal, other) – Operator safe stop sufficient generally full lockout not required

  3. Routine maintenance by authorized Maintenance personnel – includes contractors

  4. Repairs by authorized Maintenance personnel– includes contractors

  5. Other (Please specify) – Examples could include an identified health & safety concern, work refusal, following a serious incident

 

NOTE:  Once lockout has commenced, the machinery or equipment shall remain locked out until completion of the work & release into production regardless of such conditions as (i.e.) contractor scheduling, parts pick up or delivery times, shift changes, scheduled breaks, etc.

 

General Lockout Implementation Sequence – 6 Steps to PROPER Lockout:

                       

  1. Process Shutdown – stop the equipment or machinery by normal methods. (E-stop, OFF button)

  2. Recognize Energy Types & Sources – identify all types of energy powering the machine or equipment

  3. Off – shut off all energies by turning all controls to "off" & install isolating devices on disconnects

  4. Place Lock & Tag – place on all required disconnects/isolating devices

  5. Energy Release of Stored Energy – bleed, drain, block all stored energy types

  6. Re-check Controls – attempt to power machine by turning all operator controls to ON to ensure zero energy. Return all controls to OFF once verified. Verify zero energy state.

 

Maintenance Lockout Procedure (Full Lockout)

 

Pre Lockout: Notify Supervisor and Machine Operator(s) or other "Affected Employees" of intended lockout.

 

STEP 1 Process Shutdown – Authorized employee shall ensure the operating controls for all energy sources feeding power to the machine or equipment requiring work are turned to the OFF position .

 

STEP 2 Recognize Energy Types & Sources – Authorized employees shall identify all potential energy sources, the lockout points, and the required isolating devices have been identified. (See Applicable MSALO document for details)

 

NOTE:  Auxiliary equipment which may supply a secondary source of power to the machine or equipment must also be identified & locked out following this procedure.

 

STEP 3 Off – Shut off Energy Sources & Install Isolating Devices – Authorized employees shall turn off all required potential energy source controls & disconnects and place the appropriate isolating device on each control & disconnect.

 

STEP 4 Place Lock & Tag – Authorized employee shall affix his/her individual lock & tag on all isolating devices prior to commencing any work. A hasp shall be used at each lockout point where more than one authorized employee is performing work.

 

STEP 5 Energy Release of Stored Energy – Once all energy sources have been locked out & tagged, all potential energies must be released/secured/blocked to ensure no person will be exposed to injury from accidental release of stored energy.

 

STEP 6 Re-Check Controls & Return to ON Position – To ensure no unintended energy can be released, the authorized employee shall verify that all energy has been locked out by turning all controls to the "ON" position. Once verified that no energy is present, return controls to "OFF". Verify zero energy state.

 

NOTE:  Verifying lockout when performing Electrical Work: An electrician must verify a valid lockout has been accomplished prior to commencing work on circuit components which are energized or which usually convey electrical energy.  Valid verification requires going to the upstream disconnect which has power on the incoming side, and testing to be certain that the disconnecting device is functioning properly.  The disconnecting device is then locked in the "open" position.  The electrician performing the test must indicate that the circuit was tested dead using an approved test instrument.  This information plus the electrician's signature must be on the Danger Tag applied with the lock.  If the circuit to be worked on is over 600V nominal, the test equipment must be checked before and after the test.

 

Operator Lockout Procedure and Alternative Procedures

 

Generally, activities such as lubrication, cleaning, un-jamming, servicing of equipment, and making adjustments or tool changes are covered by lockout requirements if the employees may be exposed to the unexpected energization of equipment or release of hazardous energy.

 

However, certain activities, such as troubleshooting, jogging, adjusting, or setting up equipment must frequently be accomplished with circuits energized and the equipment operational.  Also, non-maintenance and/or servicing activities that are routine, repetitive and integral to the use of the equipment for production may not require lockout - provided there is no exposure of personnel to hazards.

 

When it is absolutely not possible to lock, block, tag, or due to the exceptional nature of the work being performed, and the energy sources must be powered to complete the 'work', alternative protective measures and written Safe Work Instructions (SWI) must be developed and utilized which eliminate or minimize employee exposure to potential hazards. (i.e. 'buddy system' of trained and authorized employees)

 

Safe Work Instruction, Machine Safety and Lockout Procedures and Departmental Safety Procedures must describe the minimal acceptable work practices to be followed and specify use of physical apparatus (guards, restraints, buddy system, etc.) where appropriate.  The alternative protective measures used must be under the exclusive control of the employee utilizing them.  Authorized employees must be familiarized with these procedures/protective measures, know when to use them and held accountable for adhering to them during work activities.

 

Alternative protective measures may typically include:

 

  • Guarding temporarily exposed hazards (sharp blades, chucks, spindles, etc.) while the employee is physically near a potential hazard performing a brief, routine, repetitive servicing or adjustment task occurring during normal production operations.

 

  • Hand tools such as (but not limited to) tongs, picks, hooks and rakes may be used to remove material/product from a point of operation so that hands, fingers or other body parts may be isolated from potentially hazardous areas.

 

  • Buddy system: Communicating intended direction of 'work' during lockout situation to at least one other authorized employee who shall work with you as a 'buddy' as a  'secondary safety precaution' during work which requires any energy to be powered. This would include (i.e.) acting as 'attendant' at the control station to make sure no one accidentally powers the machine while any of your body parts may be inside the machine.

 

Lockout Removal Steps

 

STEP 1: When work is finished, the equipment should be checked for proper adjustments, installation & condition. All guards and safety devices shall be re-installed.

 

STEP 2: Remove all isolating devices, locks, tags, & hasps and energize the equipment, generally in reverse of the application order. Lockout equipment must be removed by the individual who applied the equipment.

 

Note: If work was performed on circuit elements, a qualified person shall conduct tests and visual inspections to verify that all jumpers, grounds, shorts, and tools have been removed so that circuits can be safely re-energized.

 

STEP 3: Ensure area is cleaned. Remove all combustible materials, tools, & equipment from the areas that were used during work and ensure area is free of hazards prior to start up.

 

STEP 4: Check again to make sure all controls are in the "OFF" position.

 

STEP 5: Authorized employee(s) should be present at equipment or process start up for visual checks against any hazards observed during start up.  If the machine is so large that one authorized employee cannot see the entire machine, station employees around the machine as an additional safety precaution.

 

STEP 6: All guards and safety devices shall be in place and tested.

 

STEP 7: Authorized employee shall notify area supervisor and all affected employees that work is complete & the machine or equipment is ready for startup/production.

 

NOTE: If adjustments are required after start up, leave off only those guards that are absolutely necessary to get at the adjustment until the adjustment is complete. At this time, ensure all equipment has been fully re-assembled by repeating the necessary STEPS above.

 

Contractor Lockout Procedure

 

Whenever outside servicing personnel are engaged in activities covered by the scope of this procedure, it is our policy that the outside contractor's employees, and/or any sub-contractors shall be trained in and practice all required safe lockout procedures for any work which they have been commissioned to perform by River East Transcona School Division.

 

NOTE: Outside service personnel are responsible to supply their own Lockout equipment as required for the work they have been contracted to perform.

 

The contractors must submit proof that the employees they send to River East Transcona School Division have successfully completed required lockout training and possess current WCB insurance coverage.

 

Identified Safety Concern

 

STEP 1: If equipment or machinery needs to be locked out due to a confirmed safety concern, the supervisor shall immediately commence proper lockout procedure as outlined in STEPS 1-6 of Maintenance Lockout Procedure (Full Lockout) by ensuring the machine or equipment is locked out.

 

STEP 2: Once the work has been completed, the supervisor and maintenance will approve the removal of the safety lockout after reviewing the completed work ensuring that all safety guards have been re-installed & tested.  The supervisor shall forward a written investigation report detailing this action, reason for the lockout, members involved, machine involved, etc., before the end of his/her shift.

 

STEP 3: If the lockout was initiated by the Ministry of Labor (MOL), lockout shall only be removed once:

 

  • the MOL orders have been complied with, and

  • the Ministry reviews the written compliance & authorizes removal of the locks, and

  • the General Manager, Production Manager, Maintenance Supervisor & worker member of the Health & Safety Committee jointly review the work & validate the compliance.

 

STEP 4: The General Manager shall ensure all corrective actions ordered by the MOL have been completed & forward all necessary completed compliance forms to the MOL. Original compliance forms will be kept on file.

 

Serious Injury or Incident

 

A lockout situation initiated due to a serious injury or incident shall remain in effect until completion of the accident investigation conducted by the Ministry of Labor.

 

Energy Required Performing Work:

 

If during the performance of work, an energy source must be temporarily re-activated or if stored energy must be present (i.e.) troubleshooting, cycle testing etc., follow lockout removal steps as outlined in this procedure on only the energy source(s) required to be powered.

 

Ensure the machine operator and at least one other authorized employee is aware of the lockout intentions and is present during this time to assist you in a 'buddy system' as an additional safety precaution. As soon as the energy source(s) is no longer needed, lockout the energy source(s) again as per proper lockout procedure. (See Operator Lockout Procedure and Alternative Procedures)

 

Shift Change

 

If the work requires an overlap in shifts to complete, or if an authorized employee engaged in a lockout must leave the facility unexpectedly, lockout must not be interrupted. Authorized employees leaving work do not remove their locks & tags unless one of 2 conditions are met:

 

  • A replacement authorized employee is ready to immediately lockout in your place, or

  • A supervisor immediately locks out in your place.

 

Never use another employee's lock(s).  If you need additional locks, or lockout equipment, see your supervisor or contact maintenance.

Emergency Lock Removal

 

In the event that the authorized employee, or outside contractor who applied the lockout is absent from the workplace, the following steps must be taken in order to remove their locks.

 

STEP 1: The supervisor must confirm that the authorized employee, or contractor is not on site and attempt to contact that person(s).

 

STEP 2: If unsuccessful, the supervisor shall notify the Maintenance Supervisor or another "competent' person who will investigate the condition of the lockout situation and validate the safe start-up of the equipment or machinery prior to the removal of the lock(s).

 

At this point, if validated, lockout may be removed.

 

NOTE: If the Maintenance Supervisor or a "competent" person cannot be contacted or if they are unable to validate the safe start up, the machinery or equipment shall remain locked out until the safe start up can be validated.

           

STEP 3: If the lock has been removed, the Maintenance Supervisor or "competent' person shall complete and file a written report  prior to leaving the plant that shift outlining why it was necessary to remove the lock, people involved, steps taken to contact the absent employee, contractor etc..

 

COMMUNICATION

 

A combination of hard-copy postings, distributions and electronic posting will be used to communicate safety and health program information within RETSD.

 

TRAINING

 

All stakeholders shall be trained to their required level of involvement in the WSHMS to become familiar with its structure, organization, and how to look up and access information both electronically and in hard copy form through:

 

  • New employee orientation, employee manuals or employment information packages

 

  • Return to work or remedial programs, as required on an individual basis

 

  • Planned ongoing training through team meetings, individual coaching or other methods as developed or adopted

 

ENFORCEMENT

 

Ultimately, the superintendent shall be responsible for the sustainability of the WSHMS, and shall enforce compliance to standards at a divisional level.

 

Workplace safety and health management system compliance shall be managed through the application of performance management and progressive discipline policies and procedures.

 

Worker failure to comply with provisions of the RETSD safety program may lead to discipline, up to and including discharge from employment and / or other remedies available at law.


REFERENCES


Manitoba Workplace Safety and Health Act or equivalent legislation as applicable

 

Manitoba Workplace Safety and Health Regulation or equivalent legislation as applicable

 

Manitoba Workplace Safety and Health Regulation Part 38 – Electrical Safety

 

Manitoba Workplace Safety and Health Regulation Part 16 – Machines Tools and Robots

 

Manitoba Workplace Safety and Health Program Element 02 – Identifying and Controlling Hazards

 

All other associated and applicable workplace safety and health management system documents