Online Lockout / Tagout Training Program

COURSE OVERVIEW
COURSE CONTENT
COURSE COMPLETION
FAQs

3 hours duration

By covering all forms of hazardous energy, you're gaining a comprehensive view of the necessary precautions and controls in industrial, manufacturing, healthcare and construction settings. The goal is to make sure that any energy that could potentially cause harm—whether it’s electrical, mechanical, hydraulic, pneumatic, or others—is properly managed. Workers, subcontractors, supervisors, safety representatives especially those writing procedures would benefit from this course.

The CSA-Z460 standard emphasizes several key components in hazardous energy control:

1. Hazard Assessment

A crucial first step is conducting a thorough assessment to identify all the potential energy sources in the machinery, equipment, or processes involved. This is often more complex than just looking at electricity—it's about analyzing mechanical, hydraulic, pneumatic, thermal, and other energy sources that could pose risks to workers.

2. Energy Control Procedures

The standard emphasizes the creation of detailed energy control procedures tailored to the specific energy types and hazards present. This includes:

Lockout: Physically isolating energy sources using lockable devices.
Tagout: Using warning tags when lockout is not possible or as an additional safety measure.
Alternative Methods: In cases where lockout/tagout is impractical, other methods like blocking, securing, or venting energy sources are considered.

3. Training and Awareness

o CSA-Z460 stresses the importance of training for all personnel involved in the maintenance or servicing of equipment. This means everyone must know not only how to lock out specific energy types but also how to recognize the risks and hazards involved with each energy form.
o Regular retraining and refresher courses are recommended to keep the workforce up to date with best practices and changes in equipment or procedures.

4. Coordination and Communication

o In settings where multiple workers may be interacting with the same piece of equipment, CSA-Z460 emphasizes the need for effective communication and coordination between team members to ensure everyone is aware of the energy control status. This minimizes the risk of accidental energization or unintentional exposure to hazardous energy.

5. Periodic Inspections

o It’s not enough to just set up lockout/tagout procedures once and forget about them. The standard calls for regular inspections to ensure that the energy control measures are being implemented correctly and consistently. Inspections also help identify any gaps or areas for improvement in the process.

6. Alternative Methods for Hazardous Energy Control

o While lockout/tagout is often the most effective method, CSA-Z460 also looks at alternative methods when LOTO may not be feasible, like the use of blanking or double-block-and-bleed techniques for fluid or gas lines, and safety barriers for mechanical systems. This flexibility ensures that safety is maintained regardless of the situation.

The CSA-Z460 Control of hazardous energy - Lockout and other methods course provides the knowledge and tools to prevent accidents and injuries by teaching the best practices for controlling all types of hazardous energy. It’s about being prepared, preventing the unexpected, and ensuring the safety of all workers by addressing not just electrical but all forms of energy.

Why is the CSA-Z460 Standard Important?

While electrical hazards are the most common when thinking of energy sources, all forms of energy will be covered in this course. Following CSA-Z460 Control of hazardous energy - Lockout and other methods, this course reviews the requirements for controlling hazardous energy associated with potentially harmful machines, equipment, or processes.

What you will learn:

• Identify hazardous energy sources and their consequences
• Understand how to isolate, lock, and tag out energy sources
• Know how to follow LOTO procedures to safely perform maintenance or servicing tasks
• Understand the importance of coordination and communication, particularly in situations involving multiple workers

During private sessions, and when available, Act First Safety can integrate your corporate lockout/tagout program into the training.

Prerequisites: None

Key Takeaways from the Course:

Here's a breakdown of the key types of hazardous energy that are covered under CSA-Z460:

1. Electrical Energy
•    This is probably the most widely recognized form of hazardous energy, covering things like live wires, exposed circuits, and electrical panels.
•    Risks: Electric shock, burns, fires, or even electrocution.
•    Control: Locking out power sources and de-energizing circuits before work begins.

2. Mechanical Energy
•    Machines and equipment often have moving parts that store energy (e.g., springs, flywheels, or rotating shafts) even when they're powered off.
•    Risks: Crushing, pinching, or entanglement with moving parts or components.
•    Control: Blocking, securing, or locking out parts that could move during servicing.

3. Hydraulic Energy
•    Hydraulic systems, often used in heavy machinery, store large amounts of energy in pressurized fluid.
•    Risks: Leaks or sudden release of hydraulic pressure can cause crushing or puncturing injuries.
•    Control: Releasing pressure, isolating valves, and locking out controls.

4. Pneumatic Energy
•    Pneumatic systems use compressed air to power machinery, and this compressed air represents stored energy.
•    Risks: Air leaks, unintentional movement, or sudden release of pressure can lead to dangerous situations.
•    Control: Releasing air pressure, blocking or locking off air sources, and securing valves.

5. Thermal Energy
•    This includes hot surfaces, steam, or heated components. High temperatures can cause burns or other injuries.
•    Risks: Burns from hot surfaces or steam, especially in industrial settings like boilers or ovens.
•    Control: Cooling down equipment, draining steam, or insulating hot components.

6. Gravitational Energy
•    This involves the potential energy stored in objects that are elevated or have the potential to fall.
•    Risks: Falling objects, crushing injuries, or being struck by equipment.
•    Control: Securing or blocking items from falling or moving, and ensuring that suspended loads are properly supported.

7. Chemical Energy
•    Hazardous chemicals, flammable gases, or liquids under pressure can present significant risks.
•    Risks: Explosions, burns, or poisoning.
•    Control: Isolating chemical sources, shutting off valves, and properly venting systems.

What you Get

Upon successful completion of the Lockout Tagout – Control of Hazardous Energy safety training program, you receive the following:
• Individual Wallet Certificate
• Detailed Record of Training (private sessions only)
Ongoing, site-specific training is required to adhere to Ontario regulations and applicable CSA Standards. Applying classroom learning to worksite applications helps to solidify the concepts learned. Ongoing evaluation of the corporate lockout procedures is recommended.

A refresher course is recommended every 3 years in order to remain compliant.

This course is a half-day course. Due to class discussion, class size, experience of participants and equipment used and application, the course timing is subject to some variability.

The employer shall ensure that hazardous energy control training is provided to all persons whose work requires them to be aware of hazardous energy control procedures or to use hazardous energy control procedures.
CSA-Z460 Control of hazardous energy - Lockout and other methods outlines the requirements for safety training. This information should be considered in conjunction with additional relevant legislation. See the excerpt below:

7.5.2 Training

7.5.2.1
The user shall provide 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 possibly encounter. The training program shall comply with the following requirements:

(a) Individual training shall be carried out prior to authorized individuals performing service and
maintenance tasks or being potentially exposed to hazardous energy.
(b) Training shall be specific to the user’s written program.
(c) The training program shall be developed using applicable manufacturer’s documentation, industry best practices, regulatory requirements, and input from authorized individuals.
(d) Each authorized individual shall receive training related to the type and magnitude of the energy available in the workplace.
(e) Each authorized individual shall receive training related to the type of energy that might be
encountered during servicing or maintenance and the methods or means to control and isolate that energy.
(f) Training shall include samples of machine-specific procedures and enable personnel to interpret and implement procedures developed in Clause 7.3.2.2.
(g) The user shall document that all initial and additional training has been conducted. The
documentation shall include the name, date(s) of training, and the training topic(s) for each
individual trained. Documentation of the information covered during training sessions should be
maintained.

CSA-Z460 Control of hazardous energy - Lockout and other methods identifies the importance of continuously reviewing control applications for effectiveness. See the excerpt below:

7.6.3 Application of specific procedures

Compliance with specific hazardous energy control procedures (machine, equipment, or process) is critical. Therefore, the user shall establish a continual auditing plan 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. 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.

1. What is Lockout/Tagout (LOTO)?

LOTO is a safety procedure used to ensure that machinery or equipment is properly shut off and cannot be started up again while maintenance or servicing is being carried out. Lockout involves physically locking the energy-isolating devices, while tagout involves placing a warning tag to indicate that the equipment should not be operated.

2. What types of energy need to be controlled during LOTO?

Q: Are only electrical hazards covered under LOTO?
A: No! While electrical energy is a significant hazard, LOTO applies to all forms of hazardous energy, including:
•    Electrical energy (e.g., live wires, circuits),
•    Mechanical energy (e.g., moving parts, flywheels),
•    Hydraulic energy (e.g., pressurized fluids),
•    Pneumatic energy (e.g., compressed air),
•    Thermal energy (e.g., hot surfaces or steam),
•    Gravitational energy (e.g., falling objects or suspended loads),
•    Chemical energy (e.g., stored gases or liquids under pressure).

Each of these can pose serious risks if not controlled.

3. Why is LOTO so important?

Q: Why do we need to lockout or tagout energy sources before servicing equipment?
A: Lockout/Tagout is essential to prevent accidental energization of machinery or the unexpected release of stored energy, which could result in severe injuries or even fatalities.

Properly controlling hazardous energy ensures that workers are not exposed to risks like electrical shock, burns, or mechanical injuries.

4. Who is responsible for implementing LOTO procedures?

Q: Who is responsible for ensuring LOTO procedures are followed?
A: Both employers and employees have roles:

• Employers are responsible for establishing LOTO procedures, providing training, and ensuring compliance with safety regulations.
• Employees are responsible for following LOTO procedures during maintenance or servicing tasks, as well as reporting any issues with equipment or procedures.

5. What’s the difference between a lockout and a tagout?

Q: What is the difference between lockout and tagout?

• Lockout involves physically locking an energy-isolating device (like a valve or switch) to prevent it from being turned on while work is being done.
• Tagout involves placing a clearly visible warning tag on the device to indicate that it should not be operated, even if it’s not physically locked.

Lockout provides a more secure and fail-safe means of preventing accidental energization. Tagout provides a warning.

6. What is the proper procedure for lockout/tagout?

Q: What steps should I follow for a safe lockout/tagout procedure?
A: Here’s a general outline of the lockout/tagout process:

1.    Preparation: Identify all energy sources and understand the hazards they pose.
2.    Shut down the equipment: Turn off or deactivate the machine or equipment.
3.    Isolate energy sources: Disconnect or isolate all energy sources (e.g., turn off switches, close valves).
4.    Apply lockout/tagout devices: Secure energy-isolating devices with locks or tags to prevent re-energization.
5.    Release or restrain stored energy: Discharge any accumulated energy (e.g., release pressure, lower suspended loads).
6.    Verify isolation: Ensure that all energy sources are fully isolated and that the equipment cannot be operated.
7.    Perform Maintenance or Service: Once safe to do so, perform the necessary tasks like repairs, inspections, cleaning, etc.)
8.    Remove Lockout Devices: Each worker who placed a lock or tag should remove their device. A supervisor (or responsible party) should ensure no devices are left behind.
9.    Restore energy sources: Re-energize the system and follow standard restart procedures. Notify affected workers.
10.    Complete any necessary documentation: It’s a good practice to also provide feedback on the processes just completed looking for areas of improvement.

7. What if multiple workers are involved in a lockout/tagout procedure?

Q: How do you manage lockout/tagout when multiple people are working on the same equipment?
A: When multiple workers are involved, each worker must apply their own personal lock and tag to ensure that no one can accidentally restart the equipment. Group lockout or a lockbox may be used to allow multiple workers to control access to the lockout device. Each worker must be given a key, and all locks should be removed only after the work is complete.

8. How often should LOTO procedures be reviewed and updated?

Q: How often should lockout/tagout procedures be reviewed?
A: Lockout/tagout procedures should be reviewed at least annually to ensure they remain effective and relevant. Changes in equipment, processes, or safety regulations may require updates to existing procedures. Additionally, periodic inspections of the LOTO process help identify and address any shortcomings or gaps in safety measures.

9. What happens if LOTO procedures are not followed?

Q: What are the consequences of failing to follow LOTO procedures?
A: Failing to follow proper LOTO procedures can result in:

•    Serious injury or even fatalities due to accidental energization or release of hazardous energy.
•    Legal consequences, including fines or penalties from regulatory agencies (e.g., OHSA).
•    Damage to equipment, which could lead to costly repairs or downtime.
•    Loss of worker confidence and trust in the company’s safety practices.

10. What training is needed for LOTO?

Q: What type of training do workers need for LOTO?
A: Workers must be trained to:

•    Identify hazardous energy sources,
•    Understand how to isolate, lock, and tag out energy sources,
•    Know how to follow LOTO procedures and safely perform maintenance or servicing tasks,
•    Understand the importance of coordination and communication, particularly in situations involving multiple workers.

These FAQs are just a starting point. It’s important that both employers and workers understand the hazards of all energy types and follow the appropriate procedures to ensure a safe and effective work environment.

Please contact our office for further details on LOCKOUT Online training.