MACHINE/EQUIPMENT LOCKOUT

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1 PROCEDURE 420-F Adopted June 17, 2010 Last Reviewed October, 2012 Review Date October, 2017 MACHINE/EQUIPMENT LOCKOUT 1. PURPOSE It is the intent of the Hastings and Prince Edward District School Board to provide a safe and healthy environment for all employees. From time to time machinery, equipment, devices, etc., require maintenance or servicing. When servicing or maintenance is required, precautions must be taken to ensure that whoever is working on the machine, equipment, device, etc., can do so in a safe manner without the risk of injury. Any machinery, equipment, devices, etc., being serviced must have zero power at the time work is being performed. Zero power can be achieved through a process called lockout. A lockout is a process used to prevent inadvertent operation/or release hazardous energy from equipment. A lock or lockout device is used with a tag. The lock is placed on the energy isolating mechanism that is in the off or closed position. The lockout must result in a zero energy state before work can begin on equipment. Failure to abide by this procedure could result in employee or contractor being seriously injured or cause a fatal accident. 1.1 The purpose of this procedure is: to protect people, property and equipment from accidental injury or damage from the release of energy from equipment, machinery, electrical controls, pipeline or pressure systems; and to interpret and comply with the intent of Section 42 and 76 of the Industrial Establishments Regulations, R.R.O. 1990, Regulation 851 as amended by O.Reg.230/95 made under the Occupational Health and Safety Act as it applies to lockout control switches or other control mechanisms. 2. DEFINITIONS The following definitions apply to the above mentioned legislation and following procedures: Control switch referred to in Section 76, as it applies to electrical controls shall be understood to mean the main power source or disconnect switch. Electrical disconnect switch means a pull-type switch or circuit breaker which physically opens to disconnect the circuit. Start or stop switch means a toggle or push button switch usually mounted on or near the machine being started or stopped. Hastings and Prince Edward District School Board Page 1 of 5

2 Machine shall be understood to include transmission machinery, devise or thing. This includes boilers, vessels, chests, hydraulic or air driven machinery pipelines, sawdust collectors, etc., which must be isolated to safely carry out the work. Power is recognized as being any type of energy which causes materials to flow, or a machine or piece of equipment to operate. Work shall mean other than normal operation of the machine, e.g. the inspection, repair, adjustment, cleaning, maintenance, etc., for which the machine must be stopped. Person in charge means a qualified person who originates the work order, which gives him/her the authority over staff or contract persons working on a machine. Qualified person means a person designated by his/her employer as qualified because of knowledge, training and experience to safely perform an assigned task. Worker is the staff or contract person performing the work on a machine. Operator is the person responsible for the normal shutdown and starting of the machine. In actual application, the person in charge, the qualified person or the worker may be the same individual. 3. RESPONSIBILITIES This procedure applies to all employees and contractors of the Hastings and Prince Edward District School Board who are required to perform lockouts. Maintenance personnel and contractors working on building service equipment in non public areas (for example, mechanical and boiler rooms, rooftops and electrical switch rooms, etc.,) will use lockout tags and locks and are not required to record the lockout in the School Lockout Log, unless, the lockout is in excess of two hours. Maintenance personnel and contractors who work on dust collectors and other similar equipment directly used by school personnel shall abide with the full lockout procedures. 3.1 In the case of maintenance work on a ventilation system serving an area that the nature of the program requires ventilation for health and safety reasons (i.e., Science classroom fume hood, etc.) of a school, maintenance personnel and contractors will follow the full lockout procedure. 3.2 While this procedure is specific to the hazards associated with the accidental starting of a machine and general electrical shock, it does not preclude the worker s responsibility to ensure that all sources of power, including but not limited to, electrical, mechanical, compressed air and gas are locked out. 3.3 Since a very high percentage of machines and equipment use electricity as the source of power and as the control for other sources of power, this procedure will deal primarily with the locking out of electrical switches. This does not preclude the requirement for the locking out or blanking of other types of controls, mechanism or systems, e.g., valves, clutches, line shafts, etc., where accidental starting is likely to endanger the safety of any person. Hastings and Prince Edward District School Board Page 2 of 5

3 4. PROCEDURES 4.1 The worker performing the lockout shall notify the main office who will notify the affected employees of the lockout. 4.2 The drawings of the system shall be reviewed to determine all switches, power sources, controls, interlocks and all other devices necessary to isolate the system when necessary. 4.3 All pertinent information such as date, name or worker who locked out equipment and the reason for the lockout shall be recorded in the school Lockout Station Log book. 4.4 The worker or operator shall shut down the machine in the normal manner, e.g. by pushing the stop button, shutting off valves, etc. 4.5 The machine shall be safely shut down, this includes: Locking off air, gas, steam or other valves at the source of power and opening the necessary valves to bleed off residual pressure so that if such a valve were opened later there would be no pressure or release of stored energy Blocking up or otherwise immobilizing gravity devices such as rams or flywheels. 4.6 After the machine has stopped, wait for all moving parts to stop. Then the main disconnect switch shall be placed in the OFF position and a lock and tag attached to lockout the equipment. 4.7 Lockout primary switches. Do not rely on secondary protection such as limit or micro switches. This means block all power at the source. Before work commences, a zero energy state should be in effect. Ensure that all devices or connectors are disengaged. (Authorized personnel only shall remove fuses with approved and suitable fuse pullers). 4.8 Before working on a machine that has been locked out, the worker shall test the machine to ensure that all power sources are properly shut off and locked out. Interlocking or dependant systems, which would electrically or mechanically feed into the system being isolated, shall also be tested Qualified instructional personnel (teaching staff) in technical labs, performing regular machine or equipment maintenance, such as replacement of belts on instructional equipment, shall ensure that all devices are disengaged or disconnected before servicing. 4.9 After the machine has been shut down and locked out, each and every worker working in or on the machine shall place a lock and tag on the disconnect switch The presence of the lock and tag is evidence that the machine is properly and completely shut down and in safe condition for work to commence The lock shall only be removed by the worker and this responsibility shall NOT be delegated. In the event of a lost key or the departure of the worker from the worksite without removal of their lock, the person in charge shall contact their supervisor for instructions. No lock shall be cut off without authorization from the worker s supervisor If a machine is to be taken out of service, it shall be locked out during the entire period that it is out of service. For regular machine maintenance of instructional equipment, if the Hastings and Prince Edward District School Board Page 3 of 5

4 machine is to be out of service overnight, it shall be locked out and tagged with information regarding who tagged it, the reason why, date and state of repairs If work is not completed at the end of the day or shift, each worker shall report the status of the work to the person in charge of any work to be performed after hours, before removing their lock and tag. The workers performing after hour work shall place their locks and tags on the machine. Again, the person in charge shall not remove their lock until the people in charge of any workers continuing work have placed their lock on the machine Verify that the correct system has been locked out throughout service by pressing start buttons and then returning the system to the OFF position if and when it is safe to do so Once all work is completed, the same set of procedures only in reverse shall be followed to energize and activate the system. The following check list shall be used as a guide: Are guards in place? Have braces, pins, chains, blocks been removed? Are all tools that have been used accounted for? Are all valves closed in the correct position? Have tags and locks been removed by authorized persons? Are all persons accounted for? Has department(s) been notified? Has the Lockout Log been signed? 5. METHODS OF LOCKING OUT VARIOUS TYPES OF CONTROLS 5.1 Disconnect switches with a pull-down handle have lock out facilities as part of the switch equipment. If difficulty is experienced in ensuring correct lockout of parts of multiple components operated in unison or sequence, contact the appropriate trade (i.e., electricalelectricians, gas pipelines-pipe fitters, etc.), to make sure all components are locked out. 5.2 For other equipment it may be necessary to construct attachments to which locks or a lockout bar can be attached. Unless the box is locked, making it impossible to replace a fuse, the mere removal of a fuse does not constitute an adequate lockout procedure. 5.3 The attachment may consist of chains for valves; the common hasp for locking cabinets or boxes; sliding bar which when extended would prevent operation of the control handle. Reversing starters shall be locked out in both directions. 5.4 Each worker is responsible for their safety and shall individually comply with lock out procedures. No employee shall rely on someone else for lockout protection. 6. LOCK CONTROL 6.1 Lockouts shall be conducted by qualified workers. 6.2 Each school shall be equipped with lockout devices. The lockout devices shall consist of the following items: Hastings and Prince Edward District School Board Page 4 of 5

5 6.2.1 Locks; Lockout devices, for example, plug lockout, electrical switch lockout, lockout bar (supplied with kit); A supply of lockout tags, (supplied with kit); A Lockout Log Book for recording each lockout (see Figure 1); and A wall mounted station for storage of the lockout supplies. 7. MAINTENANCE STAFF Each maintenance staff member will be issued personal locks. Locks shall not be loaned or used for other purposes. 8. TRAINING AND REVIEW 8.1 All employees designated to perform lockouts must be trained on the lockout procedure. 8.2 Once per year this procedure shall be reviewed with each employee who is performing lockouts. 8.3 The training and review of these procedures will be documented and recorded. 8.4 The review of the training shall include: A review of the department or school and Board s procedures; and Use of appropriate training materials from the Health and Safety Department, if required. Legal References: Occupational Health and Safety Act, as amended by Bill 168 Education Act, section 265 Duties of Principal: Care of Property; section 283 Chief Executive Officer: Maintain Effective Organization; section 286 Duties of Supervisory Officers: Supervise Property Ontario Regulation 298 Operation of Schools District References: Administrative Procedure 149: Safety and Well-Being of Students and Staff Administrative Procedure 153: Emergency Response Administrative Procedure 162: Treatment of Injured or Ill Students and Staff Members Administrative Procedure 420: Occupational Health and Safety Administrative Procedure 420-E: Personal Protective Equipment Administrative Procedure 421: Safe Workplace Violence in the Workplace Administrative Procedure 552: Maintenance of Buildings, Grounds and Equipment Administrative Procedure 556: School Yard Improvement Areas and Playground Equipment Administrative Procedure 560: Use of Electrical Appliances and Vending Machines in Board Buildings Form 420-F-1: Lockout Record Log Hastings and Prince Edward District School Board Page 5 of 5

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