Chapter 3: Programs and Exposure Control Plans¶

Part 1: High-Hazard Programs¶

3.0 Introduction to Programs and Exposure Control Plans¶

This chapter establishes specific health and safety programs for 4Core Energy & Maintenance Ltd. operations. Each program defines requirements, responsibilities, and controls for hazards associated with thermal energy systems work.

Program Structure: Each program described at policy level in this OHS Program. Detailed procedures, permits, checklists, forms maintained as separate controlled documents referenced by document number.

Applicability: Programs apply to all 4Core workers, contractors, subcontractors. When working on client sites: comply with client programs where they meet or exceed our standards. Where client standards less stringent: follow our own programs (unless prohibited by contract). Highest standard wins - always apply most protective requirements whether from our programs, client requirements, or regulations.

Administration: Safety Officer maintains and updates programs. Annual program reviews by management. Updates following regulatory changes, incidents, or identified gaps. All workers trained on programs applicable to their work.

3.1 Confined Space Entry Program¶

3.1.1 Purpose and Scope¶

Confined space entry represents the primary and highest-hazard activity 4Core performs.

Applies to: Work inside boilers, heaters, tanks, vessels, combustion chambers, enclosed spaces; trenches, pits, underground utilities meeting confined space criteria; any space where atmospheric hazards may exist or develop.

Detailed Procedures: This section establishes confined space policy. For step-by-step procedures, see: - SOP CS-001: Confined Space Entry Permit - Complete entry procedure - Form CS-PERMIT-01: Entry Permit - Required permit form

3.1.2 Regulatory Requirements¶

WorkSafe BC OHS Regulation, Part 9 (Confined Spaces)
CSA Z1006 (Management of Work in Confined Spaces)
Technical Safety BC requirements for pressure vessel entry

3.1.3 Definitions¶

Confined Space: An enclosed or partially enclosed space that meets ALL of the following four criteria: 1. Is not designed or intended for continuous human occupancy 2. Has restricted means of entry or exit 3. Can represent a risk for the health and safety of anyone who enters (due to atmospheric hazards, engulfment, configuration, or other factors) 4. Is large enough and so configured that a worker can bodily enter to perform assigned work

Note: All four criteria must be met for a space to qualify as a confined space.

'Hey Claude! we need to mention that spaces that dont satisfy the 4 criteria may well still be dangerous and therefore restricted in some manner and rules should apply in that case as well, so we need to cover that base and follow the rules on it.'

Examples: Thermal oil heaters/expansion tanks, hot water boilers/storage tanks, steam boilers/headers, combustion chambers/fireboxes, flue gas passages/stacks, underground vaults/pits, process vessels/reactors.

Hazardous Confined Space: Confined space where hazardous conditions exist or may develop: oxygen deficiency (<19.5%) or enrichment (>23%), flammable atmosphere (>10% LEL), toxic atmosphere (CO, H₂S, combustion products, thermal oil vapor), engulfment hazards, physical hazards (moving equipment, extreme temperature, noise).

IDLH (Immediately Dangerous to Life or Health): Atmosphere presenting immediate threat to life, causing irreversible health effects, or impairing escape. Common IDLH: O₂ <19.5% or >23%, CO >1200 ppm, H₂S >100 ppm, LEL >10%.

3.1.4 Roles and Responsibilities¶

Entry Supervisor (Qualified Person): Authorize entry after verifying all conditions met, ensure permit completed/posted, verify atmospheric testing completed/acceptable, ensure entrants/attendants trained/equipped, communicate throughout entry, terminate entry if conditions deteriorate, activate rescue if needed. Minimum: WorkSafe BC Confined Space Entry Supervisor training.

Attendant (Hole Watch): Remain outside at entry point throughout operations, maintain continuous communication with entrants, monitor atmospheric conditions (if continuous monitoring required), keep unauthorized personnel away, summon rescue if emergency - DO NOT ENTER, account for all entrants at all times. Minimum: WorkSafe BC Confined Space Attendant training.

Entrant: Understand space hazards, use required PPE/monitoring equipment correctly, maintain communication with attendant, exit immediately if conditions deteriorate or on attendant's order, alert attendant to problems/concerns. Minimum: WorkSafe BC Confined Space Entrant training.

Rescue Team: On standby during hazardous entries, equipped/trained for confined space rescue specific to entry conditions, may be internal trained team (davit rescue, low-angle) OR external service (fire department, private rescue), response time appropriate to hazard severity (IDLH = immediate response).

Management: Ensure personnel trained before entry, provide equipment/resources/time for safe entry, ensure rescue services identified/available, review incidents/near-misses.

3.1.5 Entry Requirements¶

Before ANY Confined Space Entry: 1. Identify space as confined space - Use decision tree - When in doubt treat as confined space 2. Assess hazards - Identify all actual/potential hazards - Review previous entries, equipment history, process information - Consider work to be performed 3. Develop entry plan - How hazards controlled - Equipment required - PPE needed - Duration - Rescue plan 4. Obtain permit - Complete confined space entry permit (Procedure CS-001) - Valid one shift maximum - New permit if conditions change or work suspended 5. Isolate and lockout - All energy sources isolated (electrical, mechanical, thermal, chemical) - Lockout/tagout procedures followed (Section 3.4) - Physical disconnection or blanking of process lines - Verify zero energy state 6. Purge and ventilate - Remove or neutralize atmospheric hazards before entry - Flush with fresh air (never oxygen or inert gas) - Continue ventilation throughout entry - Position to prevent recirculation 7. Atmospheric testing - Test BEFORE entry in this order: Oxygen, Flammability (LEL), Toxics (CO, H₂S, others) - Test at multiple levels (top, middle, bottom - gases stratify) - Continuous monitoring during entry for IDLH atmospheres - Acceptable entry conditions: - O₂: 19.5-23% - LEL: <10% - CO: <35 ppm (8-hr TWA) / <200 ppm (15-min STEL) - H₂S: <10 ppm (8-hr TWA) / <15 ppm (15-min STEL) - Other contaminants: below OELs 8. Establish communication - Continuous visual or voice between entrant/attendant - Radio if visual/voice not possible - Emergency signals established/understood 9. Position attendant - Stationed at entry point before entry begins - Equipped with atmospheric monitor (if continuous monitoring) - Has means to summon rescue 10. Ensure rescue readiness - Rescue plan established/communicated - Rescue equipment on site/functional (tripod, davit, harness, retrieval line if applicable) - Rescue team identified/on standby - Non-entry rescue capability preferred (retrieval system)

3.1.6 Hot Work in Confined Spaces¶

Hot work (welding, cutting, grinding) requires additional controls: - Hot Work Permit in addition to Confined Space Entry Permit - LEL must be 0% (not just <10%) throughout hot work and for 30 minutes after - Continuous atmospheric monitoring during all hot work - Fire watch inside and outside space - Fire extinguisher immediately accessible - Additional ventilation to remove welding fumes/combustion products - Combustible materials removed or protected - Respiratory protection for welding fumes as required

See: Hot Work Program (Section 3.2) and Procedure HW-002.

3.1.7 Atmospheric Monitoring Equipment¶

4Core maintains calibrated 4-gas monitors (O₂, LEL, CO, H₂S) for all entries.

Requirements: Bump test daily before use (Procedure GM-001), full calibration per manufacturer (typically monthly), calibration records maintained, data logging capability preferred, spare monitor on site, inspect before use (battery, sensor function, alarms).

Alarm Setpoints: O₂: Low 19.5% / High 23.0%, LEL: 10% (entry prohibited) / 20% (evacuate immediately), CO: 35 ppm (caution) / 200 ppm (evacuate), H₂S: 10 ppm (caution) / 15 ppm (evacuate).

If Alarms Activate: Evacuate immediately, increase ventilation, re-test atmosphere, investigate contamination source, do not re-enter until acceptable conditions restored/maintained.

3.1.8 Confined Space Rescue¶

Rescue Plan Required for ALL Entries.

Options: - Non-Entry Rescue (Preferred): Entrant wears full-body harness with retrieval line, retrieval system (davit, tripod, winch) at entry, attendant can retrieve from outside without entering. Use whenever space configuration allows. - Internal Rescue Team: 4Core may train internal team for davit rescue/low-angle, requires specialized training beyond entry/attendant certification, team practices quarterly, equipment maintained/inspected regularly. Only for spaces where internal rescue feasible. - External Rescue Service: Fire department, private rescue, or client rescue team. Must be notified before entry and on standby, response time appropriate to hazard (IDLH = immediate), service must have confined space rescue capability (not all fire departments do), pre-entry coordination/site familiarization required.

Current 4Core Practice: Non-entry rescue when possible, external rescue for complex/IDLH entries, internal rescue team development under consideration.

CRITICAL: Attendants and untrained personnel DO NOT ENTER to attempt rescue. Improper rescue attempts kill more people than original emergency. Summon trained rescue - that's your job.

3.1.9 Emergency Response¶

If emergency occurs: 1. Entrant: Exit immediately if able 2. Attendant: Attempt non-entry rescue if retrieval system in place, summon rescue team, activate emergency response (call 911 if external rescue), keep others from entering, provide information to rescue team 3. Supervisor: Respond to site, coordinate with rescue team, account for personnel, secure area, notify management 4. Management: Support emergency response, notify WorkSafe BC if serious injury, preserve scene for investigation, arrange post-incident support

3.1.10 Training and Documentation¶

Training: All personnel performing confined space work must complete: - Entrant Training (WorkSafe BC approved minimum) - Attendant Training (WorkSafe BC approved) - Entry Supervisor Training (WorkSafe BC approved) - Site-specific orientation (hazards of specific spaces) - Equipment training (monitors, retrieval systems, communication) - Respiratory protection (if required - Section 3.9) - Refresher annually or following incident/near-miss

Rescue Team (if internal): - Specialized confined space rescue training - Practice drills quarterly - Annual recertification

Records: - Confined Space Inventory (all spaces on all client sites) - Entry permits (retain 2 years) - Atmospheric testing records (built into permits) - Gas monitor bump test/calibration logs - Training records (employment + 2 years) - Incident investigations - Program review/audit records

See: Confined Space Entry Procedure (CS-001).

3.2 Hot Work Program¶

3.2.1 Purpose and Scope¶

Hot work creates ignition sources that can cause fires/explosions in our work environment.

Applies to: Welding (arc, MIG, TIG, oxy-fuel), cutting (torch, plasma, arc gouging), grinding/abrasive operations producing sparks, brazing/soldering, any operation producing flame, spark, or heat sufficient to ignite combustibles.

Particularly hazardous when: On/near thermal oil systems (flammable liquid), in confined spaces, near combustible insulation/materials, in areas where flammable vapors/gases may be present.

Detailed Procedures: This section establishes hot work policy. For step-by-step procedures, see: - SOP HW-001: Hot Work Permit (in development) - Form HW-PERMIT-01: Hot Work Permit (in development)

3.2.2 Regulatory Requirements¶

WorkSafe BC OHS Regulation, Part 6.26 (Welding)
WorkSafe BC OHS Regulation, Part 9 (Confined Spaces - when applicable)
BC Fire Code requirements for hot work
Technical Safety BC requirements for work on pressure equipment

3.2.3 Roles and Responsibilities¶

Hot Work Supervisor (Authorized Person): Assess work area/identify fire hazards, authorize hot work only when safe, issue permit after verifying requirements met, ensure fire watch assigned/trained, verify fire extinguishers positioned, inspect area 30 minutes after completion.

Hot Work Operator: Perform only authorized work on permit, use required PPE (welding helmet, gloves, leathers, respiratory protection), inspect equipment before use, report unsafe conditions immediately, stop work if conditions change or new hazards appear, participate in final area inspection with fire watch.

Fire Watch: Monitor for fire/ignition during hot work, monitor for 30 minutes after completion, equipped with fire extinguisher and trained in its use, authority to stop work if fire hazard develops, sound alarm/initiate emergency response if fire occurs.

3.2.4 Hot Work Permit¶

REQUIRED for: All hot work in confined spaces (no exceptions), hot work on or within 10 meters of thermal oil systems, hot work on or within 10 meters of flammable liquid storage, hot work in areas not designated as permanent hot work areas, hot work on client sites (unless client has different permit system).

Duration: Valid one shift or one task (whichever shorter), new permit if location changes, new permit if work interrupted and conditions may have changed, supervisor signature required before work begins.

Permit Must Verify: Combustibles removed or protected (10-meter radius minimum), fire extinguisher positioned/functional, fire watch assigned/present, atmospheric testing completed (if in confined space or potential vapor area), equipment inspected/safe, hot work operator qualified, client authorization obtained (if at client site).

3.2.5 Hazard Controls¶

Before Hot Work: 1. Survey work area (10-meter radius): Identify combustibles (wood, paper, insulation, plastics, flammable liquids), check other side of walls/floors/ceilings for hidden combustibles, identify floor drains that could spread flaming liquids, look up (overhead combustibles), look down (below floors/gratings). 2. Remove or protect combustibles: Remove all from area if possible, if cannot remove: cover with fire-resistant blankets/shields, protect floor openings to prevent sparks falling to lower levels, block floor drains, wet down combustibles that cannot be removed/covered. 3. Ventilation and atmospheric testing: Verify adequate ventilation to remove welding fumes, if in confined space: continuous ventilation/monitoring required, if near thermal oil/flammable liquids: test for vapors (LEL must be 0%), continue monitoring throughout hot work in hazardous locations. 4. Equipment inspection: Welding cables in good condition (no damaged insulation), gas cylinders secured upright/valves protected, flashback arrestors installed on torch equipment, fire extinguisher type ABC/minimum 10 lbs/fully charged, within 10 meters of location. 5. Fire watch position: Fire watch can see hot work area and all areas where sparks could fall, equipped with fire extinguisher/means to sound alarm, remains for 30 minutes after completion.

3.2.6 Hot Work on Thermal Oil Systems¶

EXTREME CAUTION - Thermal oil is flammable and can ignite from hot work.

Additional Requirements: System fully isolated/drained (Section 3.4), all valves closed/locked/tagged, lines physically disconnected or blanked where possible, system purged with water or steam (never air or inert gas before hot work), atmospheric testing confirms 0% LEL before and during hot work, continuous monitoring throughout, additional fire watch to monitor for leaks/vapors, fire extinguisher/blanket immediately accessible, thermal oil SDS reviewed by hot work crew, spill containment/cleanup materials on site.

If Thermal Oil Leak/Vapor Detected: Stop work immediately, evacuate area, eliminate ignition source, increase ventilation, identify/isolate leak source, clean up spilled oil before resuming.

3.2.7 Hot Work in Confined Spaces¶

Combines two high-hazard activities - requires maximum controls.

ALL requirements of both programs apply: Confined Space Entry Permit (Section 3.1), Hot Work Permit (Section 3.2), both permits active simultaneously.

Additional Requirements: LEL must be 0% (zero) before hot work begins and continuously during work, continuous monitoring with alarm capabilities, additional ventilation to remove welding fumes, entrant wears respiratory protection (welding fumes + potential oxygen depletion), fire watch inside (if space large enough) and outside, fire extinguisher at entry point, immediate evacuation if LEL rises above 0% or O₂ drops below 19.5%.

See: Hot Work in Confined Spaces Procedure (HW-002).

3.2.8 Post-Hot Work Inspection¶

Fire watch must remain minimum 30 minutes after completion.

Final Inspection: Check all areas where sparks could have traveled (above, below, behind walls), feel walls/floors/materials for unusual heat, verify no smoldering materials (wood, insulation, paper), check for smoke/burning smell, inspect fire extinguishers used (replace/recharge if used), document completion on permit.

If Work Area Cannot Be Monitored for 30 Minutes: Inform client facility management, provide building occupants with fire extinguisher/emergency contact information, consider extended fire watch or facility fire patrol.

3.2.9 Equipment and PPE¶

Equipment: Inspected daily before use (cables, connections, regulators, hoses, torches), maintained per manufacturer specifications, flashback arrestors required on oxy-fuel equipment, gas cylinders secured/stored upright/valves protected, grounding clamps attached properly (not to building structure without permission).

PPE for Hot Work: - Welding helmet with appropriate shade lens (minimum shade 10 for arc welding) - Welding gloves (leather, gauntlet style) - Leather jacket or sleeves - Fire-resistant pants (no synthetic materials) - Safety boots (leather, no synthetic) - Respiratory protection when required (confined space, fume exposure - Section 3.9) - Hearing protection (arc welding, plasma cutting, grinding)

3.2.10 Training and Documentation¶

Training - Hot Work Operators: - Trade certification (welder certification) OR comprehensive training in welding/cutting methods used - Hot work safety including fire prevention/response - Confined space training (if hot work in confined spaces) - Respiratory protection (if respirator required) - Client-specific hot work orientation (if at client site)

Training - Fire Watch: - Fire watch training including fire extinguisher use - Recognition of fire hazards/ignition - Emergency response procedures - Communication protocols

Training - Hot Work Supervisors: - Hot work hazard assessment training - Permit authorization training - Confined space entry supervisor (if authorizing hot work in confined spaces)

Records: - Hot Work Permits (retain 2 years) - Equipment inspection logs - Training records - Incident reports (fires or near-misses)

See: Hot Work Procedure (HW-001) and permit template.

3.3 Fall Protection Program¶

3.3.1 Purpose and Scope¶

Fall from heights is leading cause of serious injury/fatality in industrial maintenance.

Applies to: Work on platforms, catwalks, elevated work areas; use of ladders and MEWPs (scissor lifts, boom lifts); work on roofs including access to rooftop equipment; any work above 3 meters (10 feet) or where fall hazard exists regardless of height.

Common Fall Hazards: Accessing boilers/heaters/thermal equipment elevated on platforms, working from MEWPs during maintenance, roof access to heating equipment, ladder use to access equipment.

3.3.2 Regulatory Requirements¶

WorkSafe BC OHS Regulation, Part 11 (Fall Protection)
CSA Z259 series (Fall Protection Equipment)
ANSI/ASSE A10.32 (Fall Protection Systems)

3.3.3 Hierarchy of Fall Protection¶

4Core applies hierarchy (highest to lowest preference): 1. Eliminate hazard - Design work to avoid heights (use ground-level controls/access points, extend tools to reach elevated equipment, relocate/reposition equipment for ground-level access) 2. Guardrails (Passive Protection) - Use existing guardrails or install temporary (permanent on platforms/catwalks if client-provided, temporary on scaffolds/work platforms). Preferred because no worker action required. 3. Fall Restraint - Prevent worker from reaching fall hazard (tied off to anchor point, lanyard length prevents reaching edge, no fall possible = no arrest system needed). Use when work location allows restraint positioning. 4. Fall Arrest - Stop fall after it occurs (full-body harness, shock-absorbing lanyard, anchor point, engineered system to arrest fall before hitting ground/obstruction, requires rescue plan - worker may be suspended). Use only when restraint or guardrails not feasible. 5. Work Positioning - Support worker in position while working hands-free (positioning belt or harness, worker leaning back against lanyard, fall arrest backup required in addition to positioning system).

Fall arrest is last resort - exhaust all other options first.

3.3.4 Roles and Responsibilities¶

Competent Person (Fall Protection): Assess work site for fall hazards, select appropriate fall protection system, ensure anchor points adequate (5000 lbs or 22 kN per person), inspect equipment before each use, supervise installation of systems, train workers in system use. At 4Core: supervisors and working owners trained as competent persons.

Workers: Use fall protection systems as required/trained, inspect personal equipment before each use, report damaged equipment immediately (remove from service), understand rescue procedures for fall arrest systems, never remove or bypass fall protection systems.

Management: Provide fall protection equipment appropriate to hazards, ensure workers trained before working at heights, maintain equipment in good condition, review incidents/near-misses involving falls or fall protection.

3.3.5 Fall Protection Requirements¶

Work at Heights (above 3 meters or above hazardous surface):

Fall protection REQUIRED unless: work from MEWP with guardrails (scissor lift, properly configured boom lift), work from scaffold with guardrails, work on platform/catwalk with permanent guardrails meeting regulation.

If Guardrails Not Present: Fall arrest system required (full-body harness, lanyard, anchor) OR work restraint system (if worker can be restrained from reaching edge).

Exceptions (per WorkSafe BC): Ladder use up to 6 meters if ladder secured and three-point contact maintained, work on low-slope roofs (<4:12 pitch) with additional controls.

3.3.6 Fall Protection Equipment¶

Full-Body Harness: CSA Z259.10 certified, D-ring positioned center of upper back (between shoulder blades), properly fitted (all straps adjusted, nothing loose/dragging), inspected before each use (no cuts, tears, abrasion, damaged stitching, corrosion), removed from service if dropped, subjected to fall arrest, or damaged.

Lanyards and Connecting Devices: CSA Z259.11 certified, shock-absorbing lanyard for fall arrest (limits arrest force to 8 kN / 1800 lbs), self-retracting lifeline (SRL) for vertical fall arrest, positioning lanyards for work positioning (no shock absorber, limited length), inspected before use (same criteria as harness), maximum length 2 meters (to limit fall distance).

Anchor Points: Must support 5000 lbs (22 kN) per attached worker OR be certified as anchor by engineer, positioned to prevent swing fall or lower-level impact, inspected before use. Common anchors: structural steel beams, permanent anchor points, mobile anchor systems. Manufacturer-certified anchor devices preferred (beam anchors, D-ring anchors).

Rescue Equipment: Retrieval system (hoist, descent device) for fall arrest applications, rescue plan must account for how fallen worker retrieved within 7 minutes.

3.3.7 Mobile Elevated Work Platforms (MEWPs)¶

4Core uses scissor lifts, boom lifts, telehandlers with work platforms for elevated access.

Operator Certification: CSA B354.7 (Aerial Work Platform) OR equivalent recognized training, machine-specific training (boom vs. scissor, indoor vs. outdoor), annual refresher.

Pre-Use Inspection: Daily by operator before use, check controls/hydraulics/tires/tracks/guardrails/platform condition, document in logbook or checklist, remove defective equipment from service.

Safe Operation: Set up on firm, level surface (avoid soft ground, slopes), retract or secure outriggers/stabilizers per manufacturer, maintain minimum clearance from overhead power lines (3 meters minimum, more for high voltage), do not exceed platform weight capacity (including workers, tools, materials), keep body/materials inside guardrails (do not lean out), do not climb on guardrails or use ladders on platform, lower platform before moving MEWP (unless designed for elevated travel).

Fall Protection from MEWPs: - Scissor Lifts: Full-body harness attached to platform anchor point required (per manufacturer and WorkSafe BC) - Boom Lifts: Full-body harness with shock-absorbing lanyard attached to platform anchor point required - Guardrails alone NOT sufficient - tie-off required

See: Mobile Equipment Program (Section 3.11).

3.3.8 Ladder Safety¶

Ladders are for access, not work platforms. Minimize ladder use where MEWPs can be used.

Ladder Selection: CSA or ANSI rated for load (Type 1 Industrial = 250 lb capacity minimum), appropriate height (top extends 1 meter above landing), correct type (step ladder for self-support, extension for leaning), good condition (no cracks, bent rails, missing rungs, damaged feet).

Setup: Firm, level surface (use leveling devices if needed), extension ladders: 4:1 angle (1 foot out for every 4 feet up), secured at top OR bottom (tied off, footed by second person, secured device), three-point contact maintained (two hands + foot OR two feet + hand), face ladder when climbing (never backwards), do not overreach (belt buckle between rails, move ladder instead), do not stand on top two rungs of step ladder or top three rungs of extension ladder.

Inspection: Before each use, look for damage/cracks/bent components/loose rungs, check feet for wear or missing pads, remove damaged ladders from service (tag "DO NOT USE").

Fall Protection on Ladders: Not required for ladder use up to 6 meters if ladder secured and three-point contact maintained, required for extended work from ladder or ladder work above 6 meters (but ask: should we use MEWP instead?).

3.3.9 Rescue Planning¶

If fall arrest system used, rescue plan REQUIRED.

Suspended Worker Trauma: Worker suspended in harness after fall can develop suspension trauma (blood pooling, circulation loss). Rescue must occur within 7 minutes (WorkSafe BC guideline for IDLH). Faster rescue is better - goal is immediate rescue.

Rescue Options: Self-rescue (some systems have self-rescue capability - descent device, escape ladder, preferred if worker conscious/able), non-entry rescue (use of descent device, retrieval winch, or lowering system by rescuers from safe position, preferred over entry rescue), technical rescue (high-angle or rope rescue by trained team, fire department or private technical rescue service, may not arrive within 7-minute window).

4Core Approach: Minimize fall arrest use (prefer restraint, guardrails, MEWP with guardrails), when fall arrest necessary: use retrieval systems (SRL with descent capability, winch systems) where possible, identify rescue resources before work begins (internal capability vs. external service), consider internal training for davit rescue and simple lowering systems, complex rescues: call 911 for fire department technical rescue.

3.3.10 Training and Documentation¶

Training - All Workers Performing Work at Heights: Fall hazard awareness (recognition, hierarchy of controls, when protection required), fall protection equipment (inspection of harness/lanyards/anchors, proper donning/adjustment, connection to anchors, limitations/capacity), rescue procedures (recognition of suspension trauma, how to summon rescue, self-rescue techniques if applicable).

Training - Competent Person (Supervisors): Fall hazard assessment, selection of fall protection systems, anchor point selection/evaluation, equipment inspection, rescue planning.

Training - MEWP Operator: CSA B354.7 or equivalent, machine-specific training, annual refresher.

Records: Fall protection equipment inspection records (harnesses, lanyards, anchors), MEWP inspection logs (daily pre-use), training records, incident reports (falls, near-misses, fall arrest activations), program audit records.

Equipment Inspection: All fall protection equipment inspected before each use, annual formal inspection by competent person (documented), remove damaged equipment from service immediately.

See: Fall Protection Procedure (FP-001).

3.4 Lockout/Isolation Program¶

3.4.1 Purpose and Scope¶

Hazardous energy (electrical, mechanical, hydraulic, pneumatic, thermal, chemical) causes serious injuries when unexpectedly released during maintenance or service.

Applies to: Maintenance, repair, service, cleaning of equipment; adjustment or setup requiring guards removed or safety devices bypassed; unjamming equipment; any work where unexpected energization or startup could cause injury.

Common Hazardous Energy in 4Core Work: Electrical (motors, heaters, controls, lighting - shock, arc flash, electrocution), mechanical (rotating equipment - pumps, fans, blowers; reciprocating - pistons, compressors), hydraulic/pneumatic (pressure in lines/accumulators - injection injury, whipping hoses), thermal (hot fluids - thermal oil 200-400°C, hot water, steam; hot surfaces - burns), chemical (process fluids under pressure, stored chemicals - exposure, release), gravitational (suspended loads, stored energy in springs/counterweights - crush, strike).

3.4.2 Regulatory Requirements¶

WorkSafe BC OHS Regulation, Part 10 (De-Energization and Lockout)
CSA Z460 (Control of Hazardous Energy: Lockout and Other Methods)
Electrical safety requirements (Part 19)

3.4.3 Definitions¶

Lockout: Placement of lock and tag on energy-isolating device to prevent energization.

Energy-Isolating Device: Mechanical device that prevents transmission/release of energy. Electrical: disconnect switch, circuit breaker (NOT push-button, selector switch, or control circuit device). Mechanical: manual valve, blind flange. NOT computer controls, software interlocks, or control circuit devices.

Authorized Person: Worker trained and authorized to perform lockout.

Affected Person: Worker whose job requires operation of equipment on which lockout is performed, or who works in area where lockout is performed.

Zero Energy State: All energy sources isolated, dissipated, and verified as zero. Equipment cannot move, energize, or release stored energy.

3.4.4 Roles and Responsibilities¶

Authorized Persons (Lockout Qualified): Identify all energy sources requiring isolation, perform lockout procedures, verify zero energy state, apply personal locks and tags, remove locks only after work complete and all personnel clear. At 4Core: all owners and experienced crew members trained as authorized persons. New employees trained before independent lockout responsibility.

Affected Persons: Understand lockout program and recognize when lockout is in effect, do not attempt to operate locked-out equipment, notify authorized person if locked-out equipment is needed.

Supervisors: Ensure lockout procedures exist for all equipment, ensure workers trained before performing lockout, verify lockout compliance, investigate lockout violations.

3.4.5 Lockout Procedures¶

Before ANY Maintenance or Service Work:

Notify Affected Persons: Inform operators/others equipment will be locked out, coordinate with client facility if at client site, post "Equipment Out of Service" signage if applicable.
Shut Down Equipment: Use normal shutdown procedures (press stop button, close valves, etc.), allow equipment to come to complete stop, do not rely on shutdown alone - lockout still required.
Identify ALL Energy Sources: Electrical supplies (main power, control power, lighting, heaters), mechanical motion (rotating, reciprocating, stored energy), hydraulic/pneumatic pressure, thermal energy (hot fluids, steam, hot surfaces), chemical energy (process fluids, cleaning agents), gravitational energy (suspended loads, counterweights). Use equipment documentation: schematics, P&IDs, manuals, client information.
Isolate ALL Energy Sources: Open electrical disconnect switches to "OFF," close manual valves on fluid supplies, block or pin moving parts, drain or vent pressurized lines, cool hot equipment or isolate hot fluid supplies, lower suspended loads or engage mechanical stops.
Apply Locks and Tags: Lock isolation devices in "off" or "closed" position, each authorized person working applies their own personal lock, tag must identify: person who applied lock, date, reason, locks are personal - only person who applied lock removes their lock. If multiple workers: use group lockout box (each person locks their lock onto box, box lock is on equipment).
Dissipate Stored Energy: Bleed residual pressure from hydraulic/pneumatic systems (open drain valves), drain liquid from lines/vessels (open drain valves), discharge capacitors in electrical equipment (only by qualified electrician), allow hot equipment to cool OR flush with cool fluid, release mechanical springs or stored energy, block or support suspended loads.
Verify Zero Energy State: Attempt to operate equipment (press start button, try to rotate by hand), use test equipment (voltmeter for electrical, pressure gauge for pressure), verify all stored energy dissipated, do not proceed if equipment still energized.
Perform Work: Maintain locks throughout work, if work interrupted or shift change: locks remain in place, if additional workers join: they apply their own locks, reinstall guards before removing locks.
Remove Lockout: Verify work complete and all tools/equipment removed, verify all personnel clear of equipment, replace guards and safety devices, remove tags, remove locks (only your own lock), restore energy sources, notify affected persons that equipment is operational, test equipment operation.

3.4.6 Group Lockout¶

When multiple workers work on same equipment:

Option 1: Individual Lockout (Preferred): Each worker applies their own lock directly to each energy isolation point, may require multiple-lockout hasps (allows several locks on one device).

Option 2: Group Lockout Box: One lock applied to each energy isolation device (supervisor's lock or "equipment lock"), key to equipment lock placed in group lockout box, each worker applies their personal lock to group lockout box, equipment cannot be energized until all personal locks removed from box.

Rules: Supervisor or lead hand responsible for group lockout integrity, each worker still applies and removes only their own lock, no one removes another person's lock under any circumstances.

3.4.7 Lockout on Client Sites¶

When performing lockout at client facilities: 1. Coordinate with client before lockout (notify client maintenance/operations, obtain approval, verify notification requirements) 2. Use client lockout procedures if required (some clients require use of their procedures, 4Core procedures must still meet or exceed, if client procedures less stringent: notify we will use ours) 3. Apply 4Core locks in addition to client locks (apply our own personal locks even if client personnel also lock out, do not rely solely on client lockout, our locks/our control) 4. Verify zero energy ourselves (do not assume client verification sufficient, perform our own voltage testing, pressure testing, equipment trial) 5. Notify client before restoring energy (remove our locks only after client approval to restore, client may have additional work/requirements before energizing)

3.4.8 Special Lockout Situations¶

Thermal Energy (Hot Fluids): Isolate fluid supply (close and lock valves), drain system or section being worked on, allow equipment to cool OR flush with cool fluid if immediate work required, verify temperature acceptable before opening equipment, use appropriate PPE for residual heat (heat-resistant gloves).

High-Temperature Thermal Oil (200-400°C): Extreme burn hazard, must drain and cool OR use specialized hot work procedures, verify oil drained before opening flanges/connections (oil under pressure can spray), do not rely on sight glass - physically verify drain.

Electrical - Qualified Workers Only: Electrical lockout performed only by qualified electricians OR under their supervision, voltage testing required to verify de-energization, assume all circuits live until proven otherwise, arc flash hazard analysis if energized work required (avoid if possible).

Thermal Fluid Heaters (Pressure Vessels): Requires Technical Safety BC permit for entry (if entering vessel), lockout heating elements (electrical), lockout fuel supply (gas, oil), lockout combustion air supply, isolate thermal oil circulation (close valves, lock out pumps), drain or verify fluid level safe, cool to safe temperature before entry.

3.4.9 Lockout Equipment and Alternative Methods¶

4Core Provides Each Authorized Person: Personal locks (keyed uniquely to individual, distinct color or ID), tags (write-on with person's name, date, reason), multiple-lockout hasps (allow several locks on one device), lockout devices (valve lockouts, electrical lockouts, cable lockouts).

Personal Lock Requirements: Unique key (only one key per lock, no master keys), durable (withstand industrial environment), standardized within 4Core (same type for all personnel), labeled with owner's name or employee number.

Lockout Devices: Electrical disconnect lockouts (fit specific switch types), valve lockouts (ball valve, gate valve, butterfly valve), cable lockouts (secure multiple valves or odd-shaped devices), stored energy blocking devices (pins, blocks, chains).

Assured Isolation (When Lockout Not Possible): Used when energy isolation device cannot accept lock (some small valves, inline shutoffs). Must use another method to prevent energization: remove handle from valve (secure in toolbox), apply cable tie and tag through valve operator, position supervisor or attendant to monitor isolation device. Document why lockout not used and what alternative method applied.

Working on Energized Equipment (Avoid if Possible): Only when de-energization creates greater hazard OR not feasible, requires written procedure/qualified workers/specialized PPE, arc flash analysis required for electrical, minimize use - de-energization always preferred.

3.4.10 Training, Violations, and Documentation¶

Training - Authorized Persons: Lockout/isolation training including: hazardous energy recognition, energy isolation methods, lockout procedure steps, verification of zero energy state, group lockout procedures, client site coordination, equipment-specific training for complex systems, annual refresher.

Training - Affected Persons: Lockout awareness training including: purpose of lockout, recognition of locks and tags, prohibition on removing others' locks, notification procedures.

Training - Supervisors: Authorized person training PLUS lockout procedure development, audit and inspection responsibilities.

Violations - Serious Safety Violations. Prohibited Actions: Removing another person's lock or tag, operating locked-out equipment, bypassing lockout devices, failing to lockout when required, failing to verify zero energy state. Consequences: First violation: immediate work stoppage, retraining, written warning. Second violation: suspension, mandatory retraining. Repeated violations: termination. Exception: Supervisor may remove lock in emergency if: worker who applied lock is unavailable, supervisor verifies equipment safe and no workers at risk, incident documented and reported to management.

Records: Equipment-specific lockout procedures (for complex equipment), training records (authorized and affected persons), lockout device inventory (who has which locks/tags), incident reports (lockout violations, failure to lockout), annual program audit records.

See: Lockout/Isolation Procedure (LO-001).

3.5 WHMIS 2015 Program (Workplace Hazardous Materials Information System)¶

3.5.1 Purpose and Scope¶

Workers have right to know about hazardous materials they may be exposed to at work.

Applies to: All controlled products used by 4Core (chemicals, materials covered by WHMIS 2015), hazardous materials encountered at client sites, products with hazard pictograms on labels.

Common Hazardous Materials: Thermal oil (flammable liquid, health hazard), welding consumables (fumes, gases), solvents and degreasers (flammable, health hazards), cutting fluids and lubricants, combustion gases (CO, CO₂, NOx, SOx), refractory materials (silica hazard - Section 3.6), cleaning chemicals, paints and coatings.

3.5.2 Regulatory Requirements¶

WorkSafe BC OHS Regulation, Part 5 (Chemical Agents and Biological Agents)
Hazardous Products Act and Hazardous Products Regulations (Federal)
WHMIS 2015 (aligned with GHS - Globally Harmonized System)

3.5.3 WHMIS 2015 Key Elements¶

Three key components: Labels (supplier labels and workplace labels identify products and hazards), Safety Data Sheets (SDS) (detailed hazard information and safe handling instructions), worker education (training on labels, SDS, and safe work practices).

3.5.4 Roles and Responsibilities¶

Management: Maintain SDS for all controlled products, ensure products properly labeled, provide WHMIS training to all workers, ensure availability of SDS at all work sites.

Supervisors: Verify SDS available for products used on jobs, ensure workers trained before using hazardous materials, verify labels present/legible, review SDS with workers before first use of product.

Workers: Read labels and SDS before using products, follow safe handling procedures from SDS, report missing labels or SDS, use required PPE for products, report chemical exposures or spills.

Safety Officer: Maintain master SDS library (digital and physical copies), update SDS as new versions received, coordinate WHMIS training, investigate chemical exposures.

3.5.5 Labels and Pictograms¶

Supplier Labels (on original container): Product identifier (name), pictograms (hazard symbols), signal word ("Danger" or "Warning"), hazard statements (what the hazard is), precautionary statements (how to minimize risk), supplier identification.

WHMIS 2015 Pictograms (Red Diamond with Symbol): Flame (flammable), flame over circle (oxidizer), gas cylinder (compressed gas), corrosion (corrosive to metals or skin), skull and crossbones (acute toxicity), exclamation mark (health hazard, irritant), health hazard (serious health effects - cancer, respiratory, reproductive), exploding bomb (explosive), environment (environmental hazard).

Workplace Labels (when transferred from supplier container): Product identifier (same as supplier label), safe handling information, reference to SDS available, simple - can be handwritten on secondary container.

Labeling Requirements: All containers must be labeled (original AND secondary containers), labels must be legible (not faded, torn, obscured), replace damaged labels immediately, do not remove supplier labels from original containers.

3.5.6 Safety Data Sheets (SDS)¶

SDS Format (16 sections): 1. Identification (product name, manufacturer, emergency contact), 2. Hazard identification (pictograms, signal word, hazard statements), 3. Composition/ingredients (chemical components), 4. First aid measures, 5. Fire-fighting measures, 6. Accidental release measures (spill cleanup), 7. Handling and storage, 8. Exposure controls/PPE, 9. Physical and chemical properties, 10. Stability and reactivity, 11. Toxicological information, 12. Ecological information, 13. Disposal considerations, 14. Transport information, 15. Regulatory information, 16. Other information.

SDS Management: Master SDS library at head office (digital and physical), field SDS (copies provided to job sites where products used), SDS accessibility (available to workers during all shifts), digital access (SDS library available on mobile devices - tablets/phones - for field access), update SDS (replace outdated when new versions received from supplier). Where to Get: from product supplier (manufacturer or distributor), supplier websites (download most current version), request from supplier if not provided. If SDS not available: do not use product until SDS obtained.

3.5.7 Safe Work Practices¶

Before Using: Read supplier label, review SDS (at least sections 2, 4, 5, 6, 7, 8), identify required PPE (Section 8), understand emergency procedures (first aid, spill cleanup, fire response).

During Use: Use product only for intended purpose, use in well-ventilated area (or provide ventilation), wear required PPE, avoid skin contact and inhalation, keep containers closed when not in use, do not eat, drink, or smoke when handling chemicals.

Storage: Store per SDS instructions (temperature, compatibility, ventilation), keep containers closed and upright, store flammables away from ignition sources, segregate incompatible materials (acids away from bases, oxidizers away from flammables), post "Flammable Liquids" signs if required, ensure storage area ventilated.

Disposal: Follow SDS disposal instructions (Section 13), do not pour chemicals down drains unless SDS allows, use approved waste contractors for chemical disposal, keep waste segregated (flammables separate from other waste), dispose of empty containers per regulations (may still be hazardous).

Spills and Releases: Small spills (<1 liter, non-hazardous): clean up using absorbent, dispose per SDS. Large spills or hazardous materials: evacuate area, contain if safe to do so, call for assistance. Review SDS Section 6 (Accidental Release Measures) before cleanup, wear appropriate PPE for cleanup, report spills to supervisor and client (if at client site).

3.5.8 Common Hazardous Products and Thermal Oil¶

Thermal Oil: Hazards: flammable liquid, health hazard (skin/eye irritant, possible carcinogen). Pictograms: Flame, Health Hazard. PPE: chemical-resistant gloves, safety glasses, fire-resistant clothing. Special concerns: high temperature (200-400°C), burns from contact, fire risk if leaked onto hot surfaces. SDS critical sections: Fire-fighting (5), Handling and Storage (7), PPE (8).

Welding Consumables: Hazards: welding fumes (metal fumes, manganese, chromium), compressed gas (shielding gas). Pictograms: Health Hazard, Gas Cylinder. PPE: welding helmet, respiratory protection (Section 3.9), welding gloves. Special concerns: fume exposure in confined spaces, oxygen-enriched atmospheres from leaking cylinders.

Solvents and Degreasers: Hazards: flammable, health hazard (inhalation, skin absorption), narcotic effects. Pictograms: Flame, Exclamation Mark or Health Hazard. PPE: chemical-resistant gloves, safety glasses, respiratory protection if inadequate ventilation. Special concerns: vapor accumulation in confined spaces, skin exposure.

Refractory Materials (Silica Hazard): Hazards: respirable crystalline silica (lung disease - silicosis, lung cancer). Pictograms: Health Hazard. PPE: respiratory protection (N95 minimum, see Silica ECP Section 3.6). Special concerns: cutting, grinding, demolition of refractory creates silica dust.

Thermal Oil - Special Considerations: Thermal oil is 4Core's most significant chemical hazard. Why Hazardous: flammable liquid (flash point varies, typically 200-250°C), used at temperatures well above flash point (300-400°C operating), spilled oil on hot surfaces can ignite, hot oil causes severe burns on contact, vapor inhalation can cause respiratory irritation, prolonged skin contact can cause dermatitis, some thermal oils contain PAHs (polycyclic aromatic hydrocarbons - carcinogenic). Safe Handling: minimize skin contact (use chemical-resistant gloves, face shield if splash risk), avoid breathing vapors (work in ventilated areas, respiratory protection if needed), prevent spills (use drip pans, have absorbent available), clean up spills immediately (hot oil spills are fire hazards), wash exposed skin immediately with soap and water, launder contaminated clothing before re-use, dispose of oily rags in covered metal containers (spontaneous combustion risk). Thermal Oil Fires: DO NOT USE WATER on thermal oil fires (causes explosive boil-over), use dry chemical, CO₂, or foam extinguishers, evacuate if fire cannot be controlled quickly, call 911 for large fires. See: thermal oil SDS for specific product hazards and controls.

3.5.9 Training and Documentation¶

Training - All Workers (before working with hazardous materials): Generic WHMIS training (applies to all): purpose and scope of WHMIS 2015, supplier labels and workplace labels, pictograms and signal words, how to read and use SDS, worker rights and responsibilities. Product-specific training (for products used): hazards of specific products used in worker's job, safe handling procedures, required PPE, emergency procedures (spill, exposure, fire). Frequency: initial before working with hazardous materials, product-specific before first use of new product, refresher every 3 years OR when new hazards introduced.

Records: SDS library (all products used or encountered), SDS inventory list (product name, location, date of SDS), WHMIS training records (worker name, date, products covered), product inventory (what hazardous materials we have, where stored), spill and exposure incident reports. SDS Retention: keep SDS for all current products, retain SDS for discontinued products for 30 years (exposure records).

See: WHMIS Procedure (WH-001).

End of Chapter 3, Part 1¶

Summary - Part 1 Covered:

3.1 Confined Space Entry (60% of work) 3.2 Hot Work Program (welding, cutting, grinding in hazardous environments) 3.3 Fall Protection (heights, MEWPs, ladders, rescue planning) 3.4 Lockout/Isolation (thermal systems, multi-energy isolation) 3.5 WHMIS 2015 (thermal oil, chemicals, SDS management)

Document Control

Field	Value
Version	0.9-DRAFT
Effective Date	December 2025
Next Review	December 2026
Approved By	[All 4 Owners]
Safety Officer	Rodney Peters

Company Information: - Business Name: 4Core Energy & Maintenance Ltd. - Address: [To Be Added] - Industry: Energy and mechanical system maintenance, retrofits and troubleshooting - WorkSafe BC Account: [Account Number]