Lockout and Tag-out Procedure

1. Introduction and Purpose

Loyalist College is committed to ensuring the safety of its community members and complying with the Occupational Health and Safety Act. This policy establishes lockout and tag-out requirements to prevent injuries caused by the unexpected energization, activation, or release of hazardous energy during the servicing or maintenance of machinery, equipment, or electrical systems through the use of lockout and tag-out processes.

This policy is supported by departmental procedures and forms that outline specific lockout and tag-out requirements.

2. Application

This procedure applies to all college employees, students, and contractors who perform servicing or maintenance on machinery, equipment, or electrical systems that may contain hazardous energy and pose a risk of injury if released unexpectedly.

All contractors performing work on Loyalist College premises are required to follow the lockout/tagout requirements outlined in this procedure. In the event that a contractor’s own lockout policy or procedure is more stringent than Loyalist College’s requirements, the more stringent procedure will take precedence and must be followed. In all cases, the most rigorous standard must prevail to ensure the highest level of safety.

This procedure does not apply to work on cord-and-plug-connected electrical equipment where the unexpected energization or start-up is controlled by unplugging the equipment and the plug is in the direct control of the person performing the work. This procedure does not apply to minor servicing, tool changes, or adjustments that do not have the potential to cause injury.

This procedure is intended to support safe work practices; however, it does not replace or override any applicable legislative or regulatory requirements. In all cases, the requirements of relevant legislation, including but not limited to the Occupational Health and Safety Act and applicable regulations, must be followed and will take precedence over this procedure.

3. Roles and Responsibilities

Authorized Individuals

• Assist in the development of lockout procedures in their area.
• Follow lockout procedures for the machines, equipment, or processes in their area.
• Immediately report any deficiencies or problems to their supervisor.

Supervisors

• Identify any machines, equipment, or processes in their area(s) that possess hazardous energy for inclusion in the lockout/tag-out procedures.
• Clearly identify all energy isolating devices to indicate their control function.
• Ensure written, equipment-specific lockout procedures are prepared for any complex machines, equipment, or processes in their area.
• Track and monitor lockout processes, documenting with OHS 012 Form A Safety Lockout Isolation Plan.
• Ensure all supervised employees are properly trained and correctly apply proper lockout procedures.
• Provide personal protective equipment and devices necessary to perform work safely.
• Periodically observe employees performing lockouts to ensure all procedures are understood and followed.
• Ensure contractors performing servicing or maintenance work in their area comply with lockout procedures.
• Ensure energy-isolating devices are designed to accept a lockout device which will positively secure them in the isolated position when purchasing, modifying, or installing equipment/designing processes.

Organizational Health and Wellness Specialist

• Assist supervisors, upon request, in evaluating equipment and/or processes so that appropriate measures for lockout/tag-out are identified.
• Assist supervisors in coordinating lockout/tag-out training.
• Conduct periodic reviews of lockout/tag-out procedures and recommend changes to the supervisor.
• Review and update this policy and procedure.

Joint Health & Safety Committee (JHSC)

• Make recommendations for the development of, or improvements to, the existing lockout/tag-out processes, as needed.

Contractors

• Communicate their lockout procedure to the designated Loyalist College representative.
• Comply with the requirements of the college’s lockout/tag-out standards and requirements.
• Provide their own locks, tags, and lockout devices.
• Remove their own locks, tags, and lockout devices when the maintenance or service work has been completed.

4. Lockout/Tag-out Device Requirements

When isolating hazardous energy sources, an approved lockout device and tagout device must be applied to each energy‑isolating device. Lockout is required wherever it is physically possible to do so. Where an energy‑isolating device cannot be locked, a tagout device may be used as an alternative control, provided that clear communication is established and maintained with all workers who may access the area, ensuring the equipment is not energized or operated.

4.1 Lockout Device Requirements

Each person performing services or working on a machine must apply their own lock and personally retain the key to the lock. All keys must be removed from locks and kept with the person who applied the lock. Locks cannot have a master key.

Each system will have as many locks on it as there are people working on it; each individual must place their own lock on the system. For multiple lockouts, a hasp or lockout bar may be used.

4.2 Tag-out Device Requirements

Tags must be made of a non-conducting material, be securely attached, and placed in a conspicuous location.

Tags must indicate:

• a warning of the hazard,
• who is performing the work,
• the date of lockout, and
• why the work is being performed (i.e. project name, task etc.).

5. Departmental Hazard Assessment Processes

5.1 Hazard Risk Assessments

A hazard analysis must be conducted to examine all the intended uses of the system from the perspective of both the manufacturer and the user. This analysis should also include any hazards related to any possible misuse of the system.

Supervisors will evaluate the likelihood and exposure of each hazard and the associated risk of each hazard in preparation for designing specific lockout/tag-out procedures. At a minimum, the following must be considered:

• Machine/process set-up.
• Teaching and programming of machinery.
• Testing and start-up.
• All modes of operation.
• Product feeding into machine/process.
• Product takeoff from machine/process.
• Process/tool changeover.
• Normal stoppages and restart.
• Unscheduled stoppages (control failure or jam) and restart.
• Emergency stoppages and restart.
• Unexpected start-up.
• Fault-finding and troubleshooting.
• Cleaning and housekeeping.
• Planned maintenance and repair.
• Unplanned maintenance and repair.

5.2 Implementing Controls and Procedures

In designing area lockout/tag-out procedures, supervisors should consult documentation from the manufacturer or designer of each system regarding:

• Where energy isolating devices are located and any procedures for their use.
• Step-by-step procedures for servicing or maintaining the system.
• How to safely address malfunctions, jams, misfeeds, or other planned and unplanned interruptions in operations.
• How to install, move, and remove any or all parts of the system safely.

Each area or specific piece of equipment requiring lockout/tag-out must be recorded with its own specific procedure on OHS 012 Form A – Safety Lockout Isolation Plan by the area supervisor in advance of the lockout. Simple equipment with one energy source and an easily identified energy isolating device may not require a separate procedure.

The written procedure must identify how the lockout process will be carried out and specify:

• The specific machine, equipment, or process involved in the shutdown and isolation process.
• The hazardous energy present and the type of energy isolating or de-energizing devices required.
• Where the lockout devices are required and how they are installed.
• The steps for shutting down, isolating, blocking, securing, and relieving stored or residual energy.
• The steps for placing and removing all lockout devices.
• How the isolation can be verified.
• How others in the area will be informed of the lockout and the return to service.

6. Requirements for Work On or Near Live Electrical Systems

All circuits and conductors are considered energized until tested. Only a qualified person, either a licensed electrician or a competent worker (a manufacturer’s trained technician), can test for voltage. The handling, determination of voltage, and the demolition and removal of electrical conductors, wires, and any equipment related to heating, ventilating, and information technology/communication systems must be performed by an approved, appropriately licensed electrical contractor.

Testing of electrical circuits and conductors must be completed by an electrical contractor to permit other contractor trades to perform their scope of work. Such workers must participate in the lockout/tag-out processes and keep their work within the parameters of the lock and tag.

Any work that involves working on or near live electrical must be documented in a safety plan and approved in advance by the area supervisor.

The individual working on live installations mustuse approved personal protective equipment (rubber gloves, mats, shields, insulating tools, etc.), rated for the voltage being worked on, and utilize the approved procedures to ensure protection from electrical shock and arc flash while performing the work.

7. Lockout Procedure

The following are general procedural steps to follow when locking out equipment. Each area or specific piece of equipment requiring lockout/tag-out must be recorded with its own specific procedure on OHS 012 Form A – Safety Lockout Isolation Plan by the area supervisor in advance of the lockout.

Step One. Identify machinery and processes to be isolated and identify all sources of hazardous energy. Use OHS 012 Form A Safety Lockout Isolation Plan to document the corresponding set of instructions that detail the specific lockout locations and lockout procedures for complex machinery or processes.

Step Two. Notify all affected employees that machinery or processes are going to be locked out.

The authorized person will communicate the following information to notify affected persons:

• What is going to be locked/tagged out.
• Why it is going to be locked/tagged out.
• For approximately how long the system will be unavailable.
• Who is responsible for the lockout/tag-out, if not themselves.
• Who to contact for more information.

Step Three. Shut down equipment following the normal stop procedures. Equipment shutdown involves ensuring all controls are in the off position and verifying that all moving parts, such as flywheels, gears, and spindles, have come to a complete stop.

Step Four. De-energize the system by following the lockout procedure for the identified machine, equipment, or process. Review the following isolation practices for various forms of hazardous energy:

Electrical

• If the equipment is operational, shut it down with the normal stopping procedure (stop button, switch, etc.).
• If the equipment is not operational, check the voltage to ensure that the correct switch is locked out. Only licensed electricians or authorized employees fully trained in using voltage meters may perform this step.
• Turn off the main and auxiliary power disconnect switches. Remove load cables or adequately ground conductors with a visible grounding mechanism if any switches exist that cannot be locked out. When disconnecting switches, stand to the right of the switch, look away, and use your left hand to disconnect the switch.
• Try the point-of-operation controls to be sure that the equipment is de-energized.

Pneumatic and Hydraulic

• Set the valves in the closed position and lock them into place. Bleed off the energy by slowly opening the pressure relief valves. Some procedures for pneumatic energy control may require that pressure relief valves be locked in the open position. Some procedures for hydraulic energy, for example, in lifting devices, may require blocking.  

Fluid and Gases

• Lock valves or drain lines to reduce pressure. If valves are not lockable, physically remove the supply line to the equipment, use a valve lock adaptor, or close the valve and remove the handle.

Mechanical

• Lower all suspended parts to the lowest position. Block moveable parts that cannot be lowered.
• Carefully release energy from any springs that may still be compressed. If this is not feasible, block the parts that may move if there is a possibility that the spring can transfer energy to it.

Chemical Energy

• Locate chemical supply lines in the system and close and lockout the valves. Where possible, bleed lines and/or cap ends to remove chemicals from the system.

Gravitational Potential Energy

• Use a safety block or pin to prevent the part of the system that may fall or move.

Step Five. Remove or dissipate anyresidual or stored energy.

In general, examples include:

• Electrical energy – To find a specific method to discharge a capacitor for the system, contact the manufacturer for guidance. Many systems with electrical components, motors, or switch gears contain capacitors. Capacitors store electrical energy. In some cases, capacitors hold a charge and may release energy very rapidly. In other cases, capacitors are used to remove spikes and surges to protect other electrical components. Capacitors must be considered and discharged, when applicable, in the lockout process to protect workers from electrical shock.
• Hydraulic and pneumatic potential energy – Setting the valves in the closed position and locking them into place only isolates the lines from more energy entering the system. In most cases, residual energy will still be left in the lines as pressurized air or fluid. This residual energy can be removed by bleeding the lines through pressure relief valves. Verify depressurization or use flange-breaking techniques. Contact the manufacturer for more specific details, or if no pressure relief valves are available, what other methods are available.
• Gravitational potential energy – If possible, bring the equipment or machine to ground level.
• Chemical energy – If available, bleed lines and/or cap ends to remove chemicals from the system.

Step Six. Apply lockout and tagoutdevices to all energy sources, ensuring they are held in the “off” position. All authorized persons performing work on machine or equipment must apply their own lock to ensure the equipment is not re-energized before they have completed their work.  If multiple individuals are working on the machine, a lockout bar or hasp will be used. Each worker will affix their lock onto the lockout bar/hasp, along with a completed tag.

The tag-out device(s) must be attached to the same point a lock would be attached. If the tag cannot be affixed at that point, the tag will be located as close as possible to the device in a position that will be immediately obvious to anyone attempting to operate the device. The tag must contain all the following information a warning of the hazard, who is performing the work, the date of lockout, and why the work is being performed.

Step Seven. Verify that equipment will not operate by trying all controls, valves, and moveable parts. All controls must be returned to the “neutral” or “off” position. Electrical circuits must be tested with an approved, appropriately rated voltage meter;only appropriately licensed electricians or authorized employees may perform this step.

Step Eight.  Complete the activity that required the system to be locked out.

8. Procedure to Release Equipment or Machinery from Lockout

Lockout locks must not be removed by anyone but the authorized person who placed the lock. Removing a lockout device belonging to someone else could result in fatality or serious injury.

Step One. After the work has been completed, the authorized employeemust verify that all tools or unessential parts have been removed, all guards have been replaced, and the equipment or process is operationally intact. Verify that all controls are in a neutral position.

Step Two. Confirm that all employees and persons are safely located away from hazardous areas and are notified that the machine or equipment is going to be released from lockout.

Step Three. Remove devices in the opposite order in which they were installed and re-energize the system. The last lock removed should be that of the authorized employee supervising the lockout.

Step Four. Energize and then restart the machine or process.

Step Five. Notify affected employees that servicing is completed.

Step Six. Complete all necessary documentation. Retain documentation for two years.

9. Procedure for Removal of Lock during Absence of the Authorized Worker

In the event a worker is absent when the locks are to be removed, the absent worker’s supervisor has the authority to remove the lock, provided the following conditions are met:

a) All reasonable attempts have been made to contact the employee to determine why the lock was left on and to request the employee’s return to remove the lock.

b) The system is deemed safe by the supervisor to remove the lock.

c) Removal of the lock is documented on OHS 012 Form B Lock Removal Authorization.

The absent worker must be immediately notified by the supervisor upon returning to work that their lock has been removed. Document this notification on OHS 012 Form B Lock Removal Authorization.

5. Related Documents

• OHS 012 Lockout and Tag-out Policy
• OHS 012 Form A Safety Lockout Isolation Plan
• OHS 012 Form B Lock Removal Authorization

6. References

• Occupational Health and Safety Act, 1990
• R.R.O. 1990, Regulation 851 Industrial Establishments, 1990
• CSA Z460-20: Control of Hazardous Energy – Lockout and Other Methods, 2020