Lockout is a crucial safety procedure that prevents machinery or equipment from being accidentally energized during maintenance or servicing. Proper lockout/tagout (LOTO) practices are essential for safeguarding workers from hazards like electrical shocks, crushing, or the sudden release of stored energy. In Ontario, lockout procedures are governed by regulations set by the Ministry of Labour, Immigration, Training and Skills Development (MLITSD). This article will cover the lockout regulations in Ontario and provide some best practices to ensure workplace safety.
Ontario Regulations Covering Lockout
In Ontario, lockout requirements are part of the Occupational Health and Safety Act (OHSA) and are further detailed in the Industrial Establishments Regulation (Reg. 851). Here are the key aspects:
Section 42 of the OHSA states that employers must ensure that any equipment that is being maintained or repaired is properly locked out to prevent accidental start-up.
Regulation 851, Section 76 specifies that any equipment that is being cleaned, maintained, or repaired must be locked out, and all energy sources must be effectively controlled.
Regulation 213/91 (Construction Projects) also includes lockout requirements for construction sites to prevent injury related to machinery and equipment.
Control of Hazardous Energy: Ontario emphasizes the control of hazardous energy sources, including electrical, mechanical, hydraulic, pneumatic, chemical, and thermal energy. Employers are required to establish procedures to control these energy sources before any maintenance or servicing work is carried out.
The CSA Standard Z460-13 ("Control of Hazardous Energy - Lockout and Other Methods") is often referred to for guidance, and though it isn’t legally binding on its own, it's recognized as a best practice for developing and implementing lockout programs in Ontario.
Key Components of Lockout Regulations
Written Procedures: Employers must develop specific written procedures for locking out machinery and equipment.
Training: All employees must be trained in the relevant lockout procedures. This training must be updated periodically to ensure workers understand any changes.
Communication: Employers must communicate lockout procedures effectively, including the use of clear tags and labels that indicate the equipment is locked out and undergoing maintenance.
Best Practices for Lockout/Tagout
Following best practices for lockout/tagout helps ensure compliance with regulations and maximizes worker safety. Below are some effective strategies to consider:
1. Develop a Comprehensive Lockout Program
A strong lockout program should include a detailed equipment hazard assessment to identify energy sources.
Develop a lockout/tagout policy that includes every department's roles, responsibilities, procedures, and guidelines.
2. Standardized Lockout Procedures
Create step-by-step lockout procedures that are specific to each piece of equipment. This should include:
Shutting down equipment.
Isolating energy sources.
Locking out the energy isolating device with appropriate lockout devices.
Dissipating any stored or residual energy.
Verifying the isolation (attempting to start the equipment).
3. Proper Training and Retraining
Provide training not only for employees responsible for locking out equipment but also for affected employees who may work near locked-out equipment.
Periodic refresher training is critical, especially after incidents or when new machinery is introduced.
4. Use Standardized Lockout Devices and Tags
Locks, tags, and devices should be standardized across the facility. Use consistent colors and shapes for easy recognition.
Devices should be durable enough to withstand the environment in which they are used (e.g., weather-resistant tags for outdoor use).
5. Test Before Starting Work
Always verify that the lockout procedure is effective before starting work. This usually means attempting to restart the equipment to ensure that all energy sources have been effectively isolated.
6. Authorized Personnel Only
Only authorized personnel should apply and remove locks. This minimizes confusion and ensures accountability.
Locks must only be removed by the individual who applied them, unless specific procedures are followed to remove the lock safely in that person's absence.
7. Coordination Between Contractors and Facility Workers
When outside contractors are involved, coordination is key. Ensure that contractors understand the lockout requirements, and communicate clearly about who is responsible for each part of the lockout/tagout process.
8. Regular Inspections
Regular inspections of lockout procedures are essential. Inspect your lockout program at least annually to ensure that all procedures are followed correctly and that equipment-specific instructions are up to date.
Document any issues or areas for improvement and make necessary adjustments to procedures or training.
9. Stored Energy Awareness
Recognize that lockout involves more than just electrical energy. Hydraulic pressure, compressed air, gravity, and even thermal energy can present serious hazards.
Ensure that steps are taken to release stored energy, such as bleeding off pressure or blocking mechanical parts that could move.
10. Proper Tagging Practices
Tags should clearly communicate that the equipment is locked out and indicate who performed the lockout, along with the date.
Tags are not to be used as substitutes for physical locks unless circumstances make the use of a lock impossible.
Common Challenges and Solutions in Lockout
Complex Energy Sources: Some machinery may have multiple energy sources, making isolation difficult. In these cases, detailed mapping of energy sources is crucial.
Communication Gaps: Make sure procedures are easily accessible and understandable to all workers, possibly translating them into multiple languages if necessary.
Time Pressures: Maintenance deadlines can pressure workers into bypassing lockout procedures. Reinforce a culture where safety is prioritized over speed, and ensure workers are supported in following protocols, even under tight deadlines.
Conclusion
Lockout is a fundamental safety measure designed to protect workers from the unexpected release of hazardous energy. In Ontario, strict regulations govern how lockout should be performed to minimize workplace injuries and fatalities. Following best practices—such as establishing a comprehensive lockout program, ensuring proper training, and maintaining effective communication—can help companies stay compliant and create a safer workplace for everyone involved.
By implementing these lockout best practices and staying informed of Ontario's regulatory requirements, you contribute to a culture of safety that prioritizes worker well-being and operational reliability.
Training from Safety.Services
Lockout Training - Handling electricity comes with significant risks. Workers servicing or maintaining machinery can be harmed by unexpected startups or the sudden release of stored electrical energy. A common and serious cause of injuries and fatalities is failing to lock out machinery before maintenance begins. Fortunately, these incidents are entirely preventable with a well-implemented lockout/tagout program. This training will cover electrical hazards, safe working practices, and the lockout/tagout procedures that are essential to ensuring your safety. It’s designed for anyone working on or near electrical machinery, helping you understand how these protocols can protect you and save lives.
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