Lockout Procedure
A lockout procedure is a written, formal sequence of steps used to de-energize, isolate, lock, and verify hazardous energy sources on machinery or equipment, preventing inadvertent start-up, energization, or release of stored energy during maintenance or repair. It includes identifying energy sources, applying personal locks, and verifying a zero-energy state before work begins, as defined by WorkSafeBC and CSA Z460.
On a manufacturing shop floor, a lockout procedure is applied during maintenance, servicing, or clearing jams. Steps include identifying equipment and energy sources (electrical, mechanical, hydraulic, pneumatic, gravity, thermal), notifying affected employees, shutting down equipment, isolating energy via main disconnects or valves, applying personal locks, relieving stored energy, and verifying zero energy by attempting to start the equipment. For group lockout, two qualified workers independently lock out devices, secure keys in a lock box, and each worker applies a personal lock. After work, locks are removed in reverse order, ensuring safe return to service.
- Locking out control circuits instead of primary energy-isolating devices, leaving hazardous energy present and risking unexpected start-up.
- Incomplete identification of all energy sources, especially stored energy like hydraulics, pneumatics, or gravity, leading to residual movement or release after lockout.
- Deficient group lockout control, such as lacking designated qualified workers, inadequate key securing, or incomplete checklists, causing premature return to service.
When is a lockout procedure legally required under WorkSafeBC Part 10?
Lockout is required whenever workers work on machinery or equipment and their health or safety could be endangered by hazardous energy release. This includes when maintenance is performed or when safeguarding is removed, bypassed, or circumvented. If no hazard exists, lockout may not be required, but this must be evaluated carefully against regulations and CSA Z460.
What are the minimum elements of a compliant lockout procedure in BC, aligned with CSA Z460?
A compliant procedure must specify scope, roles (authorized and qualified workers), preparation for shutdown (energy identification, hazard assessment, notification), shutdown steps, isolation on main energy sources, lock application (personal locks, no combination locks), stored energy control, verification of zero energy, group lockout process (two qualified workers, lock box, checklist), and release from lockout (inspection, tool removal, safeguard restoration, safe restart).
Under WorkSafeBC, can someone other than the person who applied the lock remove it?
Generally, only the worker who applied a personal lock may remove it. Exceptions are allowed under a tightly controlled, documented procedure, such as when the worker is not on site or in an emergency. This requires supervisory authorization, verification the worker is not in the danger zone, attempts to contact the worker, and documentation of the removal and reason.