Hazardous energy, for the purpose of health and safety, is considered to be any source of energy that can be deemed hazardous to workers who are responsible for servicing or maintaining machines or equipment. It is very important to note that hazardous energy, during an unexpected energization or release, can injure and even kill if not controlled correctly. The types of different energy sources may include but are not limited to, electrical, mechanical, hydraulic, pneumatic, chemical, and thermal – all of which must be respected and treated with care. Injuries that may result from failure to properly control hazardous energy may include electrocution, burns, crushing, lacerations, amputations, and breaks or fractures.

How can workers protect themselves?

Workers can protect themselves by isolating all energy sources on affected machines or equipment. This is accomplished through the use of energy control procedures and the application of locks and lockout/tagout (LOTO) devices. 

How to build an effective LOTO program:

It is recommended that the following process be considered when implementing a successful LOTO program.  

• Perform an equipment and hazardous energy source inventory.

This consists of making an initial determination of the potential energy sources for each machine or piece of equipment on site. Each machine or piece of equipment should be listed on a facility diagram and provided a discreet identifier regarding the location and/or department. 

• Develop hazardous energy control procedures.

This includes photographing all designated lockout points for each machine or piece of equipment that was identified in the inventory and implementing them into the control procedures. Each control procedure should demonstrate at least the minimum required steps for isolating hazardous energy. These steps are as follows:

1. The person performing the LOTO must be authorized. This means being trained accordingly. If a person is not authorized, then they must not be permitted to proceed with the hazardous energy control process.

2. Notification of all affected employees in the vicinity of where the LOTO is taking place to reduce the potential for any interference or intrusion.

3. Shutdown of the affected machine or piece of equipment by turning it off.

4. Isolation of all energy sources. These sources, along with the control panels, should be identified in the photos. This allows for less opportunity to make a mistake due to misidentification.

5. LOTO the energy sources. All energy sources for the affected machine or piece of equipment must be isolated and controlled to prevent accidental release or energization.

6. Release or control all energy that is stored.

7. Verification of the lockout of each energy source. Confirm that there will be no unexpected start-up of the machine or piece of equipment. This is the most important of all the steps. This must occur prior to beginning any servicing or maintenance work.

8. Maintain lockout throughout any servicing or maintenance work being performed.

9. Restore the machine or piece of equipment back to service after all work has been completed.

   • Verify affected area is clear of all personnel, tools, and other equipment.

   • Remove all locks, tags, and lockout devices.

   • Notify all affected employees in the vicinity that the LOTO equipment has been removed.

   • Test the operation of the machine or piece of equipment to ensure proper start-up.

   • Notify all affected employees that the machine or piece of equipment is ready to operate.

• Attach identification tags on all affected machines and equipment.

Such identifiers should be applied for, but not be limited to electrical, mechanical, hydraulic, pneumatic, chemical, water or coolant, and thermal energy sources as well as control panels.

• Laminate and attach all control procedures on each piece of equipment at the affected control panel for easy LOTO reference.

In summary, it is the employer’s responsibility to provide a safe place of employment that includes protecting employees from hazardous energy. Therefore, it is critical that a plan be put in place to fully implement proper LOTO practices and procedures.

KERAMIDA is a full-service Security, Environmental, Health and Safety consulting firm that has many years of experience pertaining to hazardous energy exposure control. Our qualified professionals are ready to assist in not only assessing your site for hazardous energy and developing control procedures but also providing the required authorized and affected training. Fill out our quick response form or call (800) 508-8034 to speak with one of our professionals today.

Blog Author

Andrew Tirmenstein
Senior Project Manager, Security, Health and Safety Services
ISO 45001 & ISO 14001 Auditor
KERAMIDA Inc.

Contact Andrew at atirmenstein@keramida.com.