Safety practices and leadership commitment are critical to preventing injuries and fatalities during high-risk activities (Figure i) involving machinery, equipment, or processes due to uncontrolled energy. Understanding and adhering to standardized safety practices are essential.
Figure i – Top Sources of Fatal & Serious Injuries
Uniform understanding of hazardous energy control is crucial. A review of injuries and near-miss incidents shows a lack of standardized procedures, often due to regulatory differences and inadequate hazard recognition and control.
- Hazardous Energy: Energy (Figure ii) that can cause injury or damage if unexpectedly released, including kinetic (movement) and potential (stored) energy.
Figure ii – Types of Hazardous Energy
- Zero Energy State: Condition where machinery is isolated from all hazardous energy sources, and residual energy is dissipated.
- Residual Energy: Energy remaining in machinery after shutdown.
- Task: Job activities involving machinery or equipment, such as erecting, installing, repairing, inspecting, etc.
Figure ii – Types of Hazardous Energy
- Controlling Risk Hierarchy of Controls: Eliminating the hazard is the most effective method. If not possible, use barriers (physical, administrative, or people-based) to control the hazard and reduce risk.
- Risk: Probability of harm occurring.
- Hazard: Inherent potential to cause harm.
- Exposure: Frequency and duration of contact with a hazard.
- Lockout + Tagout (LOTO) LOTO: Primary method to control hazardous energy and achieve zero energy state. Machinery must be locked out and tagged out. Lockout (LO): Physically locking machine controls. Tagout (TO): Attaching an information tag with the lock, identifying the owner and date. Locks and tags must be durable, standardized, substantial, identifiable, and unique.
- One Lock, One Person, One Energy Source Each worker must use personal locks and tags for each energy source on the machinery. Applies to both simple machines with limited energy sources and complex processes with multiple sources.
- Mandatory LOTO Sequence Prepare: Review work order and LOTO procedures. Notify: Inform operators to stay clear of machinery. Turnoff/Shut Down: Shut down machinery in an orderly manner. Isolation: Isolate machinery using energy isolating devices. Apply Locks: Affix locks and tags to energy isolating devices. Zero Energy State: Ensure all energy sources are rendered safe. Perform Task: Conduct the task or activity.
- Inspect and Restore: Ensure machinery is clear of workers, tools, and parts. Remove locks and tags, restore power, and inform that equipment is available for service.
- Training & Hazard Awareness Adequate training on LOTO procedures, hazard recognition, and control is essential. Training should cover terminology, principles, practical field training, EI procedure requirements, site rules, and local regulations.
- Clearly communicate and discuss LOTO procedures with all personnel.
- Implement the "one lock, one person, one energy source" principle.
- Align current practices with the mandatory LOTO sequence.
