These are just basic training slides, may vary from standards

Hazardous Energy Control

/ Lock out Tag out (LOTO)

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What is Hazardous Energy?
Hazardous energy is defined by the Canadian Standards Association (CSA) as: "any electrical,
mechanical, pneumatic, chemical, nuclear, thermal, gravitational, or other energy that can
harm people" (CSA Z460 "Control of Hazardous Energy - Lockout and Other Methods"). Some
energy sources are obvious, such as electricity, heat in a furnace, or something that might fall. Others
may be hidden hazards such as air pressure in a system or a tightly wound spring.

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What are Types of Hazardous Energy?
Electrical energy is the most common form of energy used in workplaces. It can be available live
through power lines or it can also be stored, for example, in batteries or capacitors. Electricity can
harm people in one of three ways:
1.By electrical shock.
2.By secondary injury.
3.By exposure to an electrical arc.
Hydraulic potential energy is the energy stored within a pressurized liquid. When under pressure,
the fluid can be used to move heavy objects, machinery, or equipment. Examples include: automotive
car lifts, injection molding machines, power presses, and the braking system in cars. When hydraulic
energy is released in an uncontrolled manner, individuals may be crushed or struck by moving
machinery, equipment or other items
Pneumatic potential energy is the energy stored within pressurized air. Like hydraulic energy, when
under pressure, air can be used to move heavy objects and power equipment. Examples include
spraying devices, power washers, or machinery. When pneumatic energy is released in an
uncontrolled manner, individuals may be crushed or struck by moving machinery, equipment or other
items.
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What are Types of Hazardous Energy?
Chemical energy is the energy released when a substance undergoes a chemical reaction. The
energy is normally released as heat, but could be released in other forms, such as pressure. A
common result of a hazardous chemical reaction is fire or explosion.
Radiation energy is energy from electromagnetic sources. This energy covers all radiation from
visible light, lasers, microwave, infra red, ultraviolet, and X-rays. Radiation energy can cause health
effects ranging from skin and eye damage (lasers and UV light) to cancer (X-rays).
Gravitational potential energy is the energy related to the mass of an object and its distance from
the earth (or ground). The heavier an object is, and the further it is from the ground, the greater its
gravitational potential energy. For example, a 1 kilogram (kg) weight held 2 meters above the ground
will have greater gravitational potential energy then a 1 kg held 1 meter above the ground.
Mechanical energy is the energy contained in an item under tension. For instance, a spring that is
compressed or coiled will have stored energy which will be released in the form of movement when
the spring expands. The release of mechanical energy may result in an individual being crushed or
struck by the object.

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Example
It is important to understand that all of these energy types can be considered as either the primary
energy source, or as residual or stored energy (energy that can reside or remain in the system)
Primary energy source is the supply of power that is used to perform work.
Residual or stored energy is energy within the system that is not being used, but when released it
can cause work to be done.
For example: when you close a valve on a pneumatic (air) or hydraulic (liquid) powered system, you
have isolated the system from its primary energy source. However, there is still residual energy stored
in any air or liquid that remains in the system. In this example, removing the residual energy would
include bleeding out the liquid, or venting out the air. Until this residual energy is removed from the
system, work can occur, whether on purpose or inadvertently
Not properly assessing and dissipating stored energy is one of the most common causes for
workplace incidents that involve hazardous energy. Control of hazardous energy includes isolating the
system from its primary power source and residual energy.

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Is Lockout and Hazardous Energy Control the
Same Thing?
The terms lockout and hazardous energy control are sometimes used interchangeably, but they are
NOT the same thing.
Hazardous energy control is a broad term describing the use of procedures, techniques, designs
and methods to protect personnel from injury due to the inadvertent release of hazardous energy.
Lockout is the placement of a lock or tag on an energy-isolating device in accordance with an
established procedure. It indicates that the energy-isolating device is not to be operated until removal
of the lock or tag. Therefore, lockout is one way in which hazardous energy control can be achieved.

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What is the purpose of a hazardous energy
control program?
In most cases, equipment or systems will have safety devices built in. These safety devices include
barrier guards and safeguarding devices to help protect workers during normal operations. However,
during maintenance or repairs, these devices may have to be removed or by-passed. In these
situations, a hazardous energy control program is needed.
A hazardous energy control program is used to maintain worker safety by preventing:
•Unintended release of stored energy.
•Unintended start-up.
•Unintended motion.
•Contact with a hazard when guards are removed or safety devices have been by-passed or removed.

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What must an energy-control procedure
include?
1. A statement on how to use the procedures;

2. Specific procedural steps to shut down, isolate, block, and secure machines;

3. Specific steps designating the safe placement, removal, and transfer of lockout/tagout
devices and identifying who has responsibility for the lockout/tagout devices; and

4. Specific requirements for testing machines to determine and verify the effectiveness of
lockout devices, tagout devices, and other energy-control measures.

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What must workers do before they begin service
or maintenance activities?
1. Prepare for shutdown;
2. Shut down the machine;
3. Disconnect or isolate the machine from the energy source(s);
4. Apply the lockout or tagout device(s) to the energy-isolating device(s);
5. Release, restrain, or otherwise render safe all potential hazardous stored or residual
energy. If a possibility exists for reaccumulation of hazardous energy, regularly verify
during the service and maintenance that such energy has not reaccumulated to
hazardous levels; and
6. Verify the isolation and deenergization of the machine.

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Lockout Process
• De-energize machinery
• Stop equipment using normal procedure
• Isolate each source.
• Each person must lockout each source of energy. The key(s) must be removed and secured in
personal control.
• Verify isolation of each energy source
• Return controls to “neutral”, “stop” or “off ” positions after the verification.
• Perform the required work.

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What are the requirements for lockout/tagout
devices?
Durable enough to withstand workplace conditions. Tagout devices must not deteriorate or
become illegible even when used with corrosive components such as acid or alkali chemicals
or in wet environments.

Standardized according to color, shape, or size. Tagout devices also must be standardized
according to print and format. Tags must be legible and understandable by all employees.
They must warn employees about the hazards if the machine is energized, and offer
employees clear instruction such as: “Do Not Start,” “Do Not Open,” “Do Not Close,” “Do
Not Energize,” or “Do Not Operate.”

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What are the requirements for lockout/tagout
devices?
Substantial enough to minimize the likelihood of premature or accidental removal.
Employees should be able to remove locks only by using excessive force with special tools
such as bolt cutters or other metal-cutting tools. Tag attachments must be non-reusable, self-
locking, and non-releasable, with a minimum unlocking strength of 50 pounds. Tags must be
attachable by hand, and the device for attaching the tag should be a one-piece nylon cable
tie or its equivalent so it can withstand all environments and conditions.

Labeled to identify the specific employees authorized to apply and remove them.

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Electrical, pneumatic, hydraulic energy

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Tag-out
Tag-out in lieu of Lockout

• Securely attach “locked out” tag in addition to the lock.

• If an energy-isolating device is not physically capable
of being locked out, use tags in place of locks.

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Release from Lockout/Tag-out
When work is complete, re-energize the machine:
Inspect the work area.
Remove locks.
Visually verify that all personnel are clear Re-energize the equipment.
Lock Removal
No one is authorized to remove another person’s lock.
Procedures to remove the lock:
The employee’s supervisor verification
An attempt to contact the lock owner
If this attempt is unsuccessful, notify the lock owner.
Evaluate the equipment.
Carry out the ‘Release from Lockout/Tag-out’ procedures.

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Lock out devices

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Lock out devices

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Examples of Tags

THE COMMONWEALTH INDUSTRIAL GASES LIMITED THE COMMONWEALTH INDUSTRIAL GASES LIMITED

DANGER DANGER
DO NOT OPERATE DO NOT OPERATE
DO NOT REMOVE DO NOT REMOVE
THIS TAG THIS TAG
DEFECT: ……………………….………………….. A PERSON’S LIFE MAY BE ENDANGERED
……………………………………………………… TO DO SO WILL RENDER YOU LIABLE
……………………………………………………… TO SEVERE DISCIPLINARY MEASURES
THIS TAG PROTECTS: ………………………….. AND/OR LEGAL ACTION
BLOCK LETTERS
IT IS HERE FOR A PURPOSE AND MAY
SIGNATURE: ……………………………………... NOT BE REMOVED EXCEPT BY THE
DATE: …………………………………….……….. PERSON WHO PLACED IT

SEE OTHER SIDE SEE OTHER SIDE

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Questions and Discussion

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