A Lockout/Tagout Guide for Safely Managing Hazardous Energy

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Summary

When it comes to workplace safety, managing hazardous energy is a critical priority—and for good reason. Every year, countless injuries and fatalities occur because of uncontrolled energy releases during maintenance, repair, or cleaning activities. For Calgary businesses in industries like construction, manufacturing, oil and gas, and utilities, the risks are even higher given the nature of the work and the equipment involved.

A properly implemented Lockout/Tagout (LOTO) program isn’t just about compliance; it’s about preventing accidents, protecting your workers, and ensuring operations run smoothly. In this expanded guide, we’ll cover what hazardous energy is, why it’s dangerous, how Alberta’s regulations apply, and the steps to implementing an effective LOTO program. Plus, we’ll show how Calgary Safety Consultants can help your business take control of hazardous energy safety.

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What is Hazardous Energy?

Hazardous energy is any form of energy that, when released or activated unexpectedly, can cause harm. Here’s a closer look at the types of hazardous energy:

  1. Electrical Energy
    • Live electrical circuits or stored charges in batteries and capacitors.
    • Risks: Electrocution, burns, or fires.
  2. Mechanical Energy
    • Moving parts like gears, pulleys, or belts under tension.
    • Risks: Crushing injuries, amputations, or lacerations.
  3. Hydraulic Energy
    • Pressurized fluid systems used in heavy machinery like forklifts or excavators.
    • Risks: Sudden release of fluid causing equipment movement or high-pressure injuries.
  4. Pneumatic Energy
    • Compressed air in tools, systems, or storage tanks.
    • Risks: Sudden releases leading to debris ejection or uncontrolled movement.
  5. Thermal Energy
    • Heat from steam, hot surfaces, or exhaust systems.
    • Risks: Burns or heat-related injuries.
  6. Chemical Energy
    • Reactions or stored pressure in chemical systems.
    • Risks: Explosions or exposure to toxic substances.

Hazardous energy is often "hidden" in systems, even when equipment appears to be off. Workers who are unaware of these risks or improperly trained may inadvertently release energy while performing routine tasks.

Why Hazardous Energy is a Serious Concern

Workplace accidents involving hazardous energy are often severe and can have lasting consequences. Some examples include:

  • A worker performing maintenance on a conveyor belt without isolating energy sources is caught in the moving mechanism when it restarts.
  • A Calgary-based technician is electrocuted while repairing an electrical panel that wasn’t properly de-energized.
  • Stored hydraulic pressure in a pressurized cylinder causes a sudden movement, crushing the hand of a maintenance worker.

The common thread? Each of these incidents could have been prevented with proper lockout/tagout procedures.

Hazardous Energy Control Regulations in Alberta

Alberta’s Occupational Health and Safety (OHS) Code requires employers to have a system in place to control hazardous energy. The key responsibilities for businesses include:

  1. Developing Written Procedures
    • Employers must create detailed, equipment-specific lockout/tagout procedures. These documents should outline each step required to isolate energy sources safely.
  2. Providing Training
    • Workers and supervisors must be trained to understand hazardous energy risks and how to implement LOTO procedures effectively.
  3. Supplying the Right Tools
    • Employers are required to provide locks, tags, and other energy-isolating devices.
  4. Ensuring Consistent Application
    • Supervisors must monitor the workplace to ensure LOTO procedures are followed every time.
  5. Maintaining Records
    • Documentation, such as training logs and lockout/tagout audits, must be kept to demonstrate compliance.

Failing to meet these requirements can result in fines, penalties, or worse—preventable injuries.

How Calgary Safety Consultants can help: We simplify compliance by helping Calgary businesses create custom LOTO programs, conduct audits, and train workers on energy control best practices.

Critical Steps in a Lockout/Tagout Procedure

An effective lockout/tagout program follows a clear and structured approach:

  1. Identify Energy Sources
    • Know all potential energy sources connected to the equipment, including secondary or residual sources.
  2. Notify Workers
    • Inform everyone in the area that a lockout is about to occur.
  3. Shut Down Equipment
    • Power down machinery using its standard operating controls.
  4. Isolate Energy Sources
    • Use valves, switches, or disconnects to block energy flow to the equipment.
  5. Apply Locks and Tags
    • Secure each energy isolation point with a lock. Attach a tag that clearly identifies the worker responsible and the reason for the lockout.
  6. Release Stored Energy
    • Safely release any energy still stored in the system, such as bleeding hydraulic lines or discharging electrical capacitors.
  7. Verify Isolation
    • Double-check that all energy sources are isolated. Test equipment controls to ensure it won’t start unexpectedly.
  8. Perform Work
    • Proceed with the task only after confirming the equipment is safe.
  9. Remove Locks and Tags
    • When the work is complete, only the worker who applied the lock should remove it, and only after ensuring the area is safe.

Common Mistakes and How to Avoid Them

Even well-meaning workers and supervisors can make mistakes with hazardous energy control. Avoid these common pitfalls:

  • Skipping Energy Verification: Always verify energy isolation before starting work.
  • Relying on Tags Alone: Tags are not a substitute for physical locks. Always use both.
  • Inconsistent Procedures: Each piece of equipment requires its own tailored LOTO procedure.
  • Inadequate Training: Workers need hands-on, practical training—not just a safety briefing.
  • Poor Communication: Make sure all affected workers know about lockout/tagout activities.

How Calgary Safety Consultants can help: Our LOTO training programs and audits ensure your team understands the importance of every step in the process.

The Role of Training in Hazardous Energy Safety

Training is the cornerstone of any effective lockout/tagout program. Workers need to:

  • Recognize hazardous energy sources.
  • Understand the specific steps required to isolate energy.
  • Know how to use LOTO equipment properly.
  • Be aware of emergency procedures if something goes wrong.

Regular refresher training is just as important, especially with worker turnover or when introducing new equipment.

Why Calgary Safety Consultants?

At Calgary Safety Consultants, we’re experts in hazardous energy control for Calgary businesses. Here’s how we can help:

  • Custom Procedures: We’ll create tailored lockout/tagout protocols for every piece of equipment in your workplace.
  • Engaging Training: Our training sessions combine real-world examples, hands-on practice, and clear guidance.
  • Compliance Support: We ensure your program aligns with Alberta’s OHS Code and helps you avoid fines or penalties.
  • Audits and Improvements: We’ll review your existing LOTO program and recommend enhancements to make it even more effective.
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A Safer Workplace Starts with You

Hazardous energy is a significant risk, but it’s also one that can be managed with the right approach. By implementing an effective lockout/tagout program, you’ll not only protect your workers but also improve operational efficiency and compliance.

Ready to take the first step? Contact Calgary Safety Consultants  and take the first step toward measurable safety success. Book your complimentary consultation today.

References

  • Government of Alberta. (2023). Occupational Health and Safety Act and Code.
  • Canadian Centre for Occupational Health and Safety (CCOHS). (n.d.). Hazardous Energy Control.
  • Occupational Safety and Health Administration (OSHA). (n.d.). Control of Hazardous Energy (Lockout/Tagout).

Stay safe, Calgary!

FAQs: A Lockout/Tagout Guide for Safely Managing Hazardous Energy

Hazardous energy refers to stored or active energy in a system that could cause harm if unexpectedly released. This includes electrical, mechanical, hydraulic, pneumatic, thermal, and chemical energy.

Lockout/tagout is a safety procedure used to isolate hazardous energy in equipment during maintenance or repair. It involves locking energy sources in the “off” position and tagging them to indicate the equipment cannot be operated.

Key steps include shutting down equipment, isolating energy sources, applying locks and tags, releasing stored energy, and verifying isolation before beginning work.

Secure Your Workplace Safety Today

Calgary Safety Consultants is here to help you ensure compliance, enhance safety, and streamline your OH&S program. Don’t wait—fill out the form, and we’ll connect with you to discuss how we can support your business. Let’s get started!