If your workplace relies on machines, you know how quickly things can go wrong when a system suddenly moves, heats up or comes alive even after it is switched off. Hazardous energies are often hidden, which makes maintenance and repair work risky. This guide helps you understand what these risks mean for your team and how the right controls and insurance can keep everyone safer.
What is hazardous energy?
Hazardous energy is any stored or active energy that can injure workers if it is released without control. It can exist in machinery, electrical circuits, pressurised systems or moving mechanical parts. Because some energy remains even after equipment is switched off, a structured process is needed to prevent accidental start up or an unexpected release.
Why controlling hazardous energy is critical in workplaces
Uncontrolled energy can cause serious injuries such as crushing, electrocution, burns or impacts. These incidents often occur during cleaning, servicing, maintenance or repair when workers assume equipment is safe. Proper control of hazardous energy prevents accidental energisation and keeps the work area safe.
Types of hazardous energy
Workplaces can be exposed to several forms of hazardous energy. These include electrical energy from live circuits or stored charges, mechanical energy from moving parts or suspended loads, hydraulic energy from pressurised fluids and pneumatic energy from compressed air or gas.
Thermal energy from extreme heat or cold and chemical energy from reactions that generate heat, pressure or harmful substances also pose significant risks.
Lockout/tagout (LOTO) procedures
LOTO isolates hazardous energy during maintenance or repair by identifying all energy sources, shutting them down and securing them with locks, tags or blocking devices. Stored energy is released or secured, and isolation is verified before work. Only authorised personnel can remove the lock, preventing accidental startup.
Guidelines for hazardous energy control
Organisations should use a structured approach to managing hazardous energy control, backed by training, documentation and routine audits. This includes keeping an inventory of all machines, systems and their hazardous energy sources, creating clear isolation procedures for each equipment type and training employees to recognise hazards, use isolation devices and follow verification steps.
Role of insurance in hazardous energy management
Insurance covers financial risks from workplace injuries despite safety controls. Relevant policies include employee accident and health insurance, public liability insurance and specialist industrial safety cover. Group personal accident plans can protect maintenance, engineering or manufacturing teams. Businesses should review exclusions, limits and eligibility to match operational needs.
Best practices for preventing hazardous energy accidents
Prevent hazardous energy accidents with technical controls, training and clear communication. Maintain accurate isolation diagrams, accessible shut-offs, documented lockout activities and durable, tamper-resistant devices. Encourage reporting of unsafe conditions or faulty equipment to enhance safety and compliance.
How to choose the right insurance cover for industrial safety
Select insurance based on operational risks, workforce size and equipment. Ensure coverage includes mechanical, electrical and process-related incidents, and review documentation, training and claim procedures. Compare providers to confirm the policy meets industry standards.
Conclusion
Controlling hazardous energy is not just a compliance task; it directly protects the people who keep your operations running. Implementing clear isolation procedures, providing proper training and conducting regular audits reduces accidents and builds confidence among workers.
By prioritising both safety practices and risk coverage, organisations can create a safer, more reliable workplace while fostering a culture where employees feel secure and valued.
FAQs
1. Can LOTO be adapted for small workplaces or less complex machinery?
Yes, even small workshops or simple equipment benefit from energy isolation procedures. The steps can be simplified while still following the principle of identifying, isolating and securing energy sources.
2. What should employees do if they encounter equipment without proper isolation devices?
Workers should stop work and report immediately to a supervisor. Temporary measures should never replace proper isolation. Management should ensure suitable devices are installed before maintenance continues.
3. How can organisations track compliance with hazardous energy procedures?
Regular audits, digital checklists and documented lockout/tagout records help track compliance. Reviewing incidents and near misses also highlights gaps and improves safety practices over time.
Disclaimer: The information provided in this blog is for educational and informational purposes only. It may contain outdated data and information regarding the topic featured in the article. It is advised to verify the currency and relevance of the data and information before taking any major steps. ICICI Lombard is not liable for any inaccuracies or consequences resulting from the use of this outdated information.