STORED ENERGY AND HYDRAULIC SYSTEMS TOOLBOX TALK
The machine may be stopped while dangerous energy remains in the system.
Control of residual hydraulic pressure, accumulators and stored mechanical energy.
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Toolbox Topic
STORED ENERGY AND HYDRAULIC SYSTEMS TOOLBOX TALK
Duration
8–10 minutes
Date
Site / Area
Supervisor
Company
Participants
Document No
OBJECTIVE
Prevent injury from residual hydraulic pressure, accumulator energy and unexpected equipment movement.
WHY IT MATTERS
Hydraulic systems can retain hazardous pressure in hoses, manifolds, cylinders and accumulators even after the pump has stopped.
Suspended or supported equipment can move suddenly when hydraulic pressure is lost, creating serious crush hazards.
Accumulators can retain stored energy after shutdown, so isolating only the main power source is not sufficient.
High-pressure hydraulic leaks can form a fine jet capable of penetrating skin and causing severe injection injuries.
Before maintenance, all energy sources must be identified, pressure released and moving loads mechanically secured.
REALISTIC SITE SCENARIO
A maintenance team began disconnecting a hydraulic cylinder line after the machine had been shut down.
The operator assumed the system was safe because the hydraulic pump was no longer running.
When the fitting was loosened, trapped pressure released oil at high velocity toward a worker's hand.
Accumulator isolation, controlled pressure release and zero-energy verification would have prevented the exposure.
REMEMBER
Machine shutdown does not automatically mean zero energy.
KEY HAZARDS
Residual hydraulic pressure.
Stored accumulator energy.
Unexpected cylinder movement.
Uncontrolled load descent.
Hydraulic injection injury.
Hose or fitting separation.
Incorrect isolation.
Maintenance before energy release.
CONTROLS
Identify all energy sources.
Apply LOTO.
Release hydraulic pressure safely.
Isolate accumulators according to procedure.
Mechanically support suspended loads.
Do not rely solely on pressure gauges.
Verify energy status before opening hoses.
Never check high-pressure leaks by hand.
Verify system integrity after maintenance.
Confirm personnel are clear before restart.
SUPERVISOR MESSAGE
Team, shutdown does not guarantee zero hydraulic energy. Before maintenance we will identify accumulators, trapped pressure and moving loads, mechanically secure equipment and physically verify that all stored energy has been released.
TEAM QUESTIONS
What energy sources are present?
Is an accumulator installed?
How will pressure be released?
Is the load mechanically supported?
Is LOTO complete?
Who authorises restart?
FIELD VERIFICATION
Energy sources identified
LOTO complete
Pressure released
Accumulator isolated
Load supported
Hoses safe
Leak method suitable
Zero energy verified
Guards ready
Crew briefed
ATTENDANCE AND APPROVAL
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Supervisor Signature
HSE Approval
SERNEM HSE Resource – Permit conditions, risk assessments and site procedures take priority.