Lockout Tagout Basics

Key Hazards

• Unexpected equipment startup
• Stored mechanical, hydraulic, pneumatic, or electrical energy
• Worker exposure during troubleshooting or maintenance
• Moving parts activating during servicing
• Communication failures between crews
• Bypassed or incomplete energy isolation

2–3 Minute Talk Script

Lockout/tagout procedures are used to protect workers from unexpected startup and stored energy release during servicing, maintenance, cleaning, adjustment, troubleshooting, or repair activities.

Many serious injuries occur because workers assume equipment is safe once it is turned off. Electrical systems, hydraulic pressure, rotating equipment, gravity loads, compressed springs, pneumatic systems, and automatic controls can still create dangerous movement or energy release.

Startup hazards often increase during troubleshooting tasks because guards may be removed, workers may position themselves closer to moving parts, and systems may be energized temporarily for testing.

Workers should understand all energy sources connected to the equipment, including remote activation systems, generators, backup power, stored pressure, elevated loads, and interconnected equipment.

Communication failures are a common contributor to lockout incidents. Operators, maintenance crews, contractors, and nearby workers should clearly understand who is working on the equipment and what systems are isolated.

Locks and tags should remain under the control of the worker performing the task. No one should remove another worker’s lock or attempt to restart equipment until all workers are clear and the system is verified safe.

Stored energy should be released, blocked, restrained, or verified before work begins. Equipment may still move unexpectedly even after power has been disconnected.

If workers are uncertain whether equipment has been fully isolated, work should stop until the energy sources can be identified and controlled safely.

Safety Reminders

• Identify all energy sources before starting work.
• Never assume equipment is safe because it is turned off.
• Release or secure stored energy before servicing equipment.
• Maintain communication between operators and maintenance crews.
• Verify isolation before entering guarded or hazardous areas.
• Keep locks and tags under the control of the assigned worker.
• Stop work if energy isolation cannot be verified safely.

Ask the Crew

• Could equipment become energized unexpectedly during the task?
• Have all energy sources been identified and isolated?
• Could stored pressure, gravity, or mechanical movement create hazards?
• Are workers exposed while troubleshooting or testing equipment?
• Would all crews know equipment is being serviced?