Machine Start-Up Safety

• Unexpected startup of machinery or equipment
• Workers positioned inside hazardous zones
• Stored energy release during startup
• Communication failures between crews
• Movement of rotating or automated equipment
• Temporary bypassing of safety systems

Machine startup creates serious hazards during maintenance, troubleshooting, cleaning, testing, adjustments, and operational changeovers. Workers may be exposed to moving parts, stored energy, automatic systems, and rotating equipment with little warning.

Many startup incidents occur because workers assume equipment is de-energized, believe nearby crews are clear, or fail to recognize interconnected systems that can activate automatically.

Startup hazards often increase during troubleshooting activities because guards may be removed, workers may enter hazardous areas, and equipment may be energized temporarily for testing or adjustments.

Communication between operators, maintenance personnel, contractors, and nearby workers is critical before equipment is started. Workers should know who is working on the system and whether anyone remains exposed to hazardous movement.

Stored hydraulic pressure, pneumatic pressure, gravity loads, electrical systems, springs, belts, rotating shafts, conveyors, and automated controls can all create dangerous movement during startup.

Temporary overrides, bypassed interlocks, disconnected alarms, or improvised repairs can significantly increase exposure during machine startup. Equipment should not be operated if critical safeguards are disabled or missing.

Workers should avoid positioning themselves between moving equipment, inside guarded areas, or near pinch points during startup activities unless proper isolation procedures are in place.

If workers are uncertain whether equipment is safe to energize, startup should stop until the hazards, worker locations, and energy sources can be verified clearly.

• Verify all workers are clear before startup.
• Communicate clearly between operators and maintenance crews.
• Inspect guards, interlocks, and safety systems before energizing equipment.
• Remain alert for stored energy hazards.
• Avoid bypassing safety devices or startup protections.
• Use lockout/tagout procedures during servicing activities.
• Stop startup if worker locations or equipment status are unclear.

• Could equipment move unexpectedly during startup?
• Are workers exposed inside hazardous zones or guarded areas?
• Have all crews confirmed equipment is safe to energize?
• Could stored energy create movement after startup?
• Are any safety systems bypassed or temporarily disabled?