Lockout / Tagout
LOTO Testing,
Repositioning & Restoration
Repositioning & Restoration
OSHA 1910.147(f)(1) · Verify De-Energization · Re-LOTO After Any Repositioning
The most dangerous moment in a LOTO procedure is not the lockout — it's the restoration. Workers are eager to get the equipment running again, the pressure to complete the job is high, and shortcuts get taken. Testing for de-energization before work starts, and following the full restoration sequence when work is complete, are the steps that separate safe LOTO from a near-miss or fatality.
Verifying De-Energization After Lockout
- After applying locks: attempt to start the equipment by pressing the start/enable control — if it doesn't operate, electrical energy is isolated
- For electrical systems: use a calibrated voltage meter to test all conductors. "Tick" detectors are not sufficient for verification — they do not measure voltage level
- For hydraulic systems: check pressure gauges after bleeding procedure — verify zero pressure before breaking any fitting
- For pneumatic systems: open a test port downstream of the lock and verify no air flow before disconnecting lines
Repositioning — Start the Sequence Over
- If you need to reposition the equipment (turn it over to check the other side, adjust a component, test a part) — this is a restoration and re-LOTO sequence, not just "moving it real quick"
- Full restoration sequence: clear all workers from the zone → remove all personal locks → restore energy → perform the test → re-apply LOTO before anyone re-enters
- No worker should re-enter the hazard zone during the repositioning step — they must be physically outside the machine's reach
Restoration — The Complete Sequence
- Step 1: Confirm all tools and temporary equipment are removed from the machine
- Step 2: Ensure all workers are clear of the machine and its hazardous areas
- Step 3: Remove LOTO devices — the authorized employee removes their lock last
- Step 4: Notify affected employees that LOTO has been removed before energizing
- Step 5: Restore energy — document completion in the LOTO log
Discussion Questions
- After locking out a piece of electrical equipment, what must you do to verify it is actually de-energized?
- You need to temporarily re-energize a pump to test whether the repair worked. Walk through the sequence of steps.
- What is the correct sequence for LOTO restoration when work is complete? Who must be notified before the energy is restored?
- Why is a "tick" voltage detector not sufficient for verifying electrical de-energization under OSHA's standard?
Sign-Off
Project Address
Date
Time
Foreman / Supervisor
SSM / SSC Name & License No.
Worker Attendance
| # | Worker Name (Print) | Signature |
|---|---|---|
| 1 | ||
| 2 | ||
| 3 | ||
| 4 | ||
| 5 | ||
| 6 | ||
| 7 | ||
| 8 | ||
| 9 | ||
| 10 | ||
| 11 | ||
| 12 | ||
| 13 | ||
| 14 | ||
| 15 | ||
| 16 | ||
| 17 | ||
| 18 | ||
| 19 | ||
| 20 |