Re-Energisation Procedures

Re-energisation is the process of restoring energy to equipment after LOTO maintenance is complete.
Premature or uncontrolled re-energisation is a leading cause of death during maintenance and repair work.
Every person who applied a lock must remove their own lock before the system can be re-energised.
A final check must confirm all tools, materials, and personnel are clear of the equipment.
Guards and safety devices must be fully reinstated before power is restored to the machine.
The responsible person must verify that the work is complete and it is safe to re-energise.
A controlled start-up procedure should be followed, with the equipment operated initially at reduced load.
Communication with all affected workers is required before any re-energisation takes place.
Shift changes are a particular risk — the incoming shift must be aware of the LOTO and re-energisation status.
The permit to work must be formally closed out before the system is returned to operational status.

Prevent fatalities	Premature re-energisation while workers are still inside or near equipment is a leading cause of workplace death.
Accountability	Personal locks ensure no one can restore energy until every worker has confirmed they are clear of the equipment.
Controlled start-up	Gradual re-energisation allows detection of faults or problems before the equipment reaches full operational power.

Do

Don't

Confirm all maintenance work is complete and the equipment is ready to operate
Verify all tools, rags, and materials have been removed from inside the equipment
Ensure all guards, covers, and safety devices are fully reinstated
Confirm every person who applied a lock has removed their own personal lock
Communicate with all affected workers that re-energisation is about to take place
Follow the controlled start-up procedure, operating at reduced load initially
Close out the permit to work formally before restoring operational status
Brief the incoming shift on the re-energisation status during shift handover
Carry out a head count to confirm all personnel are clear of the equipment
Record the re-energisation time, responsible person, and any findings on the permit

DON'T re-energise equipment until every personal lock has been removed by its owner
DON'T remove another person's lock without a formal authorised procedure
DON'T restore power before confirming all guards and safety devices are in place
DON'T skip the visual check for tools and personnel inside the equipment
DON'T re-energise without communicating with all workers in the affected area
DON'T go straight to full operational load — use a controlled start-up procedure
DON'T re-energise across a shift change without handover to the incoming team
DON'T close the permit until the responsible person has authorised re-energisation
DON'T assume everyone is clear — carry out a head count before restoring power
DON'T rush re-energisation under production pressure — safety comes first

See also: LOTO Awareness | Verification of Isolation (Proving Dead)

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