Page 2 – The Ultimate Guide to Lockout Tagout for Australian Workplaces

2. When is Lockout Tagout Required?

Lockout Tagout is required whenever there is a possibility of injury due to the accidental start-up of machinery or release of hazardous energy. This generally includes:

  • Maintenance, repair, or servicing of equipment.
  • Cleaning or unjamming machinery where body parts enter a danger zone.
  • Inspection, installation, or testing that might expose someone to moving parts or live energy.
  • Adjustments requiring guards to be removed or bypassed.

Essentially, if a worker could be harmed by unexpected motion, electricity, pressure, or other energy form, lockout/tagout must be used. This applies to:

  • Electrical energy: Locking out the circuit breaker, switch, or fuse.
  • Hydraulic/pneumatic systems: Closing and locking valves, releasing stored pressure.
  • Gravity: Securing or lowering any elevated loads or machine parts.
  • Mechanical energy: Blocking or bracing moving components, releasing spring tension.
  • Thermal/chemical energy: Cooling and isolating hot liquids or chemicals under pressure.

For example, WorkSafe Victoria has repeatedly warned that equipment must be isolated and locked out before workers do repairs or clearing tasks on conveyors, presses, mixers, or any high-risk machinery. Unfortunately, many fatalities have occurred when someone assumed hitting an “off” button was enough, only to have the machine restart unexpectedly.

The bottom line: if there’s a risk of unexpected motion or energisation, you must lock it out and tag it out to comply with Australian WHS regulations and ensure workers’ safety.

3. Policies & Procedures

Having a strong Lockout Tagout policy and documented procedures is essential for compliance. A policy generally outlines:

  • The purpose of Lockout Tagout (prevent injury from unexpected equipment start-up).
  • Responsibilities (who is authorised to lock out plant, who must be informed, etc.).
  • The scope of the program (which tasks and equipment require LOTO).
  • Training and auditing requirements.

Procedures break down the step-by-step method to:

  1. Shut down the machine using normal controls.
  2. Identify all energy sources (e.g. electricity, hydraulics).
  3. Isolate each source (e.g. turn off disconnect switches, close valves).
  4. Apply locks (one for each worker if multiple people are involved).
  5. Attach tags indicating who locked the equipment and why.
  6. Release or restrain stored energy (bleed pressure, block suspended loads, etc.).
  7. Test or “try out” the controls to verify zero energy.

Equipment-Specific Procedures

Some machinery can be locked out with a single disconnect switch; others may have multiple sources (like electrical, pneumatic, hydraulic, and a backup generator). One-size-fits-all procedures might be too generic for complex machines. Create equipment-specific instructions that list:

  • All power sources and isolation points.
  • Detailed steps to lock each point.
  • How to dissipate stored energy (e.g., bleed valves, discharge capacitors).
  • Any special hazards (like a secondary control panel hidden away).

Post these instructions near the machine or include them in your maintenance manuals so workers can easily reference them.

Good vs. Bad Documentation

Good documentation:

  • Is clear, detailed, and user-friendly.
  • Specifically names each isolator (e.g. “Electrical panel #3, breaker #2”).
  • Lists how to handle stored energy (e.g. “release hydraulic pressure via bleed valve before applying padlock”).
  • Identifies responsibilities and exactly who can remove locks.
  • Is readily accessible near the machine or in a known location.

Bad documentation:

  • Is vague or incomplete (e.g. “Turn off machine and lock it” without specifics).
  • Fails to mention multiple energy sources.
  • Is outdated or not easily accessible to workers.

Poor procedures create confusion or tempt shortcuts, ultimately leading to accidents. Regularly review your documents, especially after an incident, a near-miss, or when machinery is modified.

Storage of Lockout Documents

Your Lockout Tagout procedures should be kept:

  • At or near the equipment for quick reference.
  • In a central safety manual or company intranet.
  • Securely managed and updated (with version control).

Many workplaces have a permit-to-work system or isolation permit that tracks each lockout event. This log ensures everyone knows which machines are locked out, who did it, and why.

Continue to Page 3 for a deep dive into Industry-Specific Applications of Lockout Tagout: Mining, Construction, and Manufacturing.

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