A Practical Guide for Electrical Safety

If you work around electrical equipment, machinery, or industrial systems, you may have heard the term Lockout Tagout. However, many workers still ask the same question: what is Lockout Tagout and why is it so important?

Lockout Tagout (often shortened to LOTO) is a safety procedure used to ensure equipment cannot be energised while maintenance or repair work is being performed. The process involves locking an energy isolation point and attaching a warning tag so the equipment cannot be accidentally restarted.

This procedure is especially important in electrical environments. Unexpected energisation can cause electric shock, arc flash incidents, equipment damage, or serious injury.

In Australia, safe electrical isolation practices are supported by standards such as:

• AS/NZS 4836 – Safe Working on or Near Low Voltage Electrical Installations
• AS/NZS 4024.1603 – Safety of Machinery – Prevention of Unexpected Start-up

These standards reinforce the importance of proper isolation procedures before work begins.

Why is Lockout Tagout Important?

Electricity and industrial machinery do not provide second chances.

Unexpected equipment start-up has historically caused many workplace injuries. In some cases, machinery was restarted while someone was still performing maintenance or repairs.

Lockout Tagout prevents this by creating a physical control over the energy source.

When a lockout device is applied:

• Equipment cannot be restarted accidentally
  
• Workers know the system has been intentionally isolated
  
• Only an authorised person with the key can remove the lock

As a result, Lockout Tagout helps create a safer working environment where maintenance tasks can be performed without the risk of unexpected energisation.

What is the Difference Between Lockout and Tagout?

The terms lockout and tagout are often used together. This is why the combined phrase Lockout Tagout has become common across many industries.

However, they refer to two different components of the safety process.

Lockout refers to applying a physical locking device to an energy isolation point such as a switch, valve, or circuit breaker. The lock prevents the equipment from being operated.

Tagout refers to the warning tag attached to the lock. The tag communicates important information to others working in the area.

For example, a tag may identify:

• Who applied the lock
• Why the equipment is isolated
• The date the isolation was applied
• Instructions not to operate the equipment

However, tags alone do not physically prevent equipment from being operated. Therefore, electrical safety procedures typically require a physical lockout device whenever possible, rather than relying on tags alone.

Where is LOTO Used?

Lockout Tagout procedures are used anywhere hazardous energy must be controlled before work begins.

In electrical environments this often includes isolating:

• Switchboards
• Circuit breakers
• Distribution panels
• Motor control centres
• Industrial machinery
• Solar and battery systems
• EV charging infrastructure

However, Lockout Tagout procedures can also control other types of energy.

For example:

• Hydraulic pressure
• Pneumatic systems
• Mechanical movement
• Thermal energy
• Stored electrical energy
• Water & Gas utilities

Because many machines contain multiple energy sources, proper isolation procedures must ensure all energy sources are identified and controlled before work begins.

Lockout Tagout Procedures May Vary

While the principles of Lockout Tagout remain consistent, specific isolation procedures can vary between workplaces.

Each organisation typically develops its own safety procedures based on factors such as the equipment involved, site risks, and internal safety management systems. Workers must always follow their employer’s approved isolation procedures and safety documentation.

Site procedures may also reference Australian standards such as AS/NZS 4836 and AS/NZS 4024.1603, which provide guidance on safe electrical isolation and the prevention of unexpected equipment start-up.

However, most Lockout Tagout systems follow a similar structure. The example below outlines a typical isolation process used across many electrical and industrial environments.

Typical Lockout Tagout Procedure

Although procedures vary between workplaces, most Lockout Tagout processes follow several common steps.

1. Identify energy sources
Workers must first identify all sources of hazardous energy connected to the equipment.

2. Notify affected workers
Anyone working nearby should be informed that equipment will be shut down and isolated.

3. Shut down the equipment
The equipment is safely powered down using normal operating controls.

4. Isolate the energy source
Isolation devices such as switches, breakers, or valves are moved to the safe position.

5. Apply lockout devices
A lockout padlock or device is applied to secure the isolation point.

6. Attach a warning tag
A tag identifies the worker responsible for the isolation.

7. Verify isolation
Finally, workers must confirm the equipment cannot be energised before starting work.

This final step is particularly important in electrical environments where circuits must be tested to confirm they are de-energised.

Group Lockout Systems

In many workplaces, multiple workers may need to service the same equipment at the same time.

In these situations, group lockout procedures are used.

Common solutions include:

• Lockout hasps, allowing multiple workers to apply their own locks
• Lock boxes, where the key to an isolation lock is secured inside a locked box
• Lockout stations, which store isolation equipment for easy access

Each worker attaches their personal lock. As a result, the equipment cannot be re-energised until every worker has removed their lock. Supervisors may have access to a master key and have the ability to remove these locks under specific circumstances.

Common LOTO Mistakes

Even though Lockout Tagout procedures are widely used, safety incidents can still occur when proper steps are not followed.

Common mistakes include:

• Isolating equipment without applying a lock
• Relying on a warning tag without a lock
• Failing to identify all energy sources
• Not verifying the system is fully de-energised
• Removing another worker’s lock without authorisation
• Skipping isolation procedures for quick tasks

Because of these risks, workplaces must ensure workers receive proper training and have access to the correct lockout equipment.

Lockout Tagout Equipment

Lockout Tagout systems use specialised devices designed to secure different types of energy isolation points.

Common lockout equipment includes:

• Lockout padlocks
• Circuit breaker lockouts
• Valve lockouts
• Lockout hasps
• Lockout tags
• Lock boxes
• Lockout stations and kits

Using the correct equipment helps ensure isolation points remain secure, visible, and compliant with workplace safety procedures.

In Summary

Lockout Tagout is a critical safety procedure used to prevent equipment from being accidentally energised during maintenance or repair work.

By physically controlling energy sources, workers can safely service electrical systems, machinery, and industrial equipment.

When supported by proper procedures, training, and compliant equipment, Lockout Tagout plays an essential role in improving workplace safety across Australian industries.