Servicing machinery without isolating energy exposes workers to serious harm. Hidden pressure, heat, charge, or tension may remain even after shutdown. Stop buttons alone do not prevent movement or discharge.
Energy can release during maintenance without warning. This can lead to crush injuries, burns, or shock. These risks affect technicians, operators, and nearby staff.
Many incidents happen during quick tasks like clearing jams or replacing parts—often done without proper isolation. Equipment restarts. Valves release pressure. Moving parts return to position. Injuries follow.
Each incident leads to downtime, lost productivity, and investigation. Most are traced to skipped steps: no lock, no tag, no verification.
Lockout tagout removes this risk. Energy sources are locked and tagged before work starts. Stored force is released or restrained. The machine cannot restart until cleared.
This system applies to electrical, mechanical, and fluid systems. Isolation must occur before any maintenance begins—no exceptions.
What Lockout Tagout Controls
The lockout tagout system is designed to block access to dangerous energy. It is not limited to electric circuits. Any system using force, flow, or temperature can create risk if uncontrolled.
Hazards addressed through isolation include:
- Electrical charge in circuits or panels
- Pressure in hydraulic lines or tanks
- Compressed air in pneumatic systems
- Heat held in tanks, boilers, or pipes
- Tension in springs, belts, or mechanical parts
Isolation must address each type of energy separately. A conveyor may include electrical motors, belt tension, and compressed air—all must be locked. If any source remains active, the worker is still at risk.
The system includes not just lock placement, but draining, venting, and restraining energy. Movement is stopped physically, not just assumed based on power indicators.
When Lockout Tagout Must Be Applied
Isolation is needed anytime a worker might enter, adjust, remove, or clean machine components. Common situations include:
- Accessing rotating or pressurised parts
- Servicing control units or replacing internal sensors
- Cleaning equipment where residual heat or motion may exist
- Repairing or replacing valves and switches
- Inspecting or testing systems while open
No task is too brief or routine to require lockout. Most serious injuries occur during short servicing periods when systems were thought to be safe but were not isolated fully.
Isolation must be applied before any work starts—not during and never after. If there is risk of movement, flow, or discharge, energy control must be in place from the beginning.
How Tagout Works in Lockout Tagout
A tag provides visual notice that a lockout is active. It displays who applied the lock, the time and date, and the purpose of the isolation. The tag is not a substitute for a lock—it supports communication.
Tags prevent confusion and stop unauthorised access. If multiple people are working on the same system, group tags or lockout boxes are used so each worker applies and controls their own lock.
Tagout also supports audits and investigation. It shows accountability, confirms timing, and tracks when and why equipment was taken out of service. Each tag must remain attached and readable throughout the maintenance process.
Benefits of Lockout Tagout in Worksite Safety
Lockout tagout minimises exposure to uncontrolled energy during servicing. It provides a structured process that improves safety, reduces system risk, and enforces compliance across shifts, tasks, and departments. The procedure is consistent, traceable, and effective at removing human error from hazardous work.
Key benefits include:
- Prevents injury
- Reduces equipment damage
- Limits unplanned downtime
- Satisfies WHS compliance obligations
- Increases process accountability
Lockout tagout introduces physical isolation at each energy source. This prevents movement during inspection or cleaning and removes dependence on memory or informal checks. The presence of locks and tags ensures others cannot activate the machine without full clearance.
Equipment remains stable while open. Seals, valves, and rotating parts are protected from unintended reactivation. This lowers the chance of force damage, leaks, or failure during servicing.
When the system is applied, tasks are completed with fewer interruptions. Sites avoid long shutdowns caused by injury, damage, or internal investigation. This keeps production aligned with schedule and output targets.
WHS law requires clear procedures to isolate and discharge energy. Lockout tagout fulfils this obligation and proves that risk control measures are in place. It also supports audit and incident reporting by maintaining documented records of who performed the isolation and when.
Compliance Under Safe Work Australia Guidelines
Workplace safety regulations in Australia require that businesses identify, assess, and control all hazardous energy before maintenance work begins. These expectations are set out in the Model Code of Practice: Managing Risks of Plant in the Workplace.
Employers must:
- Develop and apply isolation procedures
- Train staff to use correct lockout tools and verify energy status
- Supply fit-for-purpose locks, tags, and restraint equipment
- Review procedures regularly and update them where needed
- Keep records of training, lockout events, and any related incidents
Lockout tagout is part of expected risk control. It cannot be replaced with verbal checks or emergency stop systems. SafeWork NSW and other regulators require physical controls backed with documentation.
Supervisors must check that isolation is applied to every job. Equipment should not be accessible for service unless all isolation points are secured and verified. Any gap in this process places workers and the site at risk.
Equipment Used to Control Energy Risks
Lockout tagout relies on tools that block access and hold systems in a safe condition. These include:
- Lockout padlocks
- Isolation switch
- Valve covers and clamp devices
- Lockout hasps and group lock boxes
All tools must be in working order and inspected regularly. Damaged locks or unreadable tags reduce effectiveness. Devices must be used according to the type of energy and system layout.
Workers must be trained to select the right device for the task. Using incorrect tools increases risk and creates false confidence that the system is secure.
Role of Workers in Applying Isolation
The success of lockout tagout depends on consistent application across all workers. Each person involved in the task must follow the system completely. No lock should be removed except by the person who applied it.
Workers must:
- Identify all energy sources linked to the task
- Use proper locking tools and tags
- Apply personal locks to each point they isolate
- Test and confirm that isolation is complete before work
- Keep control of their key and remove the lock only after work ends
Supervisors are responsible for checking compliance. They must ensure that no steps are skipped, devices are available, and the right staff are trained to apply and verify isolation.
Contractors, visitors, and third-party staff must also follow the same procedure. There are no exceptions or variations based on job title or company name.
Risks That Lead to Lockout Failures
Common causes of failure in energy control include:
- Locking the wrong device or only one of several energy sources
- Forgetting to release stored energy such as pressure or tension
- Relying on emergency stops instead of full isolation
- Allowing another person to remove a lock
- Skipping confirmation that the system cannot activate
These failures often happen during rushed work, lack of training, or overconfidence. The result is the same—equipment activates while someone is working, causing harm.
To prevent this, sites must audit procedures, test staff knowledge, and act when the system is ignored. Safety controls only work when applied without compromise.
Advice from Locksafe
At Locksafe, we’ve seen how energy risks affect sites, workers, and business operations. We build equipment that stays secure during real tasks, not just in controlled conditions.
Lockout tagout is more than tools. It’s a commitment that work will never begin until energy is contained. If you manage powered systems, your staff must have access to the right devices and know exactly how to apply them.
We supply isolation gear that stands up to vibration, heat, pressure, and field conditions across Australian worksites.
If you need to set up a reliable system, replace broken equipment, or train staff to apply isolation without shortcuts, contact us.
