Free lockout tagout procedure template
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Free lockout tagout (LOTO) procedure template (PDF-ready). Energy isolation, lock placement, verification, restoration and sign-off. Download free.
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What is a lockout tagout procedure template?
A lockout tagout (LOTO) procedure template is a standardised document that defines the step-by-step process for isolating all hazardous energy sources on a piece of plant or equipment before maintenance, repair, cleaning or inspection work begins. It covers the identification of every energy source (electrical, hydraulic, pneumatic, mechanical, gravitational, thermal, chemical and stored energy), the specific isolation points and methods for each, the application of personal danger locks and tags, the dissipation of stored or residual energy, the try-out verification of zero energy, group lockout arrangements for multi-person work, and the controlled re-energisation process once work is complete. In Australia, AS/NZS 4024.1603 and the WHS Regulations require that a documented isolation procedure is in place for all plant where uncontrolled release of energy could cause injury.
Failure to properly isolate equipment is one of the leading causes of serious workplace injuries and fatalities in Australian industry, including electrocution, crushing, burns, amputations and entanglement. A written LOTO procedure ensures that every worker follows the same systematic process regardless of the equipment type, shift or site. It removes reliance on memory or informal instruction and creates clear accountability for who authorises isolation, who performs it, and who verifies zero energy. MapTrack helps organisations manage LOTO procedures digitally, linking each isolation event to the specific asset record with electronic sign-on, photo evidence and a complete audit trail.
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Benefits of using this lockout tagout procedure template
- Injury prevention: ensures all hazardous energy sources are identified, isolated and verified as zero energy before any hands-on work begins, protecting workers from electrocution, crushing, burns and entanglement.
- Legal compliance: a documented LOTO procedure demonstrates the PCBU has met their obligations under AS/NZS 4024.1603 and WHS Regulations for managing risks associated with plant.
- Consistency: every worker follows the same isolation sequence regardless of the energy type, equipment complexity or time of day, eliminating reliance on memory.
- Clear accountability: defined roles for authorised person, competent person and affected person ensure everyone knows who approves, who performs and who is protected by the isolation.
- Group lockout coverage: the procedure addresses multi-person and multi-trade scenarios where several workers need simultaneous protection on the same equipment.
- Audit trail: completed LOTO procedures with referenced checklists provide documented evidence for regulator enquiries, insurer audits and incident investigations.
Benefits of digitising forms in MapTrack
When you digitise loto equipment procedures in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Escalate critical hazards instantly to safety managers via push notification.
- Maintain an auditable safety register that satisfies WHS regulator requests.
- Correlate incident trends across sites with built-in safety analytics.
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What to include in a lockout tagout procedure template
This lockout tagout procedure template covers 10 key areas:
- Scope and purpose: define which plant, equipment and energy types the procedure covers. State the objective of preventing uncontrolled energy release during maintenance, servicing and inspection.
- Roles and responsibilities: define the authorised person (approves isolation), competent person (performs isolation) and affected person (works on isolated plant). Include training and competency requirements.
- Energy source identification: provide a table listing all energy types (electrical, hydraulic, pneumatic, mechanical, gravitational, thermal, chemical, stored energy), the specific isolation points for each and the isolation method.
- Shutdown sequence: describe the normal operating shutdown steps that must be completed before isolation points are secured.
- Lock and tag application: specify the types of personal danger locks and tags, the rule that each worker applies their own lock, and the use of multi-lock hasps for group isolation.
- Stored energy dissipation: describe how to bleed hydraulic and pneumatic lines, discharge capacitors, block raised loads and restrain spring-loaded mechanisms.
- Try-out verification: define the zero-energy verification process, including attempting to start the equipment (try test) and testing with instruments where applicable.
- Group lockout: describe the procedure for multi-person work, including the group lockout box, the requirement for each worker to apply a personal lock, and the communication protocol.
- Re-energisation procedure: define the steps for removing locks, replacing guards, confirming personnel are clear, notifying affected persons and restarting equipment.
- Record keeping: specify the documentation requirements, including the isolation register, completed LOTO checklists and retention periods.
How to use this lockout tagout procedure template
- Identify all energy sources for the specific item of plant by reviewing the equipment isolation register, manufacturer documentation and isolation diagrams.: Conduct an energy source audit for the equipment. List every energy type: electrical (mains, batteries, capacitors), hydraulic (pressurised lines, rams, accumulators), pneumatic (compressed air, gas lines), mechanical (moving parts, springs, flywheels, conveyors), gravitational (raised loads, counterweights), thermal (steam, heated surfaces), chemical (process chemicals, pipelines) and stored energy. Record each source in the energy identification table with its isolation point and method.
- Notify all affected personnel that the equipment is being isolated and why.: Inform every worker, operator and contractor who may be affected by the equipment being taken out of service. Use a verbal briefing, toolbox talk or written notification. Obtain acknowledgement that they understand the isolation is in effect and the expected duration. This prevents anyone from attempting to operate equipment that is under isolation.
- Shut down the equipment following the normal operating shutdown sequence before applying isolation devices.: Follow the manufacturer or site procedure for normal shutdown. Do not simply switch off at the isolator, as this may leave stored energy in the system or cause damage. Allow the equipment to come to a complete stop. Verify that all moving parts have ceased and all process flows have stopped before proceeding to isolation.
- Apply personal danger locks and tags to every isolation point. Each worker applies their own lock so the equipment cannot be re-energised until every lock is removed.: Use a personal danger lock (uniquely keyed or combination) and a danger tag for each isolation point. Each worker who will be exposed to the energy hazard applies their own lock. Use a multi-lock hasp where more than one person needs to lock the same point. Do not use improvised locking devices. Ensure an adequate supply of locks, tags and hasps is available before work begins.
- Dissipate all stored and residual energy: bleed hydraulic and pneumatic lines, discharge capacitors, block raised loads and restrain spring-loaded mechanisms.: After all isolation devices are applied, stored energy may still remain. Bleed hydraulic and pneumatic lines to zero pressure and verify with gauges. Discharge capacitors using approved procedures. Block or pin raised loads, spring-loaded mechanisms and counterweights so they cannot move under gravity. Verify that all stored energy has been safely dissipated or mechanically restrained.
- Perform zero-energy verification by attempting to start the equipment (try test) and testing with instruments where required.: Press the start button or operate the controls to verify the equipment does not start. This try test confirms all energy sources have been effectively isolated. For electrical isolation, use a voltage tester to confirm zero volts at the equipment terminals. For hydraulic and pneumatic systems, check pressure gauges read zero. Return all controls to the off position after the try test.
- When work is complete, follow the re-energisation procedure: remove tools, replace guards, confirm all personnel are clear, remove locks and restart.: Before removing any lock, confirm all tools and materials have been removed from the equipment. Replace all guards, covers and safety devices. Conduct a head count or roll call to confirm every worker is clear of the equipment. Each worker removes their own lock only. Notify all affected personnel that the equipment is being re-energised. Start the equipment and verify normal operation before releasing it back to service.
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Back to download formHow often should you complete this procedure?
A LOTO procedure must be followed every time plant or equipment is isolated for maintenance, repair, cleaning, inspection or any other work that could expose workers to hazardous energy. This includes planned preventive maintenance, breakdown repairs, cleaning inside machinery, changing tooling or dies, clearing jams and blockages, and any task requiring access to parts that are normally guarded or enclosed. A new LOTO checklist is required for each isolation event. The written LOTO procedure itself should be reviewed at least annually, immediately after any incident or near miss involving isolation failure, and whenever new plant is introduced or existing plant is modified.
Frequently asked questions
- What is a lockout tagout procedure?
- A lockout tagout (LOTO) procedure is a documented standard operating procedure that defines how hazardous energy sources are identified, isolated, locked, tagged and verified as zero energy before maintenance or servicing work begins on plant and equipment. It covers the roles and responsibilities of the authorised person, competent person and affected person, the sequence for shutdown, isolation, lock application, stored energy dissipation, try-out verification and re-energisation. In Australia, LOTO procedures are required under AS/NZS 4024.1603 and WHS Regulations to protect workers from the uncontrolled release of energy.
- What energy types must a LOTO procedure cover?
- A comprehensive LOTO procedure must address all forms of hazardous energy: electrical (mains power, batteries, capacitors), hydraulic (pressurised fluid lines, rams, accumulators), pneumatic (compressed air, gas lines), mechanical (moving parts, springs, flywheels, conveyors), gravitational (raised loads, counterweights, suspended platforms), thermal (steam, heated surfaces, ovens), chemical (process chemicals, pipelines) and stored or residual energy. Each energy type requires specific isolation methods and verification techniques.
- What does AS/NZS 4024.1603 require for lockout tagout?
- AS/NZS 4024.1603 (Safety of machinery, Control of hazardous energy, Lockout tagout and alternative methods) requires documented isolation procedures, use of personal locks and danger tags, try-out verification of zero energy, group lockout arrangements for multi-person work, training and competency assessment for all affected personnel, and periodic review of the LOTO procedure. The standard applies to all plant and machinery where uncontrolled release of energy could cause injury during maintenance, servicing, inspection, cleaning or adjustment.
- Can one person remove another person s lock?
- Under AS/NZS 4024.1603 and best-practice LOTO procedures, only the person who applied a lock may remove it. This is a fundamental principle of lockout tagout safety. If a worker has left site with their lock still applied, most procedures require a documented lock-removal process authorised by a senior manager, with verification that the absent worker is not at risk and that a try test is repeated before the equipment is re-energised. Removing another person s lock without following this process is a serious safety breach.
- Is this lockout tagout procedure template free?
- Yes. Download and use this LOTO procedure template for free. Open the file in your browser and use Print then Save as PDF. No MapTrack account is required. If you want digital LOTO management with electronic isolation registers, QR code scanning at isolation points, photo evidence and automated audit trails linked to each asset, MapTrack can help. Book a demo to see how it works.
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS/NZS 4024.1603 - Control of hazardous energy (Lockout/tagout)
- WHS Regulations 2011 - Chapter 5 Part 5.1 (Plant and structures)
- OSHA 29 CFR 1910.147 - The control of hazardous energy (Lockout/tagout)
- Safe Work Australia - Code of Practice: Managing risks of plant in the workplace
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