Free lockout tagout procedure template
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Last updated: 2026-04-24 · MapTrack
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What is a LOTO procedure?
A lockout tagout (LOTO) procedure is a standard operating procedure that defines how energy sources are isolated and secured before maintenance or servicing work begins on plant and equipment. MapTrack helps operations teams manage LOTO procedures digitally so every isolation is recorded against the asset with full traceability. This overarching SOP is distinct from a per-job LOTO isolation checklist which is the field checklist completed for each specific isolation event. The procedure template defines the organisation-wide rules covering scope roles and responsibilities isolation types lock and tag requirements group isolation try-out verification and lock removal.
LOTO procedures are essential for preventing uncontrolled release of energy during maintenance. In Australia AS 4024.1603 (Control of hazardous energy - Lockout tagout and alternative methods) and the WHS Regulations set out requirements for isolation of plant. Failure to follow proper LOTO procedures is a leading cause of serious workplace injuries and fatalities in Australian industry.
Benefits
- Injury prevention: a documented LOTO procedure ensures all energy sources are identified and isolated before any maintenance work begins
- Legal compliance: a written LOTO procedure demonstrates the PCBU has met their WHS Regulations and AS 4024.1603 obligations for energy isolation
- Consistency: every worker follows the same isolation process regardless of the type of energy source or complexity of the task
- Accountability: defined roles and responsibilities ensure everyone knows who authorises isolation who applies locks and who verifies zero energy
- Group lockout coverage: the procedure addresses multi-person and multi-trade isolation scenarios where several workers need protection simultaneously
- Audit trail: documented LOTO procedures with referenced checklists provide evidence for regulator enquiries and insurer audits
Benefits of digitising forms in MapTrack
When you move your procedures from paper to 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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Manage LOTO procedures digitally
Try MapTrack free for 30 days. Link LOTO procedures to each asset and track every isolation event with full traceability.
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What to include in a LOTO procedure
- Scope and purpose: define which plant equipment and energy types the procedure covers and state its purpose in preventing uncontrolled energy release
- Roles and responsibilities: define the roles of the authorised person (who authorises isolation) the competent person (who performs isolation) and the affected person (who works on the isolated plant)
- Energy types: list all energy types covered including electrical hydraulic pneumatic mechanical gravitational thermal and chemical
- Lock and tag requirements: specify the types of locks and tags to be used personal lock requirements and the rule that each worker applies their own lock
- Isolation steps: describe the step-by-step process for isolating each energy type including shutdown sequence isolation point identification and lock application
- Try-out and verification: define the process for verifying zero energy after isolation is applied including try-start and testing with appropriate instruments
- Group isolation: describe the procedure for multi-person lockout including the use of a group lockout box or hasp and the requirement for each worker to apply their personal lock
- Lock removal and re-energisation: define the process for removing locks restoring energy and confirming the plant is safe to return to service
How to implement a LOTO procedure
- Identify all energy sources: conduct an energy source audit for each item of plant and document every electrical hydraulic pneumatic mechanical gravitational thermal and chemical energy source
- Define isolation points: for each energy source identify the specific isolation point (breaker valve bleed point block) and document it on an isolation point diagram or register
- Assign roles and responsibilities: define who is authorised to approve isolations who is competent to perform them and how affected persons are informed and protected
- Document the step-by-step procedure: write out the shutdown isolation lock application try-out and verification steps in sequence for the organisation
- Establish lock and tag standards: specify the types of personal danger locks tags and group lockout devices (hasps boxes) to be used and ensure adequate supply is available
- Train all affected personnel: ensure every worker who performs isolation supervises isolation or works on isolated plant is trained in the procedure and assessed as competent
- Review and update regularly: review the LOTO procedure at least annually after any incident involving isolation failure and whenever new plant or energy sources are introduced
How often should the LOTO procedure be reviewed?
The LOTO procedure should be reviewed at least annually as part of the organisation\'s safety management system review cycle. It should also be reviewed immediately after any incident or near miss involving an isolation failure after the introduction of new plant or equipment and whenever there is a change in legislation or standards.
AS 4024.1603 requires that procedures for the control of hazardous energy are documented maintained and reviewed. The WHS Regulations require the PCBU to ensure that risks associated with plant are managed and that isolation procedures are followed. Regular review ensures the LOTO procedure remains current and effective as the workplace evolves.
Frequently asked questions
- What is the difference between a LOTO procedure and a LOTO checklist?
- A LOTO procedure is the overarching standard operating procedure that defines the organisation-wide rules for energy isolation including roles, responsibilities, isolation types, lock requirements and removal process. A LOTO checklist is the per-job field form completed for each specific isolation event to confirm each step has been followed.
- What energy types should a LOTO procedure cover?
- A comprehensive LOTO procedure should cover electrical, hydraulic, pneumatic, mechanical, gravitational, thermal and chemical energy sources. Each energy type requires specific isolation methods. For example, electrical energy requires breaker lockoff while hydraulic energy requires valve closure and pressure bleed-down.
- What does AS 4024.1603 require for lockout tagout?
- AS 4024.1603 sets out requirements for the control of hazardous energy including documented isolation procedures, use of personal locks and tags, try-out verification of zero energy, group lockout arrangements and training for all affected personnel. It applies to all plant where uncontrolled energy release could cause injury.
- Is the template free to use without MapTrack?
- Yes. Download and use the LOTO procedure template for free. Open the file and use your browser Print to Save as PDF. No MapTrack account required.
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