Product Overview

Summary: This High-Voltage Safety in Electric Vehicles SOP sets out clear, practical steps for working safely on and around EV high-voltage systems in Australian workplaces. It helps your business control arc flash, electric shock and battery fire risks while demonstrating compliance with WHS duties and relevant electrical safety standards.

As electric vehicles rapidly enter Australian fleets, workshops and depots, the risks associated with high-voltage systems cannot be managed using traditional automotive practices alone. This High-Voltage Safety in Electric Vehicles Safe Operating Procedure provides a structured, step-by-step process for safely isolating, testing, repairing and recommissioning EVs with high-voltage components. It translates complex electrical safety requirements into clear, workshop-ready instructions that technicians can follow with confidence.

The SOP addresses the full lifecycle of EV work – from pre-job risk assessment and verification of competency, through safe shutdown, lock-out/tag-out of high-voltage systems, and controlled re-energisation, to incident response and reporting. It helps businesses prevent electric shock, arc flash, thermal burns, and battery thermal runaway events, while also protecting nearby workers and visitors. By embedding this SOP into your operations, you create a consistent, defensible safety framework that supports WHS compliance, underpins training, and reduces the likelihood of serious electrical incidents in your EV maintenance and operations.

Key Benefits

• Ensure high-voltage work on electric vehicles is carried out in line with Australian WHS and electrical safety requirements.
• Reduce the risk of electric shock, arc flash, and battery-related fires during EV inspection, maintenance and repair.
• Standardise high-voltage isolation, lock-out/tag-out and verification procedures across all workshops and sites.
• Support competency-based training for EV technicians and apprentices with clear, repeatable steps.
• Demonstrate due diligence to regulators, clients and insurers through documented, best-practice high-voltage controls.

Who is this for?

• Automotive Electricians
• EV Technicians and Mechanics
• Workshop Managers
• Fleet Maintenance Supervisors
• WHS Managers and Advisors
• Electrical Safety Officers
• Training and Compliance Managers
• Plant and Fleet Operations Managers
• Emergency Response Team Leaders

Hazards Addressed

• Electric shock from exposed or damaged high-voltage components
• Arc flash and arc blast during fault conditions or incorrect isolation
• Thermal burns from live parts, hot components or electrical faults
• Battery thermal runaway, fire and explosion involving lithium-ion packs
• Release of toxic gases or smoke from damaged battery systems
• Uncontrolled vehicle movement during high-voltage work
• Secondary injuries from falls, slips or trips while wearing insulating PPE
• Manual handling injuries associated with removal of heavy battery packs and high-voltage components

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and High-Voltage System Overview
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Guidance
• 5.0 Hazard Identification and Risk Assessment for EV High-Voltage Work
• 6.0 Required Tools, Test Equipment and PPE (Including Insulating PPE)
• 7.0 Pre-Work Checks and Vehicle Reception Procedures
• 8.0 High-Voltage System Shutdown and Isolation Procedure
• 9.0 Lock-Out/Tag-Out (LOTO) and Verification of De-energisation
• 10.0 Safe Work Practices on Isolated High-Voltage Components
• 11.0 Battery Pack Handling, Storage and Transport Controls
• 12.0 Re-energisation, Functional Testing and Return-to-Service Checks
• 13.0 Housekeeping, Workshop Layout and Exclusion Zones for EV Work
• 14.0 Emergency Response: Electric Shock, Arc Flash and Battery Fire
• 15.0 Incident Reporting, Investigation and Corrective Actions
• 16.0 Training, Induction and Competency Maintenance
• 17.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Electrical safety and risk management provisions
• AS/NZS 4836: Safe working on or near low-voltage and extra-low voltage electrical installations and equipment
• AS/NZS 3000: Electrical installations (Australian/New Zealand Wiring Rules)
• AS/NZS 3012: Electrical installations – Construction and demolition sites (as guidance for temporary electrical safety practices)
• Safe Work Australia – Model Code of Practice: Managing electrical risks in the workplace
• Safe Work Australia – Model Code of Practice: How to manage work health and safety risks
• Relevant state or territory Electrical Safety Acts and Regulations (e.g. Electrical Safety Act 2002 (Qld))