Product Overview

Summary: This SOP provides a structured, step-by-step approach for safely inspecting and diagnosing faulty plant, equipment and systems in the workplace. It helps Australian businesses control the risks of working on unknown faults, ensuring technicians identify hazards, isolate energy sources, and resolve issues without exposing workers or the public to harm.

When systems fail unexpectedly—whether electrical, mechanical, hydraulic, pneumatic, or control/ICT—the pressure to restore operations quickly can drive rushed, ad‑hoc fault finding. This is precisely when serious incidents occur: live work on energised systems, uncontrolled releases of stored energy, exposure to moving parts, and incorrect assumptions about the source of the fault. This Safe Operating Procedure establishes a clear, repeatable method for safely inspecting and diagnosing faulty systems before any repair work proceeds. It guides workers through hazard identification, isolation and verification of energy sources, systematic testing, documentation, and communication in line with Australian WHS expectations.

Designed for use across a wide range of industries—including manufacturing, utilities, construction, facilities management and service-based businesses—this SOP helps you embed a “safety first, diagnose second” culture. It reduces reliance on informal troubleshooting habits and tribal knowledge by providing a documented, defensible process that supervisors can train against and auditors can verify. By implementing this procedure, organisations can reduce unplanned downtime, avoid secondary damage to assets, and significantly cut the risk of shocks, burns, entanglement, arc flash, and other serious events arising from poorly controlled diagnostic work.

Key Benefits

• Ensure inspections and diagnostic work on faulty systems are carried out under controlled, clearly documented conditions.
• Reduce the risk of electric shock, arc flash, entanglement, crush injuries and other serious incidents during fault finding.
• Standardise troubleshooting practices across teams, improving consistency, traceability and quality of diagnostic decisions.
• Streamline communication between technicians, supervisors and management through structured reporting and sign‑off steps.
• Demonstrate due diligence and WHS compliance during audits, incident investigations and regulator interactions.

Who is this for?

• Maintenance Technicians
• Electrical Fitters and Electricians
• Mechanical Fitters
• Service and Field Technicians
• WHS Advisors and HSE Coordinators
• Engineering Managers
• Operations and Production Supervisors
• Facility and Asset Managers
• ICT and Control Systems Engineers
• Contractor Management Coordinators

Hazards Addressed

• Electric shock and arc flash during testing or fault finding on energised electrical systems
• Unexpected start-up or movement of plant and machinery during inspection
• Release of stored energy (mechanical, hydraulic, pneumatic, thermal, gravitational) when removing guards or components
• Exposure to hot surfaces, steam, pressurised fluids or gases during diagnostic work
• Slips, trips and falls around open panels, tools, test leads and temporary access arrangements
• Contact with moving parts, rotating equipment, belts and pulleys during observation and testing
• Manual handling injuries when accessing, removing or repositioning heavy components for inspection
• Exposure to hazardous substances such as oils, coolants, chemicals or refrigerants released during fault investigation
• Data and control system failures leading to unsafe plant states if diagnostics are performed incorrectly

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Pre-Inspection Planning and Risk Assessment
• 6.0 Isolation, Lockout/Tagout and Verification of Zero Energy
• 7.0 Required Tools, Test Equipment and Personal Protective Equipment (PPE)
• 8.0 General Inspection and Diagnostic Principles
• 9.0 Step-by-Step Diagnostic Procedure for Electrical Systems
• 10.0 Step-by-Step Diagnostic Procedure for Mechanical, Hydraulic and Pneumatic Systems
• 11.0 Special Considerations for Control, Automation and ICT Systems
• 12.0 Hazard Identification and Control Measures During Diagnostics
• 13.0 Managing Live Testing Where Unavoidable (Authorisation and Controls)
• 14.0 Documentation, Reporting and Communication of Findings
• 15.0 Handover, Recommissioning and Post-Diagnostic Verification
• 16.0 Incident, Near Miss and Fault Trend Analysis
• 17.0 Training, Induction and Competency Assessment
• 18.0 Review, Audit and Continuous Improvement of the Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulations 2011 (Cth and relevant state/territory variants)
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Electrical Risks in the Workplace
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 4836:2011 Safe working on or near low-voltage electrical installations and equipment
• AS/NZS ISO 45001:2018 Occupational health and safety management systems
• AS 4024 series – Safety of machinery (where plant and machinery diagnostics are involved)