Product Overview

Summary: This Insulation Resistance Testing Safe Operating Procedure sets out a clear, safe and compliant method for testing electrical insulation on plant, equipment and installations. It helps Australian workplaces verify electrical integrity, prevent shocks and equipment failures, and demonstrate due diligence under WHS and electrical safety legislation.

Insulation resistance testing is a critical control for preventing electric shock, arc faults and unplanned equipment failures in Australian workplaces. Whether you are commissioning new installations, performing periodic verification, or troubleshooting faults, a consistent and well-documented approach is essential to protect workers and maintain compliance with WHS and electrical regulations. This Safe Operating Procedure provides a structured, step‑by‑step method for planning, performing and recording insulation resistance tests on low voltage (LV) and, where applicable, high voltage (HV) systems using an insulation resistance tester (megohmmeter).

The procedure goes beyond basic test instructions by embedding WHS risk controls, lock-out/tag-out requirements, and clear acceptance criteria that align with relevant Australian Standards. It addresses common pain points such as inconsistent test methods between technicians, missing isolation steps, inadequate documentation, and uncertainty about safe discharge of stored energy. By implementing this SOP, organisations can standardise their approach to insulation resistance testing across sites and contractors, reduce the likelihood of electrical incidents, and provide defensible evidence of compliance during audits, inspections and incident investigations.

Designed for use in construction, manufacturing, facilities management, utilities and mining, this SOP is written in practical, plain English while still reflecting technical best practice. It supports duty holders in meeting their obligations under WHS legislation and electrical safety laws, and can be easily integrated into existing permit-to-work, preventive maintenance and commissioning processes.

Key Benefits

• Ensure a consistent, safe and repeatable method for insulation resistance testing across all sites and teams.
• Reduce the risk of electric shock, arc flash and equipment damage by embedding robust isolation and verification steps.
• Demonstrate compliance with Australian electrical and WHS requirements through clear criteria, records and sign‑off processes.
• Streamline commissioning and preventive maintenance activities with a standardised test sequence and documentation format.
• Improve audit readiness by capturing traceable test results, equipment details and technician competencies in one procedure.

Who is this for?

• Electricians
• Electrical Supervisors
• Electrical Engineers
• Maintenance Technicians
• HV and LV Commissioning Engineers
• Facilities Managers
• WHS Managers
• Compliance and Risk Managers
• Construction Project Managers
• Authorised Electrical Persons (AEPs)

Hazards Addressed

• Electric shock from contact with live or inadequately isolated conductors
• Arc flash and arc blast resulting from incorrect test connections or inadequate isolation
• Stored energy in cables, motors and capacitors leading to unexpected discharge
• Damage to sensitive electronic equipment due to incorrect test voltage selection
• Slips, trips and falls around testing areas with trailing leads and open switchboards
• Eye and hand injuries from arc flash, flying debris or tool misuse
• Exposure to hazardous environments (confined spaces, wet areas, explosive atmospheres) during testing activities

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 References and Applicable Standards
• 4.0 Roles, Responsibilities and Competency Requirements
• 5.0 Required Tools, Test Instruments and Calibration Requirements
• 6.0 Personal Protective Equipment (PPE) and Safety Precautions
• 7.0 Pre‑Job Planning and Risk Assessment
• 8.0 Isolation, Lock‑Out/Tag‑Out and Verification of De‑Energised State
• 9.0 Equipment Preparation and Circuit Identification
• 10.0 Insulation Resistance Test Methods (LV and HV as applicable)
• 11.0 Test Voltage Selection and Minimum Acceptable Values
• 12.0 Step‑by‑Step Testing Procedure
• 13.0 Discharge of Stored Energy and Re‑Energisation
• 14.0 Handling of Abnormal Results and Fault Conditions
• 15.0 Documentation, Test Records and Labelling Requirements
• 16.0 Integration with Permits, Commissioning and Maintenance Programs
• 17.0 Hazard Identification and Control Measures
• 18.0 Emergency Procedures and Incident Reporting
• 19.0 Training, Competency and Review of Procedure
• 20.0 Revision History and Document Control

Legislation & References

• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 3017:2007 Electrical installations – Verification guidelines
• AS/NZS 3760:2022 In-service safety inspection and testing of electrical equipment
• AS/NZS 4836:2011 Safe working on or near low-voltage electrical installations and equipment
• AS/NZS 60079.17:2017 Explosive atmospheres – Electrical installations inspection and maintenance (where applicable)
• Work Health and Safety Act and Regulations (as adopted in the relevant Australian jurisdiction)
• Electrical Safety Act and Regulations (where applicable, e.g. QLD Electrical Safety Act 2002)
• Safe Work Australia – Managing electrical risks in the workplace Code of Practice