Product Overview

Summary: This Seasonal Startup and Shutdown Procedures SOP provides a clear, step-by-step framework for safely bringing plant, equipment and facilities online at the start of a season, and shutting them down at the end. It helps Australian businesses control the heightened WHS risks associated with idle equipment, changing weather conditions and intermittent operations, while protecting productivity and compliance.

Seasonal operations – such as those in agriculture, horticulture, tourism, outdoor recreation, and temperature‑sensitive manufacturing – carry unique risks whenever plant and facilities are started up after a period of inactivity or shut down for an extended break. Equipment that has been idle can seize, corrode or become contaminated, safety systems may be bypassed or degraded, and environmental conditions such as heat, storms, dust and moisture can significantly alter risk profiles. This Seasonal Startup and Shutdown Procedures SOP provides a structured, repeatable method for planning and executing these transitions so they are safe, compliant and efficient.

The procedure sets out clear responsibilities, pre‑startup inspection checklists, isolation and lockout steps, verification of safety controls, and systematic shutdown sequences tailored to seasonal cycles. It helps businesses reduce unplanned breakdowns, manage residual energy and stored pressures, and protect workers from the heightened hazards that arise when systems are not in their normal operating state. By embedding this SOP into your WHS management system, you create a defensible, documented process that supports due diligence under Australian WHS legislation, while also improving asset reliability and minimising costly downtime at the start and end of each season.

Key Benefits

• Reduce the risk of injuries and incidents associated with restarting idle plant and equipment after seasonal downtime.
• Ensure compliance with Australian WHS obligations by documenting a systematic approach to seasonal startup and shutdown activities.
• Extend asset life and reliability through structured inspections, cleaning, lubrication and preservation steps at each seasonal changeover.
• Minimise unplanned downtime and production delays by identifying and rectifying issues before full operations resume.
• Standardise expectations and training across crews, sites and seasons with clear, role-specific checklists and responsibilities.

Who is this for?

• Operations Managers
• Maintenance Supervisors
• WHS Managers
• Facility Managers
• Production Supervisors
• Site Supervisors
• Plant Operators
• Property and Asset Managers
• Agricultural Enterprise Managers
• Utilities and Services Coordinators

Hazards Addressed

• Unexpected energisation or movement of machinery during startup or shutdown
• Failure of mechanical components due to corrosion, seizing or lack of lubrication after idle periods
• Exposure to stored energy (hydraulic, pneumatic, electrical, gravitational) during isolation and de-isolation
• Slips, trips and falls arising from seasonal conditions (wet floors, mud, leaf litter, dust, poor lighting)
• Heat stress, cold stress and weather-related exposure during outdoor seasonal work
• Electrical faults, insulation breakdown or moisture ingress in electrical equipment after inactivity
• Chemical exposure from degraded, leaking or improperly stored fuels, oils, coolants and cleaning agents
• Biological hazards such as vermin, mould, insects or plant growth in and around idle equipment and structures
• Fire and explosion risks from accumulated combustible dusts, flammable vapours or fuel residues
• Manual handling injuries during seasonal setup, relocation and storage of equipment and materials

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Seasonal Context
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Risk Assessment for Seasonal Startup and Shutdown
• 6.0 Pre-Startup Inspection and Preparation Checklists
• 7.0 Seasonal Startup Procedure – Step-by-Step
• 8.0 Seasonal Shutdown Procedure – Step-by-Step
• 9.0 Isolation, Lockout and Tagout Requirements
• 10.0 Verification of Safety Systems and Controls
• 11.0 Environmental and Weather-Related Considerations
• 12.0 Management of Hazardous Substances, Fuels and Waste
• 13.0 Maintenance, Cleaning and Preservation Activities
• 14.0 Emergency Preparedness During Startup and Shutdown
• 15.0 Training, Competency and Communication Requirements
• 16.0 Documentation, Records and Audit Trail
• 17.0 Continuous Improvement and Review of Seasonal Procedures
• Appendix A – Sample Seasonal Startup Checklists (by plant/equipment type)
• Appendix B – Sample Seasonal Shutdown Checklists (by plant/equipment type)
• Appendix C – Seasonal Risk Assessment Template

Legislation & References

• Model Work Health and Safety Act and Regulations (as implemented in each state and territory)
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing the work environment and facilities
• AS/NZS 4024.1 Safety of machinery – Series
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS/NZS ISO 31000: Risk management – Guidelines
• AS 2865: Confined spaces (where seasonal shutdown includes confined space entries)
• AS/NZS 4801 / ISO 45001: Occupational health and safety management systems