Free equipment isolation procedure template
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Free equipment isolation procedure (PDF-ready). Isolate, lock and verify zero energy across electrical, mechanical, hydraulic, pneumatic and stored energy.
Commercial Director
Key takeaways
- An isolation procedure removes and proves zero energy across electrical, mechanical, hydraulic, pneumatic, stored and thermal sources.
- It differs from a lockout checklist by isolating and verifying every energy source, not just confirming locks are on.
- Stored energy such as trapped pressure or a raised load must be dissipated or restrained, not just isolated.
- A try-test verification against each source proves the machine is dead before any guard comes off.
- A dated isolation record is evidence for WHS energy isolation duties and AS 4024 prevention of unexpected start-up.
Updated 22 June 2026
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What is a equipment isolation procedure template?
An equipment isolation procedure is the controlled method for making a machine safe to work on by removing every form of stored and live energy before maintenance begins, then proving it is gone. Unlike a single lockout tag, this procedure works across all energy sources on the plant: electrical, mechanical, hydraulic, pneumatic, gravity or stored mechanical energy, and thermal. For each source it sets out the sequence to identify the energy, isolate it at the right point, lock and tag the isolation, dissipate or restrain any stored energy, and then verify zero energy at the machine before any guard comes off or any hand goes in.
Isolation is the control that stands between a maintainer and the most severe injuries on a worksite, because unexpected start-up or the release of stored energy during a repair is a recognised cause of fatalities. A documented multi-energy procedure makes the safe sequence repeatable for every person who works on the asset, rather than relying on memory or the most experienced fitter being present. It also gives the duty holder evidence that the plant energy isolation requirements of the Work Health and Safety Regulation and the prevention of unexpected start-up principles in AS 4024 have been met, with a verification step recorded against each energy source rather than assumed.
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Benefits of using this equipment isolation procedure template
- All energy sources covered: a source-by-source method stops the common failure of locking out the power but forgetting trapped hydraulic, pneumatic or gravity energy.
- Verified dead, not assumed: a try-test verification step against each source proves zero energy at the machine before any guard is removed or work starts.
- Repeatable for everyone: a written sequence makes the safe method the same for every maintainer, not dependent on the most experienced person being on shift.
- Fewer start-up incidents: locking and tagging each isolation point removes the risk of a machine being energised while someone is working inside it.
- Clear group control: defined lock points and a permit step let multiple trades work on one asset under a controlled, accountable isolation rather than informal calls.
- Audit and incident evidence: a completed, dated isolation record demonstrates compliance with WHS energy isolation duties and AS 4024 prevention of unexpected start-up.
Benefits of digitising forms in MapTrack
When you move your service 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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What to include in a equipment isolation procedure template
This equipment isolation procedure template covers 11 key areas:
- Asset and task: machine, location, work to be done and the permit or work order number
- Energy source register: every source present on the machine and where it is fed from
- Electrical isolation: isolator or breaker, lock point, and the verified de-energised test
- Mechanical isolation: stored springs, flywheels and moving parts restrained or blocked
- Hydraulic isolation: valves closed, locked and pressure bled to zero at a gauge
- Pneumatic isolation: air supply isolated, locked and residual pressure vented to zero
- Gravity and stored energy: raised loads lowered or mechanically supported and pinned
- Thermal isolation: hot or cold surfaces and lines isolated and allowed to reach a safe temperature
- Lock and tag list: each lock applied, by whom, and the personal danger tag fitted
- Zero-energy verification: the try-test result recorded against each source before work
- Restoration: guards refitted, locks removed in order, and the machine returned to service
How to use this equipment isolation procedure template
- Identify every energy source on the machine: Before touching anything, work through the asset and list every source of energy present: electrical, mechanical, hydraulic, pneumatic, gravity or stored, and thermal. Missing a single source is the most common cause of an isolation failure, so use the machine drawings if the feeds are not obvious.
- Shut down and isolate each source at the correct point: Shut the machine down using the normal stop, then isolate every source at its designated isolation point, not just at the control panel. Open the breaker, close the valve, isolate the air, and confirm each isolation point is the one that actually breaks the supply to the machine.
- Lock, tag and control the isolation: Apply a personal lock and danger tag to each isolation point so it cannot be reopened. Where several people work on the asset, use a group lockout point and a permit so every worker has a lock on and the isolation cannot be removed while anyone is still exposed.
- Dissipate or restrain stored energy: Release the energy that remains after isolation: bleed hydraulic and pneumatic pressure to zero at a gauge, lower or mechanically support raised loads, restrain springs and flywheels, and allow hot or cold components to reach a safe temperature before work.
- Verify zero energy, then work and restore: Prove the isolation by trying to start the machine and testing for zero energy at the point of work against each source, then record the verification. After the work, refit guards, remove locks and tags in the correct order, and confirm the machine is clear before returning it to service.
In MapTrack, you can digitise safety inspections and compliance forms. Each submission is stored as a timestamped PDF against the asset record.
Get the free templateEnter your email above to download the full equipment isolation procedure template as a PDF.Back to download formHow often should you complete this service procedure?
Apply the isolation procedure every time a person needs to work on plant where unexpected start-up or the release of stored energy could cause harm, including maintenance, repairs, cleaning, clearing blockages and setting. It is used per task, not on a schedule, and a fresh isolation is performed for each job rather than relying on an isolation left in place from earlier work.
Review the written procedure for each machine when the plant changes, after any isolation-related incident or near miss, and at the regular interval set in your safety management system. New or modified plant should have its energy sources and isolation points confirmed during commissioning, so the procedure that maintainers rely on matches the machine in front of them rather than an earlier configuration.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- Work Health and Safety Regulation 2017, duties for proper use of plant controls and guarding (reg 206, reg 208)
- Safe Work Australia Code of Practice: Managing the risks of plant in the workplace (isolation and energy control before maintenance)
- AS 4024.1603 Safety of machinery, prevention of unexpected start-up
- AS/NZS 4836 Safe working on or near low-voltage electrical installations
- ISO 45001:2018 Occupational health and safety management systems
Embed this free template on your website
Run an industry blog, trade association site, or training resource? Drop a preview of this free equipment isolation procedure template straight into your page. The snippet is self-contained, needs no scripts, and links readers back to the full free template.
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<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#0E7490;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Equipment isolation procedure template</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Asset and task: machine, location, work to be done and the permit or work order number</li>
<li style="margin:4px 0;">Energy source register: every source present on the machine and where it is fed from</li>
<li style="margin:4px 0;">Electrical isolation: isolator or breaker, lock point, and the verified de-energised test</li>
<li style="margin:4px 0;">Mechanical isolation: stored springs, flywheels and moving parts restrained or blocked</li>
<li style="margin:4px 0;">Hydraulic isolation: valves closed, locked and pressure bled to zero at a gauge</li>
<li style="margin:4px 0;">Pneumatic isolation: air supply isolated, locked and residual pressure vented to zero</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/equipment-isolation-procedure-template" style="color:#071D49;font-weight:600;text-decoration:none;">Equipment isolation procedure template</a> by MapTrack</p>
</div>Please keep the “by MapTrack” attribution link in the snippet.
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