Free equipment isolation procedure template

• The MapTrack equipment isolation procedure template contains 13 checks across 2 sections. Sections covered: Step 2 to 4: Isolate, lock and tag, then dissipate or restrain stored energy for each source, Step 5: Verify zero energy at the point of work before any guard is removed.
• 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.

Learn more about compliance and inspections in MapTrack.

• 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.

• 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

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• Work Health and Safety Regulation 2025 (NSW), duties for proper use of plant controls and guarding (s206, s208)
• 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

• Model Code of Practice: Managing risks of plant in the workplace (Safe Work Australia)
• Model WHS Regulations (Safe Work Australia)
• ISO 45001:2018, Occupational health and safety management systems (ISO catalogue)
• AS 4024 series, Safety of machinery (Standards Australia listing)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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