Worked examples of
real isolation procedures.
Equipment-specific lockout/tagout worked examples, grouped by industry, with the actual isolation-point structure each one needs. Free to read, free to download, no signup. They are examples to learn from — not documents to adopt.
Lockout is equipment-specific. So are these.
A generic checklist tells you to isolate, lock, tag and verify. It cannot tell you that a wind turbine's pitch UPS must stay live so the blades can be feathered, that a converter DC link holds stored energy after the grid disconnect opens, or that blade lightning receptors cannot be isolated at all. Each example below distinguishes the points you isolate from the points you must leave alone — because on real plant, that difference is the procedure.
Find the plant that looks like yours.
Each industry below has its own page on how Setyr addresses that work — what lockout actually looks like there, the failure modes that keep recurring, and which capabilities matter most. The worked examples filed under it are listed alongside. Some examples apply to more than one industry; where an example is filed elsewhere it is marked, because structure that carries across unrelated plant is the point rather than an accident.
Cells, conveyors and presses — where most LOTO citations come from.
Full energy isolation of RC-14 for weld gun tip change and reamer service. Entry into the cell.
Die change on a 450-ton hydraulic press. Covers accumulator stored energy, slide gravity restraint, and nitrogen gas-spring die cushions that have no lockable isolation device.
Capper head rebuild plus filler bowl internal inspection. Includes DP-1 depalletizer isolation and CO2 purge.
Anode replacement and tank entry on an electrocoat dip line. Covers the DC rectifier bus, the overhead conveyor carrying bodies over the tank, circulation and heat exchange, and the ventilation that must stay live in a solvent atmosphere.
Maintenance at a module stacking and busbar welding station on an EV battery pack line. Covers the packs themselves, which arrive charged and cannot be de-energised, alongside the laser welder, station power and the gas detection that stays live.
Turret tooling change on a high-containment rotary tablet press handling a potent compound. Covers compression pre-load, turret rotation, wash-in-place lines, and the pressure cascade that must hold throughout because it is the containment.
Sanitation, CIP and bowl entry — lockout under production pressure.
Capper head rebuild plus filler bowl internal inspection. Includes DP-1 depalletizer isolation and CO2 purge.
Belt repair inside an ammonia spiral freezer. Covers refrigerant pump-down, evaporator fan isolation, belt drive restraint and defrost hot-gas lockout. Ammonia charge brings 1910.119 alongside 1910.147.
Etch chambers, toxic gas and RF — isolation with a hazard on every line.
Full energy isolation of plasma etch chamber A for scheduled chamber wet clean. Cl2/BCl3 metal etch chemistry.
Pyrophoric gas cylinder change in a bulk specialty gas cabinet. Covers process line purge, excess flow and pigtail isolation, and the detection and exhaust systems that must stay live throughout.
Crushers, conveyors and stored energy at scale.
Full isolation of CR-101 for mantle change. Includes upstream CV-200 feed conveyor isolation per interlock requirement.
Vulcanised splice on a 2.1 km inclined overland conveyor. Covers gravity take-up restraint, belt runback holdbacks and the stored energy in a tensioned belt across multiple drive stations.
Annual haul rope inspection with tower sheave assembly change. ANSI B77.1. Evacuation drive must remain available throughout.
Nacelle, hub and the UPS that must stay live.
Nacelle gearbox inspection with hub entry for pitch bearing check. Rotor lock mandatory before hub entry.
Medium-voltage cable termination at a wind farm collector transformer. Covers backfeed from adjacent turbines on the same collector circuit, capacitive charge on the array cable, and earthing before contact.
Rigs, tanks and terminals — lockout alongside permits, not instead of them.
Full rig de-energisation prior to rig down and move. Spans SCR house, drawworks, top drive, mud pump, BOP and mast. Multi-shift.
Pressure relief valve replacement on a three-phase production separator in sour service. Covers double block and bleed, depressurisation, H2S purge and the protection that must remain in service while the relief path is open.
Weld repair to the 6in outlet nozzle on TK-401. NFPA 51B hot work. Fire watch 30 minutes after work stops.
Loading arm seal replacement at a gasoline truck rack. Covers product header isolation under static head, vapour recovery return, the grounding and overfill interlocks that must stay in service, and hot work in a vapour zone.
Master valve change on a two-phase geothermal production wellhead. Covers a reservoir that cannot be switched off, quench and kill lines, silica-scaled valves that may not seat, flashing brine and hydrogen sulphide.
Tanks, pumps and confined spaces — two standards on every entry.
Permit-required confined space entry into mud tank no.2 for cleaning and internal inspection. 29 CFR 1910.146.
Removing a submersible sewage pump from a wet well. Covers duty and standby pump isolation, discharge check valve backflow, and the confined-space atmosphere over a live wet well that keeps filling during the work.
Possessions, OLE isolation and earthing — lockout across a network.
Absolute possession of the Down Main for engineering work. PICOP-controlled. Includes 25kV OLE isolation and earthing.
Traction motor change on a road locomotive in the shop. Covers main generator excitation, head-end power at 480V, the battery bank that cannot be switched off, and movement restraint on a vehicle that is itself the hazard.
Hydraulics at 3,000 psi and a flight-control surface that moves.
B737-800 flap actuator change. ALL THREE hydraulic sources must be isolated - the flight controls are redundantly driven.
APU removal from the aft fuselage. Covers fuel feed isolation, bleed air, the APU battery and start contactor, fire bottle safing, and the ground services that must remain available while aircraft power is down.
Rides, LSM cabinets and public-facing restart.
Launch track LSM cabinet service. Includes transfer track isolation and capacitor bank discharge. ASTM F770 maintenance.
Maintenance inside a wave pool caisson and pump vault. Covers the pneumatic blowers that generate the wave, surge chamber stored pressure, entrapment at the pool interface, and the chemical dosing lines that keep running.
Robot cells, press lines and takt-time lockouts.
Anode replacement and tank entry on an electrocoat dip line. Covers the DC rectifier bus, the overhead conveyor carrying bodies over the tank, circulation and heat exchange, and the ventilation that must stay live in a solvent atmosphere.
Maintenance at a module stacking and busbar welding station on an EV battery pack line. Covers the packs themselves, which arrive charged and cannot be de-energised, alongside the laser welder, station power and the gas detection that stays live.
Full energy isolation of RC-14 for weld gun tip change and reamer service. Entry into the cell.
Die change on a 450-ton hydraulic press. Covers accumulator stored energy, slide gravity restraint, and nitrogen gas-spring die cushions that have no lockable isolation device.
Haul ropes, drive terminals and stored tension.
Annual haul rope inspection with tower sheave assembly change. ANSI B77.1. Evacuation drive must remain available throughout.
Grip conveyor and tyre bank service in a detachable chairlift terminal. Covers the main drive, the auxiliary and evacuation drives that can turn the line independently, hydraulic tensioning, and rope movement driven by carriers on the line.
Blinding, hot work and the permit that should wait for the isolation.
Weld repair to the 6in outlet nozzle on TK-401. NFPA 51B hot work. Fire watch 30 minutes after work stops.
Loading arm seal replacement at a gasoline truck rack. Covers product header isolation under static head, vapour recovery return, the grounding and overfill interlocks that must stay in service, and hot work in a vapour zone.
Containment, cleaning cycles and validated equipment that fights being opened.
Turret tooling change on a high-containment rotary tablet press handling a potent compound. Covers compression pre-load, turret rotation, wash-in-place lines, and the pressure cascade that must hold throughout because it is the containment.
Shelf stack and condenser service inside a production freeze dryer. Covers hydraulic shelf collapse, clean steam sterilisation heat, silicone thermal fluid at temperature extremes, refrigerant, and vacuum that must be broken before the door.
A reservoir that cannot be switched off, and valves that may not seat.
Master valve change on a two-phase geothermal production wellhead. Covers a reservoir that cannot be switched off, quench and kill lines, silica-scaled valves that may not seat, flashing brine and hydrogen sulphide.
Condenser entry and non-condensable gas system service on a geothermal steam turbine. Covers steam admission from a header shared with other units, vacuum, turbine overspeed on residual steam, and an H2S-rich NCG stream.
All 30 worked examples.
- PE-2200 Etch Chamber A — Wet Clean Isolation Semiconductor
- CR-101 Primary Crusher — Mantle Change Isolation Mining & aggregates
- RC-14 Robot Weld Cell - Weld Tip Change Isolation Automotive manufacturing
- FL-3 Filler - Capper Head Service and Bowl Entry Food & beverage
- RIG-27 Rig Down for Relocation Drilling
- RC-01 Thunderbolt — LSM Cabinet Service Amusement & attractions
- Possession — Down Main MP12.4 to MP15.8 Rail
- AMM 27-51 — Trailing Edge Flap Actuator Replacement Aviation MRO
- TRAM-1 — Haul Rope Inspection and Sheave Change Ropeway & tramway
- WTG-07 Gearbox Inspection and Hub Entry Wind energy
- MUD-T2 Confined Space Entry - Tank Clean and Inspect Water & wastewater
- TK-401 Nozzle Weld Repair - Hot Work Tank & terminal
- PR-450 Hydraulic Press — Die Change Isolation Metal forming
- SF-2 Spiral Freezer — Belt Repair Isolation Cold chain
- GC-7 Silane Gas Cabinet — Cylinder Change Isolation Specialty gas
- CV-300 Overland Conveyor — Belt Splice Isolation Bulk materials handling
- TX-04 Collector Transformer — Cable Termination Isolation Wind energy
- SEP-2100 Production Separator — Relief Valve Change Isolation Sour production
- LS-12 Lift Station — Submersible Pump Pull Isolation Wastewater collection
- LOCO-4412 Locomotive — Traction Motor and HEP Isolation Rail
- APU-131 Auxiliary Power Unit — Removal Isolation Aviation MRO
- WP-1 Wave Pool — Caisson and Pump Vault Isolation Aquatic attractions
- EC-1 E-Coat Dip Tank — Rectifier and Tank Entry Isolation Automotive paint
- BP-2 EV Battery Pack Line — Module Station Isolation EV battery
- LIFT-3 Detachable Chairlift — Terminal Grip Conveyor Isolation Ropeway & tramway
- LR-6 Truck Loading Rack — Loading Arm and Vapour Recovery Isolation Terminal loading
- TP-12 Tablet Press — Tooling Change and Containment Isolation Pharmaceutical
- LYO-3 Lyophiliser — Chamber Entry and Shelf Stack Isolation Pharmaceutical
- GW-14 Geothermal Production Well — Wellhead Valve Change Isolation Geothermal
- GT-1 Geothermal Turbine — Condenser and NCG System Entry Isolation Geothermal
These are examples. Your procedures are yours.
Under 29 CFR 1910.147(c)(4)(i) the employer must develop, document and use energy control procedures specific to their own machines, and under (c)(6) must inspect them at least annually. A vendor cannot take on that duty and a customer cannot delegate it. Every example here refers to equipment that does not exist, and each one deliberately omits the site-specific facts only you can supply.
Built by people who ran these procedures
Setyr is purpose-built for hazardous energy control — lock registries, group lockout, person-in-charge custody and a tamper-evident record. Not a checklist bolted onto a work order system.