Heavy Industrial Lockout/Tagout Master Procedure

This procedure defines the mandatory sequence of actions required to achieve and verify a zero-energy state on any heavy industrial machine connected to multiple energy sources (electrical, pneumatic, hydraulic, gravitational, spring-loaded). The procedure eliminates the risk of unintended energization or release of stored energy that could cause severe injury or fatality. It applies to all lockout/tagout events classified as Category 1 (complex) under the plant's energy control program.

Every isolation must comply with CSA Z460-20 ("Control of Hazardous Energy — Lockout and Other Methods") and the local jurisdiction's occupational health and safety regulations (e.g., WorkSafeBC OHS Part 10, Ontario Reg. 851). Deviations from this procedure require written authorization from the site safety manager and a documented risk assessment.

This SOP covers all heavy industrial equipment with two or more energy sources and/or stored energy potential — including but not limited to hydraulic presses (200+ ton), pneumatic conveyors, industrial robots, large-bore compressors, punch presses, shears, and multi-axis machining centres. It does not cover cord-and-plug connected equipment (Category 2) or tasks requiring only tagout without lockout — those follow separate streamlined procedures.

All trades personnel (millwrights, electricians, hydraulic technicians, operators performing setup) must be trained and authorized on this procedure before performing isolation. Training records are maintained by the safety department. Unauthorized personnel attempting lockout will be subject to disciplinary action under the company's energy control policy.

• LOTONever rely on machine controls alone — always open the visible disconnect and apply a personal padlock. The E-stop circuit is not an isolation device.
• LOTOVerify stored energy dissipation using a calibrated instrument before touching any component. For hydraulic systems, crack the bleed port slowly — never stand in front of the port.
• PPELOCKOne lock — one key — one worker. Each authorized worker uses their own keyed-different padlock. Master keys are prohibited except for emergency removal under documented supervision.
• GRPGroup lockout requires a lockbox with a hasp capacity ≥ 8 padlocks. Each worker removes their own lock only. The last lock removal triggers re-energization after a full walkaround.

• Personal padlock — keyed-different, 6-pin minimum, hardened steel shackle, laser-etched with worker ID and serial number.
• Group lockbox with hasp capacity ≥ 8 padlocks — steel construction, red powder-coated, with transparent lock-out verification window.
• Lockout tag — UV-resistant laminated vinyl, pre-printed with name, photo, date, reason, and expected return time.
• Voltage tester — CAT III / 1000V rated, with self-test function, verified within 30 days (sticker affixed).
• Zero-energy verification probe — mechanical pin for pneumatic/hydraulic port verification plus pressure gauge (0–3000 psi, calibrated annually).
• Insulated valve shroud or chain-and-lock kit for ball valves and gate valves.
• Machine-specific LOTO decal — red-border decal affixed to main disconnect showing all isolation points, energy types, and bleed locations.
• Z460-compliant isolation checklist form — paper or digital (SafeDesk) with sign-off boxes for each isolation point.