Lockout device

Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures ... 

Are lockout devices affixed so as to hold the energy isolating device in a safe or off position ... 

The valve was operated by compressed air, and the two air hoses, one to open the valve and one to close it, were connected up the wrong way around. The two connectors should have been different in size or design so that this could not occur. In addition, they were not disconnected, and a lockout device on the valve—a mechanical stop—had been removed. It is also bad practice to carry out work on equipment isolated from hot flammable gas under pressure by a single isolation valve. The take-off branch should have been slip-plated, and double block and bleed valves should have been provided so the slip-plate could be inserted safely (Figure 1-1), [16, 17]. 

The accident investigation evidence showed that this safe procedure was not followed specifically, the product takeoff valve was removed, the DEMCO valve was in the open position, and the lockout device was removed. This scenario was a serious violation of well-established and well-understood procedures and created the conditions that permitted the release and subsequent explosion. 

Different security products are available to protect aboveground versus belowground valves. For example, valve lockout devices can be purchased to protect valves and valve controls located aboveground. Vaults containing underground valves can be locked to prevent access to these valves. 

As described above, a lockout device can be used as a security measure to prevent unauthorized access to aboveground valves located within chemical processing systems. Valve lockout devices are locks that are specially designed to fit over valves and valve handles to control their ability to be turned or seated. These devices can be used to lock the valve into the desired position. Once the valve is locked, it cannot be turned unless the locking device is unlocked or removed by an authorized individual. 

Many of these lockout devices are not specifically designed for use in the chemical industry (e.g., chains, padlocks) and are available from a local hardware store or manufacturer specializing in safety equipment. Other lockout devices (for example, valve-specific lockouts or valve box-locks) are more specialized and must be purchased from safety or valve-related equipment vendors. 

The three most common types of valves for which lockout devices are available are gate, ball, and butterfly valves. Each is described in more detail below. 

Butterfly valve lockouts. The butterfly valve lockout functions in a similar manner to the ball valve lockout. The polypropylene lockout device is placed over the valve handle and secured with a padlock. This type of lockout has been commonly used in the bottling industry. 

A major difference between valve-specific lockout devices and the padlocked chain or cable lockouts discussed earlier is that valve-specific lockouts do not need to be secured to an anchoring device in the floor or the piping system. In addition, valve-specific lockouts eliminate potential tripping or access hazards that maybe caused by chains or cable lockouts applied to valves located near walkways or frequently maintained equipment. 

The DEMCO valve did not have its lockout device in place. 

Computer software was able to trigger the controlled equipment into operation despite the fact that the hardwired fail-safe lockout device had been activated. 

Lockout is the process of turning off and locking out the flow of energy from a power source to a piece of equipment or a circuit, and keeping it locked out. Lockout is accomplished by installing a lockout device at the power source. 

Portable and organized storage of frequently used lockout devices helps assure compliance. Exclusively from Master Lock. 

Master Lock Company offers a complete line of Safety LockoutTagout (LOTO) products to complement the full range of Master Lock and American Lock safety padlocks. The exclusive Master Lock Safety Series (www.safetyseries.com) line of LOTO accessories includes innovative, patented and patent-pending lockout devices that are easy to use and cost-effective. 

Specific procedural steps for the placement, removal, and transfer of lockout devices or tagout devices and the responsibility for them... 

Lockout— The placement of a lockout device on an energy-isolating device, in accordance with an established procedure, ensuring that the energy-isolating device and the equipment being controlled cannot be operated until the lockout device is removed. 

Lockout device— A device that utilizes a positive means (such as a lock, either key or combination type) to hold an energy-isolating device in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds. 

A single lockout device will achieve a locked-out condition. 

The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance. 

Remove the lockout devices and re-energize the machine or equipment. The employee who applied the device will remove each lockout/tagout device from each energy-isolating device. 

Where several maintenance persons work on the same machine, are multiple lockout devices used ... 

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Portable kit brings necessary lockout devices to the jobsite... 

Panduit announced that they now offer a complete line of lockout devices for electrical circuit breakers. This is part of Panduit s Complete Safety System, which includes lockout devices for electrical and mechanical energy sources, safety signage, facility identification products, and training aids to assist with OSHA compliance. Visit Panduit at www.panduit. com/safety for more information. Booth 1156. Circle 128... 

In very rare cases, a power source cannot be physically locked out. Tagout devices may be used in lieu of lockout devices only if the tagout program provides employee protection equivalent to that provided through a lockout program. 

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