Buying lockout devices can be complicated and expensive without a plan. Purchasing the wrong devices can ruin a budget and potentially leave out devices that are necessary for safety. An efficient way to order devices is to first inventory what is already owned and make a list of what is needed. These two lists, along with knowing the number of employees and work areas, will give an accurate count of how many devices should be ordered.
The first step to purchasing the correct devices is to gather up the current devices in stock. Any damaged or unusable devices should be properly disposed of or recycled. Additionally, OSHA 1910.147 states that devices must be standardized by either having the same color, size, or shape. The industry recommendation is all red devices and locks for lockout-tagout; if the current inventory of lockout devices is not standardized, it is required to choose one type as the standard and dispose of or repurpose the remaining inventory if possible. Knowing what devices are present will prevent the purchase of duplicates and reduce the overall cost of compliance. For example: If 20 consistent padlocks are already in stock and there is a need for 100, only more 80 padlocks will need to be ordered rather than 100 new locks.
After an inventory has been completed, an assessment of the equipment valve and electrical disconnect types needs to be done. The equipment assessment should also be used to note what devices can be used to lock out these sources. When deciding on what device to use, it is important to consider if a valve can use multiple devices to lock it out. The most obvious device choice may not be the most practical. For example:
A large gate valve may accept a 10-13” gate valve device but it may be more practical to use a cable device or chain & padlock.
Ball valve & gate valve devices come in different sizes and styles; it may be necessary to purchase a variety of devices.
Thick pipe insulation may inhibit the use of certain devices; a cable device may be the only workable solution.
Circuit breaker devices need to be purchased based on size and breaker style.
Some valves may be designed to accept a padlock, eliminating the need for a device.
It is possible to save money by choosing to use universal devices over valve specific devices. For example, ball valves, gate valves, and butterfly valves all have devices specifically designed for them; however, a cable device will work for all three types.
The final step is to decide how many devices to purchase based off the inventory and equipment assessment. In general, plan on assigning 5-10 locks to each maintenance personnel and buying extra locks for large lockouts. It is also recommended to buy lockout stations to make the lockout devices more accessible. It is recommended the lockout stations be placed in high traffic and high visibility areas such as main production areas, maintenance shops, and roof access. Placing lockout stations in high visibility areas will encourage employees to use the devices rather than ignore them. Device stations should contain around 10 locks, multiple tags, and any other devices needed in that area.
In summary, without proper planning, the purchasing of lockout devices can be a complicated and expensive endeavor. Spending the time to inventory, assess, and plan will pay off when the correct devices are ordered the first time.
ESC makes the process simple by not only reviewing a company’s specific inventory, but assessing the actual needs and usage to recommend the proper quantity, type and placement of device stations to optimize the effectiveness and efficiency of a lockout-tagout program. To explore assistance with your lockout-tagout needs, contact ESC today for a no complimentary program consultation and review.
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