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FORMERLY LOCKOUTDISC.COM

"The original disc" lockout device that not only locks ball valves securely closed or open,
but will also lock gate valves securely closed or open.
This is a ball valve lockout device, and a gate valve lockout device.

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The red disc on the left is the plastic version. The gray disc on the right is the stainless steel version. Both discs are fully compliant with federal and state level OSHA standards, but the stainless version is much harder to cut through, and will withstand temperatures in excess of 180° Fahrenheit (82° Celsius). The plastic version is recommended for use on compressed air, natural gas, domestic hot and cold water, most radiant floor heating, and some hydraulic systems, but is not recommended for applications that would exceed 180° F. (ABS plastic will start to distort at 186° F/85° C). The stainless version is recommended for techs that would likely use this daily, in a high temperature environment, or where vandalism is a concern. When in doubt, check the system temperature.

This is a ball valve lockout device.

This device differs significantly from other ball valve lockout devices. Some brands only lock valves closed. Some brands won't fit over insulated valves/lines. Some brands won't fit over cast iron or goofy shaped handles. Some brands tighten onto and can damage your valve handles. Some brands can be pried off with a screwdriver. Some brands have multiple parts that can break or disappear. Some brands have multiple sizes and/or accessories needed to encompass the same spectrum of ball valve sizes that one of these discs will cover. And some brands do not prevent cracking the line open (vandalism). The plastic version of this device covers most of these, and the stainless version covers all but one (cast iron or goofy shaped handles), but both can be drilled out to fit them.

This device covers standard manual ball valve sizes up to 4 inch diameter (line size). No, you're not dreaming, and that's not a typo. For most shops, that means one size fits all. And by adding an adequate length of chain, this device will also work on any manual ball valve over 4 inches in diameter.

This device may be used to lockout any standard manual ball valve in the off position in which a slot in the disc will fit over the valve handle, and the chain will reach around the valve body.

This device may be used to lockout any standard manual ball valve in the on position in which the chain will fit between the valve handle and the valve body, and the chain will reach around the valve stem (handle pivot) and the valve body.

The stainless version of this device was designed to prevent tampering (not just suggest it). When properly installed, removal of this device would require the use of a cutting torch, bolt cutters, hacksaw, or if attainable, significant leverage that would likely break the valve before breaking the device. The chain can also be wrapped tightly enough around the valve body (and valve stem) of an insulated line valve for a quick, secure lockout. (The stainless version of this device is ideal for anti-theft and anti-vandalism use at Anhydrous Ammonia and LP-Gas dispensing stations.)

The weakest link on the stainless version of this device is a stainless steel split ring made by the Worth Co. (pressure tested to withstand 65 to 95 ft. lbs., depending on where the pressure points are applied to the ring).

The weakest link on the plastic version of this device is a nylon push mount cable tie made by Micro Plastics, Inc. (pressure tested to withstand 50 ft.lbs., the minimum required by OSHA for a lockout/tagout attachment means).

Note: The standard length of chain that is mounted on both plastic and stainless versions of this device is 24 inches long.

This is a gate valve lockout device.

This device covers standard manual gate valve sizes up to 4 inch diameter (line size) that have standard length or short handle stems. For most shops, that means one size fits all. And by adding an adequate length of chain, this device will also work on any manual gate valve over 4 inches in diameter.

This device may also be used to lockout any standard manual gate valve in the on or off position in which the chain will reach around the valve body and then around the valve stem, and the hasp jaws will fit thru one of the valve handle holes.

Both plastic and stainless versions of this device are secured with #3 welded straight link machine chain. When properly used, this device was designed to last a lifetime.

The disc is currently being cut from 1/8 inch ABS plastic engraving stock and 14 gauge stainless steel. If you have a special application that would require the disc to be larger than 6 inches in diameter, made from an environmentally specific material, or would like us to cut your disc(s) to fit over a specific valve handle, please contact us.

LOCKOUT DISC INSTALLATION INSTRUCTIONS
(BALL VALVE OFF POSITION, HANDLE GOES THRU A SLOT IN THE DISC)
USED FOR INADVERTENT POWER-UP AND ANTI-VANDALISM

BALL VALVES UP TO 4 INCH DIAMETER (LINE SIZE)
Note: The slots in this disc are offset to the left because the majority of valves rotate clockwise to close as shown. You may feed the chain thru 1 of the 2 large round "handle" holes in the disc and use the disc from the other side for valves that rotate clockwise to open and counterclockwise to close.

1. Close the valve. With the chain side of the disc facing the valve, slide the smallest slot that will fit over the valve handle (blue), and place the chain (yellow) as shown. Note: The valve handle in this drawing moves clockwise (looking down at it) to close. If your handle closes counterclockwise, the chain would go to the left of the valve stem (green).

2. Wrap the chain to the left (clockwise looking down at it) across the valve stem and the valve body/line (brown) as shown. If handle closes counterclockwise, chain would wrap to the right.

The disc slot fits loosely around the handle. Pulling the chain taut will tighten the handle against the left side of the slot, right side of the slot for handles that close counterclockwise. Pull the chain taut.

Note: Removing all of the chain slack will make it impossible to move the valve handle enough to crack the valve open. Removing all of this slack is not important in an environment where only employees trained in lockout will be present. If you are going to use this device to guard against vandalism, see additional instructions under anti-vandalism to secure it with all of the slack removed.

3. The disc has 12 holes around its outside perimeter. From the backside of the disc, place one jaw of the 6-lock hasp through the hole immediately below the line on the left all the way up to the hasp pivot, on the right for handles that move counterclockwise to close. While holding the chain taut toward the hasp and the hasp toward the chain, slip the tip of the hasp jaws through the chain link they line up with by closing the hasp. Apply employee(s) lock(s). 

BALL VALVES OVER 4 INCH DIAMETER (LINE SIZE)
If the handle of the valve will fit thru a slot in the disc, and the disc can be secured against the side of the valve body by pulling the chain taut as shown in the instructions above, follow the instructions above. If not, add a sufficient length of chain to the existing chain, and follow the instructions below.

1. Close the valve. Feed the chain thru 1 of the 2 large round "handle" holes in the disc. Before closing the loop of chain against the side of the disc, slip the loop over the top of the valve handle with the disc against the bottom or underside of the valve handle, and the loose end of the chain hanging down towards the off position. Gently pull the chain taut downward and slightly toward the off position. Be careful not to accidentally bump open the valve. Then slide the disc under the valve handle toward the valve stem until the edge of the disc stops against the valve stem or the top of the valve body near the valve stem.

2. Pull the chain parallel to the valve handle toward the valve stem immediately above the valve body, then pull the chain down against the valve body, wrapping it half way around the valve body until it touches the outside tip of the valve handle.

3. Slide the loop of chain lying against the valve body away from the valve stem until it hops down over the line connection. (This will be the point at which the handle will be secured to.) Then wrap the end of the chain once around the tip of the valve handle (where the valve handle extends past the edge of the disc) and fasten the chain to the nearest outside parameter hole in the disc with the hasp. Attach employee(s) lock(s).


LOCKOUT DISC INSTALLATION INSTRUCTIONS
(BALL VALVE ON POSITION, HANDLE LAYS FLAT AGAINST SIDE OF DISC)
USED FOR BYPASSES, INADVERTENT SHUTDOWN, AND ANTI-VANDALISM

BALL VALVES UP TO 4 INCH DIAMETER (LINE SIZE)

1. Open the valve. With the chain side of the disc facing the valve, slide the chain between the valve handle, and the valve body/line as shown. Note: The valve handle in this drawing moves counterclockwise (looking down at it) to open. If your handle moves clockwise to open, and it is on the left as shown, the disc would go against the front of the valve with the chain extending thru to the back. 2. Wrap the chain to the right (counter-clockwise looking down at it) across the valve stem and the valve body/line as shown. If handle opens clockwise, chain would wrap to the left.  


3. While holding the chain taut, pull the chain up between the disc and the valve body/line on the right as shown, on the left for handles that open clockwise.
4. While continuing to hold the chain taut, lift the chain straight up and slide the loop that wraps around the valve body toward the valve stem. Pull the chain down on the right side of the valve stem, then over the valve stem to the left as shown (down on the left and over to the right for handles that open clockwise). Attach hasp and lock(s) in the hole immediately above the line as shown and described in step 3 of off position lockout.
BALL VALVES OVER 4 INCH DIAMETER (LINE SIZE)
If the disc can be secured against the side of the valve body by pulling the chain taut as shown in the instructions above, follow the instructions above. If not, add a sufficient length of chain to the existing chain, and follow the instructions below.

1. Open the valve. Feed the chain thru 1 of the 2 large round "handle" holes in the disc. Before closing the loop of chain against the side of the disc, slip the loop over the top of the valve handle with the disc against the bottom or underside of the valve handle, and the loose end of the chain hanging down towards the on position. Gently pull the chain taut downward and slightly toward the on position. Then slide the disc under the valve handle toward the valve stem until the edge of the disc stops against the valve stem or the top of the valve body near the valve stem.

2. Pull the chain parallel to the valve handle directly across the valve stem immediately above the valve body, and wrap the chain one quarter turn around the valve stem, then once around the valve body until it touches itself.

3. Move the loose end of the chain toward the disc (along the part of the chain held taut between the disc and the valve stem). Then fasten the chain to the nearest outside parameter hole in the disc with the hasp. Attach employee(s) lock(s).


LOCKOUT DISC INSTALLATION INSTRUCTIONS
GATE VALVE OFF AND ON POSITIONS,
AND ANTI-VANDALISM

GATE VALVES UP TO 4 INCH DIAMETER (LINE SIZE)

Locking a gate valve off or on follows the exact same instructions as locking a ball valve on, with the exception of one change on step number 4. Refer to "BALL VALVE ON POSITION" above, then change number 4 as follows: 

LOCKING THE VALVE OFF (Confirm the valve is closed) - Instead of pulling the chain down on the right side of the valve stem, move the chain (and the loop of chain that is under the valve body) to the left, between the disc and the backside of the valve body/stem. When the chain touches itself, pull the chain away from the disc and wrap it to the right in front of the valve stem (counter-clockwise looking down at the face of the handle). While keeping the chain taut, lift the chain until it touches the valve handle. Then connect the chain to a hole in the valve handle with the hasp. Attach employee(s) lock(s).

Note: Gate valves can also be cracked open if you leave too much slack in the chain. However, the slack is easier to minimize on a gate valve installation than on a ball valve installation because the valve handle holes are closer together than the perimeter holes in the lockout disc. 

LOCKING THE VALVE ON (Confirm the valve is open) - Instead of connecting the chain to the disc with the hasp, you wrap the chain around the valve stem (clockwise looking down at the face of the handle), between the disc and the valve stem. One complete revolution around the valve stem will bring the chain back to the front of the valve stem. While keeping the chain taut, lift the chain until it touches the valve handle. Then connect the chain to a hole in the valve handle with the hasp. Attach employee(s) lock(s).

GATE VALVES OVER 4 INCH DIAMETER (LINE SIZE)

If the disc can be secured against the side of the valve body by applying the instructions above, follow the instructions above. If not, add a sufficient length of chain to the existing chain, and follow the instructions below.

1. Confirm the valve is open or closed. Feed the chain thru a hole in the valve handle toward the valve and pull the chain taut so the disc lies flat against the face of the valve handle.

2. Wrap the chain half way around the valve stem in the same direction that you turned the valve handle to open or close the valve.

3. Wrap the chain once around the valve body (in either direction) and fasten the chain to itself with the hasp. Attach employee(s) lock(s).

ANTI-VANDALISM

The only way to ensure the valve handle cannot be moved enough to crack the line open (valve stem rotated enough to allow a trickle of fluid to pass through the valve), is to remove all of the slack in the chain. This is important only when the valve is locked off or closed.

In many applications, the instructions already shown will allow you to pull the chain and hasp taut enough to prevent cracking the line. Before implementing the anti-vandalism instructions, try the following to remove any slack in the chain:

1. Try the entire installation procedure one more time with the chain held taut through the entire process.

2. Make sure the hasp jaws (when closed) are tight against the inside edge of the last chain link used. In other words, make sure the first chain link not used is not between the hasp jaws and the inside edge of the last link used.

There are many different configurations in which to effectively lock a valve on or off with this device. Some ball valves lock on or off tighter by placing the chain straight across the valve stem above the line, but below the swing path of the valve handle. However, if the valve is locked off or closed, there is still too much slack in the chain, and vandalism is a concern, properly executing the following procedure will remove all of the slack.

PHYSICS 101

Twisting chain will shorten it. The chain may be twisted in half turn increments, and the longer the section of chain, the shorter the distance between increments when twisted. In other words, you will get a finer adjustment per half turn (less shortening of the chain), the longer the piece of chain.

Below is diagram 3 from off position lockout. If the chain goes slack enough to crack the line, repeat this step in the next hole above the one you tried first by wrapping the chain up under the line. If the chain still goes slack, move up another hole. Stop at the hole that leaves no slack. If you reach full vertical position with the chain (as in diagram 4) and there is still slack, put a half turn in the chain. If there is still slack, give the chain another half turn. And so on, until taut. If one half turn adjustment shortens the chain too much, move back to the previous hole and adjust the amount of half turns necessary to remove slack.

   
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Every Disc shipped includes:
One (1) 6-lock hasp made by the Master Lock Company.
NOTE: Locks are not included
.
 
Lock(s) should be purchased locally. Regulations require lockout locks to be standardized within the facility in color, shape or size; and to indicate (tag, sticker or stamping) the identity (name or number) of the employee to which it is assigned. Your local locksmith or hardware store is better equipped to customize the lock(s) initially, and also when replacement or additional locks and/or keys will be necessary.

Disc is plastic, chain is steel and the connector is nylon. Disc diameter is approximately 6 inches, and the chain length is approximately 24 inches. Disc is shipped with removable protective covering.

Disc is stainless, chain is steel (not stainless) and the connectors are a steel clevis pin and stainless split ring. Disc diameter is approximately 6 inches, and the chain length is approximately 24 inches.