Facilities within critical industries such as oil and gas, heavily rely upon machinery to carry out vital operations such as drilling, extraction, refining, transportation, and distribution. In addition to this, machinery enables operatives to handle heavy equipment, process raw materials, generate power, and execute complex tasks with precision.

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With such high reliance on these machines, it is of utmost importance that regular maintenance, repair, and servicing is carried out. This essential process involves scheduled inspections, repairs, and upkeep, to ensure workplaces can run as smoothly and safely as possible, without any interruptions or incidents.

But before these maintenance processes can begin, it is crucial to isolate all machinery using a lockout-tagout (LOTO) system. This ensures that the machinery is effectively shut down and all energy sources are disconnected or deactivated, preventing potential accidental energisation or start-up of machinery. The LOTO system involves the use of locks and tags to physically secure energy-isolating devices, such as switches, valves, or breakers, and communicate the status of the equipment to workers.

In this blog, we will explore the safety, environmental and efficiency benefits of using reusable cable lockouts for industrial machinery isolation processes.

What is a cable lockout?

Cable lockouts are a type of lockout device used to secure machinery or equipment during maintenance, repair, or servicing procedures. It is designed to provide a flexible and adaptable solution for isolating energy sources and preventing the unauthorised operation of machinery.

What are the benefits of resuable cable lockouts for industrial machinery isolation?

Reusable cable lockouts offer several benefits for industrial machinery isolation. Here are some key advantages:

1. Cost-effective: Reusable cable lockouts are a cost-effective solution compared to other types of lockout devices. Once purchased, they can be used multiple times, reducing the need for frequent replacements.
2. Versatility: Cable lockouts are highly versatile and can be used to secure a wide range of valves and industrial machinery, including electrical switches, circuit breakers, and various types of equipment. The adjustable cable length allows for customization to fit different sizes and shapes.
3. Ease of use: Cable lockouts are simple to use and require minimal training. They typically consist of a cable, a lock, and a locking mechanism. The cable is threaded through the energy-isolating point, and then the lock is secured to prevent the removal of the cable. This process can be quickly and easily repeated when needed.
4. Enhanced security: Reusable cable lockouts provide a high level of security. The cable is made of durable materials, such as non-conductive nylon or steel, which are resistant to tampering and cutting attempts. The lockout device itself often has a unique key or combination, ensuring that only authorised personnel can remove it.
5. Visual identification: Cable lockouts are usually brightly coloured, with highly visible labels or tags, making them easily recognisable. This helps to visually identify which energy sources are isolated and informs employees that maintenance work is being performed, promoting safety, and preventing accidental restarts.
6. Compliance with safety regulations: Many safety regulations and standards, such as OSHA (Occupational Safety and Health Administration) guidelines, require the use of lockout/tagout procedures to ensure the safety of workers during maintenance activities. Reusable cable lockouts help organisations comply with these regulations by providing an effective method for isolating energy sources.
7. Reduced inventory: Since reusable cable lockouts can be adjusted to fit various equipment, there is no need to maintain a large inventory of different-sized lockout devices. This simplifies the management of lockout/tagout equipment and reduces costs associated with inventory maintenance.
8. Environmental sustainability: By using reusable lockout devices, organisations contribute to environmental sustainability. The reduction in single-use lockout devices helps minimise waste and conserves resources.

Why use reusable cable lockouts from REGALTAG?

The Gardus® Cable Lockouts from REGALTAG offer numerous benefits as an effective and reusable lockout device for securing valves and isolators of all sizes. Here are the advantages of using Gardus® Cable Lockouts:

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1. Ease of use: The cable lockouts are designed with a user-friendly mechanism that can be easily tightened by hand, thanks to the ribbed edges. This makes it simple for workers to apply and remove the lockout device as needed. Additionally, multiple workers can attach their personal locks to the cable lockout, enhancing safety and accountability.
2. Secure clamping: The internal grip of the lockout device ensures a secure clamping of the cable, preventing any unintentional release or tampering. This feature adds an extra layer of security to the lockout process, assuring the isolation of energy sources.
3. Locking tool options: Gardus® Cable Lockouts offer locking tool options, including a compact thumb-turn mechanism. This allows for convenient and efficient locking and unlocking of the device, streamlining the lockout process.
4. Colour coding: The availability of different colours for the cable lockouts allows for easy colour coding of different applications. For example, red can be used to indicate a locked closed valve, while green can indicate a locked open valve. This visual identification system helps workers quickly understand the status of the equipment and ensures proper isolation.
5. UV resistance: Gardus® Cable Lockouts are UV resistant, meaning they can withstand exposure to ultraviolet (UV) light without degradation. This feature ensures that the colour coding remains vibrant and visible even in outdoor or sunlit environments, enhancing safety and efficiency.
6. Compatibility with lockout tags: Using Gardus® Cable Lockouts in conjunction with Locked Open/Closed Tags further enhances safety and communication. By attaching the appropriate tag to the cable lockout, it becomes clear to everyone involved whether the valve is locked open or closed, minimising confusion, and preventing accidental manipulation.
7. Durability and reusability: These cable lockouts are manufactured using durable fade-resistant materials and stainless-steel components. This ensures their longevity and resistance to environmental factors. The locks are fully reusable, allowing for multiple applications and providing ongoing cost advantages. By choosing a reusable lockout device, organizations contribute to environmental sustainability by reducing waste and conserving resources.
8. Rapid global delivery: With large quantities of Gardus® Cable Lockouts available, rapid deliveries can be made all over the world. This enables organizations to quickly obtain the necessary lockout devices to implement proper isolation procedures and maintain compliance with safety regulations.

Cable Lockout – How Does it Work

Having dealt with the pros and cons of using a Cable Lockout device to isolate valves in our first blog vis-à-vis metal chains and rigid plastic donut shaped devices, we now focus on how these devices work and the value it brings to your Lockout Tagout program.

A Cable Lockout device generally has a plastic body of different shapes (depending on the design). A PVC coated steel cable of varying diameters and lengths from 1.0 – 10 mtrs. is fixed at one end with the other end looping through valve wheel and body. Once slack is removed the free end returns back to the base unit in which it would be clamped by a mechanism. The mechanism is locked with one or more padlocks and prevents the clamped cable from being released until all padlocks are removed.

Not all Cable lockout devices are made from Plastic – Metal Cable lockouts are also popular and used in steam and other extreme ambient temperature applications where plastic body devices would be considered impractical. Metallic cable lockouts functions however do not differ in any way from their plastic counterparts.

Cable Lockout devices come in various shapes and designs, are lightweight and quickly deployed in the field. Popular cable lockout devices usually allow 3, 4 or more padlocks to be inserted and prevents removal from the energy source until all padlocks have been disengaged.

The following infographic explain how cable lockout works

Multiple designs are available depending on customer preferences. Local availability also plays an important role in the decision making process as end users would seek assurance on sufficient stock availability with distributors in their territory especially during plant commissioning and shutdowns.

* The author of this blog is Qaid Zohar – Director at LOTO Safety, Dubai.
This blog is written to educate interested parties on Lockout Tagout products.