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Lockout/Tagout Device Design for 2-Way Valve

National Renewable Energy Laboratory

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Technology Marketing Summary

Energy sources such as electrical, mechanical, hydraulic, pneumatic, chemical, and thermal in machines and equipment can be hazardous to workers because there is a chance of unexpected energization. The Occupational Safety and Health Administration (OSHA) has standardized lockout/tagout procedures to prevent the unexpected startup or release of stored energy during the servicing and maintenance of machines and equipment. However, there is a need to make following these procedures easier, as an estimated 50,000 people are injured and 120 people are killed each year due to not properly following lockout/tagout procedures when servicing equipment containing stored energy.


In order to increase the safety of our workers, scientists at the National Renewable Energy Laboratory (NREL) have developed a recessed lockout/tagout device design for common 2-way valve designs to meet OSHA standard 29 CFR § 1010.147. A unique function of this device is the precise nesting of the handle to prevent activation of the valve and the ability to view the handle position to verify isolation of energy. Furthermore, a multi-size nested design is possible for future designs, allowing multiple valve sizes to be securely locked out with one device. There are devices currently on the market to achieve lockout for two-way valves; however, this device has significantly improved on those that are commercially available by employing a more compact and precise fit, while enabling a more lucid and fail-safe user interface. Internal testing at NREL of the proposed accessory indicated servicing these machines will be safer and will make compliance with the OSHA requirements easier.

  • Precise nesting of the handle prevents activation of the valve
  • Compact, easy-to-use design
  • Ability to visually verify valve positioning
Applications and Industries
  • Safety
  • Hazardous energy
  • Electrical
  • Gas
  • Steam
  • Water
  • Petroleum
  • Pharmaceuticals
  • Semiconductor/Microelectronics
  • Food manufacturing
Patents and Patent Applications
ID Number
Title and Abstract
Primary Lab
Application 20170130865
Valve Security Device
A device includes a control cover having a body portion with a first surface. The control cover also has at least one cavity in the first surface. The control cover may include a plurality of prongs, each of which extends, from the first surface, along a respective axis that intersects the first surface. At least one prong of the plurality of prongs includes a respective aperture configured to receive a locking mechanism. The control cover may include a compressible material disposed within the cavity that fills at least a portion of the cavity. The control cover may include at least one aperture configured to receive at least one locking mechanism.
Technology Status
Technology IDDevelopment StageAvailabilityPublishedLast Updated
NREL ROI 15-95DevelopmentAvailable12/16/201512/16/2015

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To: Jean Schulte<>