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Description Valves are utilized as control elements in water and wastewater process piping networks. They regulate the flow of both liquids and gases by opening, closing, or obstructing a flow passageway. Valves are typically located where flow control is necessary. They can be located in-line or at pipeline and tank entrance and exit points. They can serve multiple purposes in a process pipe network, including:
- Redirecting and throttling flow;
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Preventing backflow;
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Shutting off flow to a pipeline or tank (for isolation purposes);
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Releasing pressure;
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Draining extraneous liquid from pipelines or tanks;
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Introducing chemicals into the process network; or
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As access points for sampling process water.
Valves are located at critical junctures throughout water and wastewater systems, both on-site at treatment facilities, and off-site within water distribution and wastewater collection systems. They may be located either aboveground or below ground. Because many valves are located within the community, it is critical to provide protection against valve tampering. For example, tampering with a pressure relief valve could result in a pressure buildup and potential explosion in the piping network. On a larger scale, addition of a pathogen or chemical to the water distribution system through an unprotected valve could result in the release of that contaminant to the general population.
Different security products are available to protect aboveground vs. below ground 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. This Product Guide will focus on security for aboveground valves. A separate Product Guide covers security for underground valves.
As described above, a lockout device can be used as a security measure to prevent unauthorized access to aboveground valves located within water and wastewater 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 operated. 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.
Various valve lockout options are available for municipal and industrial use, including:
- Cable lockouts;
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Padlocked chains/cables;
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Valve-specific lockouts; and
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Valve box-locks.
Many of these lockout devices are not specifically designed for use in the water/wastewater industry (i.e., 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. Attributes and Features
Cable Lockout |
Cable Lockouts A cable lockout is a section of cable with an attached locking device. Depending on the valve configuration, the cable lockout is looped around or through the spokes of the valve handle, then through another part of the piping system or to an anchoring device in the floor, and finally back through the attached lock. The cable can be pulled tight so that the tension on the cable prevents the handle from being turned. For maximum security protection, cable lockouts can be manufactured from coated, braided steel, which is highly resistant to cutting. Padlocked Chains/Cables Padlocked chain/cable valve lockouts work in very much the same fashion as cable lockouts, except that they do not have an integrated locking device. Instead, they must be secured with a separate padlock. The chain/cable is looped around or through the spokes of the valve handle, and is then secured to another part of the piping system or to an anchoring device in the floor. The chain/cable can be pulled tight and secured with the padlock so that the tension on the chain/cable prevents the handle from being turned. Chains and cables are available in a wide variety of shapes and strengths, and are most easily purchased through a local hardware store. Hardened steel cables and chains are manufactured for security applications. They are designed to be wear and cut resistant, and to provide a long service life. Valve-Specific Lockouts Valve-specific lockout devices are self-contained lockouts that are typically used to cover the valve handle to prevent its rotation, which, in turn, prevents the opening or closing of the valve. They are placed over the valve handle and secured in place with a separate padlock.
Valve-specific lockout devices are typically similar in design, although they may have minor variations according to the type of valve being locked. They are typically manufactured from polypropylene, so they are nonconductive. Other design specifications include corrosion-resistance (to protect them from potential chemical or solvent spills), temperature-resistance (typically to temperatures of up to 360?F), and weather-resistance.
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.
- Gate Valve Lockouts - Gate valve lockouts are designed to fit over the operating hand wheel of the gate valve to prevent it from being turned. The lockout is secured in place with a padlock. Two types of gate valve lockouts are available: diameter-specific and adjustable. Diameter-specific lockouts are available for handles ranging from 1 inch to 13 inches in diameter. Adjustable gate valve lockouts can be adjusted to fit any handle ranging from 1 inch to 6 ? inches in diameter.
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Ball Valve Lockouts - There are several different configurations available to lock out ball valves, all of which are designed to prevent rotation of the valve handle. The three major configurations available are a wedge shape for 1 inch to 3 inch valves, a lockout that completely covers 3/8 inch to 8 inch ball valve handles, and a universal lockout that can be applied to quarter-turn valves of varying sizes and geometric handle dimensions. All three types of ball valve lockouts can be installed by sliding the lockout device over the ball valve handle and securing it with a padlock.
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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.
Gate Valve Lockout |
Butterfly Valve Lockout |
Ball Valve Lockout |
A major difference between valve-specific lockout devices and the padlocked chain or cable lockouts discussed above is that they 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 may be caused by chains or cable lockouts applied to valves located near walkways or frequently maintained equipment.
Valve-specific lockout devices are available in a variety of colors, which can be useful in distinguishing different valves. For example, different colored lockouts can be used to distinguish the type of liquid passing through the valve (i.e. treated, untreated, potable, chemical), or to identify the party responsible for maintaining the lockout. Implementing a system of different-colored locks on operating valves can increase system security by reducing the likelihood of an operator inadvertently opening the wrong valve and causing a problem in the system. Padlocks As described above, padlocks are required for securing several different types of valve lockout devices. Padlocks are available in a variety of sizes and strengths, and with a number of different locking mechanisms (for example, keyed or numerical combination padlocks). Maximum-security padlocks are manufactured with a hardened boron alloy shackle and laminated steel body for strength and cut resistance. More specific information on padlocks is available from the Locks Product Guide.
Controlling the padlocks and implementing an effective key control process is essential in ensuring that the system is adequately protected. Key control includes tracking which keys can open which locks and ensuring that authorized personnel receive the correct keys for the locks for which they are responsible. There are three general types of keying strategies when multiple valves are locked in a system. These are:
- Keyed-alike systems;
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Master-keyed systems; or
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Individually-keyed padlocks.
In keyed-alike systems, all the locks can be opened with the same key. In a master-keyed system, groups of locks can be opened with the same key. For example, locks could be individually keyed so that each individual would be responsible for his/her own padlock; groups of padlocks could be keyed alike so that only employees in a single group (for example, maintenance personnel) could access a specific group of padlocks; or all of the padlocks in a facility, whether individually- or group-keyed, could be opened by a single master key. In an individually-keyed padlock system, there is no master key, and all of the locks must be opened with their own key.
As with valve-specific lockouts, padlocks are available in different colors. Utilities can use different-colored valve locks to identify specific valves, which can enhance security as described in the Valve-Specific Lockout discussion above.
McGard's Intimidator Valve Box-
LockTM |
Valve Box-Locks Unlike the other types of lockout devices described above, which are designed to prevent a valve handle from being turned, valve box-locks are used to fully enclose the valve and prevent unauthorized access to the valve and its connection points. For example, McGard's Intimidator Valve Box-LockTM is designed to enclose both the shutoff valve and the coupling nut, thereby preventing tampering with the shutoff valve. The Box-LockTM consists of two 16-gauge steel pieces that are fastened around an existing straight through- or right angle valve using a specialized locking screw. The screw can only be removed using a specially coded T-key, which is provided by the manufacturer. Installing the box is relatively easy and no modifications are required to the existing valve. Cost Valve lockout devices are generally low cost, and thus locking out the valves in a system can be a relatively inexpensive means of protecting water and wastewater process and distribution/collection systems. Table 1 summarizes costs for several lockout devices. Table 1: Valve Lockout Costs | Lockout Device | Cost | Padlocks:
Keyed
Combination |
$6 - $12
$20 | | Cable lockout | $15 - $35 | | Cables and Chains | $2 - $20 per foot | | Ball valve lockout | $25 - $75 | | Butterfly valve lockout | $85 | | Gate valve lockout | $30 - $100 | Valve box-lock
Coded T-key | $25 - $35
$12 |
Cost information provided by emedco and McGard Inc.In addition to their low costs, valve lockouts are easy to acquire and implement. Some types of lockouts, such as chains and padlocks, can be easily purchased at local stores. Other lockouts can be obtained through the internet. The lockouts can be installed easily with minimal labor hours because they do not typically require any modification to the existing valve. Vendors
Disclaimer: The information provided in this guide does not constitute an endorsement by the Environmental Protection Agency of any non-Federal entity, its products or its services. In addition, EPA does not endorse the vendors and products listed on this site. EPA is publishing lists of vendors on this site in an effort to further public awareness of vendors identified as possible contacts for further information and possible purchase of the different types of security equipment. The Agency has selected the listed vendors on that basis. The list of vendors is not a complete list, and EPA does not endorse the products or services of these vendors. McGard, Inc.
3875 California Road
Orchard Park, New York 14127-4198
(716) 662-8980
www.mcgard.com
| emedco
P.O. Box 369
Buffalo, New York 14240
(800) 442-3633
www.emedco.com
| North Safety Products
2000 Plainfield Pike
Cranston, Rhode Island 02921
(800) 430-4110
www.northsafety.com
| USA BlueBook
PO Box 9004
Gurnee, Illinois 60031-9004
(800) 548-1234
www.usabluebook.com
| Prinzing Enterprises, Inc.
30W 196 Calumet Avenue
Warrenville, Illinois 60555
(800) 292-2914
www.prinzing.com
| Sharpe Safety Supply, Inc.
PO Box 3477
Chester, Virginia 23831
(804) 796-4777
www.sharpesafety.com
| Smith Flow Control (USA)
21 Kenton Lands Road
Erlanger, Kentucky 41018
(859) 578-2395
www.smithflowcontrol.com
| Regulatory Consultants, Inc. (RCI)
140 West 8th Street
Horton, Kansas 66439
(800) 888-9596
www.rci-safety.com
| Swagelok Company
29500 Solon Road
Solon, Ohio 44139
(440) 248-4600
www.swagelok.com
| ANI Safety & Supply, Inc.
PO Box 228
Skokie, Illinois 60076-0228
(800) 676-5581
www.anisafety.com
| Ford Meter Box Company, Inc.
P.O. Box 443
775 Manchester Avenue
Wabash, Indiana 46992-0443
(260) 563-3171
www.fordmeterbox.com
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Windsor Technologies, Inc.
The Davidson Anti-terrorism Valve (ATV)
P.O. Box 2866
Peachtree City, GA 30269
(770) 251-2035
www.watersecurity.us
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Flow Security Systems, Inc.
1080 Avenida Acaso
Camarillo, CA 93012
(805) 484-9833 x 300
www.faucetlock.com
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