A Comprehensive Guide to Circuit Breaker Lockout Devices: How to Choose the Right One for Your Safety Needs

The purpose of this guide is to describe what a circuit breaker lockout device is, what it does, what its benefits are and the different types of breaker lockout devices available on the market. In addition, this guide will cover how to select the right lockout device based on specific safety requirements, regulations, and environmental conditions.

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Table of Contents

Understanding Lockout Devices

Types of Lockout Devices

Group Lockout Boxes

Tag Out Tags

Lockout Stations

Confined Space Covers

Choosing the Right Lockout Device

Best Practice for Using Lockout Devices

Types of Lockout Devices

This section covers the different types of lockout devices available, including lockout tags, lockout hasps, and circuit breaker devices.

Lockout Padlocks

These are security padlocks used to lock LOTO devices in place [4]. While they can be keyed alike, this should be avoided for safety reasons. If this is unavoidable their distribution should be limited among employees [1].
          View Safety Padlocks

Circuit Breaker/Electrical Lockouts

These lockout devices are designed to prevent power from being restored or re-energized while equipment is being serviced. Once the power is shut off, the electrical lockout device fits over the switch and is often held in place by a padlock [4].

      View Circuit Breaker Lockouts

Valve Lockouts

This type of lockout device isolates energy in pipes by preventing valves from being opened which could affect any pipes or equipment that are being worked on downstream. The device is fixed over the closed valve and held in place by a padlock [4].

     View Valve Lockout Kits

Cable Lockouts

For harder-to-lock devices such as handles and gate valves, cable lockouts provide safety and security during maintenance and repairs. The cable passes through the handles or valves and is pulled tight, then locked in place using a padlock [4].

        View Cable Lockout Devices

Steering Wheel Lockouts

These devices attach to the steering wheel of a vehicle that is being maintained and repaired. They generally do not disable the steering wheel but rather display a warning not to use the vehicle while it is being worked on [4].

Flange Lockouts

These cover the bolts on pipeline flanges to prevent them from being opened while the pipeline is being worked on. A padlock holds the flange lockout in place to prevent it from being accidentally removed [4].

    View Flange Lockouts

Gas Cylinder Lockouts

This type of lockout device covers valve handles and handwheels to prevent access to the main tank while work is ongoing. They are held in place with a padlock to protect them from any unauthorized access [4].

       View Gas Cylinder Lockouts

Pneumatic Lockouts

These lockout devices secure pneumatic fittings and regulators in place to prevent equipment from being energized. They are held in place by a padlock to ensure the pneumatic fittings do not connect to any pressurized air sources [4].

    View Pneumatic Lockouts

Lockout Hasps

Lockout hasps allow multiple workers to service the same equipment at one time. The hasp is applied to a lockout and has multiple shackle holes to allow other lockout devices to be attached. Once all lockout devices are removed the equipment can become operational again [4].

        View Lockout Hasps

Group Lockout Boxes

These boxes are used to hold the keys used to lock padlocks in place that secure lockout devices during servicing. This provides a control point where each worker can select a padlock and key needed for maintenance or repair work [4].

        View Group Lockout Boxes

Tagout Tags

When a lockout device is in use, these tags are used to alert workers that equipment is out of service. They are placed over the shackle of the padlock and are part of the OSHA standard for the Control of Hazardous Energy (Lockout/Tagout) [4].

        View Lockout Tags

Lockout Stations and Kits

Lockout stations allow you to store multiple lockout devices in one location for easy access. Stations are often wall-mounted or sit on the counter, while kits allow you to transport multiple devices to any location [4].

        View Lockout Stations

Confined Space Covers

For confined areas, confined space covers prevent access from unauthorized personnel while work remains in progress. They also offer protection from the elements and pests during ongoing work [4].

Best Practices for Using Lockout Devices

This section provides tips for the proper use, installation, and maintenance of lockout devices to ensure optimal safety.

Safety Tips for Lockout Tag Usage

To reduce the harmful effects of hazardous energy while working on equipment and machinery, you should employ the following safety tips [7]:

• Read through the OSHA standard for The Control of Hazardous Energy (Lockout/Tagout) (29 CFR .147) to understand your responsibilities in protecting workers from hazardous energy. Make sure to keep a copy on hand for future reference.
• Create a lockout/tagout (LOTO) procedure for all workers performing maintenance and repair work. The procedures should be based on OSHA standard .147 and outline what actions workers should take when working with equipment, using, and removing lockout devices, and looking after fellow workers.
• All workers involved in the maintenance and repair of electrical equipment should be fully trained in LOTO procedures and the correct usage of lockout devices. This also includes any workers in the area who need to be aware of safety procedures while lockout procedures are in effect.

References

[1] https://safetyculture.com/topics/lockout-tagout/

[2] https://trdsf.com/blogs/news/circuit-breaker-lockout-installation

[3] https://vocal.media/fyi/comprehensive-circuit-breaker-lockouts-to-control-electrical-energies-during-maintenance/

[4] https://www.grainger.com/know-how/equipment-information/kh-guide-to-choosing-lockout-tagout-devices

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[5] https://totallockoutusa.com//08/21/which-lockout-device-will-fit-my-breaker/

[6] https://d37iywv1q.cloudfront.net/Common/Circuit_Breaker_Lockout_Reference_Guide.pdf

[7] https://www.osha.gov/control-hazardous-energy

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Imagine this: a maintenance team is gearing up to service a high-powered industrial electrical panel, the core of the factory's operations. It’s a situation filled with risks, where a single mistake or unexpected power surge could result in disaster. In these moments, breaker lockout devices become essential safety measures.

This guide will highlight the important role these breaker lock devices play in safeguarding high-stakes environments, while also equipping you with the insight needed to choose the best breaker lockout, ensuring every maintenance task concludes safely and power is restored without incident.

Key Takeaways

• Breaker lockout devices are essential for preventing accidental re-energization during maintenance, ensuring the safety of workers by isolating electrical circuits.
• Different types of breaker locks are designed for specific circuit breakers, ranging from low-voltage residential systems to high-voltage industrial setups.
• OSHA mandates that breaker locks must be durable, standardized, and identifiable to comply with safety regulations and protect workers during electrical maintenance.
• When selecting a breaker lockout, consider factors such as compatibility with the breaker type and voltage, durability, ease of use, visibility, and compliance with safety standards.

What is a Circuit Breaker?

A circuit breaker is an automated electrical switch designed to protect an electrical circuit from damage caused by excess current, typically resulting from an overload or short circuit. Its basic function is to interrupt current flow after a fault is detected. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation.

What are the Different Types of Circuit Breakers?

Understanding the different types of circuit breakers is crucial in selecting the appropriate lockout device. Each type has its unique lockout requirements and device compatibility:

1. Standard Breakers: Standard breakers are the most common type found in residential and commercial electrical panels. They typically handle low voltage applications, ranging from 120V to 240V in residential settings and up to 480V in commercial or light industrial environments. Additionally, standard breakers are used in both single-phase and three-phase systems.
2. GFCI (Ground Fault Circuit Interrupter) Breakers: GFCI breakers are specialized devices designed to detect ground faults, which can occur when the electrical current strays outside its intended path, usually due to a short circuit or contact with water. GFCI breakers trip much faster than standard breakers and are generally used in low voltage applications, commonly in the range of 120V to 240V.
3. AFCI (Arc Fault Circuit Interrupter) Breakers: AFCI breakers are designed to detect arc faults that occur when an electrical current jumps an unintended path, creating sparks that can ignite flammable materials. AFCI breakers are highly sensitive and can detect both series and parallel arcs. They are typically used in low voltage applications between 120V and 240V.

What is the Purpose of a Breaker Lockout?

A breaker lockout is a safety lockout tagout mechanism engineered to prevent the accidental or unauthorized re-energization of a circuit breaker during maintenance or repair work. When a breaker is locked out, it physically prevents the breaker from being turned on, safeguarding workers from electrical hazards such as shock or arc flash.

By using a breaker lockout, maintenance personnel can work on electrical systems with the assurance that the circuit remains de-energized, reducing the risk of serious injury or death.

Types of Circuit Breaker Lockout

Circuit breaker lockouts come in various types, each designed to fit specific breaker configurations and voltage levels. Below is a breakdown of the different types of breaker lockouts categorized by the voltage of the circuit breakers they are intended for:

Circuit Breakers with Low Voltage

• MCCB (Molded Case Circuit Breaker): MCCB lockouts securely fit over molded case circuit breakers, commonly used in residential and commercial applications. Typically compatible with systems up to 600V, these lockouts are ideal for higher current capacities compared to standard breakers.
• ACB (Air Circuit Breaker): ACB lockouts are used for air circuit breakers, primarily found in industrial environments. They are widely used in distribution panels, generally for handling larger low voltage applications up to 450V.
• MCB (Miniature Circuit Breaker): MCB lockouts are intended for miniature circuit breakers, commonly used in residential and commercial settings, usually between 120V and 240V. These lockouts are compact and designed to fit the small size of MCBs, effectively preventing accidental re-energization.
• RCCB (Residual Current Circuit Breaker): RCCB lockouts are specifically designed for residual current circuit breakers. These breaker lockout devices are used in systems typically operating between 120V and 240V, similar to MCBs but designed to fit the specific shape of RCCBs.

Circuit Breakers for High Voltage

• VCB (Vacuum Circuit Breaker): VCB lockouts are designed for medium voltage applications of vacuum circuit breakers, where the supply voltage ranges from 11 kV to 33 kV.
• SF6 (Sulfur Hexafluoride Circuit Breaker): SF6 lockouts are used for sulfur hexafluoride circuit breakers. With high insulation properties, this breaker lockout can handle a voltage supply range from 33kV to 800kV.
• OCB (Oil Circuit Breaker): OCB lockouts are designed for oil circuit breakers, often used in power grids, substations, powerlines, and transmission and distribution systems. Typically 33kV to 220kV, these lockouts are tailored to fit the unique design of OCBs.
• ABCB (Air Blast Circuit Breaker): ABCB lockouts are used for air blast circuit breakers, primarily found in arc furnaces and traction systems, with a 110kV to 400kV voltage range.

Best Brands of Breaker Lockout Devices

TRADESAFE

TRADESAFE has built a strong reputation in industrial safety by delivering reliable and industrial-grade breaker locks. Known for their durable construction, TRADESAFE breaker lockout devices are made from premium polypropylene and nylon materials, making them the preferred lockout tagout choice in diverse industrial settings.

TRADESAFE circuit breaker lockout collection features a range of products designed to meet diverse industry needs. Their Clamp-On Circuit Breaker Locks come in various sizes to fit single-pole 120/277V breakers and multi-pole 480/600V breakers, even accommodating those with larger toggles. With a rugged, impact-resistant design and quick thumb-turn installation, these locks offer both durability and ease of use. Additionally, the Universal Circuit Breaker Lockout stands out for its versatility and ability to secure single, double, and triple pole breakers.

TRADESAFE miniature circuit breaker lockout devices are also available in Pin-Out-Wide, Pin-In-Standard, Pin-Out-Standard, and Tie Bar Lockout. The PIS and POS locks are designed for smaller single-pole and multi-pole breakers, while the POW is ideal for breakers with wider toggles, providing a secure lockout fit.

The TBLO model is a versatile option for tight spaces, ensuring safe lockout procedures even in compact breaker panels. Moreover, the collection includes the Breaker Blocker Kit, which provides an all-in-one solution for locking out multiple miniature circuit breakers.

Key Features:

• Robust construction using top-grade materials, ensuring superior durability in various industrial environments.
• Versatile range of breaker locks catering to industries like construction, manufacturing, mining, and oil and gas.
• Quick thumb-turn installation for convenient application, enhancing operational efficiency.
• Exceeds OSHA standards, providing reliable safety assurance in high-risk applications.

Master Lock

Master Lock is another well-known brand of safety products, including lockout tagout devices. Included in this list for their reliable and sturdy breaker locks, Master Lock products are designed with both quality and functionality in mind. The brand emphasizes creating lock out devices that are easy to use, making them ideal for a wide range of industrial applications.

Master Lock Grip Tight™ Circuit Breaker Lockout collection includes options for different types of circuit breakers, including 120 and 240V breakers and other hi-voltage/hi-amperage breakers. Their user-friendly design, secure hold, and overall performance make them a valuable addition to any electrician's toolkit.

Key Features:

• Durable and reliable construction for industrial applications.
• Wide range for different circuit breakers.
• User-friendly design ensures ease of use.

BRADY

BRADY is also a popular brand in the safety equipment industry, known for its comprehensive approach to workplace safety. Their inclusion in this list is attributed to the high quality and functionality seen in their circuit breaker lock devices. BRADY breaker locks are suitable for many industrial settings.

Their products are designed with a focus on visibility and ease of use, but some models may be more complex to install, such as the Clamp-On Breaker Lockout with Cable. BRADY breaker lock collection is designed to assist in lockout/tagout procedures of 120/277V breakers as well as breakers that do not have a hole in the switch tongue.

Key Features:

• High-quality and functional, suitable for many industrial settings.
• Designed for enhanced visibility and ease of use.
• Suitable for breakers without a hole in the switch tongue.

OSHA Requirements for Breaker Locks

When it comes to lockout tagout devices such as breaker lockout devices, Occupational Safety and Health Administration (OSHA) has set forth specific criteria to ensure they are effective and reliable in preventing accidental energization:

• Durable: Breaker locks must be robust enough to withstand the wear and tear of regular use. This means they should be made from materials that are resistant to corrosion, impact, and deterioration from environmental factors like extreme temperatures, chemicals, or UV light.
• Standardized: To avoid confusion and ensure uniformity, these circuit breaker lockout devices should be consistent in color, shape, or size across a facility. Standardization helps in quick recognition and understanding, especially in emergencies.
• Substantial: The lockouts must be sufficiently sturdy to prevent removal without the use of excessive force or special tools. Their design should be such that accidental or unauthorized removal is virtually impossible under normal conditions.
• Identifiable: Each breaker lockout device should clearly indicate the identity of the worker who applied it, usually through tags or labels. This is crucial for accountability and ensures that lockout devices are only removed by authorized individuals.
• Exclusive for Safety: The primary function of these devices should be for safety lockout. They should not be used for other purposes that could compromise their integrity or lead to confusion about their purpose.

These rules ensure that breaker lock devices are used effectively and safely across various industries.

How to Choose the Best Circuit Breaker Lock?

Selecting the right breaker lockout device requires careful consideration of several key factors:

1. Compatibility: Ensure that the lockout device fits the specific type and size of the breaker lock it is intended for. Misfitting devices can lead to inadequate lockout and potential safety risks.

• Based on Circuit Breaker Type: Not all lockout devices fit every type of circuit breaker, so make sure the breaker lockout you choose is designed to securely fit your specific breaker type. Identify the specific type of breaker you're working with, such as MCB, MCCB, or ACB.
• Based on Voltage: Different lockout devices are designed for varying voltage ranges. Choose a breaker lockout that matches the voltage of your breaker to guarantee proper fit and functionality.

2. Durability: Choose materials and designs that can endure the specific conditions of your workplace, including exposure to chemicals, moisture, and mechanical stress.

3. Ease of Use: A good breaker lockout device should be straightforward to apply and remove, without requiring excessive time or effort. This not only improves efficiency but also ensures that workers are more likely to adhere to safety protocols.

4. Visibility: Opt for circuit breaker lockout devices with high visibility (such as bright colors) to ensure they are easily noticeable. This reduces the risk of accidental energization by clearly signaling that maintenance is in progress.

5. Compliance: Check that the device complies with or exceeds the relevant OSHA standards and guidelines. This compliance is not just about avoiding legal issues but more importantly about ensuring the highest level of safety in the workplace.

Breaker Lockout FAQs

Are all breaker lock devices one-size-fits-all?

No, breaker lock devices are not one-size-fits-all. They come in different sizes and designs to fit specific types of circuit breakers, such as MCBs, MCCBs, and ACBs. It is essential to choose a lockout that is compatible with the type and size of the breaker being used.

Can a breaker lock be used on a live circuit?

No, a breaker lock should never be applied to a live circuit. Breaker lockout devices are designed to prevent re-energization, not to operate on live circuits. Before locking out a breaker, it must be switched off to disconnect the electrical supply.

How to lock out a circuit breaker?

To lock out a circuit breaker, first switch off the breaker to disconnect the electrical supply. Attach the appropriate lockout device over the breaker switch, securing it in place so the breaker cannot be turned back on. Then, apply a padlock and tag, which should include relevant information like the worker's name and the date of the lockout. This procedure prevents accidental re-energization during maintenance or repairs.

How often should breaker lock devices be inspected?

Breaker lock devices should be inspected regularly, ideally before each use, to check for any damage or wear that could compromise their effectiveness. Scheduled inspections according to the LOTO program guidelines can help maintain safety and compliance, typically at least annually.

Are breaker locks required for all maintenance and repair work?

Yes, breaker locks are required whenever maintenance or repair work is being performed on equipment connected to an electrical circuit. This is a key part of lockout tagout procedures, mandated by OSHA, to prevent accidental re-energization and protect workers.

Can breaker lock devices be customized for specific facilities?

Yes, breaker lock devices can be customized to meet the specific needs of a facility. Customizations may include size adjustments, specific lock mechanisms, or specialized labeling to fit the facility’s equipment and enhance safety protocols.

Will a locked breaker still trip?

Yes, a locked breaker can still trip. The lockout device prevents the breaker from being manually turned on or off but does not interfere with the breaker's automatic tripping function. If an overload or fault occurs, the breaker will trip to protect the circuit, even if it is locked.

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