BACKGROUND OF THE INVENTION Field ofthe Invention (Technical Field): The present invention relates to safety devices for preventing tampering or accidental change of the manually set position of a rotatable shaft, such as the shaft on a valve or regulator that controls the flow of fluid.

Background Art.

Present lockout devices are designed to lock the handle on a valve or regulator where the handle is part of the original valve or regulator supplied by the manufacturer. Typically in these lockout devices, an enclosure is formed around the handle with a padlock that locks the enclosure in place to prevent access to the handle thus preventing the rotational position setting of the handle from being altered either accidentally or out of ignorance or maliciousness. Other lockout devices show a lock assembly that is housed within a cast valve body that with the aid of a key controls rotation of the valve shaft.

Examples of such locks are shown in United States Patent Nos. 440,714 (Lamb), 441,357 (Crowell), 1,154,389 (Fogalsong), 1,248,204 (Thomsen), 1,250,127 (Beers), 1,380,675 (Myers), 1,526,047 (Butterworth), 1,672,137 (Seng), 1,843,072 (Stone), 2,795,129 (Schoepe), 3,134,291 (Barry), 5,085,063 (Van Dyke). Additional patents were cited in the prosecution of the parent application from which this application is a continuation-in-part.

The principal objection to all of the above-identified lockout devices is the complexity of the mechanism which causes problems in reliability, increased manufacturing cost, and thus an increased price. Furthermore, many of these lockout devices require that the valve or regulator body handle be specially cast so as to house the locking assembly. Accordingly, the locking device is part of the valve or regulator when purchased and each valve or regulator manufacturer may have different types of devices which prevents uniformity of a single lockout device used throughout a manufacturing plant. It would be highly desirable to have a lockout device that could be used for a wide variety of different manufacturers' valves or regulators so that plant personnel could be taught to operate a single type of lockout device even though valves and regulators from different manufacturers are used in the same industrial plant.

Additionally, the prior art does not address the problem posed to industrial plant managers attempting to comply with government regulations setting forth the responsibility of a plant operator for the control of hazardous energy. These devices are typically referred to as "lockout" or "tagout" devices. The purpose, as set forth in the regulations of some nations, is to prevent the unexpected energization or start-up of the machines or equipment, or release of stored energy that could cause injury to employees undertaking servicing and maintenance of machines and equipment in the plant. Mandated lockout may require the placement of a lockout device on an energy-isolating device, in accordance with an established procedure, insuring that the energy-isolating device and the equipment being controlled cannot be operated until the lockout device is removed. Such safety lockout device requires some personnel-controlled means for locking, such as a key- or combination-operated lock. The regulations may further provides that safety lockout devices shall be standardized within the facility with respect to color, shape, or size.

An important feature of the safety lockout procedure is that the safety lockout device must be under the exclusive control of the authorized employee performing the servicing or maintenance. Accordingly, it is understood that compliance with these regulations will require that a safety lockout device has at least one key, or combination, that can be used only by the authorized service / maintenance person to override any other lockout device that otherwise may be applied to the energy-controlling device.

If it is desirable to have a lockout device to maintain a rotatable shaft in a fixed manual setting, during normal operation of the plant, there may be provided an "operations" lockout device that is available to the process control engineer, supervisor, or other employee responsible for establishing the settings on all energy-controlling devices. The "service/maintenance" or "safety" or "personal" lockout device then must supercede this operations lockout device so that a second key or combination lock under the exclusive control of service personnel can be applied to prevent access to the operations lockout device.

SUMMARY OF THE INVENTION The present invention comprises a lockout device for a rotating shaft, such as the shaft that controls the position or setting of a valve or regulator, to prevent any unauthorized personnel from changing the setting of the rotatable shaft due to a lack of knowledge as to why the shaft is set at a particular position, to prevent inadvertent rotation of the shaft to a new setting, or to prevent malicious resetting of the shaft to thereby change the flow of energy through the valve or regulator. In one embodiment, the lockout device includes a handle that may be attached to a drive shaft of a variety of various manufacturers' valves, regulators, etc., a gear or sprocket fixedly mounted on the drive shaft within the handle body and a key lock mechanism selectably positioned in the handle body to engage or disengage the gear and thereby prevent rotational movement of the gear and the rotatable shaft in either direction from the selected setting.

In another embodiment, the lockout device includes a gear that has specially shaped indentations between adjacent teeth so as to form a ratchet gear that is engageable by the key lock mechanism or, alternatively, a spring-actuated pivotable pawl, or spring-biased ball, that will allow the handle and the rotatable shaft to be operated in either the clockwise or counterclockwise direction, but not both. This permits the lockout device, when in the locked position, to allow the shaft to be rotated only in one direction, such as to close the energy control device, but not to open it further than the original setting.

In another embodiment of the lockout device, there is additionally provided a safety or personal lockout device comprising a cap which may be locked in position on the handle through the use of one or more second key lock mechanisms such that the cap overlies the

first lockout device whereby the safety lockout device has exclusive control of the position of the energy control device.

Additional embodiments of a safety lockout device include a cap which may be locked in position on the handle so as to prevent access to the first key lock mechanism through the use of a scissors-like bail which may be locked when in a closed position by one or more ordinary padlocks wherein the padlock key provides exclusive personal control over access to the first key lock mechanism.

A primary object of the present invention is to provide a simple, low-cost, highly reliable, compact, lockout device for use on a wide variety of rotatable shaft control devices, such as valves, regulators and the like.

Another object of the present invention is to provide a lockout device which when in the locked position will still allow the rotatable shaft to be rotated in one direction only, such as to close the setting of the shaft of the control device but not to allow opening of the control device.

Still another advantage of the present invention is to provide a lockout device that complies with government requirements for plant safety.

Still one more object of the present invention is to provide a lockout device having two lockout mechanisms; the first mechanism being in the control of plant personnel responsible for the operation of the process including the setting of various valves, regulators, and other energy-controlling devices having a rotatable shaft wherein the operations lockout device includes a key lock mechanism with a key (or combination) available only to operations authorized personnel to permit such personnel to manually set the position of a rotatable shaft so as to control the amount of energy passing through a device; and a second, safety lockout device that is under the exclusive control of a service or maintenance person and which overrides the operations lockout device so as to prevent any inadvertent release of energy while the service person is working on the equipment.

One more object of the present invention is to provide a lockout device that is equally usable on a wide range of different manufacturers' valves, regulators, or other energy control devices so that within a single industrial facility, although valves and regulators from different manufacturers are used, a single type of lockout device may be employed.

Other objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated into and form a part of the specification, illustrate several embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating these preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings: Fig. 1 is an exploded perspective view of a first embodiment of the invention; Fig. 2 is a cut-away perspective view of the embodiment of Fig. 1 shown mounted on a valve; Fig. 3 is a top view of the first embodiment shown in Fig. 1; Fig. 4 is a sectional view taken along the line 4-4 on Fig. 3; Figs. 5A and 5B are sectional views taken along the line 5-5 of Fig. 4 and showing the lockout device in the engaged position in Fig. 6A and in the disengaged position in Fig. 6B; Fig. 5C is a top sectional view of an alternative variation of the embodiment shown in Figs. 1-5B; Figs. 5D and 5E are sectional views taken along the line DE--DE of Fig. 5C and showing the lockout device in the disengaged position in Fig. 5C and in the engaged position in Fig. 5C; Fig. 6 is an exploded view of a second embodiment of the lockout device; Fig. 7 is a cutaway perspective view of the second embodiment shown in Fig. 6; Fig. 8 is a top view of the second embodiment of the lockout device shown in Figs. 6 and 7; Fig. 9 is a sectional view taken along the line 9-9 in Fig. 8;

Figs. 10A and lOB are sectional views taken along the line 10-10 on Fig. 9, showing the lockout device in its second embodiment in the unlocked position in Fig. 10A and in the locked position in Fig. 10B; Fig. 1 0C is a perspective partially sectional view of an alternative variation of the embodiment shown in Fig. 10A and 10B, with a spring-biased ball ratchet; Fig. 10D is a top sectional view of the embodiment of Fig. 10C; Fig. 11 is a disassembled exploded perspective view of a third embodiment of the lockout device, showing a first variation of a secondary or "personal" lockout.

Fig. 12 is a side view of the handle body of a second variation of the embodiment shown in Fig. 11; Fig. 13a is a bottom view of the enclosure portion of the embodiment shown in Fig. 12; Fig. 13b is a side view ofthe enclosure shown in Fig. 13a; Fig. 13c is a top view ofthe enclosure shown in Fig. 13a; Fig. 14 is an exploded perspective view of the embodiment depicted in Figs. 12 and 13a; Fig. 15 is a third variation of the personal lockout device shown in perspective; Fig. 16 is an inverted perspective view of the third variation of the safety lockout device shown in Fig. 15; Fig. 17 is a sectional view along the line 17-17 in Fig. 15; Fig. 18 is a sectional view of the handle of the second embodiment safety locking device as shown in Fig. 9 with minor modification for use with the safety lockout shown in Fig. 16; Fig. 19 is an assembled view in full section of the third variation of the safety lockout device shown in a locked position on the handle shown in Fig. 18; Fig. 20 is a perspective view of the scissors-like bail and two padlocks that are part of the third variation personal safety lockout device embodiment, shown in the locked position; Fig. 21 shows the third variation of the safety lockout device shown in Fig. 20 in the unlocked position;

Figs. 22A and 22B are plan views of a fourth variation of a safety lockout device, Fig. 22A showing the device in the unlocked position, and Fig. 22B showing the device in the position for lockout; Figs. 23A and 23B are side views of the fourth variation of the safety lockout device shown in Figs. 22A and 22B; Fig. 24 is a perspective view of the complete fourth variation of the safety lockout device shown in the locked position with two padlocks; Fig. 25 is a perspective exploded and partially sectional view of an embodiment of the invention incorporating a first variation of an indicator subassembly; Fig. 26 is a side sectional view ofthe embodiment shown in Fig. 25; Fig. 27 is an exploded and partially sectional view of an embodiment of the invention incorporating a second variation of an indicator subassembly; Fig. 27a is an enlarged bottom view of the lens element of the embodiment shown in Fig. 27, illustrating a mask portion thereon; and Fig. 28 is a perspective partially sectional view of the embodiment shown in Fig. 27 in an assembled condition.

DESCRIPTION OF THE PREFERRED EMBODIMENTS This invention relates primarily to lockout devices, particularly lockout devices designed to prevent accidental, ignorant, or malicious adjustment of the setting of a shaft in an industrial facility that controls the amount of energy passing through an energy control apparatus such as a valve, regulator, or the like.

The first embodiment of the invention is illustrated in Figs. 1 through 5 and comprises a lockout device which prevents rotation of a handle against movement in either direction.

The invention comprises a main handle body 1 constructed from machined or cast metal such as aluminum, or formed by injection molding of plastic. The handle body contains a gear or sprocket 2, that is positioned within a cylindrical cavity or opening in the lower end of the handle. The gear may be made of plastic or metal, and is rotatably supported within the lower cylindrical opening by means, such as a bearing 4, which is held in place by retaining rings 5.

Bearing 4 allows the handle body 1 to free-wheel when the lockout device is in a locked condition as described below. In accordance with an object of the invention, it is desirable to provide a lockout device for a handle that can be used on a wide variety of valves, regulators,

or other energy controlling apparatus from different manufacturers. Accordingly, the engagement means, such as gear 2, as seen best in Figs. 4, has an opening 2a and the handle has a central bore for receiving and engaging the drive shaft, i.e., the rotatable shaft of a control apparatus such as a valve or regulator.

A key locking mechanism 3 is mounted in a cylindrical opening in the upper end of handle 1, offset from the axis of the handle as seen best in Fig. 3. The key locking mechanism 3 is of an off-the-shelf construction with various key types or may be a combination lock and includes a locking dog 11 (as seen best in Fig. 2). The key locking mechanism 3 is secured within the handle body 1 by a locking mechanism retaining pin 8 (see Fig. 4). In this type of off-the-shelf locking mechanism, a key is adapted to be inserted into the locking mechanism when the center body of the mechanism has its singular notch aligned with one ofthe two notches in the locking mechanism's outer body which are positioned at 1800 apart. When the proper key is inserted, the center body may be rotated 1800 and the key may then be withdrawn.

According to this first embodiment, the setting or position of the shaft or drive stem may be manually set by inserting the key into the key locking mechanism 3, rotating the key so that the dog 11 engages the opening between adjacent teeth on the gear or sprocket 2 as seen in phantom lines in Fig. 4 and in Fig. 5A which then mechanically couples the handle 1 to the valve shaft through the gear 2 and the dog 11. In this position, the handle may be rotated in either direction and the drive shaft of the valve will be commensurately rotated so as to open or close the valve thus regulating the flow of energy through the valve. When the correct position of the valve is determined, such as by manually or automatically determining the flow of energy through the valve, in accordance with the specification of the process being controlled by the valve, the key in the key locking mechanism 3 is rotated so as to disengage the locking dog 11 from the gear or sprocket 2 as seen in Figs. 4 and 5B and the key may then be removed. In this condition, the handle 1 will then free-wheel on the drive rotatable shaft preventing any change in the setting of the rotatable shaft and therefore controlling the energy passing through the control device.

To prevent an unauthorized person from removing the entire handle body from the drive shaft, whereby the drive shaft could then be rotated with another handle or a pair of pliers, the handle body 1 is secured to the valve rotatable shaft that is positioned within the

opening 2a in the gear and extends into the bore through the use of a jam nut 6 within the handle central bore that includes a spanner wrench hole pattern 10 that matches that of an installation tool 7. To prevent the use of any common spanner wrench from being used to disengage the jam nut 6, the lockout device may be specified with the hole pattern 10 so that only a matching installation tool will be useable. A plastic handle cap 9 may be employed to cover the jam nut 6 so as to frustrate unauthorized personnel from obtaining access to the jam nut and to also evidence tampering if authorized plant personnel observe that the cap has been removed.

An advantageous alternative variation of the first embodiment of the invention is depicted in Figs. 5C-5E. This alternative is preferred in instances where the size of the handle 1 must be minimal; in the embodiment of Figs. 1-5B, the diameter of the handle 1 is dictated in part by the position of the locking mechanism 3 with respect to the sprocket 2.

Because the locking mechanism 3 is radially exterior to the sprocket 2, the axis of the locking mechanism 3 is radially offset from the central axis of the handle 1 a considerable distance, resulting in a handle 1 of relatively large diameter to accommodate and contain the sprocket- key mechanism configuration. The embodiment of Figs. 5C-5E reduces the radial offset between the locking mechanism 3 and the central axis of the handle 1 of the invention. As suggested by the view of Fig. 5C, by locating the locking mechanism 3 closer to the axis of the invention, the handle 1 may be manufactured with a smaller overall handle diameter. While this alternative embodiment is described as a modification to the embodiment of Figs. 1-5B, it will be immediately appreciated by a person skilled in the art that the additional embodiments taught in the balance of this disclosure also may be adapted to incorporate the advantageous features offered by the improvement of Figs. 5C-5E.

The embodiment of Figs. 5C-5E may be broadly characterized as relocating the teeth of the sprocket 2 from a central position opening radially outward to a circumferential position with the teeth facing radially inward. In this alternative, the sprocket 2 of Figs.1-5B is replaced with a toothed ring gear 2' which serves as the engagement means of the invention.

The function of this alternative embodiment is similar to that of the embodiment of Figs 1-5B, although the advantageous modification can be adapted for use in nearly all embodiments of the invention. In the first described embodiment, the sprocket 2 is disposed at the central axis of the invention, with the teeth thereof opening radially outward from the central axis, as best

seen in Figs. 5A and SB. In this alternative configuration ofthe first embodiment, the toothed gear ring 2' has teeth, disposed on circular flange 2b on its outside perimeter, which teeth open radially inward toward the central axis of the invention. As depicted in Figs. 5C-SE, the gear ring 2' has a central hub 2c which is penetrated by opening 2a for receiving and engaging the drive shaft (e.g. the rotatable shaft of a rotary control apparatus such as a valve or regulator).

The operation of the compact embodiment is further understood with reference to Figs. 5D and 5E. The key locking mechanism 3 is mounted in a cylindrical opening in the upper end of handle 1, offset a short distance from the axis of the handle (as seen best in Fig. 5C). The as mentioned, key locking mechanism 3 is of an off-the-shelf construction with various key types or may be a combination lock and includes a locking dog 11. The locking dog 11 is pivotally about a vertical axis, so that the dog 11 can turn its notched portion toward or away from the teeth of the gear ring 2' in accordance with the turning of a key in the locking mechanism 3. The key locking mechanism 3 is secured within the handle 1 by a locking mechanism retaining pin 8.

The setting or position of the valve shaft (not shown in Figs. 5D and 5E) may be manually set by inserting the key into the key locking mechanism 3, and then rotating the key so that the dog 11 engages the opening between adjacent teeth on the gear ring 2' as seen in Fig. 5E. With the dog 11 turned radially outward from the central axis ofthe invention as seen in Fig.SE, the handle 1 is mechanically coupled to the valve shaft through the ring gear 2' With the invention so positioned, the handle 1 may be rotated in either direction and the drive shaft of the valve or regulator will be commensurately rotated to adust the flow through the valve to the desired level.

After the valve has been rotated to the proper position, such as by manually or automatically determining the flow of energy through the valve in accordance with the specification of the process being controlled by the valve, the key in the key locking mechanism 3 is rotated so as to pivot the locking dog 11 away from the teeth of the ring gear 2'. Rotating the dog 11 from between teeth on the ring gear 2' places the dog notch into alignment with the teeth of the ring gear 2b, so that the teeth may pass through the notch, thus disengaging the locking dog from the ring gear as seen in Fig. 5E and the key may then be

removed. In this condition, the handle 1 will then free-wheel on the valve's stem, thereby preventing any inadvertent change or tampering in the valve setting.

As illustrated by Fig. 5C, the use of a gear ring 2' allows the locking mechanism 3 to be disposed near the central axis of the handle 1, yet permits the central portion of the invention to be free from the structure of a sprocket 2. This also presents advantages in certain embodiments of the invention requiring an unobstructed central bore 112 in which other supplemental security or indicating devices may be placed (Figs. 25-28).

A second embodiment ofthe invention is shown in Figs. 6 through 10. The principal difference between the first embodiment described above and the embodiment shown in Figs. 6 and 7 is the provision of a ratchet wheel 20 which is fixedly mounted to the gear or sprocket 2 and rotates therewith. A pawl comprising an arm 22 on a shaft 21 is carried in the cylindrical opening in the lower end of handle 1 and is biased by spring 23 in engagement with the ratchet wheel 20.

In this second embodiment, when the key locking mechanism 3 is in the lockout position, i.e., the locking dog 11 is disengaged from the opening between the teeth on the gear 2 the handle is free to free-wheel, but in only one direction. In use, as seen best in Fig. 7, when the housing body 1 is rotated in the clockwise direction (viewed from above) the pawl arm 22 slips over the ratchet wheel 20 in conventional manner and allows the handle 1 to free- wheel in the clockwise direction. Conversely, if the handle 1 is rotated in the counterclockwise direction, the pawl arm 22 engages the ratchet wheel 20 and therefore the handle 1 will be rotatably fixed to the shaft of the control device (in a single direction only) allowing the shaft rotational position to be reset. In application, the direction of the engagement / disengagement of the pawl and ratchet depends on whether it is desirable to allow the setting of the control device to be altered in a clockwise or counterclockwise direction. For example, it may be desirable to allow any personnel, whether or not authorized, in the case of an emergency, to close a valve or other energy-controlling device without the necessity for a key but under no circumstances to allow the valve setting to be changed so as to open the valve beyond its original setting.

Figs. 8 through 10 show a modified second embodiment in which the ratchet wheel 20 is functionally combined with the gear 2 so as to eliminate one of these parts. As seen best in Figs. 10A and lOB, a cut-away top view of Fig. 9, the gear/ratchet 30 is engaged by both the

dog 11 of the key locking mechanism 3 as well as the pawl arm 22. The ability of the lockout device with the single gear/ratchet 30 to be engaged by the locking dog 11 so that the handle 1 and the valve drive shaft, through the gear/ratchet 30, permits adjustment of the rotatable position of the drive shaft by manually turning the handle 1 is due to the shape of the opening between adjacent gear/ratchet teeth and the proper placement ofthe locking dog 11 and the pawl arm 22 in relation to the gear/ratchet 30. The advantage of the replacement of two parts with a single part will be obvious to those having skill in the art.

Figs. 10C and 10D illustrate still another version of the modified second embodiment incorporating an alternative ratchet mechanism for providing a "unidirectional" lock-out whereby the shaft can be turned one direction only without the use of a key. This embodiment is substantially similar in most respects to the embodiment of Figs. 9, 10A, and lOB, and functions similarly except that a spring-biased movable ball 22a is employed in lieu of a pivotable pawl 22. Like the embodiment of Figs. 10A and 10B, there is provided a ratchet 30a wholly integrated with the gear 2. As seen in Figs. 10C and 10D ratchet 30a is engaged by both the dog 11 of the key locking mechanism 3 as well as the ball 22a. The engageability of the gear/ratchet 30a with the locking dog 11 so that the handle 1 and the valve drive shaft, through the gear/ratchet 30a, permits adjustment of the rotatable position of the drive shaft by manually turning the handle 1, is due to the shape ofthe opening between adjacent gear/ratchet teeth and the proper placement of the locking dog 11 and the ball 22a in relation to the gear/ratchet 30a.

The ratchet 30a has a plurality of notches 31, 31', 31" disposed uniformly and circumferentially thereabout. Ball 22a, very preferably a sphere of uniform radius, is movably disposed on the handle body 1, for example by moving to-and-fro within an aperture or tunnel therein. A coil spring 23a serves to bias the ball 22a toward the ratchet 30a, so that when the handle housing is not coupled to the ratchet 30a by means of the interposition of the dog 11 between any two adjacent notches on the ratchet 30a, the ball 22a moves into selective engagement with a corresponding one 31 of the notches 31, 31', 31" to prevent the handle 1 from rotating in one direction. The notches 31, 31', 31" preferably define arcs comprising radii substantially equal to said radius of the ball 22a to provide for secure engagement of the ball with any one notch. As best shown by the bidirectional arrow in Fig. 10D, the ball 22a is movable along an imaginary line skewed in relation to the axis of the handle 1 and thus to the

rotatable shaft. Providing a skewed positional relationship, whereby the ball 22a is translatable along an imaginary line generally tangential to the wheel of the ratchet 30a, provides for a smooth rotation of the handle 1 in the "safe" direction (i.e. counterclockwise in Fig. 10D, since the relative (clockwise) rotary motion of the ratchet 30a will simply push the ball back against the bias of the spring 23a, allowing the teeth of the ratchet to pass. Any attempt to rotate the handle in the "unsafe" direction, however, immediately binds the ball 22a between the ratchet 30a and the handle 1, thus preventing further relative movement of the handle with regard to the ratchet wheel 30a. It is immediately appreciated by one of ordinary skill in the art that this ratchet modification incorporating a ball 22a and spring 23a may be readily adapted for use in the embodiment of Figs. 6 and 7, as well, where ratchet wheel 30 is distinct from but fixedly secured to the gear or sprocket 2.

In the third and fourth embodiments shown in Figs. 11 through 14, a second "personal" or "safety" lockout device is employed in addition to the lockout device previously described. The purpose is to provide a higher level of safety, through the exclusive control of a single key by a service or maintenance personnel, so as to comply with OSHA requirements.

In application, the lockout device as shown in the first or second embodiments, may be used by operations personnel to set the shaft on an energy-controlling device to a specific position that determines the amount of energy passing through the control device. While the configuration of the invention as shown in the first and second embodiments serves a safety purpose, it is also used to set a process control parameter that is necessary for proper operation of a system. The manual setting of the position of the shaft and therefore the amount of energy passing through the control device may be desirably set by various authorized personnel within an industrial plant, or any other similar setting, such as a process control engineer, a process control supervisor, or some other person with the authority to set the process control parameter. Since there are likely several such authorized personnel, there may be multiple keys available for these authorized personnel to use to set or reset the position of the shaft of the control device.

In the third and fourth embodiments, in addition to the operations lockout device, there is provided a second lockout device to which there is only a single key that is issued to a service or maintenance person who will perform repair operations on the system or equipment.

Since that person while engaged in repairing a system may be vulnerable to an inadvertent, or

ignorant change in a valve setting that could cause serious bodily harm, it is desirable to exclude all persons other than the service or maintenance person from changing the valve position. This second, safety lockout device therefore overrides the operations lockout device as will be seen and described with reference to Figs. 11 through 14.

In Fig. 11 there is shown a first variation of a safety lockout device comprising an enclosure 9' which is of generally U-shaped construction having an upper wall, a lower wall with a U-shaped opening and of a size and configuration so as to fit over the handle body 1. It will be noted that the key locking mechanism 3 of the operations lockout device, when the enclosure 9' is in place, is entirely covered thus denying access to the operations key locking mechanism 3. By inserting the padlock 12 through the opening at the outer edge of the enclosure 9', which acts like a hasp, when the padlock 12 is closed, only the person with the key to the padlock 12 will have access to the lockout device including the key locking mechanism 3 and therefore control of the valve setting. Thus, in accordance with OSHA requirements, the holder of the key to the padlock 12 has exclusive control over setting of the control device which effectively overrides the operations lockout device key locking mechanism 3 that is controllable by operations personnel. If a service or maintenance person has the exclusive control of the key to the padlock 12, there is no chance for any other person at the facility, including any operations personnel, from altering the setting of the control device during maintenance operations.

A second variation of the safety lockout device is illustrated in Figs. 12, 13a, 13b, 13c and 14. This variation is similar in form and function to the embodiment 9' of Figs. 11, but is simpler to use. Figure 12 shows that the handle 1 is provided with a circumferential groove or channel 41 which is defined around the maximum periphery of the handle body 1 at a uniform distance below the top 42 ofthe handle 1. The safety lockout device is an enclosure 40, shown in detail in Figs. 13a, 13b and 13c. The enclosure 40 has a generally U-shaped construction featuring an upper wall 43, a lower wall or lip 44 generally parallel to the upper wall and defining a U-shaped opening having a size and configuration corresponding to the size and contour of the reduced diameter of the handle 1 at the inner wall of the channel 41.

The enclosure 40 accordingly may be slipped over the exterior of the handle 1 with the lip 44 slidably engaged into the channel 41, as best seen in Fig. 14. It will be noted that the key locking mechanism 3 of the operations lockout device, when the enclosure 40 is in place is

entirely covered, thus denying access to the operations key locking mechanism 3. When a padlock 12 is inserted through the opening 46 at the outer edge of the enclosure 40 and closed, only the person with the key to the padlock 12 has access to the lockout device including the key locking mechanism 3 and, therefore, control of the valve setting. If a service or maintenance person has the exclusive control of the key to the padlock 12, there is no chance for any other person at the facility, including any operations personnel, from altering the setting of the control device during maintenance operations.

An advantage of this embodiment is that handles 1 of various heights can be manufactured with the channel 41 at a uniform distance from the top 42, permitting enclosures 40 of a corresponding standard thickness from upper wall 43 to lip 44 to be used on any particular handle, regardless of handle height. The enclosure 40 of this embodiment also is easier to fit into place. Preferably, the upper wall 43 of the enclosure 40 is completely penetrated by a centrally disposed viewing aperture 47 as seen in Figs. 13a, 13c, and 14. The viewing aperture 47 permits this variation of personal safety lockout device to be used in conjunction with the indicator embodiment incorporating a viewing rod 120, which is disposed within the handle bore 112, as further disclosed hereinafter (Figs. 25-28). When the enclosure 40 is in place upon the handle body 1, the aperture 47 is alignable with the central bore of the handle to permit viewing of the indicator components of the embodiments of Figs. 25-28 even with the personal lockout enclosure 40 in the locked position.

In Figs. 15 through 21, there is shown a third variation of a personal lockout device.

The complete personal safety lockout device 50 is shown in Figs. 20 and 21. As seen in Figs. 15-18, the device 50 comprises a cap assembly 51 having a plate 52 that is ofthe same approximate diameter as the diameter of handle 1. Plate 52 has a central opening 53 (see Fig. 17) receiving a shaft 54 having an opening 55 for receiving a pin 56. The shaft 54 is integral with a stem 57 having a rectangular free-end section 58 and a horizontally disposed cylindrical opening 59 (Fig. 17). The stem 57 is received in a cylindrical housing 60 that is welded or otherwise permanently secured to plate 52 and having a horizontally disposed cylindrical opening 61 perpendicular to the longitudinal axis of the stem 57. The stem 57 and shaft 54 are secured to the cap and cylindrical housing, 51 and 60, through a retainer collar 62 (see Fig. 16 or 17) having an opening 63 for receiving the shaft 54 and a perpendicular opening 64 for receiving pin 56 thereby securing the collar 49 to the shaft 54 and completing

the assembly of the cap 51. As may be seen in Figs. 15 through 17, the stem 57 may be rotated by the use of a wrench, such as a Crescent wrench, applied to the rectangular free end portion 58 of stem 57 so that the opening 59 in stem 57 may be aligned with the cylindrical opening 61 in the cylindrical body 60, as shown in Fig. 17. When the holes 59 and 61 are in registry, the collar 49, because shaft 54 is not co-axial with stem 57, projects laterally outwardly.

The handle 1 includes a central bore including a shoulder 36 formed in such bore.

When desired, the personal safety lockout device 50 may be employed by placing the cap assembly 51 over the top of the handle body 1 and rotating stem 57 so that holes 59 and 61 are aligned and, as seen best in Fig. 19, the collar 49, which is eccentrically mounted to the axis of stem 57 will engage the shoulder 36 of the handle 1, thereby locking the safety lockout device 50 to the handle 1. In this position, the plate 52 overlies the key locking mechanism 3, thereby preventing operations personnel access to change the setting of the handle 1 thereby changing the setting of the energy control device. As seen in Figs. 20 and 21, the stem 57 is locked in the position where the holes 59 and 61 are aligned and the collar engages the shoulder 36, thereby preventing access to the key locking mechanism 3 by a scissors-like bail indicated generally at 65. The bail 65 includes two identical scissor arms 66 and 67. Each scissor arm at one end includes one half of a ring, such ring section 68 attached to arm 67 and ring section 69 attached to arm 66. The arms 66 and 67 are pivotally connected through a hinge 70. At the opposite end of each arm 66 and 67 are integral plates 71 and 72 with multiple openings 73. The bails 74 of multiple padlocks such as 75 and 76 may be used to lock the scissors-like bail 65 in a position whereby ring portions 68 and 69 are inserted in openings 61 and 59 in the safety lockout cap 51 preventing rotation of the stem 57 and thereby removal of the plate 52 from its overlying locking position over key locking mechanism 3 in handle 1. As seen best in Fig. 21, the scissors-like bail 65, after removal of all padlocks from the registered openings 73 in the flat plate portions 71 and 72 of arms 66 and 67 may be spread so that half ring sections 68 and 69 may be removed from opening 61 in cylindrical housing 60 of lockout device cap 51 so that by applying a wrench to the rectangular body 58 at the free end of stem 57, thereby rotating the collar 49 so as to disengage from the shoulder 36 of housing 1, allowing lockout cap 51 to be disengaged from

handle 1, and in turn permitting access to key locking mechanism 3 will permit resetting of the rotational position of the shaft of the energy control device.

In Figs. 22 through 24 there is shown a fourth variation of a safety lockout device 100 comprising a safety lockout cap 101. The cap 101 has a lower plate 102 which completely overlies the upper surface of the handle 1 and is of similar configuration. Depending from plate 102 is a cylindrical housing 103 for receiving a shaft (not shown). The plate 102 has an arcuate section 104 having a plurality of holes such as 105 each of which may receive the bail of a padlock, as explained below. The safety lockout cap 101 includes an upper plate 107 with a downwardly depending shaft, as previously described, that fits through the cylindrical housing 103 and is then attached to a collar 108 that is eccentrically mounted relative to the center line of cylindrical housing 103. Upper plate 107 has an arcuate section 109 identical to arcuate section 104 on plate 102 and having the identical openings such as 110 that as seen best in Fig. 22B, when the two plates are rotated to a specific position are in registry with all ofthe openings 105.

As seen best in Fig. 24, when plates 102 and 107 are aligned, as shown in Fig. 23B, so that the openings 105 and 110 are in registry, the bail 74 of a padlock 75 may be inserted through openings 105, 110 to thereby lock plate 107 and plate 102 by engagement ofthe collar 108 with shoulder 36 in the handle 1 to prevent access to the upper surface of handle 1 and therefore the operation key locking mechanism 3.

Figs. 25 and 26 show an optional but desirable alternative embodiment of the invention, wherein there is provided a means for indicating the operative status of the valve or regulator, i.e., whether the valve or regulator is in a full open, full closed, or intermediate position. This embodiment of the invention is useful in circumstances where it is desirable or necessary to determine visually and rapidly the "open" or "closed" position of the valve, and particularly when the valve is locked by the means of the invention.

Figs. 25 and 26 depict the indicator as a variation of the embodiment shown in Figs. 10C and 10D, although it will be apparent to one of ordinary skill in the art that nearly any of the other disclosed embodiments of the invention may be adapted to incorporate the elements and benefits of the indicator. Fig. 26 is a cross sectional side view of an embodiment of the invention combining the ball 22a and spring 23a ratchet elements housed in a handle 1 similar to the embodiment shown in Figs. 10C and 10D. The ratchet 30a and lockout

mechanism 3 with locking dog 11 function in substantially the same manner as previously disclosed. The bearings 4 and retaining rings 5 also function substantially similarly to corresponding elements in previously described embodiments. The ratchet 30a has a central downwardly extending hub 2c as best seen in Fig. 26, defining therein an open cylindrical core 2d. The principal consideration affecting the incorporation of the elements of the indicator embodiment is the need for an open central bore 112 or core within the handle 1 into which the indicator components of the invention may be disposed.

Combined reference is made to Figs. 25 and 26. Principal elements of this embodiment of the invention include the handle 1, the ratchet 30a, the transparent viewing rod 120, and indicator marks 116, 117, and 118 disposed upon the interior wall of the hub 2c of the ratchet 30a. The indicator marks 116, 117, 118 include visual clues or indicia which signal, via the viewing rod 120, the operational status of the valve to which the invention is affixed.

An open bore 112 in handle 1 is coaxial with the central axis of the handle, and extends from the top of the handle to the top of the ratchet 30a. The hub 2c also is coaxial with the central axis, and extends from the top of the ratchet 30a to the bottom, valve engaging- portion 114 portion ofthe ratchet 30a. The valve-engaging portion 114 is securely attachable by any suitable means to the rotating tubular shaft 127 of the valve. Rotation of the valve shaft 127 actuates the opening/closing functions of the valve. Thus, in the practice of the invention, the bottom 114 of the ratchet hub 2e is fixed to, and immobile with respect to, the rotatable shaft 127 of the valve such that the ratchet 30a and shaft 127 rotate concurrently about their common vertical axis. The handle 1 is coupled with the ratchet 30a by selective engagement ofthe dog 11 with the ratchet as previously explained; when the dog 11 is disengaged (as shown in Fig. 26) from the ratchet 30a by the action of the locking mechanism 3, the handle 1 is free-wheeling and may not be used to adjust the valve, also generally in accordance with previous descriptions herein. Turning the locking mechanism 3 pivots the dog 11 radially inward for engagement between the teeth of the ratchet 30a.

Consequently, when the dog 11 is engaged with the ratchet 30a, the handle 1, ratchet 30a (including hub 2c) and the rotatable shaft temporarily integrated, so that rotary motion imparted to the handle 1 is transmitted to the shaft of the valve thereby to open or close the valve.

This indicator embodiment of the invention features a cylindriform viewing rod 120 disposed in the bore 112 ofthe handle and extending into the core 2d ofthe ratchet 30a, along and coaxial with the central axis of the handle 1. Viewing rod 120, which normally has a length equal to or less than the axial length of the ratchet 30a, is used to transmit indicative imagery from the walls of the hub 2c for viewing at the upper surface of the handle 1, whereby the user determines the operational position of the valve. The viewing rod 120 is in sliding contact with the interior walls of the handle 1 and ratchet 30a, or may be slightly separated therefrom, e.g., the diameter of the viewing rod 120 preferably is slightly less than the diameter of the open bore 112 and the diameter of the core 2d of the ratchet 30a. The viewing rod 120 is securely fixed to the immobile, non-rotational stem 126 which extends vertically, and coaxially with the axis of the viewing rod 120, from the body of the valve.

Thus, the viewing rod 120 is at all times immobile with respect to the non-rotational stem 126 and the housing of the valve. During the practice of the invention, the handle 1 and the ratchet 30a are rotatable around the viewing rod 120.

The viewing rod 120 is transparent to light, and thus transmits optical signals along its axial length. The rod 120 preferably is fashioned from clear acrylic. Notably, the lower end of the rod 120 is cut to form an approximately 45" angle from vertical, as best depicted in Fig. 26. The 45" cut defines a reflector face 122 which is highly polished to provide a mirror- like finish thereon. Also, the lower end of the rod 120, radially opposite the reflector face 122, is resected along a chord of the rod, and completely to the bottom end of the rod, to define a flat, substantially vertical image face 123. Accordingly, light rays from the walls of the hub 2c are incident normal to the image face 123, and pass generally undistorted radially through the rod 120 until they strike the reflector face 122, as indicated by the directional arrows in Fig. 26. Upon striking the reflector face 122, the rays coming from the hub 2c, having an incidental angle of 450, reflect from the reflecting face 122 and pass axially up the length of the rod 120 for viewing at the top of the handle 1, also as indicated by the directional arrows in Fig. 26. Viewing of visual signals reflected from the reflector face 122 occurs at the top 124 of the rod; the top 124 may be completely flat, or may have a slightly convex profile to provide for magnification of the transmitted image, or (as shown) may be flat with a beveled circumferential edge.

As best indicated by Fig. 25, the positional status of the valve is signaled by status indicator marks 116, 117, 118 disposed circumferentially about the interior surface ofthe hub 2c ofthe ratchet 30a. Indicator marks 116, 117, 118 preferably number three, e.g., "open," "closed," or "intermediate." In the illustrated Fig. 25, three indicators 116, 117, 118 are shown, but it is understood that alternative embodiments may employ as few as two or more than three indicator marks. The indicator marks 116, 117, 118 are printed, engraved, glued, painted or otherwise affixed directly upon the cylindrical inside surface of the hub 2c.

The indicator marks 116, 117, 118 preferably occupy the full 360-degree circumference ofthe of the hub core 2d.

In Fig. 25, the "open" status indicator mark 116 is given as the printed word "open," while the "intermediate" or "partially open" mark 118 is shown as an exclamation point. The "closed" indicator mark 117 is shown simply as a large "X." These particular forms of marking are only by way of example, and not by limitation. Particularly, it is desirable to have the respective indicator marks be given by bands of color, rather than by symbols or printed words. In one preferred variation, the open status indicator mark 116 is a green-colored band extending through about 2 10" of the circumference of the hub 2c, the "intermediate" or "partially closed" indicator mark 118 is a yellow band extending through about 100" of the circumference, and the "closed" mark 117 is a short, red-colored band extending through about 50° ofthe circumference. Alternatively, the indicator marks 116, 117,118 may be a spectrum of graduated coloring resembling the rainbow of visible light, with blue (full open) progressing gradually through to red (full open).

The invention is assembled such that the ratchet 30a is positioned around the viewing rod 120 with the appropriate one ofthe indicator marks 116, 117, 118 radially proximate to the image face 123. For example, at initial installation, with the valve shaft 127 situated with the valve closed, the ratchet 30a is positioned with the closed indicator mark 117 is adjacent the image face 123, so that the reflected image of the closed indicator mark 117 is visible at the top 124 of the viewing rod 120. Thereafter, any progressive rotary motion of the ratchet 30a consecutively moves other indicator marks, e.g. 116, 118 into radial alignment with the image face 123 for reflection to the top of the viewing rod 120, thereby indicating the functional status of the valve resulting from the turning of the ratchet 30a and shaft 127. In

the preferred embodiment, therefore, the transition of the valve from full open to full closed is accompanied by a 360" rotation of the ratchet 30a.

The operation of this indicator embodiment of the invention is readily understood from the foregoing disclosure. When the locking mechanism 3 is in the "lockout" position, the handle 1 may "free-wheel" around the viewing rod 30a. The user may inspect the top 124 of the viewing rod 120 to ascertain the functional position of the valve; e.g., if the valve shaft 127 is in an intermediate position, the intermediate indicator mark 118 is radially proximate the image face 123, and the image ofthe mark 118 therefor is reflected from the reflector face 122 for viewing through the top 124 of the rod 120. If it is desired to adjust the position of the valve to closed, the user inserts the key into the locking mechanism 3 and rotates the mechanism to cause the dog 11 to engage the ratchet 30a. With the dog 11 so engaged, the user turns the handle 1; the rotary motion of the handle 1 is transferred to the shaft 127 via the dog 11 and the ratchet 30a. The user rotates the handle 1 to bring the "closed" indicator mark 117 in direct alignment with the (unmoving) image face 123, at which juncture the shaft 127 will have rotated to completely close the valve. With the closed indicator mark 117 visible at the top of the rod 120 at the top of the handle, the user may then again turn the key in the locking mechanism 3 to withdraw the dog 11 from the ratchet 30a to "lock out" the valve against tampering. The ratchet 30a and viewing rod 120 are immovable, and display the functional status of the valve, until the locking mechanism 3 is again actuated to permit rotation of the ratchet 30a.

Another variation of the indicator embodiment of the invention is depicted in Figs. 27-28. This variation permits direct visualization of the indicator marker images, rather than images reflected from the inside walls of the rachet 30a. Like the embodiment of Figs. 25-26, this variation is adaptable for use in any handle body 1 of the invention in embodiments permitting for the open bore 112 in the handle 1.

This variation of the indicator embodiment is best understood with reference to Fig. 27. The object of the variation is to employ an extender tube 136 and an extender rod 130 to locate the indicator marks 132, 133, mask 137 and viewing lens 140 at or near the top 124 of the handle 1 to promote wide visibility of the marks 132, 133.

The indicator components of this embodiment include the extender tube 136 which has a top end and a bottom end and is coaxially disposed with the central bore 112. The extender

tube 136 is attached to, and is rotatable with, the ratchet 30a which functions as the means of engagement between the locking mechanism 3 and the rotatable shaft (not shown) of the valve or regulator. The extender tube 136 has a length such that it extends vertically between the ratchet 30a and approximately, or just short of the top 124 of the handle body 1. There also is provided the extension rod 130 having a top end and a bottom end, the rod 130 being disposed coaxially within the extender tube 136 in the assembled invention. The bottom end of the rod 130 is connectable to the fixed, non-rotatable central stem 126 of the valve or regulator. Typically, the connection between rod 130 and stem 126 is semi-permanent or secure, as by screwing, set screws, glue, or the like, so that the rod 130 is not rotatable but rather is fix in position.

At least two status indicator marks 132, 133 are provided upon the top of the extension rod 130. The indicator marks 132, 133 preferably are painted or printed upon a circular disk adhered to the top of the rod 130, or may be painted, engraved, or printed directly upon the circular top end of the rod 130. As seen in Fig. 27 the marks in the preferred embodiment are two semicircular or "half disk" marks of differing color (e.g. red for "open" and green for "closed") or bearing other symbols or indicia indicative of valve status.

A viewing lens 140 is secured upon the top end of the extender tube 136, through which the indicator marks 132, 133 may be viewed. The lens 140 preferably but not necessarily is convex to magnify the images of the indicator marks 132,133 viewed therethrough. A mask 137 is fixed between the lens 140 and the indicator marks 132, 133 for partially blocking image transmission along the inside of the tube 136 from the marks 132, 133 to the lens 140. The mask 137 is an opaque, semi-circular or half-disc shaped leaf or slip which may be mounted inside the tube 136 but more preferably is affixed to the underside of the lens 140 so as to occlude the passage of light through one-half of the lens 140. As seen in Fig. 27a, one desirable manner of providing a mask is to provide one-half the underside of the lens 140 with a rough, pitted, or densely scored or brushed finish 137 to serve as a mask by occluding the passage of light. The other half 139 of the underside of the lens 140 is provided with a smooth finish so that light passes directly therethrough permitting image transmission.

Combined reference is made to Figs. 27 and 28. The ratchet 30a is rotatable about the extension rod 130 to manually set the valve shaft (not shown) in a selected position. Such rotary motion also rotates the extender tube 136 to bring the mask 137 into radial alignment

with either one 132 or 133 of the indicator marks, so that the image of the one indicator mark 133 is blocked by the mask 137 and not viewable through the lens 140. The other one 132 of the indicator marks then is viewable through the lens 140.

Fig. 28 shows the alternative variation of the indicator embodiment in assembled configuration and with sections cut away to reveal that, when assembled, the indicator markers 132, 133 are proximate to the bottom ofthe lens 140. The device is assembled such that when the valve shaft is rotated to the selected position wherein the valve is closed, a "closed" indicator mark 132 is fully visible through the lense 140 while the "open" indicator mark 133 is hidden behind the mask 137. Similarly, if the valve shaft is rotated to the selected position wherein the valve is closed, an "open" indicator mark 133 is fully visible through the lense 140 while the "closed" indicator mark 132 is hidden behind the mask 137. if the locking mechanism 3 is actuated to engage the dog 11 with the ratchet 30a, rotary movement ofthe handle 1 is transmitted to the ratchet 30a and thence to the valve shaft to selectively adjust the operational status or position of the valve. Turning the ratchet 30 automatically concurrently rotates the extender tube 136 around the fixed rod 130, thereby changing the indicator images viewable through the lens 140 atop the tube 136. For example, rotating the handle 1 through one and one-half turns (540°) moves the valve into the full open position, and concurrently places the mask 137 between the lens 140 and the closed indicator mark 132, so that only the "open" indicator mark 133 is viewable through the lens 140. It will be immediately appreciated that the other embodiments of this variation of indicator device may be constructed with more than two indicator marks, by the simple expedient of providing a plurality of wedge- or "pie"-shaped indicator marks having vertices at the axis of the rod 130 and a mask having a wedge-shaped viewing window therein.

In application, it will of course be desirable to use the same lockout device throughout an entire facility. Authorized operations personnel will have a key permitting access to the handle of all of the operations control devices at such facility. Since all operations lockout devices will be the same, training will be simplified. A single key could be used for all authorized personnel. While all operations lockout devices may have the same mechanical construction, the operations lockout devices on certain equipment, or portions of a system, could be color-coded with matching color-coded keys and thus there would be various groups of authorized personnel who could operate different operating control devices. To provide the

extra level of safety protection for service and maintenance personnel, a safety or "personal" lockout device, such as 9', 40, 50, or 100, could be issued to each individual service or maintenance person at the facility. Since all handles of the control devices are identical, a service person could attach the safety lockout devices onto any handle in the facility, thus assuring that the position of the valve could not be altered during maintenance operations. It will be apparent that in some maintenance operations the service personnel must first have access to the operations key locking mechanism 3 from an authorized operations person, to allow the control device to be reset to the OFF position, at which point the personal safety lockout device could be engaged assuring that no energy could flow through the control device during the maintenance operation.

Although the invention has been described with particular reference to a number of different embodiments, still other embodiments and alternatives will achieve the same results based on the same inventive concept. Variations and modifications of these embodiments in the present invention will be obvious to those skilled in the art. However, the invention is intended to cover in the appended claims all modifications and equivalents of the physical embodiments shown and described in this specification. The entire disclosures of all references, applications, patents, and publications cited above, and ofthe corresponding application(s), are hereby incorporated by reference.