In 2022, Downer, in partnership with Logan Water and MASS Products, successfully engineered a simple and innovative isolation lock for buried water valves. The valve lock is the first of its kind for use in common square B and D class valve boxes – and is now widely used across the water industry, with further innovations in the pipeline to suit other infrastructure types.
Downer and its Logan Water Partnership delivery partners regularly isolate or shutdown parts of the water network on behalf of its water industry clients. A pressure network stores energy, which can be hazardous to workers if it is released when a work area is not appropriately isolated. When valves are operated accidentally, or don’t work properly, network isolations can fail – and the consequences are safety incidents, lost productivity, increased costs and unplanned water outages for customers.
Until recently, there has been no industry-accepted method to guarantee that a buried valve in a B or D class valve box had been isolated.
Dion Wright, Downer’s Human Operational Performance (HOP) Lead, described the process by which Downer’s signature Human Operational Performance (HOP) mindset was used to address this industry-wide issue.
“As part of our team’s HOP program, facilitated Learning Teams led by Downer and Logan Water were used to better understand how we conduct network isolations.
“All key stakeholders involved in the isolation process shared their views on why isolations can be either be successful or unsuccessful. The group noted that securing some isolations could be difficult, so we looked closely at how the nature of work could lead to an improvement in the execution of works. This sparked the development of a prototype valve isolation lock by Downer’s Commissioning Lead at Logan Water, Marlon Pritchard, in collaboration with MASS Products,” Dion said.
The lock comprises a steel plate which is secured inside a valve box, enabling physical control of a water network isolation and provides confidence that hazardous stored energy is controlled while maintenance works occur. The plate is then locked in place with an individually keyed lock and a warning tag, which makes it clear to workers who is working on the isolation and whether the infrastructure is or isn’t isolated.
“Working with MASS Products, we refined the lock design and commenced bulk fabrication, with the cost effective product available for purchase via the MASS Products online store. To date, approximately 500 valve locks have been sold and our valve lock solution is now a BAU tool across all Logan Water work sites,” Dion said.
Paul Harazin from MASS Products said they have continued to innovate and refine the technology and develop alternatives to suit other infrastructure types.
“Since launching the original prototype, a new circular model has been developed and we have begun coupling the device with other SMART technology and safety equipment, such as keyless padlock technology linked to an online program which is accessible from a smart phone or desktop computer.
“The valve locks are now being utilised by a number of organisations both locally and internationally and we are thrilled with the feedback received to date,” Paul said.
Using the valve isolation lock has resulted in a success rate of more than 90 per cent for isolations and is a great example of the outcomes that can be achieved by empowering people to manage a critical business activity in a safer, more efficient way.
“Logan Water is proud of this Australian first innovation and the benefits that it will deliver to the entire water industry,” Mike Basterfield, Logan Water’s Group Manager, concluded.
This sponsored editorial is brought to you by Downer Group. For more information, visit www.downergroup.com.
