LOTO Accidents

Line Break Gone Bad @ Power Generation Facility (ZES of Steam could not be confirmed)

Two (2) maintenance men at an electric power generation plant removed a check valve cover from a steam system. The section of the steam line was isolated and tagged, but it could not be vented or drained first. The section was only partially depressurized when the cover was loosened. When the employees removed all fasteners…...

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Line Break gone bad – pipe not at a ZES (IMCA Safety Flash)

A member of a team of workers dismantling subsea emergency shutdown valves (ESDV) on deck was badly injured when hit by parts of a valve that were ejected with force. The team had successfully and without any problems already dismantled three (3) valves / ESDV as per the plans for that night. As the last…...

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Why we NEVER give up the key(s) to our LOTO lock(s)

At approximately 6:30 a.m. on March 06, 2012, Employee #1 was prepping to perform maintenance on a pug mill. Employee one was involved in performing the job duty of replacing the ends of worn paddles with new ones at the time of the incident. Employee #1 began working on the collect auger and requested the…...

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Relied on Robot Cage Door Interlock; Operator closed the door and started the robot, killing the maintenance tech

At 10:35 a.m. on December 2, 2024, Employee #1, 18, was performing maintenance on a sensor inside a robotic enclosure. As he entered the area, the robot was stopped by the entrance sensors. While he was cleaning the sensor, a coworker reset the machine from the control panel, unaware that Employee #1 was still inside…...

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Maintenance Tech By-Passes Guard Interlock – Machine Operator turned the machine from manual to auto and reactivated the machine, killing Tech ($145K)

At 11:00 a.m. on June 7, 2024, an employee, 50, working as a machinery maintenance technician for a frozen food manufacturer, was troubleshooting a ring remover since food trays were getting stuck. The employee bypassed the magnetic safety interlock gates and crawled underneath the conveyor. A coworker, the machine operator, was not aware that the…...

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LOTO Fatality – Belt Conveyor (MSHA)

On March 5, 2025, at 10:55 a.m., a welder, 57, with over seven (7) years of mining experience, died when he became entangled in a belt conveyor tail roller. The accident occurred because the mine operator did not de-energize and block the No. 12 belt conveyor against hazardous motion. GENERAL INFORMATION The mine is a…...

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Adjusting or cleaning the electric photo eyes on a bundle breaker machine (Fatality)

At 10:00 p.m. on March 26, 2023, an employee was working as a machine operator for a corrugated box manufacturer. The employee was possibly adjusting or cleaning the electric photo eyes on a bundle breaker machine. The machine was energized, in run mode, and not locked out. The employee broke the light beam, and the…...

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Truck Maintenance, Near Hit/Near Miss

A non fatal accident occurred recently where a contract employee was performing maintenance on an operating chemical fluid pump, mounted under a Mack delivery truck, when he became entangled in the P. T. O. shaft. The injury resulted in a compound fracture of the humerus bone with avulsions of the muscle tissue of the left…...

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Burns to the hands

    Hi Bryan, Here is a classic example of not having zero energy. This guy was going to clean a screen on a line that normally runs around 80 degrees. The screen is on the suction of a centrifugal pump. The screen plugged up, causing the pump to cavitate and heat up tremendously. He…...

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