I. Power Industry (Most Likely to Ignore “Residual Charge”)
Case: Death from Electric Shock during Substation Maintenance
Process: Maintenance personnel were conducting maintenance on a high-voltage capacitor cabinet. They only disconnected the switch but did not discharge or lock it.
The capacitor retained high voltage, and upon contact, the person suffered an electric shock and died.
Core Violation:
Failure to implement LOTO energy isolation
Failure to release residual charge
Failure to test for electricity and lock
Warning:
For power equipment, LOTO must be carried out as follows: Power off → Test for electricity → Discharge → Ground → Lock and post warning signs.
II. Food/Beverage Industry (Frequent Accidents Occurring During Cleaning and Material Replacement)
Case: Accident of Hand Caught in Mixer at Beverage Factory
Process: Workers were cleaning the mixer when they did not power off or lock it. They directly reached in to clean.
Someone else mistakenly pressed the start button, and their arm was caught in the mixer, resulting in serious injury and amputation.
Core Issue:
No protection on the start/stop buttons of the equipment
Cleaning ≠ stopping the machine; LOTO must be implemented
Warning:
For food processing equipment such as mixers, shredders, conveyors, and cleaning equipment, if hands need to enter the equipment, it must be locked.
III. Paper/Printing Industry (Rollers and Belts the Most Dangerous)
Case: Death from Roller Injury in Paper Factory
Process: Workers were handling stuck paper and did not implement LOTO. They extended their bodies into the rollers.
A colleague turned on the power switch, and the person’s arm was crushed, resulting in serious injury and amputation.
Core Violation:
No energy isolation
No warnings or communication
Warning:
Rollers, belts, and traction machines in the paper, printing, and textile industries are LOTO hotspots.
IV. Sewage Treatment/Environmental Protection Industry (Valves, Pumps, Pool Bodies Common Accidents)
Case: Drowning and Mechanical Injury during Sewage Pump Maintenance
Process: During the maintenance of the sewage pump, the inlet valve was not closed and it was not locked.
The pipeline suddenly overflowed, and the worker was swept into the pool. At the same time, the pump unexpectedly started.
Core Issue:
Unisolated liquid energy
No LOTO on valves
Warning:
For pipelines, valves, pumps, and pool bodies in water treatment, sewage, and environmental protection industries, all must be locked to prevent liquid backflow and equipment sudden startup.
V. Mining/Metallurgy Industry (High Temperature, High Pressure, Heavy Equipment)
Case: Death from Being Pulled In by Conveyor during Belt Machine Maintenance
Process: The conveyor belt was deviating, and the maintenance worker did not lock or secure it. They stood on the belt to adjust.
The conveyor belt suddenly started, and the worker was pulled into the rollers and died.
Core Issue:
No LOTO
No energy verification
Warning:
For conveyors, scrapers, crushers, and kilns in mining, metallurgy, and construction industries, strict LOTO must be implemented.
VI. Construction/Engineering Machinery Industry (Mostly Skipping Steps During Maintenance and Repair)
Case: Injury from Being Crushed in Excavator Maintenance
Process: During the maintenance of the hydraulic arm, the worker did not support, depressurize, or lock it.
The hydraulic circuit depressurized, and the arm suddenly dropped, causing death.
Core Issue:
No release of hydraulic energy
No mechanical locking
Warning:
For conveyors, scrapers, crushers, and kilns in mining, metallurgy, and construction industries, strict LOTO must be implemented.
Post time: Feb-28-2026
