OCTOBER 2009
SAFETY ALERT FLASH
RISKS LINKED TO STORED ENERGY
Several accidents have occurred in the
past due to stored energy. The EI
standard will be focussing on the −
importance of releasing the stored
energy before any work.
For example, one of the most dramatic
took place in LICHTENBURG (South
Africa Cement) in September 2008
which took the life of an electrician. −
Most of the root cause analyses after
these types of accidents show that
being unaware of the risk of sudden −
movements of machinery is one of the
main causes.
Accidents could happen because the
stored energy is not obvious (the
machine may be stopped and even
locked out). Stored energy could be
present in the following forms and
could result in serious accidents or
fatalities:
− The weight of the equipment or a
piece of the equipment
− The weight of the material in a kiln
or in a mill under load
− The weight of the material in a
bucket elevator or in an inclined
conveyer belt suddenly stopped
− The weight of a piece of
equipment unbalanced by
intervention (partial dismantling of
hammers on a crusher or buckets on
an elevator…)
− Compressed
Group Communicationsfluids (air, oil, liquid
– to Sr Management, BU managers, Health & Safety & Communications networks for posting
and discussion at all sites
Some examples for complementary
operation after lock-out
Before any intervention:
− Put the arm of the reclaimer on the
material stock pile or on the ground before
intervening
− Balance the kiln and the mill in order to
prevent movement
− Unload the compressed fluids or isolate
the circuits under pressure by opening a purge
valve and by discharching the pressure with
the tap below the isolating valve of the circuit
under pressure
Ground the electrical circuit or energized
equipment.
When the zero-energy state cannot be
reached, take appropriate measures. For
example:
Block the equipment appropriately
(unbalanced crusher rotor, equipment being
dismantled…)
Block systematically the mobile piece of a
bucket elevator or an inclined unbalanced belt
conveyor which can not be unloaded or that
will be unbalanced by the work (dismantling of
bucket, intervention on the belt of the
conveyor …).
Such stored energy risks can be
prevented by:
− Using this alert to raise general
awareness around stored energy
− Ensuring measures are taken into account
in the risk analysis to remove or isolate the
stored energy.
− Follow the mandatory LOTOTO sequence
from the LOTOTO Advisory (including Step 6:
Zero Energy State)
the
 OCTOBER 2009

SAFETY ALERT FLASH

RISKS LINKED TO STORED ENERGY

Pictures of the Lichtenburg plant below which illustrate the difficulty in identifying the lethal risk linked to stored
energy for what is considered to be a simple task at a material reclaimer.

Pictures of the Stockbridge site (US A&C) above which illustrate the
wheel loader crushing fatality linked to stored energy in hydraulic lines.

The bucket, which was initially extended to allow the mechanic to access the hydraulic lines,
contracted and crushed the mechanic when the hydraulic lines were de-pressurized.

The reclaimer is in working position. The disintegrated low speed reducer

Purpose of the task: change the motor which controlled the boom incline
cable gland
The electrical lockout was carried out but not the mechanical lockout. A risk analysis was not carried out because
the task was considered simple. The energy stored by the arm of the reclaimer in a high position while the employee
was working on the boom incline control motor was not taken into account.

Mechanic was caught and crushed in pinch

Mechanic accessed the
point hydraulic
here
lines indicated here, in this position

Group Communications – to Sr Management, BU managers, Health & Safety & Communications networks for posting
and discussion at all sites