What Is “Line of Fire” in Safety?
In workplace safety, the Line of Fire (LOF) refers to any position where a person is exposed to potential injury due to moving objects, equipment, stored energy, or the sudden release of hazardous energy.
If something moves, falls, swings, rotates, releases pressure, or energizes unexpectedly — and you’re in its path — you’re in the Line of Fire.
Line of Fire incidents are among the leading causes of serious injuries and fatalities across industries such as oil & gas, chemical plants, construction, manufacturing, logistics, and mining. Most of these incidents are predictable and preventable, yet they continue to occur due to poor positioning, complacency, or failure to recognize hazards.
Why Line of Fire Incidents Are So Dangerous
Line of Fire hazards often:
- Occur suddenly
- Allow little or no reaction time
- Result in severe injuries or fatalities
- Involve routine tasks, not just high-risk jobs
The harsh reality is this:
PPE alone cannot save you if you are in the direct path of energy.
Avoidance and positioning are far more effective than protection.
Key Categories of Line of Fire Hazards
1. Struck-By Hazards
These occur when a person is hit by a moving or falling object.
Common examples:
- Vehicles such as forklifts, trucks, or mobile equipment
- Swinging crane loads or excavator buckets
- Dropped tools or materials from height
- Pressurized objects becoming projectiles
Typical root cause: Standing too close or under moving or suspended loads.
2. Caught-In / Caught-Between Hazards
These occur when a person is trapped, crushed, or pinched between objects.
Common examples:
- Hands caught in rotating machinery
- Being crushed between equipment and fixed structures
- Closing doors, valves, or mechanical arms
- Pinch points in conveyors or rollers
Typical root cause: Hands or body parts placed where movement was possible.
3. Released Energy Hazards
These occur when stored energy is suddenly released.
Types of energy involved:
- Pressure (gas, steam, hydraulic, pneumatic)
- Electrical energy
- Mechanical energy (springs, tensioned cables)
- Thermal energy (hot fluids, steam)
- Chemical energy
Common examples:
- Hose or flange failure under pressure
- Electrical arc flash
- Spring-loaded components snapping back
- Steam release during valve opening
Typical root cause: Failure to isolate, depressurize, or verify zero energy.
Real-World Examples of Line of Fire Situations
- Standing under a suspended crane load
- Walking behind or beside reversing vehicles
- Placing hands near rotating shafts or pinch points
- Working in front of pressurized hoses or pipelines
- Opening equipment without depressurizing
- Standing in the swing radius of cranes or mobile equipment
None of these are complex hazards — yet they continue to cause fatal accidents worldwide.
How to Stay Out of the Line of Fire?
1. Situational Awareness
Always ask yourself:
- What can move?
- What can fall?
- What can release energy?
- Where will it go if it fails?
If you can answer these questions, you can avoid the danger zone.
2. Maintain Safe Positioning
- Never stand under suspended loads
- Stay clear of swing radii and pinch points
- Keep a safe distance from moving equipment
- Position your body out of the path of potential energy release
Your position matters more than your PPE.
3. Control Hazardous Energy
- Follow Lockout/Tagout (LOTO) procedures strictly
- Isolate, depressurize, drain, and discharge energy
- Verify zero energy before starting work
- Never assume equipment is safe
Uncontrolled energy is one of the deadliest Line of Fire contributors.
4. Establish Clear Zones
- Respect barricades and exclusion zones
- Use spotters and flagmen for vehicle movements
- Clearly mark lifting and high-risk areas
- Enforce “no-go” zones during critical activities
Clear zones save lives — blurred boundaries cost them.
5. Improve Visibility and Communication
- Wear high-visibility clothing
- Maintain eye contact with operators
- Use hand signals and radios where required
- Never assume an operator has seen you
If you’re not visible, you’re vulnerable.
6. Use PPE — But Don’t Rely on It
PPE is the last line of defense, not the first.
- Helmets won’t stop crushing forces
- Gloves won’t save hands in pinch points
- Face shields won’t stop high-pressure failures
Avoidance beats protection — every time.
7. Plan the Job Before You Start
- Conduct a Job Safety Analysis (JSA)
- Identify Line of Fire exposures explicitly
- Modify the task sequence to eliminate exposure
- Stop work if conditions change
Poor planning puts people in the Line of Fire.
Certified Functional Safety Professional (FSP, TÜV SÜD), Certified HAZOP & PHA Leader, LOPA Practitioner, and Specialist in SIL Verification & Functional Safety Lifecycle, with 18 years of professional experience in Plant Operations and Process Safety across Petroleum Refining and Fertilizer Complexes.
