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SOP For Cleaning of Clinker Cooler Discharge

This document provides a standard operating procedure for clearing a cooler discharge at a cement plant in Ariyalur, India. It details the responsibilities, personal protective equipment needed, hazards and risks associated with the task. The key steps are to shut down related equipment, empty the air cannon, open the inspection door slowly while maintaining negative pressure, and use protective gear like a kevlar suit when removing boulders. Emergency procedures are also outlined for injuries or equipment issues. Records like clearance certificates and a job safety analysis are referenced.

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713 views3 pages

SOP For Cleaning of Clinker Cooler Discharge

This document provides a standard operating procedure for clearing a cooler discharge at a cement plant in Ariyalur, India. It details the responsibilities, personal protective equipment needed, hazards and risks associated with the task. The key steps are to shut down related equipment, empty the air cannon, open the inspection door slowly while maintaining negative pressure, and use protective gear like a kevlar suit when removing boulders. Emergency procedures are also outlined for injuries or equipment issues. Records like clearance certificates and a job safety analysis are referenced.

Uploaded by

ayaskant751001
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOC, PDF, TXT or read online on Scribd
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DALMIA CEMENT (B) LIMITED CEMENT PLANT ARIYALUR PRODUCTION DEPARTMENT Issue No. 01 Rev. No: 00 Effect ve D!

!te: 01.11."010 #OP$PROD$01 Issue% B&: M.R A''(ove% B&: )OD (P(o%uct o*) #OP +OR CLEARIN, O+ COOLER DI#C)AR,E
Scope Responsibility Accountability PPE: :

This SOP is applicable to Safe working for clearing the cooler discharge.
Section Head Pyro.

: CCR executive. :

1. 2. !. ". $.
Tools:

Kevelar suit, Safety hel et, Safety shoe, #ask. %sbestos &loves.

1. 2. !. ". $.
Hazards:

'T pu p (reaker achine )a er (o* Spanner set +ing Spanner set

Risks associated

Mitigating Measures

(urn in,ury T(! * *- *ee%s: 1. /ire fighting 2. 1 ergency preparedness !. 'T pu p operation ". %ir blaster operation
Procedure:

-ear Kevelar suit ./ire proof suit0

1. 2. !. ".

Shut down the kiln operation. 23 to be taken for cooler drive, 4P3 and clinker crusher. Take &eneral and confined space work per it. 'se Proper PP1 5 tools.

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DALMIA CEMENT (B) LIMITED CEMENT PLANT ARIYALUR PRODUCTION DEPARTMENT Issue No. 01 Rev. No: 00 Effect ve D!te: 01.11."010 #OP$PROD$01 Issue% B&: M.R A''(ove% B&: )OD (P(o%uct o*) #OP +OR CLEARIN, O+ COOLER DI#C)AR,E
$. 7. 8. 9. 3ooler 64 fan to be operated with ini u suction. %ir cannon to be switched off and the residual air to be vented out. 6nlet valve to be isolated 5 cross check with pressure gauge. Keep the vent valve in open condition for safer side. distance0.

:. ;o other persons should be per itted near the door area .!

1<. 6nspection door to be opened for cleaning the =a ing. 3heck the draft at door area by kiln hood draft fro 33+ or ano eter. 11. (efore switching O; the 'T Pu p, check the )ose condition by check list and then switch O; the pu p. 12. The person, who is breaking the boulders, should be wearing hel et, gloves, asbestos fire suit, and shoes and should not be directly e*posed to the poking hole. 1!. 6f boulders are cleared, then ain door can be opened for cleaning the aterial. 1". %fter co pletion of ,a re oval close the door and keep all air canon air line valves in nor al operation condition. 1$. %ll first>aid edicines for burn in,uries are to be readily available near the area. 17. 1ither wireless ? phone should be available.
Emergency / Emergency Shut !!:

1. 6f burn in,ury is there, give /irst aid and infor to the Safety depart ent or 3all 1 ergency nu ber !1<9?:8$<:7!8<:?:8$<:7!871. 2. 6f any hose pipe got punctured or busted, then stop 'T pu p with the 1 ergency switch.
Records/Anne"ure:

1. +efer 2ine clearance certificates. 2. =S% as enclosed below.

.OB #A+ETY ANALY#I#:(.#A)

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DALMIA CEMENT (B) LIMITED CEMENT PLANT ARIYALUR PRODUCTION DEPARTMENT Issue No. 01 Rev. No: 00 Effect ve D!te: 01.11."010 #OP$PROD$01 Issue% B&: M.R A''(ove% B&: )OD (P(o%uct o*) #OP +OR CLEARIN, O+ COOLER DI#C)AR,E
Job Safety Analysis Job: Clinker discharge jam cleaning +#*er%isor: +ection ,ngineer Date: 15 06 - 2012 Analysis by: !"! "athiresh k#mar! +ection: -$. $e%ie&ed by: '!Chandrasekaran! A**ro%ed by: "!/inayagam#rthi

(itle o) em*loyee doing job: Attendant $e01d2recommended Sequence of Basic Job Steps
#t on ,

De*artment: rocess

,: "e%elar s#it3 +a)ety helmet3 +a)ety shoe3 'ask 4 Asbestos 5lo%es! Potential Hazards
,7*os#re to clinker d#e to body not )#lly co%ered 8#rn inj#ry

Recommended Safe Job Procedure


6se "e%elar s#it! 9ns*ection o) s#it &ith checklist Close the Air line inlet %al%e to the canon! ,m*ty air canon and ens#re that it is em*tied by o*ening the %ent line or )rom the *ress#re ga#ge <o other *ersons sho#ld be *ermitted near the door area = >m distance?! .*en the door a)ter the abo%e slo&ly! 'aintain the negati%e *ress#re in the ins*ection door area by $#nning the cooler %ent )an #ntil the job is )inished! Con)irm the s#ction &ith manometer or hood dra)t indication )rom CC$ Check the tightness o) the hose joints by checklists3 eriodic hose maintenance and re*lacement!

What Could Go Wron


Damaged s#it

Correcti!e Action
eriodic re*lacement! Don1t o*en the ins*ection door #ntil air canon is em*tied! "ee* the %ent %al%e o*en

.*en the ins*ection door

;ot clinker s*ill o#t &hile o*eration o) the air canon 9nlet air line is leaking or )ailed

Check the s#ction at the ins*ection door

8#rn3 8ody 9nj#ry

Cooler %ent )an may tri* and hot gases may *#)) o))!

+to* the last )o#r cooler )ans )or s#))icient s#ction in cooler

+&itch .n the 6( *#m*

:ater hose hit to the *erson

:ater hose *i*e got b#rst

+&itch o)) the 6( #m* 4 $e*lace the ;ose!

$emo%ing o) the bo#lders

;ot material bo#ncing

6se "e%elar s#it =@ire *roo) s#it?

Clinker *iece can bo#nce and hit the *erson o%er the "e%elar s#it!

'aintain the sa)e distance!

3/3

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