DALMIA CEMENT (B) LIMITED – CEMENT PLANT

ARIYALUR
PRODUCTION DEPARTMENT
Issue No. 01 Rev. No: 00 Effective Date: 01.11.2010 SOP/PROD/01
Issued By: M.R Approved By: HOD (Production)
SOP FOR CLEARING OF COOLER DISCHARGE

Scope : This SOP is applicable to Safe working for clearing the cooler discharge.
Responsibility : CCR executive.
Accountability : Section Head – Pyro.
PPE:
1. Kevelar suit,
2. Safety helmet,
3. Safety shoe,
4. Mask.
5. Asbestos Gloves.

Tools:

1. UT pump
2. Breaker machine
3. Hammer
4. Box Spanner set
5. Ring Spanner set

Hazards:

Risks associated Mitigating Measures

Burn injury Wear Kevelar suit (Fire proof suit)

Training needs:
1. Fire fighting
2. Emergency preparedness
3. UT pump operation
4. Air blaster operation

Procedure:

1. Shut down the kiln operation.

2. LC to be taken for cooler drive, DPC and clinker crusher.
3. Take General and confined space work permit.
4. Use Proper PPE & tools.

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 DALMIA CEMENT (B) LIMITED – CEMENT PLANT
ARIYALUR
PRODUCTION DEPARTMENT
Issue No. 01 Rev. No: 00 Effective Date: 01.11.2010 SOP/PROD/01
Issued By: M.R Approved By: HOD (Production)
SOP FOR CLEARING OF COOLER DISCHARGE

5. Cooler ID fan to be operated with minimum suction.

6. Air cannon to be switched off and the residual air to be vented out.
7. Inlet valve to be isolated & cross check with pressure gauge.
8. Keep the vent valve in open condition for safer side.
9. No other persons should be permitted near the door area (3m distance).
10. Inspection door to be opened for cleaning the Jamming. Check the draft at door area by
kiln hood draft from CCR or manometer.
11. Before switching ON the UT Pump, check the Hose condition by check list and then
switch ON the pump.
12. The person, who is breaking the boulders, should be wearing helmet, gloves, asbestos
fire suit, and shoes and should not be directly exposed to the poking hole.
13. If boulders are cleared, then main door can be opened for cleaning the material.
14. After completion of jam removal close the door and keep all air canon air line valves in
normal operation condition.
15. All first-aid medicines for burn injuries are to be readily available near the area.
16. Either wireless / phone should be available.

Emergency / Emergency Shut OFF:

1. If burn injury is there, give First aid and inform to the Safety department or Call Emergency
number 3108/9750963709/9750963761.
2. If any hose pipe got punctured or busted, then stop UT pump with the Emergency switch.

Records/Annexure:

1. Refer Line clearance certificates.

2. JSA as enclosed below.

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 DALMIA CEMENT (B) LIMITED – CEMENT PLANT
ARIYALUR
PRODUCTION DEPARTMENT
Issue No. 01 Rev. No: 00 Effective Date: 01.11.2010 SOP/PROD/01
Issued By: M.R Approved By: HOD (Production)
SOP FOR CLEARING OF COOLER DISCHARGE

JOB SAFETY ANALYSIS:(JSA)

Job Safety Analysis Job: Clinker Date: 15 – 06 - 2012 Analysis by: P.K. Reviewed by:
discharge jam Kathiresh kumar. M.Chandrasekaran.
cleaning

Title of employee doing Supervisor: Section Department: Process Section: PYRO Approved by:
job: Attendant Engineer K.Vinayagamurthi
Req’d/recommended PPE: Kevelar suit, Safety helmet, Safety shoe, Mask & Asbestos Gloves.
Sequence of Basic Job Recommended Safe What Could Go
Potential Hazards Corrective Action
Steps Job Procedure Wrong
Put on PPE Exposure to clinker due Use Kevelar suit. Damaged suit Periodic replacement.
to body not fully covered Inspection of suit with
checklist Don’t open the
Burn injury Close the Air line inlet valve inspection door until air
Open the inspection door Hot clinker spill out
to the canon. canon is emptied.
while operation of the
Empty air canon and air canon Keep the vent valve
ensure that it is emptied by open
Inlet air line is leaking
opening the vent line or from or failed
the pressure gauge
No other persons should be
permitted near the door area
( 3m distance).
Open the door after the
above slowly.

Maintain the negative

pressure in the inspection
Burn, Body Injury door area by Running the
Check the suction at the
inspection door cooler vent fan until the job
is finished.
Confirm the suction with
manometer or hood draft
indication from CCR
Stop the last four
cooler fans for
Cooler vent fan may
sufficient suction in
trip and hot gases
cooler
may puff off.

Check the tightness of the

hose joints by checklists, Switch off the UT Pump
Water hose hit to the & Replace the Hose.
person Periodic hose maintenance
Switch On the UT pump Water hose pipe got
and replacement.
burst

Clinker piece can

bounce and hit the Maintain the safe
Use Kevelar suit (Fire proof person over the distance.
Hot material bouncing suit) Kevelar suit.
Removing of the boulders

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