The document outlines the safe procedure for removing blockages in the cyclone of a cement factory's preheater. It involves 13 steps: 1) informing operators of the blockage, 2) conducting a risk assessment, 3) isolating the area, 4) isolating energies, 5) checking safety devices, 6) using proper PPE, 7) preparing for intervention, 8) starting energies, 9) performing the unclogging, 10) ending intervention, 11) checking the area is secure, 12) restoring equipment, and 13) communicating completion. The procedure is designed to safely remove blockages while protecting workers through risk assessment, energy isolation, PPE use, and following defined steps.
The document outlines the safe procedure for removing blockages in the cyclone of a cement factory's preheater. It involves 13 steps: 1) informing operators of the blockage, 2) conducting a risk assessment, 3) isolating the area, 4) isolating energies, 5) checking safety devices, 6) using proper PPE, 7) preparing for intervention, 8) starting energies, 9) performing the unclogging, 10) ending intervention, 11) checking the area is secure, 12) restoring equipment, and 13) communicating completion. The procedure is designed to safely remove blockages while protecting workers through risk assessment, energy isolation, PPE use, and following defined steps.
The document outlines the safe procedure for removing blockages in the cyclone of a cement factory's preheater. It involves 13 steps: 1) informing operators of the blockage, 2) conducting a risk assessment, 3) isolating the area, 4) isolating energies, 5) checking safety devices, 6) using proper PPE, 7) preparing for intervention, 8) starting energies, 9) performing the unclogging, 10) ending intervention, 11) checking the area is secure, 12) restoring equipment, and 13) communicating completion. The procedure is designed to safely remove blockages while protecting workers through risk assessment, energy isolation, PPE use, and following defined steps.
The document outlines the safe procedure for removing blockages in the cyclone of a cement factory's preheater. It involves 13 steps: 1) informing operators of the blockage, 2) conducting a risk assessment, 3) isolating the area, 4) isolating energies, 5) checking safety devices, 6) using proper PPE, 7) preparing for intervention, 8) starting energies, 9) performing the unclogging, 10) ending intervention, 11) checking the area is secure, 12) restoring equipment, and 13) communicating completion. The procedure is designed to safely remove blockages while protecting workers through risk assessment, energy isolation, PPE use, and following defined steps.
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Al Ain Cement Factory
Tool Box Talk
Job description Cyclone blockage removal
Shift Date
Topic discussed Safe procedure for removal of cyclone blockage
S. No Name Signature
SOP for Cyclone blockages removal in Pre heater
1. Information: CCR operator will inform to Engineer and Plant operators about cyclone blockage 2. Debriefing: a. Before every intervention, Shift Engineer makes a risk assessment with his team about the task to be performed. The team is composed of at least 2 persons 3. Isolation of the area of the intervention: a. The team members will put in place physical barriers, signs to forbid access to the pre heater b. Team members perform a visual check at all floors to ensure that there is no one in the pre heater
4. Isolation of Energies:
a. Team members must lock air pressure circuit and discharge manually one by one each air blaster, In case high pressure water lance is used, team members must check that all valves supplying lances are locked except the one they will use.
5. Check safety/rescue devices:
a. Team members must block the elevator (lift) at the floor where is performed the cleaning operation (In order to be immediately available in case evacuation is required) b. Team members must check that hoses and connections are in proper shape 6. PPE : a. Team members must ensure that all the PPE required for the operation are available and are in proper working condition. Once they have put PPE on, each member of the team check his colleagues to ensure that PPE are correctly worn. 7. Preparation of the intervention: a. Team members must ensure that no falling objects can compromise their safety b. Team members must ensure that there is an emergency exit in case they need to escape. 8. Open Energies: a. Start of the high pressure pump/compressed air lance b. The operator working as the coordinator must ensure that the HP lance control is working properly. 9. Intervention: a. Open one door at a time (always close the door before opening another one). b. Start unclogging jobs from the upper doors and perform going from upper floors to lower floors. c. If the system is running, open the door as few as possible (a widely open door should be avoided). d. The operator should stand as far as possible from the open door. e. Other team members never stay in the trajectory of the material (in case of flushing out) and must stay on the side where the door acts as a protection screen. f. Specific PPE must be worn at all times
10. End of intervention:
a. Team members must check the tools used, hoses, connections and store them in their designated area. b. Team members to ensure working area is cleaned. 11. Check: a. Team members must check all doors in pre heater are closed b. Team members to remove physical barriers, signs, lights c. Team members to restore the elevator (lift) 12. Restoring Equipments: a. Team members must restore equipments they locked (Air circuit for air blasters) 13. Communication: a. Shift Engineer to communicate to the CCR and superior that the operation is finished. embers must
