Project work jay pee balaji cement palnt

JAYPEE BALAJI CEMENT PLANT
(A Unit of Jaypee Cement Corporation Limited)

Sl. No
1
Contents Description
Introduction
Pa e
2
2 Company Profile 2
3 Safety, Health and Environmental Policy 3
4 SHE Management System 4
5 Terms and Definitions 5
6 Management Responsibilities 7
7 Manufacturing Process 8
8 Process Safety Management 10
9 Potential Hazards and Precautions to be taken 32
10 Risk Assessment 41
11 Management Review 56
12 Record of Revision 56
13 Disaster ManagementOrganization Chart 57
14 Emergency Action Line 58
15 Emergency Duty Location 59
16 Plant Control & Shut Down (SOPT) 60
17 Chlorine Leak Stoppage Team 61
18 Fire & Rescue Team 62
19 Traffic Control Team 63
20 List ofKey Govt official and response service 64
21 List ofkey personal in the plant 65
22 List ofFire Equipment Available 66
23 Details ofFire Tenders 68
24 Earthquake Emergency Procedure 69
25 Identify Assembly Point 70
26 Disaster Management Chart (Mines) 71
27 Presentation
INDEX
Nos.
Page 1 of 73

INTRODUCTION:
Jaiprakash Cement Corporation Ltd. (JCCL) decided to create an integrated cement manufacturing facility in
the state of Andhra Pradesh to cater to the markets of southern India. Accordingly a giant 10,000 tpd
clinkerisation plant known as Jaypee Balaji Cement Plant (JBCP) was constructed. The commercial production
of Cement at JBCP started in the month of November 2011.
The plant is located in the village Budawada of Jaggayyapet Mandal, Krishna District, Andhra Pradesh. It is
about 210 KM from Hyderabad and 90 KM from Vijayawada. The plant and affiliated facilities cover nearly
816 hectares of land. Water requirement of the plant is met by Krishna River.
The technology of plant comprise of magnificent preheater having double string ILC a state of art technology
and the use of SF cross Bar cooler for the optimized pyro process. Using MVR and Ball Mill with Roller Press
is intended to achieve high energy efficiency and would meet the continuous market demand.
JBCP has got the mining lease of about 629.22 hectares of land to carry out its mining activities and to use the
lime stone for the Cement plant. The mine life is envisaged to be more than 40years. Computer Aided Deposit
Evaluation (CADE) is being used to produce uniform quality of Lime Stone.
Captive Power Plant (CPP)
JCCL has set – up a coal based 35 MW Captive Power Plant to meet out the power requirement for Cement
plant and to make the cement cost effective. The installed boiler is circulating fluidized bed combustor (CFBC)
Type. The fuel for the boiler is Indian coal or lignite or pet-coke with blending of lime stone.
Page 2 of 73

SHE POLICY:
SAFETY AND HEALTH OF EMPLOYEES AND THE PUBLIC ARE OF PARAMOUNT
IMPORTANCE TO US. WE BELIEVE THAT SAFE OPERATIONS AND PRESERVATION OF
ENVIRONMENT ARE ESSENTIAL PART OF OUR ACTIVITY.
OUR COMMITMENT
Compliance with all applicable legislations, regulations and other requirements
Continual improvement in environment, health & safety performance
Prevention of pollution, accidents & health problems in all spheres of our activities
OUR ENDEAVOUR
Conserve naturalresources
Reduce emissions & waste
Ensure operational safety and reduce risks to people, plant, machinery and environment
To improve workplace conditions through training and involvement of employees, contractors and
concerned statutory body
OUR MOTTO
“WORK FOR SAFE, HEALTHY, CLEAN& GREEN ENVIRONMENT”
February 2012 MANAGING DIRECTOR
Page 3 of 73

SHE MANAGEMENT SYSTEM:
Safety Management System (SMS) is a term used to refer to a comprehensive business management system
designed to manage occupational safety and health elements in the work place.
Safety Management System is applicable to Jaypee Balaji Cement Plant in Andhra Pradesh. The activities at
this location include manufacturing and marketing of the cement and clinker.
The company has adopted Safety management system based on The Factories Act 1948, AP Factories Rules
1950, The building and other construction workers (Regulation Of Employment and Conditions of
Service) Act 1996, MSIHC Rules 1989, which specifies the requirements for a Safety Management system in
order to:
a. Demonstrate its ability to consistently provide services and information that meets employees and
applicable statutory and regulatory requirements.
b. Enhance prevent pollution and ensure employee safe working procedures, safe working conditions
through the effective application of the Safety management system, including the processes for
continual improvement of the system and the assurance of conformity to worker and applicable
regulatory requirements.
c. It is the Policy of Jaypee Balaji Cement Plant to take all possible steps to ensure the health, safety and
welfare of all employees and other persons engaged in work for the organization and any third parties
who come into contact with the business.
d. It is the duty of each employee to comply with the company safety policy and to cooperate with the
management of the company to ensure that the work place remains as safe as possible.
e. If any person is in any doubt as to whether anything is safe or unsafe then they must assume that it is
unsafe until further guidance has been given by their manager or by the safety officer.
f. The Top Management of the company is fully committed to maintaining safe systems of work and
fully recognizes their overall responsibility for safety in the work place.
g. Any member of staff who does not comply with this safety policy or any other safety requirement will
be liable to disciplinary action.
Page 4 of 73

TERMS AND DEFINITIONS:
The following terms & definitions have been used at various places in Safety management system
Terms
Company / Organization:
Jaypee Balaji Cement Plant, a Unit of Jaiprakash Associates Limited.
Supplier:
One who provides materials and services to the company.
Customer:
Marketing is the immediate customer. However,all authorized dealers,end users of products, interested parties
including government regulatory bodies are also the customers.
Definitions
Safety Manage ment system:
The part of the overall management system that includes organizational structure, planning activities,
responsibilities, practices, procedures, processes and resources for developing, implementing, achieving,
reviewing and maintaining the SHE policy
SHE Policy:
Statement by the organization of its intentions and principles in relation to its overall SHE performance which
provides a frame work for action and for the setting of its objectives and targets.
Target:
1. Compliance with all applicable legislations, regulations and other requirements
2. Continual improvement in environment, health & safety performance
3. Prevention of pollution, accidents & health problems in all spheres of our activities
4. Conserve naturalresources
5. Reduce emissions & waste
6. Ensure operational safety and reduce risks to people, plant, machinery and environment
7. To improve workplace conditions through training and involvement of employees, contractors and
concerned statutory body
Corrective Action:
Action(S) to eliminate the cause of a detected nonconformity or other undesirable situation.
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Preventive action:
Action(S) to eliminate the cause of a potential nonconformity or other undesirable potential situation.
Correction/Remedial Action:
Action(S) to eliminate a detected nonconformity.
Record:
Document stating results achieved are providing evidence of activity performed.
Review:
Activity undertaken to determine the suitability, adequacy and effectiveness of the subject matter to achieve
established objectives.
Interested Parties:
Individual or group concerned with or affected by the Safety management system performance of the
organization.
Environment:
Surroundings in which organization operates,including air, water, land, natural resources,flora, fauna, humans
and their interrelation.
Note surroundings in this context extend from with in an organization to the global system.
Environmental Aspect:
Element of an organizations activities, products or services that can interact with the environment.
Environmental Impact:
Any change to the environment, whether adverse or beneficial, holy or partially resukting from and
organizations activities, products or services.
Prevention of pollution:
Use of process, practices, materials or products that avoid, reduce or control pollution, when may include
recycling, treatment, process changes, control mechanisms, efficient use of resources and material
substitutions.
Occupational Health and Safety:
Conditions and factors that affect or could affect the health and safety of employees or other workers
(including temporary workers and contractor personal), visitors or any other person in the workers.
Incident:
Work related event(s) in which an injury or ill health (regardless of severity) or fatality occurred or could have
occurred.
Note: An accident is an incident which has given rise to injury, ill health or fatality.
Hazard:
Source, situation, or act with a potential for harm intense of an injury or ill health, or a combination of these.
Hazard Identification:
Process of recognizing that a hazard exists and defining its characteristics.
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Risk:
Combination of the likelihood of an occurrence of a hazardous event or exposure(s) and the severity of injury
or ill health that can be caused by the event of exposure(s).
Risk assessment:
Process of evaluating the risk(s) arising from a hazard(s), taking in to account the adequacy of any existing
controls, and deciding whether or not the risk is acceptable.
Safety:
Freedom from unacceptable risk of harm.
Acceptable risk:
Risk that has been reduced to a level that can be tolerated by the organization having regard to its legal
obligations and its own SHE policy.
Effectiveness:
Extent to which plant activities are realized and planned results achieved.
Efficiency:
Relationship between the result achieved and the resources used.
Work environment:
Set of conditions under which work is performed.
SHE MANAGEMENT RESPONSIBILITIES:
Overall responsibility for the health and safety of all persons within the company rests with the Top
Management of Jaypee Balaji Cement Plant.
The Top Management delegates this responsibility to the individual operations managers/HODs for the
purposes of the day to day running of the operation with the direct assistance of individual line managers and
supervisors.
The JBCP has a nominated safety officer who has overall group responsibility for reviewing and making
recommendations on all matters relating to health and safety.
The safety officer will ensure through the management organization that:
• All persons employed by the company receive adequate health and safety training. In addition
employees will receive adequate instruction and supervision to enable them to undertake their work in
a safe manner.
• All plant and equipment are suitable for their intended purpose and that it is maintained in a safe
condition at all times.
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• All persons working on site, whether or not employees of the company, are adequately notified of all
known hazards and protective measures.
• That the company risk assessments, along with all other safety documentation, are brought to the
attention of all relevant parties.
• All employees are required to comply with their legal requirements under current National statutory
provisions. All staff must co-operate with the management of Jaypee Balaji Cement Plant to allow it to
comply with the legal requirements for health and safety.
• Individual members of staff, who have any concern regarding their own safety, or that of a third party,
are responsible for reporting the matter to their manager without delay.
The HOD/Area manager/Safety Officer should familiarize, explain the SHE policy of Jaypee Balaji Cement
Plant to all in the plant and assist them work in a safe manner.
MANUFACTURING PROCESS
The cement manufacturing is done by using Calcareous & Argillaceous as main raw materials. The
coal is used for providing heat for clinkerisation which is an intermediate product. When Clinker is
mixed with Gypsum, OPC is produced and when clinker is mixed with Gypsum & Fly Ash, PPC is
produced.
The following steps are involved in cement manufacturing process:
1. Mining/Quarrying: Mining of calcareous material having min. Cao content 42.5% is required
or alternatively high and low grade lime stone quarries are developed to meet out average
requirement.
2. Crushing: Lime Stone obtained from quarry is crushed in single rotor double impactor to
reduce its size from 1.2 m (edge to edge) to ≤75 mm for Vertical Roller mill. During crushing,
dust generates causing pollution for which Bag filters are installed to control the pollution.
3. Raw material Grinding: Grinding will be done in VRM to reduce the size to 12 % R on 90 µ
known as raw meal. The hot gas is supplied at 250 o
C during raw material grinding for
demoisturisation up to <1 % and better grind ability. The feed moisture will be maintained
within 6 – 8 %. The corrective/additive materials viz. Bauxite, Laterite/Iron Ore will be added
as per raw mix design for grinding with lime stone. The Pre-heater exhaust gases will be
utilized for drying/demoisturisation. In case Kiln is not running, hot gas will be supplied by
hot gas furnace. Cyclones, RABH etc. are provided in the circuit for recovery of raw meal and
energy /waste heat utilization. The raw meal is stored in CF/ Blending Silo.
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4. Coal Grinding: Coal will be ground/pulverized in VRM. The feed size for VRM is ≤ 55mm.
The feed moisture will be controlled to 8 %. Hot air from cooler vent will be supplied at
temperature ≤ 300 o
C to demoisturise up to < 1%. The product fineness will be maintained
at15 % R on 90 µ. The pulverized coal will be stored in fine coal bunker connected with bag
filter for degusting.
5. Pyro-processing:
(i). Preheating & Calcinations: Raw meal will be extracted from blending silo and fed to
Preheater top cyclones which descends through cyclones to calciner and ultimately to
Kiln. The flue gases coming out from kiln and cooler will be counter-currently passed
through calciner and cyclones upwardly. The heat transfer will take place to raw meal
in Preheater and calciner decomposing lime stone as under:
800 o
C
CaCO3 CaO + CO2
The raw meal temperature at kiln inlet coming in will be >800 o
C and degree of
calcination from 65 % to 90% will be achieved before feeding to the kiln. The hot
gases from cooler will be supplied through TAD to KRTP/Calciner for increasing
degree of calcination.
(ii). Clinkerisation: The raw meal enters at kiln inlet in Pre-heating zone after completing
calcination i.e. decomposition of lime stone, then to presintering/transition zone, to
sintering/burning and cooling zone. The temperature inside kiln will be increased by
adjusting required coal feed and achieved maximum temperature will be achieved in
burning zone up to 1450-1500 o
C at which clinkerisation/silicate- formation will take
place as under:
SiO2
+ 1450 o
C 3CaO SiO2
CaCO3 + Al2O3 2CaO SiO2
+ 3Cao Al2O3
Fe2O3 4Cao Al2O3 Fe2O3
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The kiln speed, raw meal feed and coal feed will be adjusted after optimization of
system. The produced clinker phases i.e. C3S, C2S, C3A & C4AF will be discharged
to cooler.
(iii). Cooling: Cooling will be done through cross bar ‘SF Cooler’ by quick air quenching
to arrest glass-content of clinker avoiding formation of periclase. After cooling, the
temperature of Clinker comes out to be around 90o
C.
6. Clinker Storage: Clinker will be stored in covered yard and silo to avoid moisture.
7. Cement Grinding: Clinker with Gypsum up to 5 % will be ground to produce OPC. Clinker
with gypsum up to 5% and fly ash from 10 to 35 % is ground to produce PPC as per IS 1489
part-1.
8. Packing & Dispatch: Cement after grinding will be conveyed to storage silo and from there
extracted by aeration to packing plant for loading to wagons/ trucks.
PROCESS SAFETY MANAGEMENT:
Process Safety Management describes the safety parameters to be noted when a machine/equipment
is in operation or in maintenance.
LIME STONE CRUSHING, STACKING AND RECLAIMING:
Lime stone mined from the mines is brought to the Plant by Dumpers of 50MT capacity. The size of
the material received is 1.2 m (edge to edge). This is crushed by the LS crushers to the size of 75 mm.
There are TWO crushers of IMPACT type.
The crushed LS of 75 mm size are taken through a series of Belt conveyors to a STACKER for
piling.
Details of Equipments:
DUMP HOPPER:
Function:
Limestone coming from mines by dumper is unloaded in Dump hopper from which the material will
be conveyed for size reduction.
Safety Precautions:
• Railings to be provided at the sides of the dump hoppers
• Proper signaling is to be provided for truck drivers when they are reversing the truck for
dumping the material.
• Strict instructions to be passed for the personnel to not to go near to the dump hopper at the time
of dumping.
Pollution Control Measures:
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• Water sprays system to ne provided in the dump hopper for suppressing the dust generated at
the time of dumping.
LIME STONE CRUSHER:
Function:
Impact Crusher is mainly used to crush the main kinds of large, medium and small material. This
impactor crushes the materials with impact force. When the material enters the blow bar area, they are
crushed due to high impact of the blow bar and get thrown to the impact plate. This process is
repeated until the materials are crushed to the required size so that they pass through the discharge
section in lower point of machine. The size and shape of the product can be changed by adjusting the
gap between impact rack and rotor.
Safety Precautions:
• Do not start the machine unless all the Protective Devices like Belt Guard, Shaft Guard are
fixed.
• Do not open Doors when the machine is running.
• Ensure that nobody stands behind the Rear Housing, while opening / when it is tilted. This may
come down on a malfunction.
• Gap adjustment should be done only when the machine is STOPPED.
• Ensure that the Hydraulic Pump is OFF during the running of the Impactor.
Pollution Control Measures:
• Covering of the Dump Hopper with curtains to contain any dust generated.
• Water spray nozzles provided at the dump hopper to suppress dust generated.
• Degusting Bag Filters are provided for collecting the dust.
WOBBLER:
Function:
All Wobblers are rotated in the same direction and at the same speed. Thereby ensuring a constant
gap of 80 mm between the Wobblers shaft all along the wobblers bed. Because of alternate, vertical
and horizontal elliptical wobblers’ shaft, the feed material on the wobblers’ bed experiences a rocking
and tumbling motion. Therefore, over size is wobbled and feed to the downstream Crusher, whereas
the undersize slit through the gap in the wobblers bed directly on to a downstream Belt Conveyor.
For a special case, in handling of Wet materials, due to high moisture content, all elliptical wobblers
shaft are constantly cleaned by spring mounted scrappers is attached.
Safety Precautions and Instructions:
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• Before repair/adjustment or performing routine maintenance, Cut off the power supply to the
equipment and let the machine come to a standstill.
• After repair/adjustment or performing routine maintenance, Check that the tools, tackles, etc.
have not been left on the machine.
• Check for wobblers’ shaft timing and free rotation of the shaft.
• Mount coupling guards if dismounted for maintenance
OMNI SCREEN:
Function:
Screen is a machine used to classify the materials by size.
• Don’t go close to the machine when it is in operation.
• When work is to be carried out inside or around the screen, the main power switch must be
isolated and locked out, and a sign “Under repair” Must be displayed
APRON CONVEYOR:
Function:
The Apron Conveyor is a type of chain conveyor, the typical design involves the series pans mounted
between two strands of roller chain with pans overlapping to eliminate driveled and often equipped
with end plates for deeper loads.
• Cover the sides of the equipment throughout its length with safe guards.
• Don’t go close to the machine when it is in operation.
• At discharge end dedusting provision is to be provided for controlling dust emission.
SCRAPER CONVEYOR:
Function:
The Scrapper Conveyor is a type of chain conveyor arranged below the Apron conveyor to carry out
spillage material from Apron conveyor.
• Cover the sides of the equipment throughout its length with safe guards.
BELT CONVEYOR:
Function:
The Belt conveyor is for transporting the material from one place to another place.
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• Should not go close the belt conveyor when it is operating
• At the time shut down, LC to be taken for carrying out the shut down works
• It should be covered at sides and top.
• At discharge end dedusting provision is to be provided for controlling dust emission
HAND OPERATED CRANE (EOT CRANE):
Function:
Over head cranes are typically used in maintenance application, where efficiency or downtimes are
critical factors.
• The capacity of the lifting material should not be more than the design capacity of the Crane.
• While lifting the material, it should be ensured that no personnel are come below the lift system.
COMPRESSOR (AIR):
An air compressor is a machine that uses an electric motor or gas engine to power a device that sucks
in successive volumes of air from atmosphere, compresses(squeezes)each volume of air in a confined
space to increase its pressure by making the volume smaller, and then transfers the high pressure air
to a receiver tank.
• Safety Valves etc. should be checked for ensuring their proper working.
DRYERS:
A compressed air dryer is a device for removing water vapor from compressed air. Vapor is removed
from compressed air to prevent condensation from occurring and prevent moisture from interfering in
sensitive industrial proven.
RECEIVERS:
An air receiver is essential to every compressed air system to act as a buffer and storage medium
between the compressor and the consumption system.
• Shell Thickness of the receiver should be as per specification.
• Any Leakages identified should immediately be reported.
BAG FILTER (TYPE: PULSE JET):
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The dust laden air enters in the bag filter by suction. The heavier dust particles fall immediately into
the hopper, while the lighter dust gets deposited on the outside of the filter bags.
• Bags should be regularly checked for ensuring there are no damages. The damaged bags
decrease the efficiency of the equipment.
• The structures should be as per specification & standard so as to sustain the wind loads etc.
Ruling out any possibility of collapsing which can make a loss to life & property.
CROSS BELT ANALYSERS:
The equipment is fixed above Limestone Conveyor. Limestone passing the through Cross Belt
analyzer, which carries out the analyses and indicate online values of CaO, Fe2O3, Al2O3, SiO2.
• Since the equipment uses radioactive source for the detection, hence regular checkup of
radiation by nucleonic gauges should be done. In case if radiation is crossing the permissible
limits immediately the matter must be brought into the knowledge of the concerned officer-in-
charge & supplier of the equipment.
ROTARY AIR LOCKS:
It is discharge control equipment with special arrangement to avoid false air entry into the system.
• Before repair/adjustment or performing routine maintenance, Cut off the power supply to the
equipment and let the machine come to a standstill.
• After repair/adjustment or performing routine maintenance, Check that the tools, tackles, etc.
have not been left on the machine.
STACKS:
It is used to evacuate the hot flue/ dust laden gas from furnace/system to open atmosphere at a height,
so that surrounding area is not affected.
• The structures should be as per specification & standard so as to sustain the wind loads etc.
Ruling out any possibility of collapsing which can make a loss to life & property.
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• Proper installation & working of dust monitoring systems so as to ensure no hazardous
contamination of surrounding environment.
LIMESTONE STACKER & RECLAIMER:
LIMESTONE STACKER:
Function:
The STACKER is equipment used for preparing pile with the coming lime stone from crusher. The
pile will be formed as per the required quality of Limestone by continuously moving throughout the
length of the stack pile by pouring the material layer by layer.
• To start with, the operator should accustom himself to the working of the various features of
Stacker/Reclaimer. The brakes, limit switches, controls and the various safety devices should be
thouroughly checked and workability ensured.
• In the event of accident or if any drive goes out of control,the operator should press the
emergency push- button to trip the circuit breaker/Main contactor.
• When the operator resumes duty, the first thing he has to do is to carry out the daily inspection
procedure.
• Operator should be vigilant about :-
Change in sound during operaton which is indicative of a developing mechanical or
electrical fault.
Mechanical faults like loose key, coupling bolts etc.
• The hoists or drive mechanism should never be operated if it is not in perfect working condition
• When any device is idle or when the operator leaves the Stacker/Reclaimer, he must place
controls in off position.
• No one should operate the stacker/Reclaimer if he is not fully familiar with its
working/Operation or who has not been trained in its safe operating practice. Also somebody
who is not fully fit physically and mentally should not perform the duty of an operator as long
as he is not totally cured.
• As soon as a leak is observed in hydraulic system of luffing cylinder of stacker, the same should
be rectified forthwith.
• Since safe working of both Stacker and reclaimer are very much dependent on proper
functioning of all limit switches, it is essential to periodically check that all limit switches are in
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position and these are hundred percent operational to perform the duty for which have been
provided.
• When wind velocity exceeds 20m/s or 70 kilometers/hour, both Stacker & Reclaimer Operation
should be stopped and the machines should be promptly brought to parking position(near end
buffer of rail track) and wedge blocks(made of timber) should be pushed from inside underneath
the extreme wheels of main machine on either end on both rigid and pendulam sides and pushed
tightly against the body of the wheels.
Further, the rail clamps should be tightly engaged with the runway bills.
The slew anchor pins should be inserted into holes on slew upper frame penetrating into the bottom
car(through the hole provided for this purpose on top plate of bottom car) to resist storm wind load.
In this condition the stacker boom should be horizontal and shall be parallel to track rails.
Further, the rail clamps should be tightly engaged with the runway rails.
LS RECLAIMER (TYPE : BRIDGE)
Function:
The RECLAIMER will cut the pile perpendicular to the axis of the pile and the material , this method
helps in getting a blended quality so that large scale variations are ruled out.
Safety norms to be observed during operation and also when machine is out of operation
To start with, the operator should accustom himself to the working of the various features of
Stacker/Reclaimer. The brakes, limit switches, controls and the various safety devices should be
thouroughly checked and workability ensured.
• In the event of accident or if any drive goes out of control,the operator should press the
emergency push- button to trip the circuit breaker/Main Contactor.
• When the operator resumes duty, the first thing he has to do is to carry out the daily inspection
procedure.
• Operator should be vigilant about :-
Change in sound during operaton which is indicative of a developing mechanical or
electrical fault.
Mechanical faults like loose key, coupling bolts etc.
• The hoists or drive mechanism should never be operated if it is not in perfect working condition
• When any device is idle or when the operator leaves the Stacker/Reclaimer, he must place
controls in off position.
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• No one should operate the stacker/Reclaimer if he is not fully familiar with its
working/Operation or who has not been trained in its safe operating practice. Also somebody
who is not fully fit physically and mentally should not perform the duty of an operator as long
as he is not totally cured.
• As soon as a leak is observed in hydraulic system of luffing cylinder of stacker, the same should
be rectified forthwith.
• Since safe working of both Stacker and Reclaimer are very much dependent on proper
functioning of all limit switches, it is essential to periodically check that all limit switches are in
position and these are hundred percent operational to perform the duty for which have been
provided.
• When wind velocity exceeds 20m/s or 70 kilometers/hour, both stacker & Reclaimer. Operation
should be stopped and the machines should be promptly brought to parking position(near end
buffer of rail track) and wedge blocks(made of timber) should be pushed from inside under
neath extreme wheels of main machine on either end on both rigid and pendulam sides and
pushed tightly against the body of the wheels.
Further, the rail clamps should be tightly engaged with the runway bills.
• The rake car is to be taken to one end near fixed side of reclaimer bridge and parked there until
reclaiming operation is resumed when there is operative wind of 20m/s or 70km/hour
maximum.
RAW MATERIAL HOPPER BUILDING:
Function
Limestone and Corrective material comes from Reclaiming stockpile to Raw material hopper
building through belt conveyors. This material is then stored in hopper.
RAW MILL:
Function
Raw material Grinding involves in size reduction of raw materials (Lime stone, Laterite A, Laterite F)
from 75 mm to fine powder of size < 12 % residue on 90 micron sieve. Two Vertical Roller Mills
(VRM’s) of capacity 450 tph each are installed for grinding the raw materials.
CONTINUOUS FLOW SILO:
The CF-Silo is a continuous-operation homogenizing and storage silo for storage, extraction and
feeding of raw meal for clinker production.
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The main function of CF Silo is to blend & homogenize the material of different quality, this is
achieved by extracting the raw meal from several points of silo bottom.
Further on being extracted this Raw Meal is stored & continuously aerated in a Bin Under the Silo for
the well-mixing.
The CF Silo incorporates a programmable control unit for extraction equipment and extraction
distribution. Consequently, optimum extraction distribution can always be selected on the basis of
actual operating conditions.
Standard Operation and Safety Instructions:
1. Avoid any operational mode that might be prejudicial to safety
2. Operate the machine only if all protective and safety-oriented devices, such as removable safety
devices, emergency shut-off equipment, sound proofing elements and exhausters, are in place
and fully functional.
3. Before starting up or setting the machine in motion make sure that nobody is at risk.
4. Never switch off or remove suction and ventilation devices when the machine is in operation.
Special work in Maintenance and repairs during operation, disposal of parts and consumables:
5. In any work concerning the operation, conversion or adjustment of the machine and its safety-
oriented devices or any work related to maintenance, inspection and repair, always observe the
start-up and shut-down procedures set out in the operating instruction and the information on
maintenance work.
6. Ensure that the maintenance area is adequately secured.
7. For carryout overhead assembly work always use specially designed or otherwise safety-
oriented ladders and working platforms. Never use machine parts as climbing aid. Wear a safety
harness when carrying out maintenance work at greater heights.
8. Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or
preservatives before carrying out maintenance/repair. Never use aggressive detergents. Use lint
free cleaning rags.
9. Any safety devices removed for set-up, maintenance or repair purposes must be refitted and
checked immediately upon completion of the maintenance and repair work.
Gas, Dust, steam, and Smoke:
Carryout welding, flame-cutting and grinding work on the machine only if this has been expressly
authorized, as there may be a risk of explosion and fire.
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Before carrying out welding, flame-cutting and grinding operations clean the machine and its
surroundings from dust and other inflammable substances and make sure that the premises are
adequately ventilated (risk of explosion.)
Hydraulic and Pneumatic equipment:
Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair the
damage immediately. Splashed oil may cause injury and fire.
Depressurize all system section and pressure pipes (hydraulic system, compressed air system) to be
removed in accordance with the specific instructions for the unit concerned before carrying out any
repair work
Safety instruction for the user:
Inspection door must not be opened unless the machine is at standstill.
When opening any inspection doors, bear in mind that rotating parts may continue to run for several
minutes even after stopping the drive.
If person is required to enter the machine for eliminating any malfunction, it must be ensured that the
drive cannot be restarted unintended and that the relevant values (maximum workplace concentration)
Person that need to enter any metal containers for inspection and repair work are allowed to use hand
lamps and electric tools with a maximum 48V only.
REVERSE AIR BAGHOUSE – I & II:
RABH - Process Description
a. Overall de-dusting description:
The dust laden gasses from Preheater fan outlet & raw mill fan outlet enter into the bag house where
the dust is collected in the bags & dust free gases escape out.
Since the temperature of the gases entering the baghouse is high when the mill is not running, air
dilution cooling is being provided by Dilution air fan.
Bag House ID Fan is positioned between outlet of Bag House and Stack.
Filter Bag Cleaning Operation:
The outlet damper of the compartment to be cleaned closes, cutting off the main dust laden gas
supply. The reverse air damper will open and clean hot gas will flow through the fabric in the reverse
direction. The bags are prevented from totally collapsing by steel rings surrounding the bags. The
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collapsing action plus the flow of gas dislodges the dust from the inside of the bags. This dust falls
into the hoppers below while the reverse air stream travels back through the open inlet damper to the
inlet plenum and to the remaining operation compartments.
The reverse air flow occurs for about 30seconds (typical) after which the reverse air damper closes
stopping all air flow and allowing dust to settle. After a settling period of approximately 30 seconds
(typical), the reverse air damper opens and the outlet damper opens. This action gradually reinflates
the filter bags. This keeps the bags from popping open that is detrimental to bag life. The reverse air
damper then closes, and the compartment is now back on-line. The remaining compartments are
cleaned in turn until each has been cleaned. The bag house cleaning cycle will not start unless the
cleaning interval timer, or the cleaning resets the cycle – set point is reached.
The time span between cleaning cycles will be dependent on various factors, the most significant
being inlet dust loading. Each bag house can and should be set up for its own conditions. An optimum
timing sequence should be determined taking into account pressure drop versus frequency of cleaning
and bag life. The total time cycle is adjustable as well as the individual settings. Final settings of
timers, total cycle time per compartment and interval between complete cleaning cycles of all
compartments should be determined after the units are placed in operation. The best condition is the
shortest possible cleaning time per compartment with longest possible interval time between
compartment cleaning. The time settings for cleaning cycle can be changed from the PLC. The bag
house cleaning interval timer can be adjusted to change between baghouse cleaning cycle.
b. REVERSE AIR FAN:
Safety during operation and reporting procedure:
In order to obtain the best possible bag life, the following points should be strictly adhered to:
• The bag house must be started, operated and maintained strictly as per the guide lines laid down
under this Operation & Maintenance manual
• All temperature peaks beyond 260˚C must be reported to Alstom Projects India limited,
immediately.
• Daily records of the temperature should be maintained in a strip chart recorder and the same
should be forwarded to Alstom Projects India limited on a monthly basis. The bag house should
always be operated at a temperature below 240˚C. The gas composition and moisture should be
analyzed and recorded in each shift. The operating temperature should be at least 40˚C above
the dew point temperature. The records are to be sent to Alstom Projects India limited every
month.
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Any abnormal condition experienced by the bag house such as very high dust load, shock transmitted
because of an explosion in the circuit, all high temperature excursions beyond 260˚C must be
reported within 24hour of the occurrence over a fax/e-mail. In case of any damage APIL
representative will take action for determining the cause. No repair/ modification shall be carried out
before such investigations are completed by APIL representative.
• No adjustment of cleaning cycle should be done without prior approval from Alstom Projects
India Limited during warranty period.
• Bags must be kept at recommended tensioning level as mentioned elsewhere in the Operating &
Maintenance manual. Do not allow the bag tensioning to drop below the specified level. Re-
tensioning of bags is important for long bag life.
• The bag house should always be operated with bleed in dilution air during kiln running
condition in order to restrict the temperature to 220˚. Proper mixing of cold air and hot gases
from the pre-heater should be ascertained before it is allowed to pass through the bag house.
COAL MILL:
The raw coal from coal hoppers will be metered and fed into mill for grinding into fine powder, two
VRM’S of capacity 58 MT/hr each are installed for raw coal of size <55 mm to fine powder of size
<15% residue on 90 micron. The raw coal enters into VRM, the material will move on the mill table
due to its rotation, when the material enters between the fixed rollers mounted on spindle and the
table, it gets ground into fine powder. Hot air will be supplied into mill for removing moisture
resulting in better performance of the mill. The grounded material i.e. fine coal will lift to classifier
by the air supplied into the mill for separating the fines and coarse material. The coarse material will
fall back on to the grinding zone for further grinding and the fines will be carried away into a Bag
house for collecting the finer material, the collected material will be transported to fine coal bins
through screw conveyors and F.K. pumps for storage and for further coal dosing.
The fine coal will be extracted from coal bins by aeration and it will be metered by weigh feeders and
will be conveyed for firing in Kiln & Pre-Calciner by F.K. Pumps.
Safety Precautions & Consideration in handling of Raw Coal & Coal Mill Operation :
• Safe operation of the system requires use of coal with lesser volatile matter
(<15%)
• Do not store different types of coal in the same pile.
• Operation and maintenance of the coal mill related system should only be
performed by well trained personnel.
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• Carrying the wireless system is a must in coal mill area to have a on the hand
contact with CCR.
• Attendants, operators, mechanical technicians or electricians and labours must
work under the supervision of an individual who understand the hazards
associated with work in the coal mill system. This also applies to contractors.
• A hot work permit is required for any welding or cutting in all areas defined by
the scope.
• Proper care is to be taken for cleaning up coal piles.
The vertical roller mill with air-swept classifier is designed for operation with drying gases.
Under the following conditions, however, there is a risk of fire and pulverized coal
explosions:
-an inflammable substance
-an oxygen concentration sufficient for combustion
-an effective ignition source
-a sufficient pulverized coal fineness
-a sufficient pulverized coal-air ratio
Warning!
Keep the grinding-drying plant clean to prevent the propagation of a potential explosion or
fire. Any deposits of pulverized coal on ducting’s and floors must be removed immediately.
Cleaning intervals are a must adopted.
A smoldering fire can develop into an open fire when supplied with oxygen.
A draft may whirl up the pulverized coal which may then mix with the oxygen contained in
the air and form an explosive mixture.
Before opening the plant ensure that all CO indicators show safe values.
Risk of burning!
In addition, check the plant parts (finished product silo, filter etc.) for unusually high
temperatures.
The person opening the inspection doors must wear fire protective clothing. Escape routes
must exist and are to be clear.
Before carrying out any maintenance work inside the mill, ensure that the mill has been
sufficiently vented. If necessary, wear adequate protective equipment.
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If the safety limit values (CO and Temperature values) are exceeded, stop the grinding process
(auto interlock) and flood the plant with quenching gas.
Warning!
• Danger of suffocation!
When the plant is flooded during standstill, be aware that quenching gas might escape from
certain plant parts. Therefore before entering the plant, make sure there is no danger of
suffocation.
• Because of the pressure- shock proof design of the mill and classifier housings, no
welding, grinding, and flame cutting work or other modifications are allowed on
these housings.
Since the pulverized coal bag houses present an explosion and fire hazard, extreme care should be
taken when entering them.
Bag House entry may be required due to the following circumstances:
• Alarm Condition of broken bag detector.
• Routine Planned maintenance on bag houses.
• Flow Problems with coal in the bag house hopper
Safety Precautions & Consideration in Maintenance of Coal Mill Bag House :
Entering the baghouse
Under all circumstances, prior to entrance into baghouse, approval must be
received from CCR.
• The baghouse should only be entered when confined space conditions are met and a permit is
issued
• Once these conditions are met turn off the air supply to the baghouse pulsing unit and bleed
the air manifold, lock and tag out the inlet valve for the compressed air to the baghouse.
• If CO is not increasing, open the entry door and confirm that atmosphere is safe for operation.
• Check internal conditions carefully.
• Before entering into the bag house ensure that lock out/tag out is met.
If at any time during the bag house entry the CO analyzer indicates a rising CO concentration
in the bag house, all personnel must evacuate the area immediately. The doors must be closed
and the CCR will initiate an inerting sequence after all locks and tags are removed.
Superiors should be notified as soon as possible if the CO levels in the bag house indicate a
smoldering fire during entry.
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Bag replacement
The main reason for bag house entry is to replace a broken bag. There are a few important points to
consider.
• Through the bag change process, CO should be monitored for any increase. If CO is seen to
be rising, all personnel should leave the dust collector, close the door and exit the coal mill
area. Once clear initiate an inertizing sequence.
• A broken bag results in coal contamination of the upper plenum of the baghouse. It is
important to clean the upper plenum completely before replacing the broken bags. This is to
ensure that no coal dust falls into the clean side of the bags. Coal collecting on the clean side
of the bags may cause bag breakage due to smoldering.
• Always replace the broken bag, as well as all the bags surrounding the broken one. The bags
surrounding the broken bag will already have coal in them and will most probably be
the next to fail.
• Always inspect the bag house hopper for obvious signs of bag misalignment or damage.
1. Pyro processing – Clinkerisation
The required quantity of raw meal from C.F silo will be extracted by aeration into a kiln feed bin then
it will be metered and fed into Preheater top cyclones by bucket elevators. The material fed at the top
cyclones will be heated up with flue gases coming up from coal fired Kiln as the material and gas
flows counter currently and heat transfer takes place. Hot gas will be supplied to the material from
cooler through TA Duct for further heating and coal firing in calciner thereby increasing the degree of
calcination. At kiln inlet the material will attain a temperature of 950 o
C and 94 % calcination, due to
kiln rotation and its inclination the material will travel towards discharge end. The material moves to
pre-heating zone for further heating by firing coal at the other end, the material will enter to
calcination and burning zone and here the temperature will increase to 1450 o
C, here the complete
calcination and clinker formation will takes place, due to kiln rotation clinker nodulization takes
place.
Safety procedures to activities at or near cyclones during operation:
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During operation, hot raw meal may accumulate in cyclones, riser ducts and feed pipes. Such
accumulations will often have a disruptive effect on the process, entailing need for frequent
inspections and subsequent clean-out operations. Any inspection, as well as cleaning, of cyclones,
riser ducts and feed pipes, however, involve certain risks for the personnel assigned to such tasks. For
minimization of such risks, strict compliance with the following rules must be ensured.
Before any such work is initiated, it is essential to ensure that the voltage to all control cabinets for air
blasters is cut off. Check also that all blasters are cut off from air supply by closing the compressed
air valve & the blasters have been vented.
A minor negative pressure must be maintained in the system whenever clean-up operations are being
carried out. This negative pressure will reduce the likelihood of any outflow of hot air and dust which
would pose danger to the personal involved in the clean-up operations. Check that a negative pressure
is present at the specific location; this is done by cautiously opening the inspection holes. If this is not
the case, the clean-up procedure must be interrupted.
To avert the risk in terms of an outflow of dust or gas, it is a mandatory requirement that anyone
working on the Pre-heater installation is equipped with respiratory protective equipment (class P1) as
well as goggles.
During operation, any cleaning of cyclones, riser ducts and feed pipes must ALWAYS be carried out
from the outside. It is essential not to allow anyone access to a cyclone which is in operation.
Any person(s) involved in clean-up operations must know the exact routes of escape.
Operating personnel involved in the inspection or cleaning of cyclones, riser ducts or feed pipes must
be equipped with face masks, protective helmets, long heat insulating, fire proof gloves and wooden-
soled boots or other appropriate footwear.
Where work may involve presence of substantial dust accumulations or where there is a risk of being
hit by falling objects, the operator undertaking the operation must be equipped with a safety belt and
lifeline which must be held by an assistant who is positioned at a safe location, while maintaining
constant eye contact with his colleague.
To reduce the extent of any burn injury, each storey of cyclone Preheater must be provided with at
least one cold-water shower.
Prior to opening any clean-out doors or hatches, check through the small inspection hole for any
presence of dust accumulations behind the door/hatch, dust which will flow out when the door/hatch
is opened.
Due to the attendant risk of hot dust or raw meal flowing out, the personnel involved must never be
standing directly on the ordinary floor or on a platform when opening the clean-out doors and
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hatches. Instead, scaffolding, raised above the floor level, and fabricated from non-flammable
materials, must be used to carry out such activities. In case a platform is used, it must be designed as
a grate to allow hot material, if any, to fall through the gaps without any possibility for such material
to accumulate.
In case of an accident, attention must be focused on the specific direction of the material flow and the
potential damage it may cause, for example in relation to electrical cables etc…
In case of dust accumulations, attempts to remove such accumulations must be made before any
doors/hatches are opened. This is done through the small inspection hole. Dust accumulations and
caking are best removed by means of air lances.
When cleaning cyclones, riser ducts and feed pipes, the operation must be started from the bottom.
This will prevent a build-up of any dislodged material in accumulations and caking below, instead
allowing them to be moved smoothly through the system. In connection with the performance of this
operation, due attention must be given to the risk of hot material surges coming from cyclones at
higher elevations.
If during operation hot material is to be extracted from cyclone Pre-heater or a tertiary air duct, this
must be done in a safe manner. The outflow of hot material must not involve any risk(s) to the
personnel or equipment.
The hot material must be allowed to cool off by itself, i.e. un-aided (use of hot water or the like may
cause serious steam explosions). The necessary shields and guards must be installed.
To avoid the risk of any person(s) engaged in work in the splitter gate of the Pre-heater being trapped,
it is essential to ensure that all safety guards and shields have been installed. If work is to be done
while the safety guard is not installed, the emergency stop of the splitter gate must be activated for
safety reasons.
Anyone engaged in activities on any of the storeys of the Pre-heater, involving presence of sluices,
must be fully familiarized with the risk of impacting from the activation arms of the sluice flaps. This
risk can be reduced by posting of signs or by erecting protective guards.
SAFETY PROCEDURES DURING OPERATION OF ROTARY KILN PLANT:
The high temperatures inside the kiln represent the major hazards for personnel working in proximity
of the rotary kiln.
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Pulsation in the pyro process and in the material feed may, from to time, give rise to a transient
blowout of hot dust and air from the inlet and outlet seals of kiln
For this reason, the necessary precautions must be taken to equip any persons working in the
immediate proximity of kiln with appropriate clothing and safety equipment to protect them against
such extreme impacts.
Because of the attendant danger of burn injuries, signs should be posted to warn about the hazards
associated with any physical contact with kiln shell.
Protective guards must be installed around the points of engagement between kiln tyres and
supporting rollers and between kiln tyres and thrust roller to eliminate the risk of injuries due to
crushing, entrapment or pinching. These guards must remain fitted throughout the operation of the
rotary kiln.
The supporting roller bearing housings are provided with inspection ports which cover the associated
inspection openings in which protective grates are fitted. To eliminate any risk of entrapment, which
may occur, for example, when stretching a hand/arm into the bearing housing, these grates must
always be fitted while the kiln is in operation.
CLINKER COOLER:
The clinker leaves the kiln at around 1450˚C and fall down onto the cooler inlet zone, after which
they are transported slowly down through the cooler. While being transported through the cooler the
clinker are constantly exposed to a cooling air stream from below with the purpose of cooling down
the clinker as well as recuperating heat back to the kiln system.
The cooling air is provided by the 12Fans installed for the cooler. When the cooling air passes up
through the clinker bed, it is heated by the clinker and for the first part of the cooler the heated air is
drawn back into the kiln system and used as combustion air. Approximately 45% of the total cooling
air is returned back to kiln system and recuperates approximately 75% of the clinker heat back to kiln
system. The remaining air is extracted as excess air from the Cooler.
The excess air extracted from the outlet end of the cooler and is de-dusted in the cooler ESP filter.
The clinker dust from the cooler filter is transported to clinker conveyor.
At the outlet of the cooler a clinker crusher is installed for breaking the lumps that are larger than.
~25-30 mm.
Safety Instruction:
• Requirement for work inside the SF Cooler: Due to safety reason no personnel must enter the
Cooler when the flame is ignited or being ignited in the pyro processing system. Before
personnel enter the machine ensure that there is enough oxygen in the air and that no toxic
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fumes exist. Normal lock out procedures for electrically equipment must be followed. Also
make sure that all valves in the hydraulic lines are closed before any work is done inside the
Cooler.
Safety and Protection:
• No entry IN and around the Cooler is allowed when flame is lit in the Kiln.
• Certify that Cyclones and Calciner are empty and free of material before entering the Cooler
• Air Blasters are empty and isolated such that air cannot flow into the air tank intentionally or
unintentionally.
• Inspection of the Under grate compartments and the Mechanical Flow Regulator’ s must be
carried out exercising care as oscillating hydraulic drive bars will cause danger if started during
inspection.
ELECTROSTATIC PRECIPITATOR (ESP):
An Electrostatic precipitator (hereafter referred to as precipitator) removes dust from flue gases by
charging the dust particles through a high voltage. The dust particles are collected on the collecting
plates and to lesser extent, on the discharge electrodes.
The dust particles are detached from the electrodes by means of Vibration arrangements, and the dust
is conveyed out of the hopper by means of conveying equipment.
Safety Instructions:
• Operating Situation : In the operating condition all access doors on the precipitator are locked
and therefore the precipitator presents no particular danger to personnel or surroundings
• External inspection and service work : No contact with rotating parts or parts which are in
contact with high voltage and flue gas during operation
• High Voltage :
Safety measures against high voltage in trunking or insulator compartment and relevant working
condition
• The general safety procedures must be known.
• Disconnect the power supply to all transformers/rectifiers at the distribution board.
• The earthing connector placed on the rectifiers or between the rectifier and insulator
compartment must be locked in the earthed positioned, earthing the precipitator and rectifier.
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• The power supply to the heating elements in the insulator compartment must be disconnected at
the distribution board.
• The high voltage distribution parts must be earthed with earthing cables at all hatches and
manholes, hereby earthing the discharge system.
• Before entering the ESP through the bottom hopper hatch, the high voltage distribution parts
must be earthed with earth cables.
Before entering the precipitator:
The high voltage safety points to be added.
• In precipitators consisting of several separate electrode systems across the flue gas flow, each
individual system must be earthed.
• Disconnect the power supply at the distribution board for the conveying equipment in the
hopper
• To prevent fan operation, the power supply must be disconnected at the distribution board
• Disconnect the power supply at the distribution board for the heating elements in the hopper
• Disconnect the power supply at the distribution board for the rapping drives, heating elements,
vibrators, Purge air fan, Hot air fan, rapping devices etc.
Disconnect compressed air supplies, if any..
• In case where production is to continue by means of a by-pass while there is access to the
precipitator, the valves before and after the precipitator must be sealed and locked.
• Ozone Content :
The high voltage in the precipitator produces ozone gas, which can cause people in the
precipitator to suffocate. Ozone has a very distinct and characteristic smell, and has to be
removed by ventilating the precipitator. If the smell has gone after ventilation, the danger has
also gone. Where there is doube, the ozone content should be determined with an analyzer. The
concentration must not be higher than 0.7 ppm, if that also satisfies local requirements.
• Important, actual dust and flue gas
Checks must be made for toxic substances in the air and dust on the basis of the actual operating
situation, for which the raw materials involved should be known. The raw materials and their
precise treatment change almost continuously, with the composition of the air and dust changing
at the same rate.
Fire risk
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In precipitators where there may be a risk of fire or self-ignition in dust deposits, greater vigilance
must be exercised with regard to flashes when opening the inspection hatches.
CLINKER STORAGE AND TRANSPORT:
The cooled clinker will be transported to Clinker Stockpile & Silo for storage by Deep Pan
Conveyors. Clinker will be extracted from clinker storage silo by Deep Pan Conveyor provided
underneath the silo and will be transported to Cement mill hoppers by Deep pan conveyors and
Reversible shuttle Belt conveyors.
Safety Instructions:
• Before working on rotating or moving parts, ensure that these are stationary and cannot start to
move during work.
• Do not reach into rotating parts and maintain an adequate distance in order to avoid clothing or
hair becoming caught up.
• Special care has to be taken in case of repair and maintenance work on inclined conveyors.
Especially when disassembling backstops, shafts, and drive units.
• If the inclined conveyor strand is loaded only on one side, the conveyors may start to move, e.g.
due to conveying material being still inside the pans and buckets.
GYPSUM AND WETFLYASH:
Gypsum & Wet Flyash are stored in a covered yard. These materials are then collected by a Crane &
dumped in to respective hoppers. From the yard the material is conveyed to hoppers through belt
conveyors.
Safety device for Rotor:
Safety device is meant for protection of rotor from over load and uncrushable material. Under normal
condition, this device is the gap adjustment for breaker plate. The bottom part of the breaker plate is
supported by stud and helical spring. Due to over load the breaker plate will be compressed against
spring and oversize trempiron material will fall down. Pre compression of the spring is set to suit the
material.
BALL MILLS:
The materials Clinker, Gypsum and Fly Ash will be metered by weigh feeders and fed into Ball mills
by belt conveyors. When the material enters into the ball mills the grinding media present in the mill
will hit material due to centrifugal action created by mill rotation there by material will be ground to
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fine powder. Mill vent is provided by a mill vent fan to provide velocity for material discharge. The
discharge material will be transported to a separator through air slide and bucket elevator for
separating the fine particles and coarse particles, in separator a rotor & stator assembly will be there,
air will be supplied into it, when the material enters into separator, due to the rotor rotation and
dispersion of material due to air flow the fines and coarse will be separated, the fines will be carried
away by the air to cyclones for separating the fine material and air and the coarse particles will once
again fed into mill inlet by air slide for further grinding to fine powder. The separator speed can be
adjusted to get required fineness of the cement. The fines thus collected in cyclone will be transported
to silo through air slides for storage and packing. A part of air separated at cyclone will be
recirculated to separator and part of it will be vented out into atmosphere through bag filters after
collecting the fine dust present in the exhaust air. One of the Ball mill (Cement Mill- 01) is being
fitted with Roller press. The capacity of Ball Mill Cement Mill- 01 is 280tph & Ball Mill Cement
Mill-02 is 165tph.
Safety precautions (General notes on safety for the UMS Mill)
• Dust masks should be used to extent deemed necessary(for example, in connection with clean-
up operations) and hearing protectors must be used by anyone while inside the mill building
when the mill is in operation or if noise intensive tolls(such as angular grinders, jackhammer
drills or pneumatic spanners)are used.
• Goggles MUST be worn by operators involved in grinding and torch-cutting operations.
• It is essential to ensure that there are no persons inside the mill, on or under the mill prior to
initiating any turning operation, given the danger of structural collapse or exposure falling parts.
• When the mill is to be turned in side-heavy condition, it is very important to ensure that the mill
is under control at all times and that unintended turning of the mill is prevented by means of
wires and pulley block.
• In operation, ball mills are very noisy and the noise level (sound pressure) will normally be
higher than 110Dba. Therefore, hearing protectors must be used by any personnel working in
the mill plant while the mill is in operation.
• Requirement of work inside the Mill :
Prior to entry in to mill, it is essential to make sure that effective lockout of mill feed has been
affected. Net, the mill must be turned until a set of manholes are at the top position,
simultaneously ensuring that the charge is in neutral position, i.e. in horizontal position. In
actual practice this is done by turning the mill slightly beyond the point where the manholes are
in top position, subsequently allowing the mill to be turned back to the desired position.
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Any person who is unwell should never be allowed access into a mill. Any person who is about
to enter the mill must never be unaccompanied. At least one person must be at the manhole
outside the mill, having contact to the person inside the mill, either in the form of visual contact
or through verbal communication. The mill charge is uneven and difficult to walk on,
particularly in the coarse grinding compartment, and due care is needed to avoid falling.
• Replacement of Lining Plates :
When replacement of lining plates and grates is required, adequate precautions are needed to
prevent the plates and/or grates from falling down on any person(s) or on the unprotected mill
shell. In case of the lining plates falling down on other lining plates, this may cause fragments
of the plate to be knocked off. Endangering the personnel assigned to perform take inside the
mill. Scaffolding inside the mill will be necessary to ensure safe working conditions.
MVR:
The metered quantities of Clinker, Gypsum, Fly Ash will be into MVR by belt conveyors and in the
mill the materials will be ground to fine power as soon as the material enters between rollers and
rotating table, hot air will be supplied to the mill for removing moisture present in the material and
the fine powder will be lifted to the classifier by supplied air. In the classifier, the fines and coarse
will be separated and the course will fall back on to the table for further grinding and the fines will be
lifted to Bag houses for collecting the material. The overflow reject material in the mill will be out of
mill as reject and it will be fed into to fresh feed belt conveyor for recycling by belt conveyor and
bucket elevator for grinding in the mill again. The fines collected in Bag houses will be transported to
silo by air slides and bucket elevator. The capacity of MVR is 320 tph.
PACKING AND LOADING:
The cement from cement silo will be extracted by aeration, the extracted cement will be transported
to a bin through air slides, bucket elevator and vibrating screen, from the bin the required quantity of
material will flow into a packer through a pneumatic gate for packing into the bags. Five Roto
Packers of 240 MT/hr capacity each are installed for packing the cement, at the top portion of the
Packer one bin is there with level sensors and compressed air assembly for passing the required
quantity of material into the packing spouts, at the bottom of Packer 16 spouts are there with load cell
and bag stool assembly for packing cement into bags, the load cells will meter the each bag for
required quantity and then the bag will discharge to dispatch belt conveyor for loading into the trucks
Safety Precautions
• Ensure that the machine works only in safe and functional condition
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• Operate the machine only when all protection units and units for a safe operation, e.g.
removable protection units, emergency shutdown units, sound absorbers, and suction devices
are available and ready to work.
• Check the machine at least once per shift for externally noticeable damages and short comings.
Any unexpected/abnormal occurrence (including the way of working) must be informed to the
relevant officer/person immediately.
• Clean machines, especially connections and joins/testing before maintenance/repair from oil or
cleaning products.
POTENTIAL HAZARDS AND PRECAUTIONS TO BE TAKEN:
Sl.No
POTENTIAL
HAZARD
LOCATION PRECAUTIONS TO BE TAKEN.
1 Fire Coal Stock
Pile
Water spray on the pile
Periodic cleaning of the pile – First in first out
Prolonged storage to be avoided
Diesel Tank Keep the area isolated and enclosed
No open flames allowed near by
No smoking in the enclosed area
All Tankers should have back – fire arrestors
Tankers to be Earthed before unloading starts
Electrical
Premises
Load Centres
Offices &
Residential
buildings
Periodic check up of panels for abnormal temperature rise – correct
loose connections / replace pitted contacts
Use appropriate size of cable lugs and use a proper crimping tool.
Earth fault protection must be maintained
Do not keep any inflammable material inside the electrical premise
Do not bring eatables inside the premise so as to avoid rodents –
use rodent repellents if necessary
Use of extension cords – do not overload by using many appliances
on a single point.
Use a tight fitting Plug Top – do not insert loose wires into the
socket.
Use the correct size of fuses / breakers.
Unplug all appliances after use – do not leave them plugged in.
Replace any cracked / frayed wire / cord.

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Avoid running a wire / cord beneath a carpet – wires will get
overheated.
Provide sufficient clearance for equipments like TV or computers
which generate more heat. Do not keep combustible items like
paper or clothes near them.
Use an Earth fault isolator in the mains.
Cable cellar Keep the racks clean
Do not keep any inflammable material in the premise
Cable joints are to be staggered on the racks
Monitor cable joints regularly for temperature rise – correct
abnormalities immediately
Belt
Conveyors
Keep the drive end, deck and tail end, clean.
Keep the belt tension proper- do not allow the belt to slip on the
drive drum
ZS Switch to be maintained functional – never bypassed.
Periodically inspect the idlers / rollers for free movement and
replace defective ones immediately.
Take adequate precautions to quench any fire while undertaking
any gas cutting or welding work on the gallery.
Gas cylinders Check the cylinder for leakage and correct.
Store oxygen and gas cylinders separately.
Hydraulic oil
Cellar/ power
pack
Check up for leakages and correct them immediately.
Clean spillages thoroughly.
Ensure that the alarm / trip settings of temperature and pressure
interlocks are functional.
Do not keep any inflammable material in the premise.
Gas cutting / welding in this area needs a specialprotocol.
Transformers Monitor temperature rise of terminations / joints and correct
abnormalities
Monitor winding temperature and take corrective action
Maintain the oil level.
Do not repeatedly switch on, on faulty condition.
Do not bypass protective gear.
2 Boiler Hot Fly Ash Hot flyash is fluid and can cause Fatal burns. Workmen to be made
aware of the locations where fly ash can accumulate.
Special care to be taken and specialPPEs to be used while handling

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choking in lines/ bunkers.
Remote
Starting of
equipments
In a running unit, the equipments start through REMOTE control &
automatic mode. Personnel must be educated.
Sudden Noise Sudden, unexpected noise, due to starting of equipments / release of
steam,can be startling. Personnelto be educated.
Steam
Leakage
Sudden burst of steam from a safety release / steam trap / sprouted
leak, can scald. To educate workmen.
Hot surfaces Most of the surfaces in a boiler are hot. All steam lines to be
insulated. Workmen to remain careful.
3 Chlorine gas
Leakage
Leakage from
cylinders
Leakage at
CPP
This is an Emergency.
SOP to handle this has to be prepared and practiced through Mock
Drills.
Effects of exposure can be lethal. Oxygen for administration to the
affected, Shower for washing the affected limbs, Fountain for
washing the eyes are to be readily available in good condition.
Chlorine leak stoppage kit to be available.
All workmen who handle Chlorine are to be made knowledgeable
on the properties of the gas, its reactivity, Safe method of handling
a spill and special PPEs to be used.
Mock Drills to be conducted at regular intervals.
4 Burns due to
Hot material
Pre Heater While poking the cyclones to clear a jamming / choking, the
Jamming may get cleared suddenly and hot, fluidized material can
spew out. This job needs special PPEs like asbestos/ woolen gloves,
face mask, apron/ coat.
Personnel to be educated
PPEs to be available at site
5 Handling Inert
Gas
Coal Mill Inert gases are not Toxic. They do not Burn or Explode. Still, they
can be highly dangerous and even Fatal. They can displace Air,
resulting in Oxygen starvation.
Confined space where inert gas is being used, is to be ventilated
before anyone enters. Test the space for Oxygen content before
entering. Minimum 18% oxygen is necessary.
Inert gas containers can explode when exposed to fire. In case of
fire, move the container away or cool the container with water.
Move the affected person away to a well ventilated place and

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administer oxygen.
Immediate medical attention is required in case of over exposure
6 Handling
acids
Sulphuric acid
Hydro chloric
acid
All strong acids will cause severe chemical burns to living tissues.
Sulphuric acid reacts strongly with Protein and other components
that make up skin and muscle.
Inhaling fumes can cause irritation of throat, coughing, and severe
damage to lungs.
Sulphuric acid combines with water violently, generating a lot of
heat. Add acid to water and never water to acid while diluting acid.
On physical contact with body parts, wash with plenty of water.
Shower, eye fountain and tub are to be maintained in good
functional condition where acid is used.
Hydro Chloric acid has a corrosive effect on human tissues. Can
cause damage to respiratory organs, skin , eyes or intestines.
To be stored in well ventilated rooms.
In case of fire, container to be cooled with a spray of water, taking
care to see that acid does not come in contact with water.
On physical contact, wash the affected part with plenty of water.
While handling, special protective appliance to be used – hand
gloves made of rubber, PVC, Neoprene: eye goggles, chemical
resistant clothing to be used.
Spills have to be neutralized with a base material before disposal.
This has to be done carefully as the reaction with base is violent.
7 Noise Blowers,
Compressors,
Crushers,
DG sets,Fans,
Grinding mills
Exposure to noise can cause the following problems.
Annoyance, Sleep disturbance, Hearing impairment, Hyper tension,
Ischemic heart disease.
Maintain the equipments in excellent condition.
Install noise barriers.
Use an appropriate PPE like an ear plug / muff
8 Explosion Coal There is an inherent risk involved in pulverizing, drying, blending,
transporting and storing coal.
Coal dust explosion is described as a Rapid Burning of combustible
particles in a confined area, with resultant generation of
considerable Heat and corresponding increase in Pressure.
The cause of explosion can be listed as below :-
*Presence of coal dust in suspension at a concentration above

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Flammable level.
*Presence of sufficient Oxygen to enable combustion.
*Source of ignition of the mixture of coal dust and air.
*A certain degree of confinement to the mixture.
Preventive / precautionary measures will attempt at elimination of
the causes.
**Use of an oxygen deficient (inert) atmosphere in the pulverizer.
**Use of magnets to remove tramp metalfrom coal feed.
**Cutting / welding jobs in the area to be done as per safety norms
and under supervision.
**Electrical installations in the area are to be explosion proof /
flame proof.
**Static Electricity – all equipments must be earthed including the
bag house bags.
**Hot coal not to be charged in the pulverizer.
**Coal dust accumulation in nooks & corners to be avoided.
Training of personnel to avoid unsafe conditions and unsafe
practices.
Kiln The major causes of explosion in the Kiln are as below :-
*Poor combustion of fuel – low flame temperature.
*Firing increased too rapidly during start-up.
*Waste flue gas accumulation.
ESP Electrical spark is readily available in the precipitator. Rapping can
produce mechanicalsparks.
The products of Incomplete Combustion can get accumulated inside
the precipitator and cause an explosion.
*Ensure that the fuel is fully burnt.
*Ensure that the precipitated dust is evacuated continuously.
9 General Working at
height
Persons who are required to work at heights should be medically
examined for fitness.
Appropriate protective gear should be used – safety net, safety full-
body harness.
Safety belts should be anchored to proper, strong structures.
Safety belts with two anchoring lines only to be used – even while
changing the point of anchoring, one line should remain anchored.
10 Handling gas Gas cylinders are of different categories viz.

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cylinders Liquefied Gases; Non Liquefied (compressed / pressurized) Gases;
Dissolved Gases.
Liquefied: Gases which can become liquids at normal temperature
when stored in cylinders at high pressure. Initially the cylinder is
almost full of liquid and a small volume of gas occupies the space
above the liquid. When gas is removed from the cylinder, further
liquid evaporates to occupy the space and the pressure inside the
cylinder is maintained constant.
Eg. Ammonia , Chlorine , Propane , CO2
Non Liquefied (compressed):Gases which do not become liquids at
normal temperature even when compressed to very high pressure.
eg. Oxygen , Nitrogen , Helium
Dissolved: In the case of certain gases, the cylinders are fully
packed with fillers and the fillers are saturated with a solvent. The
gas dissolves in the solvent and is stored as a liquid.
Eg. Acetylene dissolved in Acetone.
Precautions in handling Gas cylinders :
*Store the cylinders in upright position.
*Store in a cool, dry and well ventilated place.
*Protect against physical damage.
*Protect from heat.
*Have the valve protection cap firmly secured.
*While using the cylinder, use a pressure reducing regulator.
*Do not drop or roll the cylinders. Use a wheel barrow to shift the
cylinders.
*Do not transport liquefied gases in confined spaces like the boot of
a car.
*Use a back fire arrestor while using the cylinder.
*Check the cylinders for leakage with soap solution.
In case of accidental release of Chlorine, N2, CO2 special
precautions as described to be taken.
11 Working in
confined
spaces
A confined space has a restricted opening for Entry or Exit which
may be on account of Size or location or means of approach.
*Not designed for continuous worker occupancy.
*May contain a Potentially Hazardous substance.
*May contain a substance which may flow freely and engulf an

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entrant.
*May have walls that converge/ floor that may slope downwards,
tapering into a narrow space.
60% ofthe victims are would-be rescuers.
Some such confined spaces are :-
Tunnels, Tanks, Silos, Hoppers, Cellars,Wells,Man-holes,
Transfer Chutes.
A system of issuing a Work Permit has to be installed for entering a
confined space.
*Before entering a confined space, quality of air inside must be
tested to find out whether sufficient Oxygen is present and to detect
the presence of any Poisonous / Inflammable substances that may
be present.
*In case some poisonous material is present,it should be purged out
and air tested again.
*Oxygen must be in the range of 18% to 23%. More Oxygen may
lead to explosion in the presence of inflammable substance.
*In case Oxygen is less than 18%, mechanical ventilation is
adopted.
*PPEs like Respirators, Gas mask, Ear plugs are used.
*Safety belts with long leads may be worn. This will help to pull
out a person in emergencies.
*Any free flowing material present in the area must be cleared out
before anybody entering.
12 Conveyor
Belts
Do not wear loose clothes while working near the belt conveyor.
The loose clothes may get entangled with the moving parts and
cause injury.
Arrange for a proper Shut-Down and permit to work before starting
any maintenance activity on the equipment.
Do not cross over a conveyor belt – it may start at any time. Use the
cross –over bridge.
Do not run the conveyors with any of the protective devices
bypassed.
13 Wire ropes &
slings
Safe Lifting Load of a sling depends upon the diameter of the rope,
constructional features of the rope, the way the sling is used –
single or multiple lays and included angle.

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*Display a chart of SWL of different sizes of slings at the work
place.
*Select the correct size of sling for the application.
*Do not shorten slings with knots or nut bolts or makeshift devices.
*Do not load slings beyond their rated capacity.
*Do not kink sling legs.
*When not in use, keep the slings suspended on hooks.
*Inspect the slings for defects as per the standard procedure.
*Remove damaged /defective slings out of service, immediately.
*Use padding to protect the slings from getting cut, when put
around sharp edges.
*After the use, slings should be cleaned thoroughly, before storing.
14 Exposure to
Mercury
Energy saving
lighting bulbs
Energy saving bulbs are widely used to reduce expenditure on
electricity. These bulbs contain Mercury which is poisonous- in fact
more poisonous than Lead and Arsenic.
*Inhalation of Mercury vapour may cause Migraine, imbalance,
disorientation and other healyh problems.
*Touching or inhaling this substance, in the case of most of the
people, causes allergies and severe skin diseases.
In case a bulb of this kind breaks in a room, special precautions are
to be taken as enumerated below.
*Immediately vacate the room for at least 15 min. to avoid inhaling
the vapour.
* Put on a glove before cleaning the debris.
*Be careful to avoid stepping on the debris.
*Use a normal broom / brush to gather the debris.
*Do not use a vacuum cleaner. It will spread the vapour to the other
places where used subsequently.
*Collect the debris in a plastic bag and dispose it off in a secured
land fill. Should not be disposed in a way that others may come in
contact with this.
Awareness to be created in the people who are likely to come across
this danger.
15 Lifting
Tackles
Chain Blocks Chain Blocks are commonly used lifting tackle. They are designed
for vertical lifts only.
*Store the blocks by hanging them by the top suspension,with

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The chains clear off the ground.
*Check the block before use and before putting to storage.
*While fixing, ensure that the trolley width is suitable for the beam.
*Do not drop, throw or drag the block.
*Do not replace the original chain with a longer one.
*Do not allow oil or grease to enter into the brake system.
*Check that the bottom hook will reach the lowest point desired
without the chain fully running out.
*Before lifting the load, check the suspension point and the
anchorage for suitability.
*Do not use the load chain as a sling.
*Do not exceed the SWL.
*Do not permit the load to swing out of control.
*While lifting a load, raise the load just clear and hold it to check
the block, sling, anchorage and brake.
*Do not leave a hanging load unattended.
*Check the Chain Block periodically for fitness to use and perform
the Load Test.
16 Material
Handling
Using a Hand
Trolley /
Wheelbarrow
Hand Trolleys or Wheel Barrows with wheels of large diameter are
convenient for shifting material.
*Keep the wheelbearings in good condition.
*Ensure that the handle of the Barrow is convenient for holding and
pushing.
*Avoid overloading of the barrow.
*Push rather than pull.
*Ensure the load does not block the vision.
*Beware of slippery surfaces and slopes.
Using a Fork
Lift
*Have the Safe Lifting Capacity of the equipment displayed.
*Do not overload the equipment.
*Centre the load on the forks as close to the mast as possible to
avoid tipping of the Fork Lift.
*Do not place extra weight on the rear of a counter- balanced Fork
Lift to allow an overload.
*While travelling, keep the fork as low as possible.
*Do not use the Fork Lift for reaching objects stored at a height, in
place of a ladder.

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*Do not allow anybody to travel with the driver.
Stacking
Material
Stacking materials at site or stores is important and can become
dangerous if not done properly. Falling material or a collapsing
stack can be lethal.
*Ensure that stacks are stable and self- supporting.
*Stack bags and bundles in interlocking rows to keep them secure.
*Remove all nails from used timber before stacking.
*Stack barrels and drums symmetrically.
*Observe height limitations while stacking material.
*Use proper packing and dunnage at suitable gaps to enable
slinging and removal.
*Stack the heavier material in the lower racks and the lighter
material in the upper racks.
Using Cranes The lifting capacity of a mobile / crawler crane varies according to
the boom length, lifting radius and angle of the boom.
*All cranes with adjustable booms should have Boom Angle
indicators.
*Telescopic booms should have some means of indicating the boom
length.
*Load rating charts should be available in the crane to identify
whether the operation that is being performed is safe or not.
*Outriggers / Thrust pads of mobile cranes should rest on firm
ground. Travel path of the crane should be firm without abrupt
undulations.
*Keep hoisting chains and ropes free of kinks or twists.
*Take additional precautions while working near Power Lines.
*Pad sharp edges of loads to protect slings from getting cut.
*All the protective appliances of the crane should be checked for
correct functioning before commencing usage.
*While moving with a load in a mobile crane, sudden acceleration /
deceleration is to be avoided.
*Beware of the load swinging uncontrollably and hitting the boom.
*When the crane is in use, only one single authorized person should
give signals to the operator.

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RISK ASSESSMENT:
Jaypee Balaji Cement Plant has done the Risk assessment. All staffs are required to read the Jaypee Balaji
Cement Plant risk assessments and abide by their requirements at all times.
IF AT ANY TIME YOU ARE CONCERNED BY ANY ASPECT OF SAFETY IN THE WORK PLACE
THEN STOP WORK AND IMMEDIATELY CONTACT YOUR SUPERVISOR. IF YOU CANNOT
CONTACT THE SUPERVISOR THEN CONTACT THE SAFETY OFFICER.
Introduction
A risk assessment is the systematic identification of potential hazards in the work place by personnel as a first
step to control the possible risks involved.
A hazard is anything that has the potential to cause harm.
A risk is the likelihood of someone being exposed to that hazard and harmed as a result.
Essentially, individual, who are familiar with the working area and working practices are involved with the
risk assessment process.
Supervisors are responsible for developing a risk assessment plan for their area of responsibility, and
completing assessment in accordance with this plan.
The top Management of Jaypee Balaji Cement Plant has ultimate responsibility to ensure that risk assessments
are done.
It is also important to remember that risk assessments need to be done before new procedures are introduced.
Risk levels are categorized in a numbered format. Each hazard is given a rating and this is multiplied by the
probability that these hazards will occur, as shown in the following equation.
Risk level = Hazard severity x Likelihood ofoccurrence
= Severity XProbability
Step One
Give each hazard a severity marking as indicated in the table below:

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Risk Level Effect of hazard (Severity)
5 Fatal injury
4 Disabling injury
3 LTI (Lost time injury)
2 Minor Injury
1 First aid only
For example:
If slipping on the stairs (hazard), could result in death or disablement, then it must be given a rating of 4 or 5.
Step Two
The next step is to consider how often each hazard is likely to occur as indicated in the table below
Risk Level Likelihood ofoccurrence (Probability)
5 Once per month
4 Once in six months
3 Once in a year
2 Once in 1 – 5 years
1 Once in 5 or more years
For example:
If slipping on the stairs (hazard) was very likely to happen, then it must be given a rating of 3.
Step Three
Multiply the two scores together and you will get the risk level. This figure should be entered into the risk
assessment form.
For example:
5 (hazard Severity) multiplied by 3 (occurrence or Probability) = 15

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Step Four
The following bullet points are guidelines to help you gauge how quickly you need to put the controls in place.
• Where any hazard is given a risk ranking of 22-25 then action must be taken immediately to reduce
that risk.
• Where any hazard is given a risk ranking of 16-22 then the line manager must be informed before the
end of that working day.
• Where any hazard is given a risk ranking of between 1 and 15, then action needs to be taken at the
earliest opportunity, as soon as it is reasonably practicable to do so, taking into account local
circumstances.
Employers must ensure that risks are reduced to the lowest extent reasonably practicable.
The legal definition of 'reasonably practicable' is 'any measure which can be reasonably carried out having
regard to technical knowledge and acceptable expense'.
The aim is to eliminate or reduce the risks as small as possible.
To control the risks the following points should be considered:
• Eliminate the hazard completely
• Suggest a safer alternative
• We can control the risks so that harm is unlikely to occur
• We can Use required PPEs
The use of personal protective equipment should only be considered when there is nothing else you can
reasonably do.
People affected by hazards
• Employees
• Contractors
• Visitors
• General public
Identified Hazards
The following hazards have been identified in the operation of Jaypee Balaji Cement Plant:
• Dust emission
• Slips and trips
• Noise Pollution
• Exposure to heat
• Fall of objects from height
• Fall of persons

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• Trapping in the rotating machineries
• Fire & Explosion
• Electric shock
• Unauthorized operations
• Spillage & Leakages
• Burns from hot water or steam
• Drowning
• Hit to/by an object
• Injection, inhalation and contact with the chemicals
• Acid / Alkali burns
• Exposure to the Radioactive Radiation
• Failure of lifting tools and tackles
• Over speed of vehicles
Risk Assessments
Identified Hazard: 1. Dust emission
Hazard : Occurrence of occupational diseases like asthma, silicosis
etc.
Activities involved : Grinding, Crushing, Conveying, Welding etc.
Work Locations where the hazard may exist : Grinding unit, crushing unit, conveyors, chimneys, silos,
packing plant etc.
Control Methods : Controlling the risk so that harm is unlikely to occur
Persons at Risk : Employees
Contractors
Visitors
General public
Risk Rating : 3 x 5 = 15
Controlling Techniques : 1. Using dust collection systems like bag filters, ESPs etc.
2. Sprinkling of water in highly dust prone area
3. Plantation or vegetation around stock piles and
conveyors
4. Use of PPEs like Nose masks etc.

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Identified Hazard: 2. Slips & Trips
Hazard : Sprain, Strain, fracture etc.
Activities involved : walking, stretching / bending the body, hitting to or by an
object etc.
Work Locations where the hazard may exist : Office, plant area,home etc.
Control Methods : 1. Suggest a safer alternative
2. Use The required PPEs
Contractors
Visitors
Controlling Techniques : 1. Developing proper ergonomic postures.
2. Applying the easier and safe techniques in lifting,
walking, running, sitting in front of computer etc.
Identified Hazard: 3.Noise Pollution
Hazard : Occurrence of occupational diseases like permanent hearing
loss / deafness.
Activities involved : Standing near, Working with noise making equipments like
boiler, turbine generator set, compressor etc.
Work Locations where the hazard may exist : TG floor, ID fans, Mills (VRMs / Ball mills), crushers etc.
Control Methods : 1. control the risks so that harm is unlikely to occur
Contractors
Visitors
Controlling Techniques : 1. Guard / cover / seal / encase all the rotating / revolving
parts / tail ends of motors, fans, mills, TG sets, DG sets
etc.
2. Use of PPEs like Ear Plugs, ear muffs etc.
Identified Hazard: 4. Exposure to Heat
Hazard : Heat Stress, Heat Stroke,faint, burn etc.

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Activities involved : 1. Standing near, Working with high heat producing
equipments like boiler, Kiln, Pre-heater etc.
2. Clearing the Jam of Pre-heater cyclones, taking the
samples from kiln, pre-heater cooler, clinker stocks etc.
Work Locations where the hazard may exist : Kiln, Boiler, Pre-heater,
Control Methods : 1. Controlling the risk so that harm is unlikely to
occur
Contractors
Visitors
Controlling Techniques : 1. Insulate all hot surfaces to minimize the heat radiation.
2. Provide cautionary notice wherever applicable.
3. Ensure all are using heat resistant PPE’s while working
near hot zone.
Identified Hazard: 5. Fall of Objects from Height
Hazard : Major Injury/fracture, fatal
Activities involved : Repair, maintenance, inspection and any other activity
going to happen at more than 1.5mtr.
Work Locations where the hazard may exist : Plant (Viz. Pre-heater,Silos …etc.)
CPP (boiler building, TG building, Conveyors…etc.)
Control Methods : 1. Eliminate the hazard completely
Contractors
Visitors
Controlling Techniques : 1. Using safety nets, handrails with toe guards.
2. By securing the objects/hand tools firmly
3. Using right kind of lifting tools and tackles with

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proper lifting plan
4. Using appropriate PPEs
Identified Hazard: 6. Fall of Persons
going to happen at more than 1.5mtr.
Work Locations where the hazard may exist : Plant (Viz. Pre-heater,Silos …etc.)
CPP (boiler building, TG building, Conveyors…etc.)
Contractors
Visitors
Controlling Techniques : 1. Using safety nets, proper platform, handrails with
toe guards.
2. By securing the safety belts firmly to a fixed rigid
object
3. Using right kind of lifting tools and tackles with
proper lifting plan
Identified Hazard: 7. Trapping in the Rotating Machineries
which is going to happen at or near rotating machineries
like un covered Mills, un guarded motors, un fenced
rotating machineries, conveyor belts & equipments, etc..
Work Locations where the hazard may exist : Mills, motors, conveyor belts, rollers & at all rotating
machineries.

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Contractors
Visitors
Controlling Techniques : 1. Always Cover/Fence/guard the rotating parts
2. Provide cautionary notice wherever applicable.
Identified Hazard: 8. Fire & Explosion
Hazard : Major Burns, Fatal
Activities involved : Working with inflammable compounds viz. Diesel, Coal,
boiler, HSD.
Work Locations where the hazard may exist : Pre-heater, kiln, CPP-boiler, DG set, All Electrical power
distribution load centers, coal mill, Coal yard, stores,
cylinder storage, petrol pump, wooden work shop etc.
Control Methods : 1. Controlling the risk so that harm is unlikely to
occur
Contractors
Visitors
General public
Controlling Techniques : 1. By installing automatic fire detection and
extinguishing equipments viz. inert gas system,
water sprinklers, CO2 flooding system etc.
2. By continuous monitoring the levels of heat near
coal firing points and raw meal firing points etc.
3. By using appropriate PPEs
Identified Hazard: 9. Electric Shock
Hazard : Faint, giddiness, cardiac arrest,burn etc

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Activities involved : Charging/discharging any power lines/cables/panels etc for
repair, maintenance,inspection, installation etc.
Work Locations where the hazard may exist : All MCC rooms, Load centers, Substation, Switch yard,
Panelboards etc.
Contractors
Visitors
Controlling Techniques : 1. Use of line clearance permits
2. Providing proper earthing
3. Providing ELCBs where ever required
4. Providing proper insulation to the bear cables
5. Providing rubber mats in all Load centers/MCC
rooms etc.
6. By using appropriate PPEs
Identified Hazard:10. Unauthorized Operations
Hazard : Trapping/dragging/struck/crush in the machineries,
electrical shock, pressure line bursts, fire, explosion, fatal
etc.
Activities involved : All operations related to the startup / shutdown / inspecting
/ repairing of any equipment etc. in plant and CPP.
Work Locations where the hazard may exist : All mills, electrical Panels, vehicles etc. and all other
locations in the plant, CPP etc.
2. Controlling the risk so that harm is unlikely to
occur
Contractors
Visitors
General public

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Risk Rating : 3 X 5 = 15
Controlling Techniques : 1. Using the permit to work system effectively for all
activities
2. Using Lock-out and Tag-out (LOTO) systems
3. Tightening the security system and a round
vigilance by the section crew at all desirable
locations.
Identified Hazard: 11. Spillage & Leakages
Hazard : Faint, fire, burn, slip, fracture, injury etc.
Activities involved : Refilling/repairing/dewatering/ma intenance of hazardous
gas installations/process points/Oil tanks etc.
Work Locations where the hazard may exist : Water treatment plant, HSD installation, Petrol pump,
hydraulic power packs, oil tanks, raw water tanks, drainage
tank, stores, Cylinder storage
occur
Contractors
Visitors
General public
Risk Rating : 2 X 5 = 10
Controlling Techniques : 1. Use proper housekeeping techniques
2. Perform mock drills in time
3. Arrest the leakages in time by expertise staff
4. Seal the spill ways,leakages
5. Wipeout the leakages immediately
6. Make surprise/random checks

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Identified Hazard: 12. Burns from Hot water or Steam
Hazard : Burn injuries, unconsciousness, faint, fatal
Activities involved : Repairing/maintenance/installation of process points, Oil
tanks, boiler, steam lines, pressure vessels etc.
Work Locations where the hazard may exist : Pre-heater, Kiln, Clinker cooler building, DPC(deep pan
conveyor), Boiler Building, Laboratory etc.
occur
Contractors
Visitors
Controlling Techniques : 1. Effective sealing of all Steam/Pressure lines
2. Effective safe working distance at pre-heater
cyclones & kiln etc.
3. Avoiding unauthorized operations
4. Use of appropriate PPEs
Identified Hazard: 13. Drowning
Hazard : Unconsciousness, injury, fatal.
Activities involved : Dewatering jobs, water tank repair & maintenance jobs etc.
Work Locations where the hazard may exist : Raw water tank, Drinking water tank etc.
Contractors
Visitors
Controlling Techniques : 1. Barricading the water tanks to avoid unauthorized
entry
2. Always working with an attendant and life line
3. By using the appropriate PPEs

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