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Page 1 of 36
UNITED CEMENTS PVT. LIMITED
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Page 2 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/001
Rev.No: 00
Operation & Maintenance Page 1 of 3
of Lime Stone Crushers Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
To establish a system for operation and maintenance of Lime Stone Crusher to
reduce the idle running and maximize the utilization of system & for proper operation of dust
control units.
2. SCOPE: -
Applicable to Lime Stone Crushers –
Single Rotor Impact Crusher &
Hammer Crusher
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
a) OPERATION OF CRUSHER: -
I. Before start of crusher all the operative staff should be instructed to check the circuit
and to give feedback regarding the condition of the same.
II. Crusher Operator will check the logbook and Interact with control room regarding
the crusher operation.
III. Crusher Operator will ask to control room for checking the condition of the
equipment and give clearance to him for start of the crusher group.
IV. After start of the crusher circuit crusher operator will give instruction to operatives
to keep watch on the crusher and regulate the crusher apron feeder according to
the material Quality / size of Boulders.
V. The operator should be in contact with the quality department and stop idle
running of the crusher during non availability of the dumpers for long duration and
regulate the apron feeder speed for optimum utilization of the crusher.
VI. In case of breakdown / jamming in crusher or any problem, operator will stop the
crusher and inform to control room to take action accordingly.
Page 3 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/001
Rev.No: 00
Operation & Maintenance Page 2 of 3
of Lime Stone Crushers Eff. Dt.:
Approved By: Issued By:
Date: Date:
VII. In case of jamming in crusher, operator will perform the cleaning jam only after
proper Isolation of the power supply by issue of work permit. Jamming of the
crusher rotor by proper wedging .Operator and other workman will take all the
precaution and safety measures.
VIII. Crusher operator will place the safety display board “Crusher is not in operation”
in front of truck tippler area, to stop the dumper unloading until the jam is cleared.
b) MAINTENANCE OF CRUSHER: -
I. Before any maintenance power supply is isolated by work permit system and “LC”
from all concerned departments.
II. Ensure that all the members are well aware with the nature of the job and safety
measures required during the work.
III. No one should be allowed without PPE’S in the crusher area.
IV. Working area should be barricaded to avoid entry of any outside person in the
area.
V. At the time of Maintenance job in Crusher / Apron Conveyor etc. Operator and
other workman will take all the precaution and safety measures.
VI. During the job in crusher, rotor should be jammed by proper wedging.
VII. After completion of the job remove all the lifting devices & wedges properly,
with all care.
VIII. Close the housing etc and after tightening the bolts, clearance may be given for
removing the electrical isolation.
All the operatives should use the PPE’S i.e. ear muffs, safety helmet etc
as per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
Cutting, welding & grinding activities should be carried out with its safety
devices.
Working area should be clean before & after the work.
Page 4 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/001
Rev.No: 00
Operation & Maintenance Page 3 of 3
of Lime Stone Crushers Eff. Dt.:
Approved By: Issued By:
Date: Date:
7. APPLICABILITY: -
Page 5 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/002
Rev.No: 00
Operation & Maintenance Page 1 of 3
of Bag Filters Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
To establish a system for controlling the dust emission from bag
filter stack by proper Operation and Maintenance of bag filters.
2. SCOPE: -
Applicable to all bag filters used in the plant.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
I. Ensure that persons working in the area are well aware with the working of the bag
filter and using PPE’s.
II. Visual inspection is done for any emission from bag filter stack.
III. If dust is coming from stack, Bag filter is checked for-----
Damage of filter bags.
Filter bags full of dust but not damage is made empty & can be reused after
cleaning.
Sealing of filter’s bag with punch plate.
Breakage for venturi.
Cylindricalness of Cage & breakage of its wire.
Baffle plate for any holes.
Page 6 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/002
Rev.No: 00
Operation & Maintenance Page 2 of 3
of Bag Filters Eff. Dt.:
Approved By: Issued By:
Date: Date:
IV. If stack is clear but the transfer points area connected to the bag filter are dusty,
check----
DP of the B/F
Check purge air pressure
Check timing of the solenoid valves
Check condition of the bags & reason of jamming.
Check moisture in purge air
Checking of purging of solenoid valves
V. Solenoid valve is checked for direct air supply to bags or not purging, if found,
informed to instrumentation department.
VI. It is ensured that the compressed air is dry and air pressure is up to required
working pressure for B/F.
I. Before start of the maintenance work ensure that the drives are properly isolated
or not. Take LC for doing any maintenance.
II. Check for any looseness of V- belts of the B/F fan.
III. Any entry of false air is prevented in bag filter circuit.
IV. Checking is done for any jamming of suction line connected to bag filter, if any,
it is cleaned
V. It is ensured that seating of flap / rotary air lock is proper in the hopper to avoid
entry of fresh air in the circuit.
VI. Checking is done for any jam in hopper.
VII. All the bags should be aligned and nozzle pipe centering is done for proper
purging and cleaning of the bags effectively.
VIII. Ensure that all the transfer point connections are re-positioned after maintenance.
IX. Check all the Solenoid valves, its diaphragms etc. and replaced the damaged
diaphragms.
X. After maintenance ensure that the clean air chamber doors and hopper doors are
sealed properly.
Page 7 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/002
Rev.No: 00
Operation & Maintenance Page 3 of 3
of Bag Filters Eff. Dt.:
Approved By: Issued By:
Date: Date:
All the operatives should use the PPE’S i.e. ear muffs, safety helmet etc as
per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
Cutting, welding & grinding activities should be carried out with its safety
devices.
Working area should be clean before & after the work.
7) APPLICABILITY: -
Page 8 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/003
Rev.No: 00
Area Cleaning and Page 1 of 2
Housekeeping Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
Area cleaning and housekeeping & avoided to unsafe works and generate
revenue
2. SCOPE: -
Applicable in entire plant area.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
All the operatives should use the PPE’S i.e. ear muffs, safety helmet etc as
per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
7. APPLICABILITY: -
1. PURPOSE: -
To establish a system for handling, storage & disposal of used oil &
grease generated in the plant.
2. SCOPE: -
Applicable to used oil & grease generated in whole plant.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
The used oil & grease generated in the plant is kept on the secondary
containment like steel tray / drum at specified place of respective area.
The place is properly identified as “USED OIL & GREASE”.
The drums are kept vertical and cap/ lid cover on used oil drum & cover of
grease drum are properly closed.
Used grease/oil is unloaded at identified area in scrap yard in presence of
authorized Store’s person.
Disposal of grease & oil from scrap yard is the responsibility of stores.
Avoid spillage of Oil / Grease on ground during the shifting work to avoid earth
contamination.
Page 11 of 36
For Doc.No. UCPL/ME/SOP/004
Rev.No: 00
Handling, Storage Page 2 of 2
& Disposal Eff. Dt.:
(Lubricants)
All the operatives should use the PPE’S i.e. ear muffs, safety helmet etc as
per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
7. APPLICABILITY: -
Page 12 of 36
For Doc.No. UCPL/ME/SOP/005
Rev.No: 00
Operation & Maintenance of Page 1 of 3
Coal Mill Bag House Eff. Dt.:
1. PURPOSE: -
To establish a system for proper Operation and Maintenance of Coal Mill
Bag House.
2. SCOPE: -
Applicable to Coal Mill Bag House.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
I. Ensure that persons working in the area are well aware with the working of
the bag house and using PPE’s.
II. Visual inspection is done for any emission from bag house stack.
III. If dust is coming from stack, following points are to be checked -----
Damage of filter bags.
Filter bags full of dust but not damage is made empty & can be reused
after cleaning.
Breakage for venturi.
Cylindricalness of Cage & breakage of its wire.
Baffle plate for any holes.
Smooth purging in the bag house chamber.
Page 13 of 36
For Doc.No. UCPL/ME/SOP/005
Rev.No: 00
Operation & Maintenance of Page 2 of 3
Coal Mill Bag House Eff. Dt.:
VII. If stack is clear but the transfer points area connected to the bag filter are dusty,
check----
DP of the B/F
Check purge air pressure
Check timing of the solenoid valves
Check condition of the bags & reason of jamming.
Check moisture in purge air
Checking of purging of solenoid valves
VIII. Solenoid valve is checked for direct air supply to bags or not purging, if found,
informed to instrumentation department.
IX. It is ensured that the compressed air is dry and air pressure is up to required
working pressure for B/F.
X. After the stoppage of coal mill the pneumatic gate at bag house outlet
duct should closed smoothly.
XI. Ensure any leakages from bag house chamber & in duct lines.
XII. Look after the condition of V-belt tightness and also the status of mounted safety
guard.
I. Before start of the maintenance work ensure that the drives are properly isolated
or not. Take LC for doing any maintenance.
II. Check for any looseness of V- belts of the B/F fan.
III. Any entry of false air is prevented in bag filter circuit.
IV. Checking is done for any jamming of suction line connected to bag filter, if any,
it is cleaned.
V. It is ensured that seating of flap / rotary air lock is proper in the hopper to avoid
entry of fresh air in the circuit.
VI. Check for any jam in hopper.
VII. All the bags should be aligned and nozzle pipe centering is done for proper
purging and cleaning of the bags effectively.
VIII. Ensure that all the transfer point connections are re-positioned after maintenance.
IX. Check all the Solenoid valves, its diaphragms etc. and replaced the damaged
diaphragms.
X. After maintenance ensure that the clean air chamber doors and hopper doors are
sealed properly.
Page 14 of 36
For Doc.No. UCPL/ME/SOP/005
Rev.No: 00
Operation & Maintenance of Page 3 of 3
Coal Mill Bag House Eff. Dt.:
All the operatives should use the PPE’S i.e. ear muffs, safety helmet etc as
per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
Beware during the use of cutting & welding activities & take necessary
precautions.
Working area should be clean before & after the work.
10) APPLICABILITY: -
1. PURPOSE: -
To establish a system for safe working at height on scaffolding & steel
Structures.
2. SCOPE: -
Applicable to all activities carried out at high elevations.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
To carry out the jobs at height following safe work instructions must befollowed.
Competent persons are deployed for the job and Safety Talk is given to
all work man before start of the job.
Proper scaffolding/arrangement is made to reach there.
Proper use of all PPEs such as----
Safety belt
Safety Helmet.
Hand gloves.
It must be ensured that challis is properly bonded on pipes with suitable wire /
clamps and before start of work the same should be checked for its stability.
Before start of the job the concerned supervisor will check and ensure the above
points including the status of the platform made with MS Grating, whether it is
intact and may be used for safe working.
The work force engaged in the nearby area should be instructed, to check the
scaffolding condition before start of work.
All the rules of scaffolding must be followed.
All the scaffolding pipes should be free from dust and having wet surface.
All the operatives should use the PPE’S i.e. ear muffs, safety helmet etc as
per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
Working area should be clean before & after the work.
7) APPLICABILITY: -
The procedure is applicable for to any area of the plant where there is
need to work at high elevation.
Page 17 of 36
For Doc.No. UCPL/ME/SOP/007
Rev.No: 00
Working at High Noise Area Page 1 of 1
(Compressors & Blowers) Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
To establish a system to wear ear plugs while working at blowers
running area.
2. SCOPE: -
Applicable to at the positions of high noise level in the plant.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
At high noise area, the stay should be as per the norms and wear proper
PPE’s, to avoid the permanent disability.
Page 18 of 36
For Doc.No. UCPL/ME/SOP/008
Rev.No: 00
Operation & Maintenance Page 1 of 2
of Cooler Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
To ensure the equipment safety & avoided unplanned stoppages of
the plant.
2. SCOPE: -
Cooler area of rotary cement kiln.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
6. OPERATION OF COOLER : -
Page 19 of 36
For Doc.No. UCPL/ME/SOP/008
Rev.No: 00
Operation & Maintenance Page 2 of 2
of Cooler Eff. Dt.:
Approved By: Issued By:
Date: Date:
Ensure proper working of all the flap valves, below the cooler
hoppers to avoid jamming and fugitive dust generation in the
drag chain area.
7. MAINTENANCE OF COOLER
Ensure for proper illumination in under grate compartment & over the
grate.
Cooler fans & grate drive power is made off (work permit system) before
carrying out any job.
All grate door & door just above hammer crusher kept open for proper
ventilation.
Before going inside the grate, close the air line valve to blaster & then
empty the blaster cylinder by operating solenoid.
After opening grate plate bolt, plate is taken out immediately.
Ensure at working area above grate the roof bricks are intact and may
not fall while working. Loose bricks / Castable should be removed before
start of work.
Only trained and experienced staff may be engaged for the work.
Before closing the under grate compartment & grate door, thorough
inspection is done.
During trial of cooler for checking / adjustment of the grate etc. no one
should be allow to touch or adjust while the grate is running.
For the adjustment of grate the supply must be put off.
All the operatives should use the PPE’S i.e. ear muffs, safety helmet etc as
per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
Working area should be clean before & after the work.
Page 20 of 36
For Doc.No. UCPL/ME/SOP/008
Rev.No: 00
Operation & Maintenance Page 1 of 3
in Ball Mill Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
To establish a system for Operation & Maintenance of Ball
Mill for maintaining the same in Healthy & Safe condition.
.
2. SCOPE: -
Applicable to Ball Mills such a Raw Mill, Coal Mill & Cement Mill.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
Page 21 of 36
For Doc.No. UCPL/ME/SOP/008
Rev.No: 00
Operation & Maintenance Page 2 of 3
in Ball Mill Eff. Dt.:
Approved By: Issued By:
Date: Date:
All the operatives should use the PPE’S i.e. ear muffs, safety helmet
etc as per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
Working area should be clean before & after the work.
7. APPLICABILITY: -
Page 23 of 36
For Doc.No. UCPL/ME/SOP/010
Rev.No: 00
Operation & Maintenance Page 1 of 2
Belt Conveyor Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
To establish a system for the operation & maintenance of belt conveyor.
.
2. SCOPE: -
Applicable to raw material handling & feeding section, coal handing &
Feeding and gypsum & clinker extraction belt conveyors.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
All the operatives should use the PPE’S i.e. ear muffs, safety helmet
etc as per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
Working area should be clean before & after the work.
7. APPLICABILITY: -
All the areas of material handling and feeding section along with coarse return of
material in ball mills.
Page 25 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/011
Rev.No: 00
Safe Welding & Gas Cutting Page 1 of 5
Operation Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
To establish a system for safe welding & gas cutting process.
.
2. SCOPE: -
Adherence to relevant codes and employment of qualified and tested
welder are two basic requirements for welding and gas cutting process.
Hazards such as electricity, heat / flame, flammable gas etc. are present
in this process.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
Following safety precaution during required welding & gas cutting must be
followed. The following set of instructions is to be follow.
Be of approved make.
Be stored upright, and is kept away from hot work and care shall be
taken to prevent heating of gas cylinders.
Gas cylinder valves shall always be checked and shall be closed
when not in use.
Be stored in a well-ventilated area.
Page 26 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/011
Rev.No: 00
Safe Welding & Gas Cutting Page 2 of 5
Operation Eff. Dt.:
Approved By: Issued By:
Date: Date:
Page 27 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/011
Rev.No: 00
Safe Welding & Gas Cutting Page 3 of 5
Operation Eff. Dt.:
Approved By: Issued By:
Date: Date:
Page 28 of 36
Receptacles of power cables for portable welding unit should be
used so that it is impossible to remove the plug without opening
the power supply switch.
Page 29 of 36
Ear protection (wool or rubber plugs) in case of noise pollution or overhead
welding.
In a confined place or where fumes/gas emissions cannot be below the toxic
level, respiratory protective equipment duly certified for the exposure by reputed
Government organization, like DGFASLI, shall be used.
Space of more than 284 cum. per welder should be provided.
Clothing should be free form oil & grease. Collars and cuffs should be buttoned
and turned up inside. Pockets would be eliminated from the front vests, shirts
and apron.
After welding or cutting is completed a warning sign would be provided to keep
workers away from heated surfaces.
Electrode rod stubs should be kept in a proper waste container.
Welding Lead and earthing lead with lugs should be properly connected to
welding machine by bolting.
Direct earthing, from welding m/c to the job, is done.
It is ensured that there is no sparking from supply board, connection board of
welding m/c & at the welding lead connection to welding m/c.
6. APPLICABILITY: -
Page 30 of 36
Page 31 of 36
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/012
Rev.No: 00
Operation Of Chain Pulley Page 1 of 1
Block & Use of Sling Eff. Dt.:
Approved By: Issued By:
Date: Date:
1. PURPOSE: -
To establish a system for operation of chain pulley block & sling.
2. SCOPE: -
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
It is ensured that only tested chain pulley block & sling of valid colour codes are
used.
Certified person with the co-ordination of safety in-charge does periodic
checking of chain pulley block & sling.
Chain pulley block & sling are used as per its safe working load (SWL).
Competent persons are deployed for the job.
Repair of the chain pulley block should be done periodically as per the
requirement through reputed agency and the same may be tested for SWL in
presence of the authorized testing agency.
Before using chain pulley block & sling, user should have the knowledge of
weight of the job.
Storage of the Chain pulley blocks should be done in proper way
32 | P a g e
UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/013
Rev.No: 00
Safe Working Of Page 1 of 1
Inert Gas Receiver Eff. Dt.:
1. PURPOSE: -
To establish a system for Safe working of inert gas receiver.
2. SCOPE: -
Applicable to inert gas receiver.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
Inert gas pressure in receiver should not be more than safe working pressure.
Safety valve should operate below the safe working pressure.
Hammering etc. should not done on receiver.
Good quality pressure gauge with Safe working pressure marking should be
provided on the tank.
Do not fill water in the receiver.
Clean the receiver tank from inside time to time.
Outer surface of receiver is always kept painted.
Tank should be tested / certified periodically by the authorized agency for its
suitability.
33 | P a g e
6. DATA AND RECORD: - NIL
1. PURPOSE: -
2. SCOPE: -
Applicable to in all sections where rotary air lock is installed.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
Work Permit and isolation of the system is taken to start the work as
per the procedure.
Now open all flange bolts to swivel the rotary air lock.
Insert a dummy plate & bolted from hopper flange.
Now rotary air lock is swiveled.
Check for jamming of rotary air lock rotor & rectified the same.
Rotary air lock is positioned back.
Bolted dummy plate is taken out.
Tighten back the rotary air lock flange bolts.
34 | P a g e
6. DATA AND RECORD: - NIL
1. PURPOSE: -
To facilitate safe operation & maintenance of packing machine.
2. SCOPE: -
Applicable to packing machine.
3. ABRIVIATIONS: -
4. RESPONSIBILITY: -
5. PROCEDURE: -
Power supply is made off before carrying out any job in packing machine
with work permit system.
Leakages/wear of slide plates, metallic buffers, bag guide plates & saddle
plate’s etc.is checked to arrest the leakages of cement & damage of cement
bags.
Suction pipes of packing machine are checked to ensure proper suction
at all venting points.
All pneumatic cylinder leakages are arrested.
Proper pulse valve operation of bag filter is ensured.
35 | P a g e
Aeration silencers & filters are checked to avoid the choking.
Flexible rubber hoses condition is checked to avoid leakage.
After completion of job, work permit is surrendered and power supply
is made switch on.
All the operatives should use the PPE’S i.e. ear muffs, safety helmet etc
as per the requirement of working area.
All the operatives should be aware of using the tools & tackles.
Working area should be clean before & after the work.
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