You are on page 1of 36

UNITED CEMENTS PVT.

LIMITED

TABLE OF CONTENT Doc.No. UCPL/ME/SOP/CONTENT


For Rev.No: 00
STANDARD OPERATING Page 1 of 2
PROCEDURE (SOP) Eff. Dt.:
Approved By: Issued By:
Date: Date:

S.N. DESCRIPTION IDENTIFICATION REV. PAGE


NO.
1 Operation And Maintenance Of Lime Stone Crushers UCPL/ME/SOP/001 00 3-4

2 Operation And Maintenance Of Bag Filter UCPL/ME/SOP/002 00 5-6

3 Area Cleaning and Housekeeping UCPL/ME/SOP/003 00 7

4 Handling, Storage & Disposal Of Used Grease & Oil UCPL/ME/SOP/004 00 8

5 Operation And Maintenance (Coal Mill Bag House) UCPL/ME/SOP/005 00 9

6 Safe Working At Height On Scaffolding And Steel Structures UCPL/ME/SOP/006 00 10

7 Working at High Noise Area (Compressor / Blowers) UCPL/ME/SOP/007 00 11

8 Operation And Maintenance Of Cooler UCPL/ME/SOP/008 00 12

9 Operation & Maintenance In Ball Mill UCPL/ME/SOP/009 00 13-14

10 Operation & Cleaning Of Belt Conveyors UCPL/ME/SOP/010 00 15

11 Safe Welding & Gas Cutting Operation UCPL/ME/SOP/011 00 16-19

12 Operation Of Chain Pulley Block & Use Of Sling UCPL/ME/SOP/012 00 20

13 Safe Working Of Inert Gas Receiver UCPL/ME/SOP/013 00 21

14 Clearing of Rotary Air Lock Jam UCPL/ME/SOP/014 00 22

15 Operation And Maintenance of Packing Machine UCPL/ME/SOP/015 00 23

16 Operation And Maintenance Of Blowers UCPL/ME/SOP/016 00 24-25

Operation of Air Slides And Diversion Of Recirculation 26


17 UCPL/ME/SOP/017 00
Material

18 Fabrication Of Jobs UCPL/ME/SOP/018 00 27

19 Removal Of Conveyor Belt With New Belt. UCPL/ME/SOP/019 00 28

20 Heating Of Bearing For Fitment On Shaft And Housings UCPL/ME/SOP/020 00 29

Removal Of The Coupling / Bearing / Any Part With The Help Of 30


21 UCPL/ME/SOP/021 00
Hydraulic Jack And Heating With Gas Torch

Lifting Of Material To Height (Silo / Preheater Level) With The 31


22 UCPL/ME/SOP/022 00
Of Winch Machine

Page 1 of 36
UNITED CEMENTS PVT. LIMITED

TABLE OF CONTENT Doc.No. UCPL/ME/SOP/CONTENT


For Rev.No: 00
STANDARD OPERATING Page 2 of 2
PROCEDURE (SOP) Eff. Dt.:
Approved By: Issued By:
Date: Date:

23 Operation And Maintenance Of Air Compressors UCPL/ME/SOP/023 00 32-33

24 Operation And Maintenance of Bucket Elevator UCPL/ME/SOP/024 00 34

25 Operation And Maintenance Screw Conveyor UCPL/ME/SOP/025 00 35

Schedule For Periodic Inspection Of Tools Tackles , Work


26 Equipments And Welding Machine Etc.
UCPL/ME/SOP/026 00 36-37

27 Operation And Maintenance of Lift UCPL/ME/SOP/027 00 38

28 Operation And Maintenance Of Process Fans UCPL/ME/SOP/028 00 39

30 Operation And Maintenance Hydraulic Jack UCPL/ME/SOP/029 00 40

31 Operation And Maintenance Lathe Machine UCPL/ME/SOP/030 00 41-42

……..……………………..……>>>>>>….<<<<<<……………..……………….…..

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments
LC -- Line Clear (Power Cut-off)
SE/C -- Shift Engineer/Coordinator

4. RESPONSIBILITY: -

 HOD (Mech. Dept) is responsible for implementation of procedure.


 Section In-charge (SI) is responsible for procedures undertaking.
 Shift Engineer/Coordinator follows the instructions.

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.

6. HEALTH & SAFETY WARNING

 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: -

The procedure is applicable for following activities----


 Repair / Replacement of front and rear Impact arms.
 Replacement of crusher body liners / chute Plates.
 Replacement of blow bars, grinding bars & hammers.
 Replacement and checking of crusher bearings.
 Any repair / replacement in Apron Feeder.
 Mechanical repair jobs in Apron feeder.

8. DATA AND RECORD: -

 Proper record should be maintained in shift log register /maintenance


register related with operation and maintenance jobs.
 Safety i.e. work permits should be maintained as per the requirement.

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments
DP -- Differential Pressure
SE/C -- Shift Engineer/Coordinator

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility for any implementation.


 Respective SI (Mech.) is responsible for operation and maintenance
of Bag Filter.
 SE/C is responsible for smooth operation & follow the instructions.

5. PROCEDURE: -

a) OPERATION OF BAG FILTER: -

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.

b) MAINTENANCE OF BAG FILTER: -

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:

6) HEALTH & SAFETY WARNING

 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: -

The procedure is applicable for ----


 Operation & maintenance of all B/F in the plant.

8) DATA AND RECORD: -

 Proper record should be maintained in shift log register /maintenance


register related with operation and maintenance jobs.
 Safety i.e. work permits should be maintained as per the safety requirement.
 Keep damaged bags record in maintenance register

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments
MS – Mild Steels

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for operation of this procedure and
disposal of waste cotton/cloth & steel scrap to scrap yard area.

5. PROCEDURE: -

 Collecting container printed as “waste bin” are placed in specified areas.


 After using the waste cotton/cloth (not grease/oil soaked) the user placed the
same into the bin.
 During rainy season, the collecting containers to be covered properly.
 Whenever the bin gets filled up of cotton/cloth the same it should be shifted to
specified area.
 Scrap generated is placed at specified area of respective sections.
 The scrap segregated as M.S, castings, bag filter bags, rubber & V- belts etc.
should be in the knowledge of respective SI’s.
 Unloading of scrap is done at scrap yard in the presence of stores person for
unloading the right grade material at identified area.

UNITED CEMENTS PVT. LIMITED


Page 9 of 36
STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/003
Rev.No: 00
Area Cleaning and Page 2 of 2
Housekeeping Eff. Dt.:
Approved By: Issued By:
Date: Date:

6. HEALTH & SAFETY WARNING

 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: -

The procedure is applicable to ----


 Each section/locations in the plant.

8. DATA AND RECORD: -

 Proper record should be maintained in shift log register /maintenance


register related with operation and maintenance jobs.
 Safety i.e. work permits should be maintained as per the safety requirement.
 Keep record to hand over to store department.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
Page 10 of 36
For Doc.No. UCPL/ME/SOP/004
Rev.No: 00
Handling, Storage Page 1 of 2
& Disposal Eff. Dt.:
(Lubricants)

Approved By: Issued By:


Date: Date:

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible to their individual areas for proper
storage of used oil and grease at site and disposal of used oil & grease
to scrap yard.

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.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

Page 11 of 36
For Doc.No. UCPL/ME/SOP/004
Rev.No: 00
Handling, Storage Page 2 of 2
& Disposal Eff. Dt.:
(Lubricants)

Approved By: Issued By:


Date: Date:

6. HEALTH & SAFETY WARNING

 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: -

The procedure is applicable for the entire plant

8. DATA AND RECORD: -

 Proper record should be maintained in shift log register /maintenance


register related with operation and maintenance jobs.
 Safety i.e. work permits should be maintained as per the safety requirement.
 Keep record of used oil stock & hand over to store.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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.:

Approved By: Issued By:


Date: Date:

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments
SE/C -- Shift Engineer/Coordinator

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for Operation and Maintenance of Coal
Mill Bag House.
 SE/C will follow the instructions as given by SI of the area.

5. PROCEDURE: -

a) OPERATION OF COAL MILL BAG HOUSE: -

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.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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.:

Approved By: Issued By:


Date: Date:

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.

b) MAINTENANCE OF COAL MILL BAG HOUSE: -

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.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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.:

Approved By: Issued By:


Date: Date:

9) HEALTH & SAFETY WARNING

 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: -

The procedure is applicable for ----


 Operation & maintenance of Coal Mill Bag House.

11) DATA AND RECORD: -

 Proper record should be maintained in shift log register /maintenance


register related with operation and maintenance jobs.
 Safety i.e. work permits should be maintained as per the safety requirement.
 Keep damaged bags record in maintenance register

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
Page 15 of 36
For Doc.No. UCPL/ME/SOP/006
Rev.No: 00
Safe Working at Height on Page 1 of 2
Scaffolding & Steel Eff. Dt.:
Structures
Approved By: Issued By:
Date: Date:

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for safe working procedures.
 Scaffolding for working at height should be done in supervision of trained /
authorized person as per the norms.

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 is ensured that no unwanted material lying on the scaffolding.


 It is ensured that Guards/railings surrounding the work area are proper.
 It is ensured that Proper illumination at work place.
 Work permit for work at height is issued before carrying out the job at height.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
Page 16 of 36
For Doc.No. UCPL/ME/SOP/006
Rev.No: 00
Safe Working at Height on Page 2 of 2
Scaffolding & Steel Eff. Dt.:
Structures
Approved By: Issued By:
Date: Date:

 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.

6) HEALTH & SAFETY WARNING

 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.

8) DATA AND RECORD: -

 Work Permit for work at Height

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for safe procedures.
 Every individual employee who is working at blower area.

5. PROCEDURE: -

 At high noise area, the stay should be as per the norms and wear proper
PPE’s, to avoid the permanent disability.

 Blower/ Compressor attendant should wear earplugs/ Ear muffs,


whenever he works at blower/compressor area to protect from
sound pollution.
 All the maintenance personnel should wear ear plugs whenever
they work at stand by blower / Compressor repairing, to protect
from sound pollution.
 All the personnel get issue the ear plugs individually from the main
store.
 No one should be allowed to enter in the area without ear plugs.
 Ensure that “HIGH NOISE AREA” display board is displayed at
entry point.

6. DATA AND RECORD: - Record for Issue of PPE’s to workman.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments
SE/C -- Shift Engineer/Coordinator

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for safe working procedures.
 SE/C will follow the instructions of SI.

5. PROCEDURE: -

 It is ensured for proper use of PPEs


 Safety helmet.
 Hand Gloves
 Dust Mask.
 Safety Shoes

 Before start of work the safety talks should be given to Operation


and Maintenance Staff. Ensure work permits for isolation ,
confined space and hot work is issued as Per the requirement of
the jobs

6. OPERATION OF COOLER : -

 Ensure that all the guards are placed in position on coupling,


jack shaft, zero speed switches and motors.
 No work is performed during the running of cooler.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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.

8. HEALTH & SAFETY WARNING

 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.

9. DATA AND RECORD: -

 Proper record in log book.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments
SE/C -- Shift Engineer/Coordinator
HP – High Pressure (Pump)
LP -- Low Pressure (Pump)

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for safe working operation &
maintenance of their ball mills.
 SE/C will follow the instructions & guidelines of SI.

5. PROCEDURE: -

a) OPERATION OF BALL MILL : -

 To avoid material spillage from mill inlet ensures following points


should be checked and maintained.
 That mill is not overfilled.
 Mill feed is not Flushing through feed belts.
 Mill diaphragm is checked periodically for removal of chocking
and any damages.
 Cement mill draught is maintained properly.
 Grinding Media charging is done periodically.
 Routine checking for Trunion lubrication pump’s including HP & LP pumps
to operating pressures and working temperatures.
 Taking care for any abnormal sounds from gear boxes and lubrication pumps.
 Regular inspection of grease level in girth gear grease pump’s barrel.
 Flow and pressure of cooling water passing through the lubrication pumps
and forced lubrication pump system.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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:

b) MAINTENANCE OF BALL MILL : -

Designated persons are deployed for cleaning / inspection maintenance


of Ball Mill.

 All persons are instructed to wear PPEs in the area.


 During running nobody is allowed near Ball Mill without earplug / muff
since it is high noise zone.
 All the local stop, emergency stop, oil pressure gauge, temp. Gauge, is
operational.
 Proper guard is provided on coupling, shafts& other rotating part of mill.
 Before stop it is ensured that Mill is properly emptied for inside maintenance
 Before maintenance, power supply of Mill is switched off by work permit
system.
 Proper ventilation & illumination is maintained inside mill for maintenance/
inspection work.
 Safe working instructions are given to work inside the mill through work
permit of confined area.
 Before starting the Ball Mill it is ensured that nobody is working in the
Ball Mill.
 Before starting / switch on, the power supply by work-permit system of
the Ball Mill and material feeding equipments.
 Before starting of Ball Mill a hooter is used as an alarm.
 Mill is properly emptied to avoid dust spillage in mill area.
 Mill area is barricaded with a temporary wall showing caution note before
discharging grinding media.
 Competent persons are engaged for maintenance jobs and equipped with
PPEs.
 Proper venting & illumination is maintained inside mill.
 During charging of media nobody is allowed below the mill
 After completion of jobs power supply is made on with work permit system.
 To provide proper access for work inside the mill while cleaning of the mill

6. HEALTH & SAFETY WARNING

 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.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
Page 22 of 36
For Doc.No. UCPL/ME/SOP/008
Rev.No: 00
Operation & Maintenance Page 3 of 3
in Ball Mill Eff. Dt.:
Approved By: Issued By:
Date: Date:

7. APPLICABILITY: -

The procedure is applicable for following activities----


 Raw Mill,
 Coal Mill and
 Cement Mill

8. DATA AND RECORD: -

 Record is maintained by respective area in charge.


 Mill major maintenance record in history card.
 Shut down job records in the respective registers.
 Work permit for different activities in mill area.
 Ball mill shell linear & head linear wear rate to maintain in record
 Grease consumption & oil consumption maintain in log book.
 Gear box oil replacement record and calculate consumption
by running hours.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments
SE/C -- Shift Engineer/Coordinator

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for safe working operation &
maintenance of belt conveyors.
 SE/C will follow the instructions & guidelines of SI.

5. PROCEDURE: -

During the Operation of belt conveyors, feeding from stockpile to hopper


& then hopper to ball mill, following work instructions should be followed
To avoid/minimize the dust emission from the transfer points/belt conveyors.

a) OPERATION OF BELT CONVEYOR : -

 All the operatives to be instructed to use PPE’s i.e. Dust Mask,


Helmet, Hand Gloves, Ear Plugs etc. while working near the
belt conveyor.
 Only competent person may be deployed for the operation of
the Belt Conveyors.
 The above persons are instructed not to wear loose cloths.
 Checking of all the pull cords and other equipments and safety
devices provided in the system.
 It is ensured that belt conveyor is not overfilled to avoid
spillage of material.
 Proper operation of dust collectors and there should be proper
suction in the transfer point.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
Page 24 of 36
For Doc.No. UCPL/ME/SOP/010
Rev.No: 00
Operation & Maintenance Page 2 of 2
Belt Conveyor Eff. Dt.:
Approved By: Issued By:
Date: Date:

 If fugitive emission is there near the transfer points following


points should be checked/rectified.
 It is ensured that all venting line is clear at all the transfer
points.
 Plugging of entry of false air from dust collector & from circuit.

b) MAINTENANCE OF BELT CONVEYOR : -

 Competent person is deployed for cleaning below belt conveyor.


 The above persons are instructed not to wear loose cloths.
 Before starting the belt ensure that nobody is working in the vicinity of belt
conveyor.
 No work is performed in belt conveyor during running of belt conveyor.
 Operating it checks pull cord/sway switch.
 The Guards to be placed properly in tail drum to protect the person from any
eventuality while cleaning below the tail drum.

6. HEALTH & SAFETY WARNING

 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.

8. DATA AND RECORD: -

 Record is maintained by respective area in charge.


 Mill major maintenance record in history card.
 Shut down job records in the respective registers.

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: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective Section /Area in-charges are responsible for this procedure.

5. PROCEDURE: -
Following safety precaution during required welding & gas cutting must be
followed. The following set of instructions is to be follow.

5.1. SAFETY PRACAUTION: -


 Hot work permit shall be obtained wherever applicable before
commencement of the work.
 All fire precautions as stipulated in IS: 3016 (code of practice for fire
precautions in welding and cutting operations) shall be followed
while welding/gas cutting.
 Fire extinguishers, sand buckets, water and gunny bags shall be
provided when hot work is in progress.
 Gas cylinders used for gas cutting and welding shall-----

 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:

 Be fitted with safety caps when not in use.


 Not be lifted by nozzle and rolled.

5.2. GAS CUTTING AND WELDING : -

 All gas and oxygen regulators shall be fitted with Flashback


arrestors, being non-return valves designed to prevent and
explosive mix developing in cylinder. Checking for leaks shall be
with help of soapy liquid applied to any part of the cylinder.
 When working at height, do not place cylinders directly beneath the
working area, as molten metal may fall onto the hoses, causing
leaks and possibly igniting the gasses.
 Hose shall be in good condition, and properly clamped.
 Gas cylinders for each type of gas should be stored separately. They
should be kept away from any source of heat and shielded from
direct sun light. If retained upright in rack or trolley and not be left
free standing.
 While unloading / loading gas cylinder nozzle valve guard cap must
be properly fitted and cylinder shall be unloaded over rubber/soft
mat.
 Regulators, noses, torches and other oxy-fuel gas equipment shall
be kept free from grease, oil and other combustibles.
 Lubricants should never be used on Oxy-fuel gas equipment.
 Oxygen pressure reducing regulator, hose or other pieces of
apparatus should never be used with any other gases.
 Oxygen cylinders should never be used without first connecting a
suitable pressure-reducing regulator to the cylinder valve.
 Acetylene cylinder should be turned & kept in such a way that the
valve outlet will point away from oxygen cylinder.
 While opening acetylene cylinder valve, key or spindle would not be
turned more than one and one half turns.
 Acetylene cylinder key for opening valve must be kept on valve stem
while cylinder is in use so that it may be quickly turned off in case of
emergency.
 Acetylene should never be used at pressures in excess of 15PSI.
The use of higher pressures is prohibited by all insurance
authorities and by law in may localities. The gas hoses should be in
a good condition and easily distinguishable and protected against
heat, sharp objects, dirt, oil & grease.
 Cylinders full or empty should never be stored upright with the valve
uppermost.

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:

 If an outlet valve of acetylene cylinder becomes clogged with ice or


frozen, if should be thawed with warm water (not boiling), applied
only to the valve. A flame should never be used. This is because the
fusible safety plugs on acetylene cylinder melts at about boiling point
of water.
 Cylinders are not designed for temperatures in excess of 54deg.
Centigrade and hence storage/handling should be done keeping this
in mind.

5.3. ELECTRIC WELDING: -

 All equipments shall be properly earthed, and cables properly


insulated and connected.
 During electric welding process, very high ultra violet radiation
is generated. The welder and any person working in close
proximity, in order to prevent permanent damage to the eyes
must wear suitable eye protection. When not in use, power
supply to the holder and electrode shall be turned off.
 ELCB / RCCB shall be provided in every welding circuit.
Earthing shall be dedicated for each circuit. Diesel generating
set shall have separate earthing. Circuit shall always be made
by cables of right quality and cross section only.
 Diesel generating set shall be connected with welding
transformer through switch board fitted over a rigid support at
height of 100 cm from ground with appropriate ELCB / RCCB.
 The welder or welding operator shall be insulated from both the
work and metal electrode and holder. The bare metal part of an
electrode holder shall never be permitted to touch the
operator’s bare skin or wet clothing. Consistent use of well
insulated electrode holders and cables, dry clothing on hands
and body and insulation from the ground shall be helpful in
preventing contact with electricity.
 Electrode should never be changed with bare hand or wet
gloves or when standing on wet floor/ground.
 Frame of welding unit (portable/stationery) should be grounded
using correctly rated wire/strip and earth pit.
 Resistance to earthing must be checked, before start of work.

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.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/011
Rev.No: 00
Safe Welding & Gas Cutting Page 4 of 5
Operation Eff. Dt.:
Approved By: Issued By:
Date: Date:

 If the cable is worn, exposing bare conductors, it must be


immediately replaced / insulated. Welding cable shall have
proper insulation and minimum number of joints.
 Welding cables shall be kept dry and free of grease and oil to
prevent premature breakdown of the insulation.
 Cable laid on the floor/ground shall be protected in such a way
that they will not interfere with safe passage or become
damaged or entangled.
 Welding cables shall be kept way from power supply cable and
high tension wires.
 Welding cables shall be not coiled or looped around any
structure.
 While coupling several lengths of cables for use as welding
circuit, insulated connectors on both the ground and electrode
holder line shall be used if occasional coupling an un coupling
is necessary.
 It is ensured , that the portion in the circuit of liquid or gas
circulation e.g. the storage tank, pipelines, valves, pumps etc.
where welding/cutting work is to be carried out, is blanked or
isolated and purged with inert gas or washed thoroughly, so as
to make absolutely certain that no inflammable liquid/gas is
present in an amount, which can catch fire under action of heat,
spark, flame, welding spatter or red hot objects. The area shall
be checked and ascertained that concentration of combustible
gas in the air is within permissible limit.

 PPE’S REQUIRED:- Other personal protective Equipment shall


be as under…………

 Protective cloth/apron long enough to cover wrists and forearms against


heat, sparks molten metal and radiation. Leather or asbestos apron can be used
for this purpose. Flame resistant gloves & Safety shoes.
 Helmet/ shoulder cover for over head welding as necessary
 Safety harness while working at heights.

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.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/011
Rev.No: 00
Safe Welding & Gas Cutting Page 5 of 5
Operation Eff. Dt.:
Approved By: Issued By:
Date: Date:

 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.

5.4. IMPORTANT POINTS: -




 Portable fire fighting facilities and first aid facilities should be made
available in ready condition.
 Adequate water should be made available at work spot for
emergency requirements. While welding job is going on at height,
particularly on temporary platform or on scaffolding, the proper care
should be taken by removing the cotton, plastic etc from lower floor
• and spread raw dust on oily surface to protect it to catch fire

6. APPLICABILITY: -

The procedure is applicable for the entire plant

7. DATA AND RECORD: - NIL

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: -

Applicable in entire plant area as per the requirement.

3. ABRIVIATIONS: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for operation of this procedure.
 Skilled manpower to follow the instructions.

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

6. DATA AND RECORD: - NIL

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.:

Approved By: Issued By:


Date: Date:

1. PURPOSE: -
To establish a system for Safe working of inert gas receiver.

2. SCOPE: -
Applicable to inert gas receiver.

3. ABRIVIATIONS: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for operation of this procedure.

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

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/014
Rev.No: 00
Clearing of Rotary Page 1 of 1
Air Lock Jam Eff. Dt.:
Approved By: Issued By:
Date: Date:

1. PURPOSE: -

To establish a system for clearing of rotary air lock jam.

2. SCOPE: -
Applicable to in all sections where rotary air lock is installed.

3. ABRIVIATIONS: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for operation of this procedure.

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

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/015
Rev.No: 00
Operation & Maintenance Page 1 of 2
of Packing Machine Eff. Dt.:

Approved By: Issued By:


Date: Date:

1. PURPOSE: -
To facilitate safe operation & maintenance of packing machine.

2. SCOPE: -
Applicable to packing machine.

3. ABRIVIATIONS: -

HOD – Head of Department


SI – Section In-charge
PPE – Personal Protective Equipments

4. RESPONSIBILITY: -

 HOD (Mech.) has overall responsibility.


 Respective SI (Mech.) is responsible for operation of this procedure.

5. PROCEDURE: -

During the weekly maintenance of respective packing machine, the


following points are to be checked for healthy operation of packing machine.

5.1. DURING THE WEEKLY MAINTENANCE: -

 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.

UNITED CEMENTS PVT. LIMITED


STANDARD OPERATING PROCEDURE (SOP)
For Doc.No. UCPL/ME/SOP/015
Rev.No: 00
Operation & Maintenance Page 2 of 2
of Packing Machine Eff. Dt.:

Approved By: Issued By:


Date: Date:

5.2. DURING RUNNING OF PACKING MACHINE: -

 Only competent persons are allowed to operate the Packing Machine.


 It is ensured that all emergency switches, push buttons are in working
condition.
 It is ensured that all safety interlocks are working properly.
 All the packer machine operators are ensured to use PPEs.
 Proper illuminations and venting are ensured near packing machine.

6. HEALTH & SAFETY WARNING

 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. DATA AND RECORD: -


Maintain record in daily log book

36 | P a g e