Anda di halaman 1dari 263

Ambuja Cements Limited

Unit- Rabriyawas

Ambuja Cements Limited


Unit: Rabriyawas
Department: Production

Register - Standard Operating


Procedure
Original date of issue:

Revision No.: Number of Pages:

Revised Date of Issue:

Compiled by: Approved by: Department Head

Signature: …………………………….. Signature: ……………………………

Name: S S Singh Name: V Saxena

Ambuja Cements Limited


Unit- Rabriyawas
P.O. DLF Rabriyawas - 306709,
Distt. Pali (Rajasthan), India.
PBX Phone: - 02939-288011 to 288018

B-03.2_Register - Standard Department: Production Page No. 1


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
Table of Contents:

# Ref. No. Details Page


No.
01 ACL-WI-RM-001 WI - ADDITIVE FEEDING BY PAYLOADER
02 ACL-WI-RM-002 WI - LIME STONE FEEDING BY L/S RECLAIMER
03 ACL-WI-RM-003 WI - RAW MILLS CIRCUIT INSPECTION
04 ACL-WI-RM-004 WI - RAW MILLS SEPARATOR INSPECTION
05 ACL-WI-RM-005 WI - RAW MILLS TABLE/ROLLER LINER WEAR MEASURMENT
06 ACL-WI-RM-006 WI - RAW MILLS INTERNAL/WATER SPRAY NOZZLES INSPECTION
07 ACL-WI-RM-007 WI - HOUSE KEEPING IN RAW MILLS CIRCUIT
08 ACL-WI-RM-008 WI - RAW MILL-1 HAG OPERATION
09 ACL-WI-RM-009 WI - RAW MILLS LIME STONE/ADDITIVE HOPPER CLEANING
10 ACL-WI-RM-010 WI - CHUTE CLEANING JOB
11 ACL-WI-TT-001 WI - COAL UNLOADING THROUGH TRUCK TIPPLER
12 ACL-WI-TT-002 WI - COAL STACKING IN COAL YARD THROUGH COAL STACKER
13 ACL-WI-TT-003 WI - COAL RECLAIMING IN COAL YARD THROUGH COAL RECLAIMER
14 ACL-WI-TT-004 WI - COAL MILLS CIRCUIT INSPECTION
15 ACL-WI-TT-005 WI - HOUSE KEEPING IN COAL MILLS CIRCUIT
16 ACL-WI-TT-006 WI - COAL MILL-1 TABLE/ROLLER LINER WEAR MEASURMENT
17 ACL-WI-TT-007 WI - COAL MILLS SEPARATOR INSPECTION
18 ACL-WI-TT-008 WI - COAL MILLS INTERNAL INSPECTION
19 ACL-WI-TT-009 WI - COAL MILL-1 HAG OPERATION
20 ACL-WI-TT-010 WI - COAL MILLS RAW COAL HOPPER CLEANING
21 ACL-WI-TT-011 WI - COAL MILLS FINE COAL BINS CLEANING
22 ACL-WI-TT-012 WI - INERT GAS PLANT OPERATION
23 ACL-WI-TT-013 WI - CHUTE CLEANING JOB
24 ACL-WI-TT-014 WI - CLEANING OF BOOSTER FAN
25 ACL-WI-KL-001 WI - SHIFTING OF BRICKS BY CRANE TATA-280
26 ACL-WI-KL-002 WI - SHIFTING OF BRICKS BY ELECTRIC WIRE ROPE HOIST
27 ACL-WI-KL-003 WI - SHIFTING OF BRICKS BY BRICK ELEVATOR
28 ACL-WI-KL-004 WI - SHIFTING OF BRICKS BY PH LIFTS
29 ACL-WI-KL-005 WI - SHIFTING OF BRICKS BY ELECTRIC WINCH MACHINE
30 ACL-WI-KL-006 WI - SHIFTING OF CASTABLE BAG BY ELECTRIC WIRE ROPE HOIST
31 ACL-WI-KL-007 WI - SHIFTING OF CASTABLE BAG BY ELECTRIC WINCH MACHINE
32 ACL-WI-KL-008 WI - SHIFTING OF CASTABLE BAG BY PH LIFTS
33 ACL-WI-KL-009 WI - SHIFTING OF SCAFFOLDING PIPE/JALI BY ELEC. WINCH MACHINE
34 ACL-WI-KL-010 WI - KILN CIRCUIT(COOLER) INSPECTION
35 ACL-WI-KL-011 WI - KILN CIRCUIT(ROTARY KILN) INSPECTION
36 ACL-WI-KL-012 WI - KILN CIRCUIT(ILC & SLC PH) INSPECTION
37 ACL-WI-KL-013 WI - INLET COATING CLEANING
38 ACL-WI-KL-014 WI - BURNER PIPE COATING CLEANING
39 ACL-WI-KL-015 WI - INSPECTION OF HAMMER CRUSHER INLET CHUTE

B-03.2_Register - Standard Department: Production Page No. 2


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
# Ref. No. Details Page
No.
40 ACL-WI-KL-016 WI - HOUSE KEEPING IN KILN CIRCUIT
41 ACL-WI-KL-017 WI - CYCLONE JAM REMOVAL JOB
42 ACL-WI-KL-018 WI - COOLER SNOWMAN REMOVAL JOB
43 ACL-WI-KL-019 WI - HAMMER CRUSHER INLET/DISCHARGE CHUTE CLEANING JOB
44 ACL-WI-KL-020 WI - CLINKER DPC DISCHARGE CHUTE CLEANING JOB
45 ACL-WI-KL-021 WI - KILN FEED AIR SLIDE JAM REMOVAL JOB
46 ACL-WI-KL-022 WI - ILC & SLC PH CYCLONE REFRACTORY BRICKS MAINT. JOB
47 ACL-WI-KL-023 WI - ILC & SLC PH CYCLONE REFRACTORY CASTABLE MAINT. JOB
48 ACL-WI-KL-024 WI - ILC & SLC CALCINER REFRACTORY BRICKS MAINT. JOB
49 ACL-WI-KL-025 WI - ILC & SLC CALCINER REFRACTORY CASTABLE MAINT. JOB
50 ACL-WI-KL-026 WI - KILN INLET SMOKE CHAMBER REFRACTORY CASTABLE MAINT. JOB
51 ACL-WI-KL-027 WI - ROTARY KILN REFRACTORY BRICKS MAINTENANCE JOB
52 ACL-WI-KL-028 WI - ROTARY KILN REFRACTORY CASTABLE MAINTENANCE JOB
53 ACL-WI-KL-029 WI - KILN HOOD REFRACTORY BRICKS MAINTENANCE JOB
54 ACL-WI-KL-030 WI - KILN HOOD/COOLER REFRACTORY CASTABLE MAINTENANCE JOB
55 ACL-WI-KL-031 WI - SLC TA TAKE OFF DUCTS REFRACTORY BRICKS MAINTENANCE JOB
56 ACL-WI-KL-032 WI - SLC TA TAKE OFF DUCTS REFRACTORY CASTABLE MAINTENANCE JOB
57 ACL-WI-KL-033 WI - ILC & SLC TA DUCT REFRACTORY BRICKS MAINTENANCE JOB
58 ACL-WI-KL-034 WI - ILC & SLC TA DUCT REFRACTORY CASTABLE MAINTENANCE JOB
59 ACL-WI-KL-035 WI - CF SILO RESIDUAL MATERIAL CLEANING
60 ACL-WI-KL-036 WI - BURNER PIPE REFRACTORY CASTABLE MAINTENANCE JOB
61 WI - ILC, SLC PH CYCLONE & SLC PC RISER DUCTS REFRACTORY BRICKS
ACL-WI-KL-037 MAINT. JOB
62 WI - ILC, SLC PH CYCLONE & SLC PC RISER DUCTS REFRACTORY CASTABLE
ACL-WI-KL-038 MAINT. JOB
63 ACL-WI-KL-039 WI - STARTING/RUNNING OF SLC PC DIESEL FIRING
64 ACL-WI-KL-040 WI - SLC TA BEND HOPPER CLEANING JOB
65 ACL-WI-KL-041 WI - CLINKER DPC SPILLED CLINKER CLEANING JOB
66 ACL-WI-KL-042 WI - SLC TA DUCT MATERIAL CLEANING JOB
67 ACL-WI-KL-043 WI - STARTING/RUNNING - KILN DIESEL FIRING
68 ACL-WI-KL-044 WI - SHIFTING OF CLINKER THROUGH PAY LOADER
69 ACL-WI-KL-045 WI - SHIFTING OF CLINKER THROUGH EXTRACTION CHUTE
70 ACL-WI-KL-046 WI -CASTABLE MIXER MACHINE CLEANING
71 ACL-WI-KL-047 WI - BLASTER INSPECTION
72 ACL-WI-KL-048 WI – HIGH BEARING TEMPRATURE
73 ACL-WI-KL-049 WI - CLEANING OF ROTARY FEEDER
74 ACL-WI-KL-050 WI - CLEANING OF SOLID FLOW METER
75 ACL-WI-KL-051 WI - CLEANING OF CORIOLIS
76 ACL-WI-KL-052 WI - CLEANING OF WEIGH FEEDER
77 ACL-WI-KL-053 WI - CLEANING OF AIR SLIDE
78 ACL-WI-KL-054 WI - CLEANING OF SCREW CONVEYOR
79 ACL-WI-KL-055 WI - CLEANING OF BAG FILTER HOPPER
80 ACL-WI-KL-056 WI - KILN INLET MATERIAL HANDLING
81 ACL-WI-KL-057 WI - CLEANING OF TPS MACHINE

B-03.2_Register - Standard Department: Production Page No. 3


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

# Ref. No. Details Page


No.
82 ACL-WI-CM-01 WI - CLINKER FEEDING INTO CLINKER STORAGE HOPPER
83 ACL-WI-CM-02 WI - GYPSUM FEEDING THROUGH PAY LOADER
84 ACL-WI-CM-03 WI - GYPSUM UNLOADING THROUGH TRUCK TIPPLER
85 ACL-WI-CM-04 WI - CEMENT MILLS CIRCUIT INSPECTION
86 ACL-WI-CM-05 WI - HOUSE KEEPING IN CEMENT MILLS CIRCUIT
87 ACL-WI-CM-06 WI - FLY ASH UNLOADING THROUGH TRUCK TIPPLER
88 ACL-WI-CM-07 WI - GRINDING MEDIA LOADING BY ELECTRIC WIRE ROPE HOIST
89 ACL-WI-CM-08 WI - CEMENT MILLS INTERNAL/WATER SPRAY NOZZLE INSPECTION
90 ACL-WI-CM-09 WI - CEMENT MILLS SEPARATOR INSPECTION
91 ACL-WI-CM-10 WI - CHAMBER SAMPLING IN CEMENT MILLS
92 ACL-WI-CM-11 WI - CEMENT MILL OUT LET HOOD COATING CLEANING
93 ACL-WI-CM-12 WI - FLY ASH SILO RESIDUAL MATERIAL CLEANING
94 ACL-WI-CM-13 WI - GRINDING AID PREPARATION & DOSING
95 WI - WET FLY ASH FEEDING THROUGH METALLIC HOPPER BY JCB/PAY
ACL-WI-CM-14 LOADER
96 ACL-WI-CM-15 WI - GRINDING AID PREPARATION & DOSING OF KARE-FAA
97 ACL-WI-CM-16 WI - -EIGN MATERIAL CLEANING IN FLY ASH FEEDING/DOSING SYSTEMS
98 ACL-WI-CM-17 WI - CHUTE CLEANING JOB
99 ACL-WI-CM-18 WI - ROLLER PRESS INTERNAL INSPECTION
100 ACL-WI-CM-19 WI - STATIC SEPARATOR INSPECTION
101 ACL-WI-CM-20 WI - GRINDING AID PREPARATION & DOSING OF NaOH & KOH
102 ACL-WI-CM-21 WI - PROCESS FLOW MEASUREMENT
103 ACL-WI-CM-22 WI - CLEANING AND INSPECTION OF SOLID FLOW METER
104 ACL-WI-CM-23 WI - INSPECTION AND CLEANING OF AIRSLIDE
105 ACL-WI-CM-24 WI - BAG FILTER HOPPER CLEANING
106 ACL-WI-CM-25 WI - HOPPER CLEANING FROM OUTSIDE
107 ACL-WI-CM-26 WI - INSPECTION AND CLEANING OF SCREW CONVEYOR
108 ACL-WI-CM-27 WI - RP REJECT HANDLING
109 ACL-WI-CM-28 WI - FLY ASH BULKER UNLOADING
110 ACL-WI-CM-29 WI - FLY ASH & GYPSUM DOSING
111 ACL-WI-CM-30 WI - CEMENT MILL INTERNAL INSPECTION & DIAPHRAGM CLEANING
112 WI - GYPSUM PLANT CIRCUIT INSPECTION DURING STARTING/RUNNING
ACL-WI-SG-01 CONDITION
113 ACL-WI-SG-02 WI - HOUSE KEEPING IN GYPSUM PLANT
114 ACL-WI-SG-03 WI - UNLOADING OF ACID INTO SERVICE TANK FROM TANKER
115 ACL-WI-SG-04 WI - ACID TRANSPORT INTO ACID TANK FROM SERVICE TANK
116 ACL-WI-SG-05 WI - ACID TRANSPORT FROM ACID TANK TO MIXER
117 WI - RAW MEAL DUST TRANSPORT TO 50 TON BIN FROM DENSE PHASE
ACL-WI-SG-06 SYTEM
118 ACL-WI-SG-07 WI - CLEANING OF MIXER
119 ACL-WI-SG-08 WI - CHUTE CLEANING JOB
120 ACL-WI-SG-09 WI - INSPECTION AND CLEANING ROTARY FEEDER
121 ACL-WI-SG-10 WI - HUGE ACID SPILLAGE FROM ACID STORAGE TANK

B-03.2_Register - Standard Department: Production Page No. 4


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Pages.: 2 Nos


SOP No.: ACL-WI-RM-001 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Additive feeding through dump hopper by pay loader
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs

Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3.Body ergonomics

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 5


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools and tackles:

 Hexagonal Crow Bar 2 Nos, 1.5 mtrs long & 15mm dia.
 Hammer with wooden handle 2 Nos 2 Kg
 Hand shovel with handle 2 Nos

 Spade with wooden handle 2 Nos

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Place the shuttle for required additive.


 Check additive group in all respect.
 Inform to CCR to run the group.
 Ask loader operator to feed additive.
 Clean the feeding hopper grizzly by labor.
 Ask CCR to stop the group after feeding require additive.
 Any spillage i.e. oil, coal dust, lime stone dust etc, the site attendant should inform to CCR or Concerned deptt.
 Site attendant will check that all machines are fully guarded & where machine guard not available inform to CCR or
concerned department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details:

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 6


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Pages.: 2 Nos


SOP No.: ACL-WI-RM-002 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Lime Stone feeding through Lime Stone Reclaimer
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Exposure to dust
2. Slip /Trip /Fall from stairs
3. Body ergonomics
4. Noise

Consequences of the deviation:

1. Respiratory Problems.
2. Injury fracture due to hit of material /slip and trip.
3. Hearing problem.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 7


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

05. Responsibility: HOD

06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check lime stone group in all respect.


 Inform to CCR to run the group.
 Check the venting JPF of transfer tower & belt conveyor.
 Ask CCR to stop the group after feeding requires lime stone.
 Site attendant will check that all machines are fully guarded & where machine guard not available inform to CCR or
concerned department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details:

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 8


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Pages.: 2 Nos


SOP No.: ACL-WI-RM-003 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Raw Mills circuit inspection during mill Starting/Running condition
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3.Body ergonomics
4.Caught in under or between

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

1. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

2. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

3. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

4. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 9


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
5. Responsibility: HOD

6. Tools & Tackles:


 Hand shovel with handle 2 Nos
 Spade with wooden handle 2 Nos

7. Manpower Requirements: 02

8. Results & Acceptance: Working person will not get injured during feeding

9. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check entire mill circuit in all respect.


 Inform to CCR to run the group.
 Keep in touch with CCR while starting the mill.
 Again check the mill circuit after starting the mill.
 Inform to CCR for any abnormality at site.
 Check mill circuit JPF i.e. suction, purging, compressed air pressure etc.
 Check that all machines are fully guarded & where machine guard not available inform to CCR or concerned
department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 10


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-RM-004 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Raw Mills separator inspection.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3. Caught in under and between the equipments /parts.
4. Exposure to high temperature.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 11
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the inspection door & allow separator to cool at workable temperature.
 Take the isolation permits for entrance into separator.
 Take the confined space entry permit.
 Do not allow to work in upper & down stream while inspecting.
 Inspect the separator.
 Remove measurement/cleaning tools from work place after completion of job.
 Check inside the separator.
 Close the separator inspection door.
 Return the confined space entry permit after completing the job.
 Return the isolation permits after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 12


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-RM-005 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Raw Mills Table/Roller liners wear measurement
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3. Caught in under and between the equipments/parts.
4.Exposure to high temperature
5.Accidental start of equipments

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

1. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

2. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

3. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

4. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 13


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
5. Responsibility: HOD

6. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Electric Chipper 1 No

7. Manpower Requirements: 02

8. Results & Acceptance: Working person will not get injured during feeding

9. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the mill inspection door & allow mill to cool at workable temperature.
 Take the isolation permits for entrance into mill.
 Take the confined space entry permit.
 Do not allow to work in upper & downstream while taking measurement.
 Take the mill Table/Roller liners wear measurement.
 Remove measurement/cleaning tools from work place after completion of job.
 Check inside the mill.
 Close the mill inspection door.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 14


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-RM-006 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Raw Mills internal/water spray nozzles inspection.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Dust exposure
2. Slip /Trip /Fall from stairs
3. Caught in under and between the equipments /parts.
4. Exposure to high temperature.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 15
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Electric Chipper 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the mill inspection door & allow mill to cool at workable temperature.
 Take the isolation permits for entrance into mill.
 Take the confined space entry permit.
 Do not allow to work in upper & downstream while mill inspecting.
 Check the mill water spray nozzles.
 Do the mill internal inspection.
 Remove cleaning tools from work place after completion of job.
 Check inside the mill.
 Close the mill inspection door.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 16


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-RM-007 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for House Keeping in Raw Mills circuit.
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3. Caught in under and between the equipments/parts.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 17


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Basket MS 2 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Identify the area where housekeeping is required.


 Do not allow to work in upper & downstream from work place.
 Check opening regarding falling object.
 Check machine guarding is proper if housekeeping is being carried in nearby area.
 Ensure that housekeeping to be carried out in presence of mill Attendant/Supervisor.
 Dispose of cleaned material at safe place.
 Remove cleaning tools at work place after completing of job.
 Check venting JPF of mills circuit.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 18


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-RM-008 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Raw Mill-1 HAG operation.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Slip /Trip /Fall from stairs
3. Caught in under and between the equipments/parts.
4. Exposure to high temperature.
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Burning of skin due to exposure of high temperature.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

HAG: Hot air generator

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 19


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check the firing nozzle is properly inserted & cleaned.


 Check the coffee pot damper is opened.
 Check the HAG outlet hoisting damper is opened.
 Check the compressed air pressure.
 Start the diesel pump in recirculation mode.
 Open the regulator of LPG cylinder & regulate the LPG flow.
 Ignite the LPG by igniter & observed the LPG flame.
 Open the main oil valve & regulate the diesel flow through diesel pressure.
 Switch off the LPG supply after stabilizing the diesel flame.
 Monitor the HAG outlet temperature.
 Regulate the diesel flow according to the temperature.
 Maintain the HAG outlet temperature according to CCR instruction.
 Inform CCR for any leakage in diesel, oil, gas etc.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 20


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-RM-009 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Raw Mills Lime stone/Additives hopper cleaning.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Exposure to dust
2.Slip /Trip /Fall from stairs
3. Caught in under and between the equipments/parts.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 21


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos
 Electric Chipper 1 No
 Crow Bar, 1.5 mtrs long & 15 mm dia 2 Nos
 Hammer with wooden handle, 2 Kgs 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Remove all possible set material by mechanized system.


 Only residual material to be removed manually by labor.
 Ensure no set material available on hopper walls above the work point.
 Take the isolation permits for entrance into hopper.
 Take the confined space entry permit.
 Open the inspection/man hole door of the hopper.
 Do not allow to work in upper & downstream while hopper cleaning.
 Ensure proper ventilation inside hopper before starting the job.
 Prepare scaffolding with hand rail & proper working platform.
 Do the hopper cleaning.
 Remove cleaning tools from work place after completion of job.
 Check inside the hopper.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 22


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-RM-010 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for chute cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3. Caught in under and between the equipments/parts.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 23


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 Crow Bar/Cleaning pipe: 1 Nos
 Hammer: 1 Nos

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start chute cleaning job.


 Stop the drive by applying local emergency/Local stop and pull chord at site & confirm from CCR.
 Open inspection/cleaning door by keeping yourself in front of door.
 Inform CCR to get proper ventilation if pressurization occurs.
 Start cleaning of chute through inspection/cleaning door by the help of hammer & crow bar or cleaning pipe. Handle
crow bar or cleaning pipe & hammer carefully during cleaning.
 Check the chute after complete cleaning.
 Close inspection/Cleaning door.
 Release the local emergency/Local stop and pull chord at site & confirm from CCR.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 24


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-TT-001 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for coal unloading through truck tippler.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Fall from staircase


2.Hit by fixed or moveing object
3.Truck moving by weight or slopes
4.Derail on ramp
5.Lock failure
6.Hydrulic pipe line damage
7.Coal dust spilage

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 25


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Park the Coal truck at designated place.


 Back horn should blow while reversing the truck & reversing should be guided by traffic marshal.
 Truck should be parked on flat horizontal surface & wheel choke should be fixed while waiting for his queue.
 Place coal stacker in required position according to coal.
 Check tippler group in all respect.
 Inform to CCR to run the group.
 Place the truck at tippler lift. Site attendant will guide to truck driver to take truck on tippler lift safely.
 Tie the both front chain hook with truck. Ensure minimum two hooks be engaged.

 Lift the rear jacks.


 Lift the tippler lift up to 75 % and observe material start releasing or not, if not down the lift and loose the coal with
JCB and lift the truck again slowly till the entire coal is unloaded.
 Start water spray to suppress coal dust if required.
 Clean the unloading hopper grizzly by JCB machine.
 Deploy labor for cleaning of remaining coal which is not in approach of JCB machine.
 Ask CCR to stop the group after empty out entire coal.
 Any spillage i.e oil, coal dust etc, the site attendant should inform to CCR or Concerned deptt.
 Site attendant will check that all machines are fully guarded & where machine guard not available inform to CCR or
concerned department.
 . In case of any residual material accumulation below lift, special care to be taken for housekeeping
 Mechanical isolation of Lift to be provided by applying mechanical stopper before entering inside

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 26


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 27


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-TT-002 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for coal stacking in coal yard through coal stacker.
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Ignation of fire
2.Derail on ramp
3.Coal dust spillage
Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 28


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Place coal stacker in required position according to coal.


 Check the group in all respect.
 Start the coal stacker.
 Inform to CCR to run the group.
 Run the stacker according to pile length.
 Prepare coal pile according to instruction given.
 Stop the stacker after stacking of coal.
 Site attendant will check coal pile & inform to CCR if any fire in coal. CCR officer/ Site Attendant will inform for fire
tender.
 Site attendant will check that all machines are fully guarded & where machine guard not available inform to CCR or
concerned department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 29


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-TT-003 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for coal reclaiming in coal yard through coal Reclaimer.
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Ignition of fire
2.Derail on ramp
3.Coal dust spillage
Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire

01.Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 30


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Place coal Reclaimer in required position according to coal.


 Check the group in all respect.
 Inform to CCR to run the group.
 Start coal Reclaimer.
 Run the Reclaimer according to pile length.
 Stop the Reclaimer after reclaiming of coal.
 Site attendant will check coal pile & inform to CCR if any fire in coal. CCR officer/ Site Attendant will inform for fire
tender.
 Site attendant will check that all machines are fully guarded & where machine guard not available inform to CCR or
concerned department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 31


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-TT-004 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Coal Mills circuit inspection during mill Starting/Running condition.
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Ignation of fire
2.Derail on ramp
3.coal dust spillage
Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles: Nil

B-03.2_Register - Standard Department: Production Page No. 32


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check entire mill circuit in all respect.


 Inform to CCR to run the group.
 Keep in touch with CCR while starting the mill.
 Again check the mill circuit after starting the mill.
 Inform to CCR for any abnormality at site.
 Check mill circuit JPF i.e. suction, purging, compressed air pressure etc.
 Do not work in improper position.
 Any spillage i.e oil, coal dust etc, the site attendant should inform to CCR or Concerned deptt.
 Check that all machines are fully guarded & where machine guard not available inform to CCR or concerned
department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 33


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-TT-005 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for House Keeping in Coal Mills circuit.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Ignition of fire
2.Derail on ramp
3.Coal dust spillage
Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 34


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Basket MS 2 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Identify the area where house keeping is required.


 Do not allow to work in upper & down stream from work place.
 Check opening regarding falling object.
 Check machine guarding is proper if house keeping is being carried in near by area.
 Check the mills venting JPF.
 Ensure that house keeping to be carried out in presence of mill Attendant/Supervisor.
 Dispose of cleaned material at safe place.
 Remove cleaning tools at work place after completing of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 35


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-TT-006 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Coal Mill-1 Table/Roller liners wear measurement.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to coal dust
2. Slip /Trip /Fall from stairs
3.Falling object
4. Caught in under or between the equipments.
5.Sudden start of equipments
Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 36
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Electric Chipper 1 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the mill inspection door & allow mill to cool at workable temperature.
 Take the isolation permits for entrance into mill.
 Take the confined space entry permit.
 Do not allow to work in upper & down stream while taking measurement.
 Take the mill Table/Roller liners wear measurement.
 Remove measurement/cleaning tools from work place after completion of job.
 Check inside the mill.
 Close the mill inspection door.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 37


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-TT-007 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Coal Mills separator inspection.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to coal dust
2. Slip /Trip /Fall from stairs
3.Falling object
4. Caught in under or between the equipments.
5.Sudden start of equipments
Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 38
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the inspection door & allow separator to cool at workable temperature.
 Take the isolation permits for entrance into separator.
 Take the confined space entry permit.
 Do not allow to work in upper & down stream while inspecting.
 Inspect the separator.
 Remove measurement/cleaning tools from work place after completion of job.
 Check inside the separator.
 Close the separator inspection door.

 Close the confined space entry permit after completing the job.
 Close the isolation permits after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 39


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 40


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-TT-008 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Coal Mills internal inspection.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to coal dust
2. Slip /Trip /Fall from stairs
3.Falling object
4. Caught in under or between the equipments.
5.Sudden start of equipments
Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 41


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Electric Chipper 1 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the mill inspection door & allow mill to cool at workable temperature.
 Take the isolation permits for entrance into mill.
 Take the confined space entry permit.
 Do not allow to work in upper & down stream while mill inspecting.
 Do the mill internal inspection.
 Remove cleaning tools from work place after completion of job.
 Check inside the mill.
 Close the mill inspection door.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 42


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 43


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-TT-009 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Coal Mill-1 HAG operation.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to coal dust
2. Slip /Trip /Fall from stairs
3.Falling object
4. Caught in under or between the equipments.
5.Sudden start of equipments
Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 44


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check the firing nozzle is properly inserted & cleaned.


 Check the coffee pot damper is opened.
 Check the HAG outlet hoisting damper is opened.
 Check the compressed air pressure.
 Start the diesel pump in recirculation mode.
 Open the regulator of LPG cylinder & regulate the LPG flow.
 Ignite the LPG by igniter & observed the LPG flame.
 Open the main oil valve & regulate the diesel flow through diesel pressure.
 Switch off the LPG supply after stabilizing the diesel flame.
 Monitor the HAG outlet temperature.
 Regulate the diesel flow according to the temperature.
 Maintain the HAG outlet temperature according to CCR instruction.
 Check the leakage of diesel, gas, oil etc & inform to CCR or Concerned department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 45


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 46


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-TT-010 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Coal Mills raw coal hopper cleaning.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to coal dust
2. Slip /Trip /Fall from stairs
3.Falling object

Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen.

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

B-03.2_Register - Standard Department: Production Page No. 47


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Remove all possible set material by mechanized system.


 Only residual material to be removed manually by labor.
 Ensure no set material available on hopper walls above the work point.
 Take the isolation permits for entrance into hopper.
 Take the confined space entry permit.
 Open the inspection/man hole door of the hopper.
 Prepare scaffolding with hand rail & proper work platform.
 Do not allow to work in upper & down stream while hopper cleaning.
 Ensure ventilation inside hopper before starting the cleaning job.
 Do the hopper cleaning.
 Remove cleaning tools from work place after completion of job.
 Check inside the hopper.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 48


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 49


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-TT-011 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Coal Mills fine coal bin/silo cleaning.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to coal dust
2. Slip /Trip /Fall from stairs
3.Falling object

Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 50


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos
 Electric Chipper 1 No
 Crow Bar, 1.5 mtrs long & 15 mm dia 2 Nos
 Hammer with wooden handle, 2 Kgs 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Remove all possible set material by mechanized system.


 Only residual material to be removed manually by labor.
 Ensure no set material available on hopper walls above the work point.
 Take the isolation permits for entrance into hopper.
 Take the confined space entry permit.
 Open the inspection/man hole door of the bin.
 Prepare scaffolding with hand rail & proper work platform.
 Do not allow to work in upper & down stream while bin cleaning.
 Ensure ventilation inside bin before starting the job.
 Do the bin cleaning.
 Remove cleaning tools from work place after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 51


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-TT-012 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Inert Gas Plant operation.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to coal dust
2. Slip /Trip /Fall from stairs
3.Falling object

Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 52


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Isolate the booster fan locally before cleaning start informs to CCR and apply emergency stop.
 Open inspection door.
 Try to clean set material through manually and crow bar.
 After cleaning close the inspection door.
 Remove the Isolation of conveyor.
 Informed to CCR for clearance.
 Remove tools from work place after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 53


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-TT-013 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning and inspection of booster fan.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to coal dust
2. Slip /Trip /Fall from stairs
3.Falling object

Consequences of the deviation:

1. Respiratory Problems
2. Burning of skin due to fire
3. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 54


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Isolate the booster fan locally before cleaning start informs to CCR and apply emergency stop.
 Open inspection door.
 Try to clean set material through manually and crow bar.
 After cleaning close the inspection door.
 Remove the Isolation of conveyor.
 Informed to CCR for clearance.
 Remove tools from work place after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 55


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-001 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Belt Conveyor discharge chute cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure to dust
2. Slip /Trip /Fall from stairs
3. Caught in under and between the equipment/parts.
4. Exposure to high temperature.
5. Falling object
6. Electric shock
7. Accidental start of gas /material circuit
8. Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 56
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Nylon Sling 2 Nos –5mtr long –Capacity – 5 MT

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Place two pallets of bricks one over other by means of a fork lift truck.
 Tie the sling from bottom base of lower pallet folding it to the top of upper pallet.
 Fix the eye of both the slings on the crane hook.
 Guide the operator to lift the load slowly.
 Place the pallets on the kiln platform and lower the hook at ground again.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 57


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-002 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for shifting of brick by Electric Wire Rope Hoist (Rope-Master)
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit
8.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 58


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Nylon Sling 2 Nos –5mtr long –Capacity – 5 MT


 D-Shackle 1 No -Capacity – 5 MT

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Place one pallet of bricks by means of a fork lift truck.


 Tie the one sling from one end of bottom base of pallet.
 Tie the other sling from other end of bottom base of pallet.
 Fix the eye of both the slings on the D-shackle & hook of hoist.
 Guide the operator to lift the load slowly.
 Place the pallets on the kiln platform and lower the hook at ground again.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 59


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-003 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for shifting of brick by Brick Elevator
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Falling object
6.Accidental start of gas /material circuit
7.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 60


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Spade with wooden handle – 02 Nos

07. Manpower Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Keep rubber pad below the discharge of elevator to collect the brick.
 Keep two men power at ground floor.
 Keep 3-4 men power at burner platform.
 Start the elevator.
 Place a brick in elevator bucket.
 Collect the brick at burner platform.
 Transport the bricks in such a way that these can be collect easily at burner platform.
 Make the staging of brick.
 Stop elevator after completion of brick shifting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 61


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-004 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for shifting of brick by PH Lifts
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Respiratory Problem
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Falling object
6.Accidental start of gas /material circuit
7.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 62


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Take the lift at required floor from where brick to be shifted.


 Place 70-80 bricks in lift gently.
 Close the door of lift.
 Start the lift.
 Stop the lift at required floor where bricks are to be unloaded.
 Remove the bricks from lift cabin & staging at floor.
 Repeat the above procedure for further shifting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 63


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-005 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for shifting of brick by Electric Winch
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Falling object
6.Accidental start of gas /material circuit
7.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage
4 .Electric shock

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 64
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Steel Cage 2 Nos –Capacity – 2 MT

07. Manpower Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Place steel cage at ground floor below the winch hook.


 Place 70-80 bricks in cage gently.
 Tie a nylon rope at top of cage.
 Fix the winch hook in cage sling.
 Guide the operator to lift the load slowly.
 Pull the nylon rope to avoid hitting of load with PH wall.
 Stop the winch where bricks are to be unloaded.
 Keep the nylon rope loose.
 Catch the nylon rope & pull the load inside the floor.
 Start inching the winch to place the load inside floor.
 Remove the bricks from cage & staging at floor.
 Repeat the procedure for next shifting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 65


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-006 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for shifting of Castable bag by Electric Hoist (Rope Master)
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Falling object
6.Accidental start of gas /material circuit
7.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage
4.Electric shock

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 66
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Steel Cage 2 Nos –Capacity – 2 MT

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Place steel cage at ground floor below the hoist hook.


 Place 12-15 bags (50 Kg) in cage gently.
 Tie a nylon rope at top of cage.
 Fix the winch hook in cage sling.
 Guide the operator to lift the load slowly.
 Pull the nylon rope to avoid hitting of load with wall.
 Stop the hoist at burner platform floor.
 Keep the nylon rope loose.
 Take the hoist inside floor.
 Remove the castable bag from cage & staging at floor.
 Repeat the procedure for next shifting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 67


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-007 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for shifting of castable bag by Electric Winch
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Falling object
6.Accidental start of gas /material circuit
7.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage
4. Electric shock

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 68
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Steel Cage 2 Nos –Capacity – 2 MT

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Place steel cage at ground floor below the winch hook.


 Place 10-12 bags (50 Kg) in cage gently.
 Tie a nylon rope at top of cage.
 Fix the winch hook in cage sling.
 Guide the operator to lift the load slowly.
 Pull the nylon rope to avoid hitting of load with PH wall.
 Stop the winch where bags are to be unloaded.
 Keep the nylon rope loose.
 Catch the nylon rope & pull the load inside the floor.
 Start inching the winch to place the load inside floor.
 Remove the bags from cage & staging at floor.
 Repeat the procedure for next shifting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 69


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-008 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for shifting of castable bag by PH Lifts
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles: Nil


B-03.2_Register - Standard Department: Production Page No. 70
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Take the lift at required floor from where brick to be shifted.


 Place 10-12 bags (50 Kg) in lift gently.
 Close the door of lift.
 Start the lift.
 Stop the lift at required floor where bags are to be unloaded.
 Remove the bags from lift cabin & staging at floor.
 Repeat the above procedure for next shifting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 71


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-009 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for shifting of scaffolding pipe/jali by Electric Winch
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Electric shock

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 72


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Wire rope sling 1 No , 6.0 mtrs long –Capacity – 2 MT


 D-Shackle 2 Nos - Capacity – 2 MT
 Nylon rope 2 nos , 120 mtrs long, 10 mm dia
 Wooden Sleeper , 4 Nos , 100x100x2000 MM

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Place 20-30 pipes/jali at ground floor on wooden sleeper below the winch hook.
 Tie wire rope sling at the same distance from both of pipe/jali.
 Fix 2 nos D-shackles in eye of wire rope sling
 Check the tightness of sling over pipes
 Tie two nylon ropes at both ends of sling.
 Fix the winch hook in center of sling.
 Guide the operator to lift the load slowly.
 Pull the nylon rope to avoid hitting of load with PH wall.
 Stop the winch where pipes/jali is to be unloaded.
 Keep the nylon rope loose.
 Catch the nylon rope & pull the load inside the floor.
 Start inching the winch to place the load inside floor on wooden sleeper.
 Unlock the D-Shackles & storing pipes/jali at floor.
 Repeat the procedure for next shifting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 73


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-010 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln circuit (Cooler) inspection during Kiln Starting/Running condition.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 74
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check entire cooler circuit in all respect.


 Inform to CCR to run the group.
 Keep in touch with CCR while starting the cooler group.
 Again check the cooler circuit after starting the kiln.
 Inform to CCR for any abnormality at site.
 Do not work in improper position.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 75


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-011 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln circuit (Rotary Kiln) inspection during Kiln Starting/Running condition
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 76


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check entire rotary kiln circuit in all respect.


 Inform to CCR to run the group.
 Keep in touch with CCR while starting the kiln group.
 Again check the kiln circuit after starting the kiln.
 Inform to CCR for any abnormality at site.
 Check the venting JPF of kiln circuit.
 Inspect conditions of kiln through inspection hole.
 Check cooler snowman through inspection window.
 Remove burner rhino horn.
 Do not work in improper position.
 Any spillage i.e oil, coal dust etc, the site attendant should inform to CCR or Concerned deptt.
 Check that all machines are fully guarded & where machine guard not available inform to CCR or concerned
department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 77


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-011 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln circuit (Rotary Kiln) inspection during Kiln Starting/Running condition
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 78


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check entire rotary kiln circuit in all respect.


 Inform to CCR to run the group.
 Keep in touch with CCR while starting the kiln group.
 Again check the kiln circuit after starting the kiln.
 Inform to CCR for any abnormality at site.
 Check the venting JPF of kiln circuit.
 Inspect conditions of kiln through inspection hole.
 Check cooler snowman through inspection window.
 Remove burner rhino horn.
 Do not work in improper position.
 Any spillage i.e oil, coal dust etc, the site attendant should inform to CCR or Concerned deptt.
 Check that all machines are fully guarded & where machine guard not available inform to CCR or concerned
department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 79


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-013 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Inlet Coating cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust emission
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 80


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Water hose , 1 No, 30 mtrs long, 20MM Dia


 GI Pipe with handle, 1 No 4 mtrs long, ½” Dia
 Heat Resistance suit with Helmet, Hand Gloves & Shoe

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start cleaning job.


 Close main compressed air valve & empty out the shock blaster vessel.
 Start coating cleaning job.
 Check one by one all poking doors.
 Inform to CCR for any abnormality at site.
 Close the poking door after completion of coating cleaning job.
 Restore the shock blasters operation.
 Inform CCR after finishing the cleaning job.
 Do not work in improper position.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 81


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-014 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Burner Pipe Coating cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 82


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Burner Coating breaking pipe ,1 No, 8 mtrs long, 75MM Dia

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start cleaning job.


 Open cleaning door.
 Start coating cleaning job.
 Take coating breaking pipe out if it overheated.
 Inform to CCR for any abnormality at site.
 Close the cleaning door after completion of coating cleaning job.
 Inform CCR after finishing the cleaning job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 83


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-015 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for inspection/checking of Hammer crusher inlet chute.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust emission
2.Slip /Trip /Fall from stairs
3.Falling object
4.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 84


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start inspection.


 Open inspection door.
 Check proper suction is available at inspection door.
 Observe through inspection door.
 Close inspection door.
 Inform to CCR for any abnormality at site.
 Do not work in improper position.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 85


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-015 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for inspection/checking of Hammer crusher inlet chute.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust emission
2.Slip /Trip /Fall from stairs
3.Falling object
4.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 86


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start inspection.


 Open inspection door.
 Check proper suction is available at inspection door.
 Observe through inspection door.
 Close inspection door.
 Inform to CCR for any abnormality at site.
 Do not work in improper position.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 87


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-016 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for House Keeping in Kiln circuit.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust problem
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 88


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Hand shovel with handle 1 No
 Spade with wooden handle 1 No
 Basket MS 2 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Identify the area where house keeping is required.


 Do not allow to work in upper & down stream from work place.
 Check opening regarding falling object.
 Check machine guarding is proper if house keeping is being carried in near by area.
 Ensure that house keeping to be carried out in presence of site Attendant/Supervisor.
 Dispose of cleaned material at safe place.
 Remove cleaning tools at work place after completing of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 89


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-017 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Cyclone jam removal job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust problem
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 90
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Air Hose 1 No, 30 mtrs long, 20 MM dia


 GI Pipe 1 No , 4-5 mtrs long, 1/2:” dia
 Heat Resistance suit - 2 Nos ( As per Work Category -4 )

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Ensure non availability of personnel at kiln inlet, Hood door, Cooler and DBC area before starting the job.
 Inform CCR & take permission prior to start cyclone jam removal job.
 Temperature profile to be check by Thermal Imager in jamming condition.
 Ensure the free path below the jamming portion.
 Ensure severity of jamming before starting of job.
 Remaining Cyclone door should not be open during cleaning process.
 Always start release from bottom of the jamming.
 Avoid crowed at work place. Only required persons will be available at work place.
 A negative pressure must be established in the plant.
 Work may only be carried out at one opening in the entire area at any one time, the other openings must be kept
shut.
 The cleaning point must be opened with great care and at an adequate safe distance.
 Person who is handling the job must not stand in front of door opening.
 Open one by one poking hole & clean it till the all material is removed.
 As far as possible always choose a position above and to the side of the rodding opening.
 Start air lancing through eye hole and necessary pocking holes.
 Check the cyclone after complete cleaning by drop test.
 Inform CCR after finishing the cleaning job.
 Restore the shock blaster operation.
 Entire cleaning process to be co-ordinate by Appointed Supervisor.
 After confirmation of solidity of jamming use metal pipe or air lancing.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.
B-03.2_Register - Standard Department: Production Page No. 91
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 92


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-018 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cooler snowman removal job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 93
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 High Pressure water Hose 1 No, 50 mtrs long, 16 MM dia
 Rigid lance with Gun 1 No, 4 mtrs long , 8MM dia
 Heat Resistance suit 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start snowman removal job.


 Start UT Pump & set require water pressure.
 Open eye hole of poking hole.
 Inform CCR to get proper ventilation if pressurization occurs.
 Start snowman removal through eye hole.
 Break snowman into small pieces through water jet.
 Check after complete removal of snowman.
 Stop UT Pump.
 Inform CCR after finishing the job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 94


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-019 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Hammer crusher inlet/discharge chute cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust problem
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 95


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 High Pressure water Hose 1 No, 50 mtrs long, 16 MM dia


 Rigid lance with Gun 1 No, 4 mtrs long , 8MM dia
 Heat Resistance suit 2 Nos
 Electric Chipper with chisel 1 No
 Pneumatic Breaker with chisel 1 No
 Crow Bar, 2 Nos, 1.5 mtrs Long, 16 MM dia
 Hammer with wooden handle 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start chute cleaning job.


 Start UT Pump & set require water pressure.
 Open poking hole.
 Inform CCR to get proper ventilation if pressurization occurs.
 Start cleaning of chute through poking hole.
 Break coating into small pieces through water jet.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 96


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-020 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for clinker DPC discharge chute cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust problem
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 97
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 Electric Chipper with chisel 1 No
 Crow Bar, 2 Nos, 1.5 mtrs Long, 16 MM dia
 Hammer with wooden handle 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start chute cleaning job.


 Hammering the discharge chute from out side.
 Check the clinker flow.
 Stop the DPC if clinker flow is not proper.
 Open inspection door.
 Try to clean it through crow bar & Hammer.
 Use electric chipper if coating piece is big.
 Close the inspection door.
 Inform CCR to run DPC.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 98


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-021 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for kiln feed air slide jam removal job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 99


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Air Hose, 1 No , 20-25 mtrs length, 20MM dia
 GI Pipe with handle 1 No , 4-5 mtrs long, ½” dia
 Hammer with wooden handle 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start air side cleaning job.


 Hammering the air slide body.
 Check the material flow.
 Open air slide inspection door if material flow is not proper.
 Start air lancing through inspection door till the complete material is cleaned.
 Close the inspection door of air slide.
 Inform CCR to run the kiln feed recirculation.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 100


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-022 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for ILC & SLC PH Cyclone Refractory Bricks maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Expoure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 101


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Scaffolding Pipe 80 Nos, 6.0 mtrs long & 48 MM dia
 Scaffolding Pipe 30 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 100 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory Bricks , As per drawing
 Alumina Mortar , As per Bricks consumption
 Ceramic blanket , 25 MM Thick
 Hysil Block , 15 MM & 100 MM thick
 Basket MS 3 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Wear safety helmet, safety boots.


 Wear protective hand gloves while doing refractory maintenance job.
 Wear dust mask & safety goggle.
 Do not use loose clothes
 Keep area of movement free of plates, rods and other heavy scraps and jams.
 Follow good house keeping practices i.e. maintain cleaning in work place.
 Do not allow to work in improper position.
 Keeps strict supervision while doing work by labor.
 Ensure three point contacts while using stairs.
 Ensure proper ventilation during maintenance job.
 Scaffolding pipe should be free from grease or oil.
 Ensure no work is to be carried out in upper & down stream while doing refractory job.
 Use 24 Volt supply for illumination inside cyclone.
Keep fire extinguisher at work place or Ensure high pressure water availability

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 102


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 103


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-023 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for ILC & SLC PH Cyclone Refractory castable maintenance job.
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust problem
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 104


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Scaffolding Pipe 80 Nos, 6.0 mtrs long & 48 MM dia
 Scaffolding Pipe 30 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 100 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Castable Mixer , 01 No.
 Hysil Block , 100 MM thick
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the cyclone inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into cyclone.
 Take the confined space entry permit.
 Fix dummy at cyclone discharge.
 Prepare scaffolding with hand rail & proper work platform where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform.
 Check the scaffolding prior to start the refractory job.
 Remove old castable lining.
 Clean the castable lining surface.
 Weld the anchor at specified spacing as per drawing.
 Check the Anchor welding by hammering the anchor.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Fix 100 MM Hysil block on casting area.
 Fix the GI wire among the anchors to hold hysil in its position.
 Prepare shuttering for 900x900 MM (Maximum) area.
 Prepare castable in castable mixer according to water addition & mixing time as per supplier recommendation.
 Pour the castable into shuttering & mix it with vibrator.
B-03.2_Register - Standard Department: Production Page No. 105
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Allow castable 2-6 hours for setting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 106


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-024 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for ILC & SLC Calciner Refractory Bricks maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 107
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 Scaffolding Pipe 80 Nos, 6.0 mtrs long & 48 MM dia
 Scaffolding Pipe 30 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 100 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory Bricks , As per drawing
 Alumina Mortar , As per Bricks consumption
 Ceramic blanket , 25 MM Thick
 Hysil Block , 15 MM & 100 MM thick
 Basket MS 3 Nos

07. Manpower Requirements: 06

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the Calciner inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into Calciner.
 Take the confined space entry permit.
 Fix dummy at kiln inlet smoke chamber for ILC.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jail for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old brick lining.
 Clean the brick lining surface.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Place the retainer brick on retainer plate & provide 15 mm Hysil block back side of brick.
 Apply alumina mortar & fix another brick.
 Fix 100 MM Hysil block on retainer brick.
 Fix the Calciner brick according to refractory drawing.
 Do the brick lining in require area.
 Remove tools & tackle from work place after completion of job.
 Check the lining.
 Remove the scaffolding.
 Clean the debris material by open the dummy.
 Check the Calciner & closed the inspection doors
 Close the confined space entry permit.
 Close the isolation permits.

B-03.2_Register - Standard Department: Production Page No. 108


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 109


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-026 Rev. No. 02
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln inlet smoke chamber Refractory castable maintenance job
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1. Slip /Trip /Fall from stairs
2. Caught in under and between the equipement/parts.
3. Falling object
4. Exposure of high temperature.

Consequences of the deviation:

1. Injury fracture due to hit of material /slip and trip


2. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles:


B-03.2_Register - Standard Department: Production Page No. 110
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Scaffolding Pipe 10 Nos, 6.0 mtrs long & 48 MM dia
 Scaffolding Pipe 15 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 10 Nos, 180 Deg.
 Scaffolding coupler 10 Nos, 90 Deg.
 Scaffolding Jali 20 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Castable Mixer , 01 No.
 Hysil Block , 65 & 100 MM thick
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos

07. power Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the smoke chamber inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into smoke chamber.
 Take the confined space entry permit.
 Fix dummy in inlet smoke chamber.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old castable lining.
 Clean the castable lining surface.
 Weld the anchor at specified spacing as per drawing.
 Check the Anchor welding by hammering the anchor.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Fix 100 MM Hysil block on casting area.
 Fix the GI wire among the anchors to hold hysil in its position.
 Prepare shuttering for 900x900 MM (Maximum) area & Ensure that no blockage of poking doors/hole opening.
 Prepare castable in castable mixer according to water addition & mixing time as per supplier recommendation.

 Pour the castable into shuttering & mix it with vibrator.


 Allow castable 2-6 hours for setting depending upon castable type.
 Open the shuttering & Check the castable filling.
B-03.2_Register - Standard Department: Production Page No. 111
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Allow castable for curing according to castable type ( conventional or Low Cement)
 Remove tools & tackle from work place after completion of job.
 Check the castable lining.
 Remove the scaffolding.
 Clean the debris material.
 Check the smoke chamber & closed the inspection doors
 Close the confined space entry permit.
 Close the isolation permits.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 112


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-026 Rev. No. 02
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln inlet smoke chamber Refractory castable maintenance job
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1. Slip /Trip /Fall from stairs
2. Caught in under and between the equipement/parts.
3. Falling object
4. Exposure of high temperature.

Consequences of the deviation:

1. Injury fracture due to hit of material /slip and trip


2. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles:


 Scaffolding Pipe 10 Nos, 6.0 mtrs long & 48 MM dia
B-03.2_Register - Standard Department: Production Page No. 113
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Scaffolding Pipe 15 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 10 Nos, 180 Deg.
 Scaffolding coupler 10 Nos, 90 Deg.
 Scaffolding Jali 20 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Castable Mixer , 01 No.
 Hysil Block , 65 & 100 MM thick
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos

07. power Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the smoke chamber inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into smoke chamber.
 Take the confined space entry permit.
 Fix dummy in inlet smoke chamber.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old castable lining.
 Clean the castable lining surface.
 Weld the anchor at specified spacing as per drawing.
 Check the Anchor welding by hammering the anchor.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Fix 100 MM Hysil block on casting area.
 Fix the GI wire among the anchors to hold hysil in its position.
 Prepare shuttering for 900x900 MM (Maximum) area & Ensure that no blockage of poking doors/hole opening.
 Prepare castable in castable mixer according to water addition & mixing time as per supplier recommendation.

 Pour the castable into shuttering & mix it with vibrator.


 Allow castable 2-6 hours for setting depending upon castable type.
 Open the shuttering & Check the castable filling.
 Allow castable for curing according to castable type ( conventional or Low Cement)
B-03.2_Register - Standard Department: Production Page No. 114
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Remove tools & tackle from work place after completion of job.
 Check the castable lining.
 Remove the scaffolding.
 Clean the debris material.
 Check the smoke chamber & closed the inspection doors
 Close the confined space entry permit.
 Close the isolation permits.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 115


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-027 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln inlet smoke chamber Refractory castable maintenance job
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 116


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Brokk Machine 1 No
 Brokk Machine walk way 1 No
 Brokk Machine Operator safety cage 1 No
 Electric Chipper 1 No
 Brick laying Machine 1 No
 Sprit Level 1 No
 Wooden Hammer 4 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory Bricks , As per Brick lining chart
 Alumina/Basic Mortar , As per Bricks consumption
 Ceramic blanket , 25 MM Thick

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the kiln hood door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into kiln.
 Take the confined space entry permit.
 Fix walk way along with hand rails in between burner platform & kiln.
 Check the walk way.
 Take the coating thickness.
 Take the Brokk Machine inside kiln through walk way.
 Break entire coating of kiln with the help of Brokk machine.
 Take the Brokk machine out.
 Remove the walk way.
 Rotate kiln on auxiliary drive & empty out coating.
 Again fix walk way along with hand rails in between burner platform & kiln.
 Take the residual brick thickness.
 Take the Brokk Machine inside kiln through walk way.
 Remove old brick lining. Start from feed end.
 Clean the dismantled bricks through man holes by Bob Cat machine
 Clean the brick lining surface.
 Take the center of brick lining.
 Start manual brick lining job from discharge end. Use brick mortar both side of brick as per supplier
recommendation.
 Complete lower half lining up to cone lining.
 Fix the screw jack horizontally by packing with wooden rafter.
 Fix a jack at every meter brick lining.
 Tight the all jack properly.
 Check the jack.
 Fix the wooden wedge in between brick & wooden rafter to avoid brick spillage.
 Take the jack vertically by rotating kiln on auxiliary drive.
B-03.2_Register - Standard Department: Production Page No. 117
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Do the brick lining for 3rd quarter.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 118


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-028 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Rotary Kiln Refractory castable maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust emission
2.Slip /Trip /Fall from stairs
3. Caught in under and between the equipement/parts.
4.Falling object
5. Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3.Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 119


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Scaffolding Pipe 10 Nos, 6.0 mtrs long & 48 MM dia


 Scaffolding Pipe 15 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 15 Nos, 180 Deg.
 Scaffolding coupler 15 Nos, 90 Deg.
 Scaffolding Jali 15 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Scaffolding Pipe 10 Nos, 6.0 mtrs long & 48 MM dia
 Scaffolding Pipe 15 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 15 Nos, 180 Deg.
 Scaffolding coupler 15 Nos, 90 Deg.
 Scaffolding Jali 15 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Castable Mixer , 01 No
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the kiln hood door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into kiln.
B-03.2_Register - Standard Department: Production Page No. 120
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Take the confined space entry permit.
 Fix dummy in inlet smoke chamber.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old castable lining.
 Clean the castable lining surface.
 Weld the anchor holder at specified spacing as per drawing.
 Check the holder welding by hammering.
 Fill the gap between sectors by ceramic blanket.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Fix the shuttering pattern.
 Prepare castable in castable mixer according to water addition & mixing time as per supplier recommendation.
 Pour the castable into shuttering & mix it with vibrator.
 Allow castable 4-6 hours for setting depending upon castable type.
 Open the shuttering & Check the castable filling.
 Rotate kiln on auxiliary drive for next sector.
 Allow castable for curing according to castable type ( conventional or Low Cement)
 Remove tools & tackle from work place after completion of job.
 Check the castable lining.
 Remove the scaffolding.
 Clean the debris material.
 Check the kiln & closed the kiln hood doors.
 Close the confined space entry permit.
 Close the isolation permits

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 121


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-029 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln Hood Refractory Bricks maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to
identify the precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

B-03.2_Register - Standard Department: Production Page No. 122


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles:


 Scaffolding Pipe 50 Nos, 6.0 mtrs long & 48 MM dia
 Scaffolding Pipe 30 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 100 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory Bricks , As per drawing
 Alumina Mortar , As per Bricks consumption
 Ceramic blanket , 25 MM Thick
 Hysil Block , 50 & 100 MM thick
ISMB 175x90 MM, As per Requirement

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the cooler inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into cooler.
 Take the confined space entry permit.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old brick lining.
 Clean the brick lining surface.
 Check the retainer plate & ISMB welding.
 Fix the hysil block.
 Fix the refractory brick.
 Apply alumina mortar both side of brick
 Do the brick lining in require area.
 Remove tools & tackle from work place after completion of job.
 Check the lining.
 Remove the scaffolding.
 Clean the debris material.
 Check the hood & closed the inspection doors
 Close the confined space entry permit.

B-03.2_Register - Standard Department: Production Page No. 123


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Close the isolation permits.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm
should be given by TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 124


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-030 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln Hood/Cooler Refractory castable maintenance job
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4 .Falling object
5. Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 125


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Scaffolding Pipe 40 Nos, 6.0 mtrs long & 48 MM dia


 Scaffolding Pipe 30 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 50 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Castable Mixer , 01 No.
 Hysil Block , 50 & 100 MM thick
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the cooler inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into cooler.
 Take the confined space entry permit.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old castable lining.
 Clean the castable lining surface.
 Weld the anchor at specified spacing as per drawing.
 Check the Anchor welding by hammering the anchor.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Fix 100 MM Hysil block on casting area.
B-03.2_Register - Standard Department: Production Page No. 126
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Fix the GI wire among the anchors to hold hysil in its position.
 Prepare shuttering for 900x900 MM (Maximum) area & Ensure that no blockage of poking doors/hole
opening.
 Prepare castable in castable mixer according to water addition & mixing time as per supplier
recommendation.
 Pour the castable into shuttering & mix it with vibrator.
 Allow castable 4-6 hours for setting depending upon castable type

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 127


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-031 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for SLC TA Take off ducts Refractory Bricks maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6. Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3.Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to
identify the precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

B-03.2_Register - Standard Department: Production Page No. 128


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles:

 Scaffolding Pipe 80 Nos, 6.0 mtrs long & 48 MM dia


 Scaffolding Pipe 30 Nos, 2-3 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 100 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory Bricks , As per drawing
 Alumina Mortar , As per Bricks consumption
 Ceramic blanket , 25 MM Thick
 Hysil Block , 50 MM thick

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the cooler inspection door & allow TA take off duct to cool at workable temperature.
 Take the isolation permits for entrance into cooler.
 Take the confined space entry permit.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old brick lining.
 Clean the brick lining surface.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Place the retainer brick on retainer plate.
 Apply alumina mortar & fix another brick.
 Fix 50 MM Hysil block on retainer brick.
 Fix the standard brick according to requirement.
 Do the brick lining in require area.
 Remove tools & tackle from work place after completion of job.
 Check the lining.
 Remove the scaffolding.
 Clean the debris material.

B-03.2_Register - Standard Department: Production Page No. 129


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Check the duct & closed the inspection doors
 Close the confined space entry permit.
 Close the isolation permits.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm
should be given by TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 130


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-032 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for SLC TA take off ducts Refractory castable maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 131


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Scaffolding Pipe 40 Nos, 6.0 mtrs long & 48 MM dia


 Scaffolding Pipe 30 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 50 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Castable Mixer , 01 No.
 Hysil Block , 50 MM thick
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the cooler inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into cooler.
 Take the confined space entry permit.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old castable lining.
 Clean the castable lining surface.
 Weld the anchor at specified spacing as per drawing.
 Check the Anchor welding by hammering the anchor.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Fix 50 MM Hysil block on casting area.
 Fix the GI wire among the anchors to hold hysil in its position.
 Prepare shuttering for 900x900 MM (Maximum) area & Ensure that no blockage of poking doors/hole opening.
B-03.2_Register - Standard Department: Production Page No. 132
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Prepare castable in castable mixer according to water addition & mixing time as per supplier recommendation.
 Pour the castable into shuttering & mix it with vibrator.
 Allow castable 4-6 hours for setting depending upon castable type.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 133


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-033 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for ILC & SLC TA Duct Refractory Bricks maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 134


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Electric Chipper 2 Nos


 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory Bricks , As per drawing
 Alumina Mortar , As per Bricks consumption
 Ceramic blanket , 25 MM Thick
 Hysil Block , 100 MM thick
 Basket MS 3 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the TA duct inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into duct.
 Take the confined space entry permit.
 Remove old brick lining.
 Clean the brick lining surface.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Fix the hysil block for lower half brick lining.
 Do the lower half lining with alumina mortar.
 Fix the arch according to duct size.
 Fix Hysil block for upper half lining.
 Do the brick lining for upper half with alumina mortar
 Do the brick lining in require area.
 Remove tools & tackle from work place after completion of job.
 Check the lining.
 Clean the debris material.
 Check the duct & closed the inspection doors
 Close the confined space entry permit.
 Close the isolation permits.

B-03.2_Register - Standard Department: Production Page No. 135


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 136


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-034 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for ILC & SLC TA Ducts Refractory castable maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust problem
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 137


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Scaffolding Pipe 20 Nos, 6.0 mtrs long & 48 MM dia


 Scaffolding Pipe 15 Nos, 2 mtrs long & 48 MM dia
 Scaffolding coupler 20 Nos, 180 Deg.
 Scaffolding coupler 20 Nos, 90 Deg.
 Scaffolding Jali 50 Nos, size: 400x 2000 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Castable Mixer , 01 No.
 Hysil Block , 100 MM thick
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the TA duct inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into duct.
 Take the confined space entry permit.
 Prepare scaffolding if necessary like SLC TA duct bend.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old castable lining.
 Clean the castable lining surface.
 Weld the anchor at specified spacing as per drawing.
 Check the Anchor welding by hammering the anchor.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Fix 100 MM Hysil block on casting area.
 Fix the GI wire among the anchors to hold hysil in its position.
 Prepare shuttering for 900x900 MM (Maximum) area & Ensure that no blockage of poking doors/hole opening.
 Prepare castable in castable mixer according to water addition & mixing time as per supplier recommendation.
B-03.2_Register - Standard Department: Production Page No. 138
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Pour the castable into shuttering & mix it with vibrator.
 Allow castable 4-6 hours for setting depending upon castable type.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 139


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 1 / 2


SOP No.: ACL-WI-KL-035 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for CF Silo residual material cleaning.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 140


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos
 Electric Chipper 1 No
 Crow Bar, 1.5 mtrs long & 15 mm dia 2 Nos
 Hammer with wooden handle, 2 Kgs 2 Nos

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Remove all possible set material by mechanized system.


 Only residual material to be removed by manually by labor.
 Ensure no set material available on silo walls above the work point.
 Take the isolation permits for entrance into silo.
 Take the confined space entry permit.
 Open the inspection/man hole door of the silo.
 Do not allow to work in upper & down stream while silo cleaning.
 Do the silo cleaning.
 Remove cleaning tools from work place after completion of job.

 Check inside the silo.


 Close the silo inspection/man hole doors.
 Close the confined space entry permit.
Close the isolation permi

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 141


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 142


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-036 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Burner Pipe Refractory castable maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1.Exposure to hot gas
2.Slip /Trip /Fall from stairs
3.Falling object

Consequences of the deviation:

1. Skin damage
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 143


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 Scaffolding Pipe 10 Nos, 6.0 mtrs long & 48 MM dia
 Scaffolding Pipe 20 Nos, 2-3 mtrs long & 48 MM dia
 Scaffolding coupler 20 Nos, 180 Deg.
 Scaffolding coupler 20 Nos, 90 Deg.
 Scaffolding Jali 50 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , Hasle, D57SC or ACCMON-CRC BP, 3.5 MT
 Steel Anchor & Nut Swing type SS310H & Nut M12 (SS310), 750 Nos each.
 Anchor Cap , 750x2 Nos
 Ceramic blanket , 6 MM Thick & 17 m2
 Castable Mixer , 01 No.
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos
 Wax or Bituminous paint 2 Ltrs
 Card Board 3 MM Thick & 2.0 m2
 Fevicol for pasting ceramic fiber 5 Kgs
 Measuring can 02 liter & 01 liter 01 Each
 Ice 03 Slab (To maintain castable mix temperature)
 Thermometer (0 – 500C) 1 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Weld Nut M12 staggered at a distance 150 MM Axially & Radially.(DW:FLS 1.252116)
 Fix steel anchor into nut & tack weld at right angle to the Burner pipe surface.
 Check the nut welding.
 Take burner into vertical position keeping burner tip downward.
 Fix the burner upper portion with wire rope & chain block.
 Take the working at height permit.
 Prepare scaffolding for burner refractory castable maintenance job.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jail for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Paste 6 MM thick ceramic fiber blanket with the help of Fevicol.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Apply thin layer (0.5 MM) of wax or bituminous paint over anchor & allow it to dry.
 Fix shuttering pattern along with card board expansion joint Radially & Axially.
 Prepare castable in castable pan mixer. Mixer should be cleaned prior to mixing castable.
Hasle D57SC ACCMON-CRC BP
B-03.2_Register - Standard Department: Production Page No. 144
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
Water Quantity 4.5 Liter/100 Kgs 5.0-5.5 Liter/100 Kgs
Dry Mixing Time 3 minutes 3 minutes
Wet Mixing 8 minutes 8-10 minutes
Castable Mix Temperature 10 -15 Deg.C 20 – 22 Deg.C
 Pour the castable into shuttering & mix it with vibrator.
 Vertical casting joint should be staggered.
 Allow castable 4-6 hours for setting.
 Open the shuttering & Check the castable filling.
 Cover castable with polythene sheet for at least 24-48 hours for castable curing.
21. Remove tools & tackle from work place after completion of job.
 Remove the scaffolding.
 Clean the debris material.
 Close the working at height permit.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 145


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-037 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for ILC, SLC PH Cyclone & SLC PC Riser duct Refractory Bricks maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 146
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Scaffolding Pipe 30 Nos, 6.0 mtrs long & 48 MM dia


 Scaffolding Pipe 30 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 50 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory Bricks , As per drawing
 Alumina Mortar , As per Bricks consumption
 Ceramic blanket , 25 MM Thick
 Hysil Block , 15 MM & 100 MM thick
 Basket MS 3 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

Open the riser duct inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into duct.
 Take the confined space entry permit.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old brick lining.
 Clean the brick lining surface.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Place the retainer brick on retainer plate.
 Apply alumina mortar & fix another brick.
 Fix 100 MM Hysil block on retainer brick.
 Fix the riser duct brick according to refractory drawing.
 Do the brick lining in require area.
 Remove tools & tackle from work place after completion of job.
 Check the lining.
 Remove the scaffolding.
 Clean the debris material.
 Check the riser duct & closed the inspection doors
 Close the confined space entry permit.
 Close the isolation permits.

B-03.2_Register - Standard Department: Production Page No. 147


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 148


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-038 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for ILC, SLC PH Cyclone & SLC PC Riser duct Refractory castable maintenance job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 149


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Scaffolding Pipe 30 Nos, 6.0 mtrs long & 48 MM dia


 Scaffolding Pipe 30 Nos, 2-4 mtrs long & 48 MM dia
 Scaffolding coupler 50 Nos, 180 Deg.
 Scaffolding coupler 50 Nos, 90 Deg.
 Scaffolding Jali 100 Nos, size: 400x 2500 MM
 Electric Chipper 2 Nos
 Crow Bar 2 Nos, 1.5 mtrs long, 16 MM dia
 Hammer with wooden handle 2 Nos, 2Kgs
 Refractory castable , As per requirement
 Steel Anchor , As per requirement
 Anchor Cap or PVC Tape roll, As per requirement
 Ceramic blanket , 25 MM Thick
 Castable Mixer , 01 No.
 Hysil Block , 100 MM thick
 Basket MS 3 Nos
 Hand Shovel 2 Nos.
 Spade with wooden handle 2 Nos
 Motorized Vibrator 2 Nos
 Vibrator Lead 2 Nos

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the riser duct inspection door & allow it to cool at workable temperature.
 Take the isolation permits for entrance into riser duct.
 Take the confined space entry permit.
 Prepare scaffolding where refractory maintenance is to be carried out.
 Scaffolding staging should not more than 1.2 mtrs height.
 Fix scaffolding jali for working platform & provide hand rails.
 Check the scaffolding prior to start the refractory job.
 Remove old castable lining.
 Clean the castable lining surface.
 Weld the anchor at specified spacing as per drawing.
 Check the Anchor welding by hammering the anchor.
 Check the retainer plate & supporting ribs welding.
 Wrap ceramic blanket both side of retainer plate.
 Fix the anchor cap or wrap PVC tape 2-3 times at the tip of anchor.
 Fix 100 MM Hysil block on casting area.
 Fix the GI wire among the anchors to hold hysil in its position.
 Prepare shuttering for 900x900 MM (Maximum) area.

B-03.2_Register - Standard Department: Production Page No. 150


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Prepare castable in castable mixer according to water addition & mixing time as per supplier recommendation.
 Pour the castable into shuttering & mix it with vibrator.
 Allow castable 2-6 hours for setting.
 Open the shuttering & Check the castable filling.
 Allow castable for curing according to castable type ( conventional or Low Cement)
 Remove tools & tackle from work place after completion of job.
 Check the castable lining.
 Remove the scaffolding.
 Clean the debris material.
 Check the riser duct & closed the inspection doors
 Close the confined space entry permit.
 Close the isolation permits.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 151


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-039 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for starting/running for SLC PC Diesel firing.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Fall from staircase


2.Struck by or against fixed
3.Fire hazard
4.Pressurization
5.Diesel leakage
Consequences of the deviation:
1. Injury fracture due to hit of material /slip and trip
2. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles: Nil

B-03.2_Register - Standard Department: Production Page No. 152


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start diesel firing for SLC Pc.


 Prepare the firing torch.
 Check SLC PH fan is in operation & sufficient suction is available in Pc.
 Check the firing nozzle/burner is properly inserted & cleaned.
 Check the compressed air pressure.
 Start the PA fan.
 Open PA fan out let damper.
 Start the diesel pump in recirculation mode.
 Check the diesel leakage.
 Divert diesel for burner by burner command.
 Ignite the torch & keep in front of burner.
 Remove the torch after stabilizing the diesel flame.
 Regulate the diesel flow according to temperature requirement.
 Stop the firing system after getting SLC PC into operation.
 Take the firing burner out of pc.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 153


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 1 / 2


SOP No.: ACL-WI-KL-040 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for SLC TA Duct bend hopper cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exposure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 154


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Water Hose 1 No, 50 mtrs long, 20 MM dia
 GI Pipe 1 No, 2-3 mtrs long, ½” dia
 Heat Resistance suit 2 Nos
 . Crow Bar/Pipe, 2 Nos, 1.5 mtrs Long, 16 MM dia
 Hammer with wooden handle 2 Nos

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start hopper cleaning job to take care of all process parameters (Kiln inlet draft, all cyclone
drafts) and system should not be in pressurized condition.
 Open poking hole.
 Inform CCR to get proper ventilation if pressurization occurs.
 Ensure all cyclone flap is operating condition.
 Check water tap for water availability.
 Start cleaning of hopper through poking hole.
 Break coating into small pieces through water jet.
 Check hopper after complete cleaning.
 Close poking hole.
 Inform CCR after finishing the job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 155


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 156


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-041 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for clinker DPC spilled clinker cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 157
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 Hand shovel with handle 1 No
 Spade with wooden handle 1 No
 Basket MS 2 No

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check machine guarding is proper if house keeping is being carried in near by area.
 Keep the safe distance of your self & tool.
 Ensure that cleaning to be carried out in presence of site Attendant/Supervisor.
 Start cleaning with the help of hand shovel.
 Dispose of cleaned material at safe place.
 Remove cleaning tools at work place after completing of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 158


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-042 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for SLC TA Duct elbow material handling job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exprosure of dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.
5.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 159
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 Hand shovel with handle 1 No
 Spade with wooden handle 1 No
 Basket MS 2 No

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check machine guarding is proper if house keeping is being carried in near by area.
 Keep the safe distance of your self & tool.
 Ensure that cleaning to be carried out in presence of site Attendant/Supervisor.
 Start cleaning with the help of hand shovel.
 Dispose of cleaned material at safe place.
 Remove cleaning tools at work place after completing of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 160


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-044 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Shifting of Clinker through pay loader.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exprosure of dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.
5. Exposure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 161
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Truck load beds should be cleaned prior to the point of loading. No dirty trucks will be allowed onto the premises.
 All drivers are to secure their trucks, switch off the engines, remove keys from ignition and leave their cabins before
loading. They must supervise the loading from a safe vantage point.
 Inform the CCR before starting the loading of clinker.
 Start loading the clinker in the bucket by moving the bucket into the pile.
 Lift the filled bucket and move the loader towards the truck.
 Drop the clinker in the bucket by keeping two things in mind a) Clinker spillage does not takes place b) Fall height
should not be greater than 1 mtr from trailer top otherwise dust will be very high.
 Fill the truck and inform the driver.
 Repeat the above procedure for further shifting.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 162


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-046 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Castable Mixer machine cleaning
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
gfRelated Hazards:

1. Exposure of dust
2.Accidental start of mixer
3.Spillage of liquor
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles:


 Crow bar 1 No
 Hammer 1 No
B-03.2_Register - Standard Department: Production Page No. 163
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Isolate the mixer machine locally before cleaning start.


 Try to clean set material through crow bar & Hammer.
 Residual material to be removed by labor manually.
 Remove cleaning tools from work place after completion of job.
 Site attendant will check machine after cleaning job completed.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 164


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-047 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for blaster inspection
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.
5.Exposure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 165


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 Spanner 2 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Before commencing the job, inlet energy source of blaster is to be isolated and inform CCR.
 Closed and lock the manual valve for air supply to blaster.
 Release the residual air inside the blaster by manually operating the blaster
 Disconnect the air line from blaster
 Check cylinder, sealing and piston of blaster and replace any if needed
 Report instrument department for the issues related to solenoid valve.
 Closed the cylinder after inspection and remove all tools and tackles from the place.
 Connect the air line and open the air supply valve.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 166


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-049 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning and inspection of rotary feeder.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.
5.Exposure of hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 167
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Isolate the rotary feeder locally before cleaning start inform to CCR and apply emergency stop.
 Open rotary feeder door.
 Try to clean set material through crow bar.
 After cleaning close the inspection door.
 Remove the Isolation of rotary feeder.
 Run the feeder locally by taking CCR permission.
 Stop the RAL if it is OK.
 Informed to CCR for clearance.
 Remove cleaning tools from work place after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 168


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-050 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning and inspection of Solid flow meter.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.
5.Exposure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 169
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Isolate the Solid flow meter locally before cleaning start inform to CCR and apply emergency stop before cleaning
job start.
 Ask CCR to stop respective feeding aeration blower.
 Wait for two minutes for setting the aerated material.
 Close the compressed air valves for pneumatic gate.
 Open the inspection door and open pneumatic gate solenoid value.
 Clean the foreign material with the help of compressed air.
 Close the inspection door.
 Inform CCR to run the system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 170


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-051 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning and inspection of Coriolis.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.
5.Exposure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to
identify the precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

B-03.2_Register - Standard Department: Production Page No. 171


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start the cleaning job.


 Wait for two minutes for setting the aerated material.
 Close the compressed air values for the system.
 Open the inspection door.
 Clean the foreign material with the help of manually.
 Close the inspection door and open aeration values.
 Inform CCR to run the system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm
should be given by TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 172


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-052 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning and inspection of Weigh feeder Discharge.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.
5.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 173
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Isolate the Weigh feeder locally before cleaning start by applying emergency stop and inform to CCR.
 Open discharge door.
 Try to clean set material through crow bar.
 After cleaning close the inspection door.
 Remove the Isolation of weigh feeder.
 Run the feeder locally by taking CCR permission.
 Stop the feeder.
 Informed to CCR for clearance.
 Remove cleaning tools from work place after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 174


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-053 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Air slide jam removal job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.
5.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 175
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start air slide cleaning job.


 Hammering the air slide body.
 Check the material flow.
 Open air slide inspection door if material flow is not proper.
 Start air lancing through inspection door till the complete material is cleaned.
 Close the inspection door of air slide.
 Inform CCR to run the system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 176


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-054 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Screw conveyor jam removal job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 177
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Isolate the screw conveyor locally before cleaning start inform to CCR and apply emergency stop.
 Open discharge door.
 Try to clean set material through manually.
 After cleaning close the inspection door.
 Remove the Isolation of conveyor.
 Run the conveyor locally by taking CCR permission.
 Stop the conveyor.
 Informed to CCR for clearance.
 Remove cleaning tools and scrap materials from work place after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 178


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-055 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Bag filter hopper cleaning.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 179
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 Hand shovel with handle 2 Nos
 Spade with wooden handle 2 Nos
 Crow Bar, 1.5 mtrs long & 15 mm dia 2 Nos
 Hammer with wooden handle, 2 Kgs 2 Nos

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform to CCR before cleaning starts.


 Ensure bag filter fan and RAL is running.
 Open the inspection/man hole door of the hopper.
 Remove all possible set material by crow bar and hammer from outside.
 Only residual material to be removed manually by labor.
 Ensure proper ventilation inside hopper before starting the job.
 Use proper working platform.
 Do the hopper cleaning.
 Remove cleaning tools from work place after completion of job.
 Check inside the hopper.
 Close the hopper inspection/manhole door.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 180


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-KL-056 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln inlet hot material handling job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Caught in under and between the equipement/parts.
3.Falling object
4.Exposure of high temperature.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
3 .Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 181
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 JCB Machine 1 No
 Hydraulic Tractor with Trolley 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Inform CCR prior to start Material handling job.


 Do not open the barricade until material is properly cool down up to 4 hours.
 Check water tap for water availability.
 Inform CCR operator before starting the work, to take care of all process parameters (Kiln inlet draft, all cyclone
cone drafts) and system should not be in pressurized condition.
 Ensure all cyclone flap is operating condition.
 Ensure proper lighting at working area.
 Ensure availability of vehicle to tackle any emergency.

 Unwanted person should not stay at working platform.


 JCB driver cabin should be in closed condition.
 Take the wet & cool material out through JCB machine.
 Load the material in tripper trolley.
 Shift the material in designated place.
 Close the rolling shutters after completion of cleaning work.
 Take the both flap valves in working position.
 Inform CCR after finishing the job.

Note: - After we install Professional Atomized water Sprinkler System, we will start water spray for hot material
cooling.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 182


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 183


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-057 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for TPS machine operation.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure to dust
2.Caught in under and between the equipement/parts.
3.Falling object

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material
.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 184
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:
 JCB Machine 1 No
 Hydraulic Tractor with Trolley 1 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 First check the vehicle before shifting from parking area to the scheduled place.
 Normal checking before shifting is as follows-
a. Engine oil
b. Radiator water
c. Diesel tank level
d. Air compressor functioning or not after start-up of DG set of the TPS machine.
e. Air pressure of all the Tyres.
f. Light
g. Horn
h. Reverse gear
i. Brake
j. Reverse camera functioning or not.
 After checking vehicle shifted to designated place as per TPS movement schedule.
 Wheel chalk has to be position near 01 front & 01 Rear tire.
 Hose pipe has to be fix with TPS tank inlet suction coupling & it should be lock properly & hose pipe should be also
tighten by rope to avoid scattering during vibration.
 After that DG set should be start .
 One sensor has been provided for indication of filling of dust tank. After filling of tank sensor indicate tin red colour
then suction automatically stop but Generator should run continue. Then Operator will stop the DG set.
 After that Inlet hose pipe has to be remove from coupling properly & rope should also remove.
 Then Tire wheel Chalk has to be remove.
 Then start the Vehicle for unloading the designated place which is WET FLYASH YARD .
 Wind velocity should be consider during the parking for unloading in such a way that Operator should stand in wind
direction so, dust should go to opposite direction.
 Park the vehicle in Wet f.ash area & wheel chalk has to be fix near the tire. One in front & another in rear tire.
 Vehicle should be start for of dust tank unloading.
 TPS dust tank First lock bottom side will be open properly.
 TPS dust tank discend side lock should be open.
 Discend has to be open.
 Dust tank should be taper by handle for unloading the material.
 After emptying of dust tank , DG set should be start & JPF should run automatically for 10 minutes to clean the
filter.
 After 10 minutes DG Set should be stop .
 TPS tank should be re-posioned in a normal condition.
 After that TPS Descend should be close & lock in side as well as bottom.
B-03.2_Register - Standard Department: Production Page No. 185
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
 Then Remove the wheel chalk & shifting for another trip or parking.

NOTE
1. In Rainy season it should be not operated.
2. Hot material should be not handle through this material
3. Coal should be not handle through this material
4. Wet material should be also avoided for handling.
5. After running 50 hrs.of DG set TPS filter should be clean .
6. During the cleaning of filter Height Permit should be taken by individual section in-charge in which machine is
working.
7. Vehicle should not move in uneven area.
8. In case of any abnormality, inform to In-charge immediately.
9. Weekly maintenance should be fulfil without fail

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 186


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-KL-058 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Kiln circuit (ILC & SLC PH, Cooler) inspection by visitors during Kiln
Starting/Running condition.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Falling object
5.Exposure of high temperature.
6.Exprosure to hot gas

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 187
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles: Nil

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Before inspection starts Inform to Production head.


 Visitors will allow during in general shift.
 Visitors should go on site with authorized person only.
 Visitors should not go close to hazardous area like kiln inlet, SLC elbow, cyclone jamming process, Blasters,
Moving machineries, kiln hood door, DPC etc..
 While site visit don’t carry any bags etc..
 Don’t take any photograph without permission of Zone owner/Production Head

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 188


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-001 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Clinker feeding into clinker storage hopper.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Accidental start of gas /material circuit
7.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 189
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check clinker hopper level at site.


 Check clinker feeding group in all respect.
 Inform to CCR to run the group.
 Inform CCR for any abnormality at site.
 Maintain clinker apron & belt conveyor load.
 Check the venting JPF for clinker apron & belt conveyor.
 Ask CCR to stop the group after feeding requires clinker.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 190


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 1 / 2


SOP No.: ACL-WI-CM-002 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for gypsum feeding into gypsum storage hopper.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit
8.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 191
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

Hand shovel with handle 2 Nos


Spade with wooden handle 2 Nos

07. Manpower Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check gypsum hopper level at site.


 Check gypsum feeding group in all respect.
 Inform to CCR to run the group.
 Inform CCR for any abnormality at site.
 Maintain gypsum apron & belt conveyor load.
 Check the venting JPF for gypsum apron & belt conveyor.
 Ask CCR to stop the group after feeding requires gypsum.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 192


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-003 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Gypsum truck unloading
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Exposure of dust
2. Exposure to high temperature.
3. Sudden fall
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 193


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hexagonal Crow Bar 2 No’s, 1.5 meters long & 15mm dia
 Hammer with wooden handle 2 No’s 2 Kgs
 Hand shovel with handle 2 Nos
Spade with wooden handle 2 Nos

07. Manpower Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Back horn should blow while reversing the truck & reversing should be guided by traffic marshal.
 Truck should be parked on flat horizontal surface & wheel choke should be fixed while waiting for his queue.
 Place gypsum stacker in required position.
 Check tippler group in all respect.
 Inform to CCR to run the group.
 Place the truck at tippler lift. Site attendant will guide to truck driver to take truck on tippler lift safely.
 Tie the front chain hook with truck.
 Lift the rear jacks.
 Check the venting system of gypsum tippler area.
 Lift the tippler lift & unload the truck slowly till the entire gypsum is unloaded.
 Clean the unloading hopper grizzly by labor.
 Divert the belt diverter for gypsum yard.
 Ask CCR to stop the group after empty out entire gypsum trucks.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 194


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-004 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Cement Mills circuit inspection during mill Starting/Running condition
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:
1. Exposure of dust
2. Slip /Trip /Fall from stairs
3. Caught in under and between the equipment/parts.
4. Falling object
5. Electric shock
6. Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 195
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos

07. Manpower Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check entire mill circuit in all respect.


 Inform to CCR to run the group.
 Keep in touch with CCR while starting the mill.
 Again check the mill circuit after starting the mill.
 Inform to CCR for any abnormality at site.
 Check mill circuit JPF i.e. suction, purging, compressed air pressure etc.
 Do not work in improper position.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 196


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-005 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for House Keeping in Cement Mills circuit.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Falling object
5.Electric shock
6.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 197


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Hand shovel with handle 1 No
 Spade with wooden handle 1 No
 Basket MS 2 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Identify the area where house keeping is required.


 Do not allow to work in upper & down stream from work place.
 Check opening regarding falling object.
 Check machine guarding is proper if house keeping is being carried in near by area.
 Ensure that house keeping to be carried out in presence of mill Attendant/Supervisor.
 Dispose of cleaned material at safe place.
 Remove cleaning tools at work place after completing of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 198


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-CM-006 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Fly Ash unloading through truck tippler.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles:


B-03.2_Register - Standard Department: Production Page No. 199
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

 Hexagonal Crow Bar 2 Nos, 1.5 mtrs long & 15mm dia
 Hammer with wooden handle 2 Nos 2 Kgs
 Hand shovel with handle 2 Nos
Spade with wooden handle 2 Nos

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Park the fly ash truck at designated place.


 Back horn should blow while reversing the truck & reversing should be guided by traffic marshal.
 Truck should be parked on flat horizontal surface & wheel choke should be fixed while waiting for his queue.
 Wear safety harness while open the tarpaulin or top lid/cover. It should be only under the tarpaulin shed.
 Check tippler group in all respect.
 Inform to CCR to run the group.
 Place the truck at tippler lift. Site attendant will guide to truck driver to take truck on tippler lift safely.
 Tie the front chain hook with truck.
 Lift the rear jacks.
 Lift the tippler lift & unload the truck slowly till the entire fly ash is unloaded.
 Check the venting JPF i.e. compressed air pressure, purging, venting line, JPF hopper etc.
 Clean the unloading hopper grizzly by labor.
 Ask CCR to stop the group after empty out entire fly ash trucks.
 Any spillage i.e oil, Fly ash dust etc, the site attendant should inform to CCR or Concerned deptt.
 Site attendant will check that all machines are fully guarded & where machine guard not available inform to CCR or
concerned department.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 200


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 201


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 1 / 2


SOP No.: ACL-WI-CM-007 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Grinding Media loading by Electric Wire Rope Hoist.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3.caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit
8.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 202
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Hammer with wooden handle 2 Nos, 2 Kgs
 Bucket MS 3 Nos
 Safety Harness 2 Nos

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Take the isolation permits of cement mill.


 Take the working at height permit.
 Place grinding media loading bucket below the electric hoist.
 Load the grinding media into bucket.
 Fix the hook of hoist into eye hole of loading bucket.
 Guide the operator to lift the load slowly.
 Place the loading bucket over man hole of mill.
 Lower the bucket on the man hole of mill.
 Release the bucket lock by hammering the bucket eye hole.
 Unload the media into mill.
 Repeat the procedure for next loading.
 Close the permit after completion the job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 203


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 1 / 2


SOP No.: ACL-WI-CM-008 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Cement Mills internal/water spray nozzle inspection.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Falling object
5.Electric shock
6.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 204


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Electric Chipper 1 No
 Safety harness 2 Nos.

07. Manpower Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the mill inspection door & allow mill to cool at workable temperature.
 Take the isolation permits for entrance into mill.
 Take the confined space entry permit for entrance into mill.
 Do not allow to work in upper & down stream while mill inspecting.
 Check the mill water spray nozzle.
 Do the mill internal inspection.
 Remove cleaning tools from work place after completion of job.
 Check inside the mill.
 Close the mill inspection door.
 Close the confined space entry after completing the job.
 Close the isolation permits after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 205


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 1 / 2


SOP No.: ACL-WI-CM-009 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Cement Mills separator inspection.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1.Dust exposure
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit
8.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 206


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Hand shovel with handle 1 No


 . Spade with wooden handle 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the inspection door & allow separator to cool at workable temperature.
 Take the isolation permits for entrance into separator.
 Take the confined space entry permit.
 Do not allow to work in upper & down stream while inspecting.
 Inspect the separator.
 Remove measurement/cleaning tools from work place after completion of job.
 Check inside the separator.
 Close the separator inspection door.
 Close the confined space entry permit after completing the job.
 Close the isolation permits after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 207


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-010 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Chamber sampling in Cement Mills.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 208
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Safety harness 2 Nos.

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the mill inspection door & allow mill to cool at workable temperature.
 Take the isolation permits for entrance into mill.
 Take the confined space entry for entrance into mill.
 Do not allow to work in upper & down stream while chamber sampling.
 Do the chamber sampling as per requirement.
 Remove cleaning/sampling tools from work place after completion of job.
 Check inside the mill.
 Close the mill inspection door.
 Close the confined space entry after completing the job.
 Close the isolation permits after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 209


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-011 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Cement Mills out let hood coating cleaning.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Falling object
5.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 210
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Crow Bar/Pipe 2 Nos.

07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Open the mill out let hood door.


 Allow it to cool at workable temperature.
 Take the isolation permit for mill.
 Do not allow to work in upper stream while coating cleaning.
 Clean the coating by the help of crow bar or pipe.
 Take the coating pieces out of mill hood.
 Remove cleaning tools from work place after completion of job.
 Close the mill hood door.
 Close the isolation permits after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 211


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-012 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Fly Ash Silo residual material cleaning.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Falling object

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 212


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 2 Nos


 Spade with wooden handle 2 Nos
 Electric Chipper 1 No
 Crow Bar, 1.5 mtrs long & 15 mm dia 2 Nos
 Hammer with wooden handle, 2 Kgs 2 Nos

07. Manpower Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Step by Remove all possible set material by mechanized system.


 Only residual material to be removed manually by labor.
 Ensure no set material available on silo walls above the work point.
 Take the isolation permits for entrance into silo.
 Take the confined space entry permit.
 Open the inspection/man hole door of the silo.
 Do not allow to work in upper & down stream while silo cleaning.
 Do the silo cleaning.
 Remove cleaning tools from work place after completion of job.
 Check inside the silo.
 Close the silo inspection/man hole doors.
 Close the confined space entry permit.
 Close the isolation permits.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 213


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-CM-013 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for grinding aid preparation & dosing
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 214
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Grinding aid barrel empty pump 1 No


 Grinding aid dosing pump 1 No
 Water 440 Kgs
 Compressed air For Mixing
 Mixing Tank 02 Nos

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Open one barrel (220 Kgs) of ACC-2051.


 Enter the suction pipe of barrel empty pump into barrel.
 Start the pump & empty out complete barrel into mixing tank.
 Open 2nd barrel of ACC-2051.
 Start the pump & empty out complete barrel into mixing tank.
 Note down the mixing tank level reading.
 Open the water valve & add water into mixing tank until tank level increase 255 mm from previous reading.
 Open one barrel of ACC-1635.
 Start the pump & empty out complete barrel into mixing tank.
 Open one more barrel of ACC-1635.
 Start the pump & empty out 1/3 barrel into tank.
 Start the low pressure (2-3 Kg/cm2) air into tank for mixing the liquids & air remain ON for 5-10 minutes.
 Clean the floor with cement dust & reprocess it if any spillage is there during empty out the barrels..
 Start the grinding aid dosing pump from CCR & maintain the flow rate as per requirement.

B-03.2_Register - Standard Department: Production Page No. 215


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 216


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-016 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for foreign material cleaning in fly ash feeding/dosing systems
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3. Caught in under and between the equipment/parts..
4.Electric shock
5.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 217
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Compressed air pipe for foreign material cleaning

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Inform CCR prior to start the cleaning job.


 Ask CCR to stop respective feeding aeration blower.
 Wait for two minutes for setting the aerated material.
 Close the isolation compressed air valve for pneumatic slide gate.
 Take pneumatic slide gate solenoid valve in manual mode.
 Open the air slide inspection door.
 Clean the foreign material with the help of compressed air.
 Close the air slide inspection door.
 Inform CCR to run the system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 218


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos

SOP No.: ACL-WI-CM-018 Rev. No. 00


Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Roller press internal inspection
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Exposure to high temperature.
4.Electric shock
5.Accidental start of gas /material circuit
6.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 219


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Take necessary isolation of drive while roller press inspection.


 Open the mill inspection door after 4 hour of mill stoppage.
 Take the confined space entry permit in case for entrance into discharge chute area.
 Do not allow to work in upper & down stream while mill inspecting.
 Check the roller condition & cheek plate gap.
 Remove cleaning tools from work place after completion of job.
 Close the mill inspection door.
 Close the confined space entry after completing the job.
 Close the isolation permits after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 220


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos

SOP No.: ACL-WI-CM-018 Rev. No. 00


Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Roller press internal inspection
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Exposure to high temperature.
4.Electric shock
5.Accidental start of gas /material circuit
6.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 221


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Take necessary isolation of drive while roller press inspection.


 Open the mill inspection door after 4 hour of mill stoppage.
 Take the confined space entry permit in case for entrance into discharge chute area.
 Do not allow to work in upper & down stream while mill inspecting.
 Check the roller condition & cheek plate gap.
 Remove cleaning tools from work place after completion of job.
 Close the mill inspection door.
 Close the confined space entry after completing the job.
 Close the isolation permits after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 222


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-CM-020 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for grinding aid preparation & dosing of NaOH &KOH
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit
8.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant


B-03.2_Register - Standard Department: Production Page No. 223
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 NaOH solid flakes 25kg


 KOH solid flakes 50kg
 Grinding aid dosing pump 1 No
 Water 7000 Kg
 Agitator 1 Nos
 Mixing Tank 02 Nos

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Close the outlet manual valve of mixing tank for preparation of solution
 Fill half of the tank with water by opening the manual valve of water into the mixing tank
 Put 25kg of NaOH and 50kg of KOH into mixing tank
 Wear chemical resistant hand gloves, nose mask and safety goggle while unloading the bag. Otherwise it may leads to
skin irritation.
a. If the irritation increases wash the body part with water and in worst case take medical help
 Start the agitator for better mixing of solid and liquid in tank.
 Fill both the tank completely with water by opening the outlet valve of mixing tank.
 After solution preparation remove the waste bag from site
 Clean the floor with the cement dust & reprocess it if any spillage is their during solution preparation & dosing.
 Inform CCR after solution preparation to start the dosing pump
 Start the pump & empty out 1/3 barrel into tank.
 Start the low pressure (2-3 Kg/cm2) air into tank for mixing the liquids & air remain ON for 5-10 minutes.
 Clean the floor with cement dust & reprocess it if any spillage is there during empty out the barrels..
 Start the grinding aid dosing pump from CCR & maintain the flow rate as per requirement.

B-03.2_Register - Standard Department: Production Page No. 224


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 225


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-CM-021 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Process flow measurement
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit
8.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 226


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Spanner 1 No
 Pitot tube 1 No
 Manometer 1 No
 Thermocouple with digital indicator 1 No
 Anemometer 1 No
 Flue gas analyzer 1 No
 Thermometer 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Define the area for flow measurement and inform CCR not to change major parameter while flow measurement.
 Flow measurement points are defined at site
 Open the socket cautiously and do not stand in front of socket while opening it
 Measure static and dynamic pressure with pitot tube and pressure meter for flow measurement in duct.
 Measurement the velocity at fan inlet or blower’s inlet to calculate the air quantity delivered by equipments using
anemometer.
 Measure the temperature by inserting thermocouple inside the measuring point.
 Measure false air through portable flue gas analyzer.
 While flow measurement ensure proper sealing of socket to avoid false air inside the system
 Ensure all blaster must be off while measuring oxygen at kiln inlet.
 Close the socket properly to avoid false air into system.
 Inform responsible mechanical engineer for any air leakage or spillage at site

B-03.2_Register - Standard Department: Production Page No. 227


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 228


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 3 Nos


SOP No.: ACL-WI-CM-021 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Process flow measurement
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit
8.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 229


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:

 Spanner 1 No
 Pitot tube 1 No
 Manometer 1 No
 Thermocouple with digital indicator 1 No
 Anemometer 1 No
 Flue gas analyzer 1 No
 Thermometer 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Define the area for flow measurement and inform CCR not to change major parameter while flow measurement.
 Flow measurement points are defined at site
 Open the socket cautiously and do not stand in front of socket while opening it
 Measure static and dynamic pressure with pitot tube and pressure meter for flow measurement in duct.
 Measurement the velocity at fan inlet or blower’s inlet to calculate the air quantity delivered by equipments using
anemometer.
 Measure the temperature by inserting thermocouple inside the measuring point.
 Measure false air through portable flue gas analyzer.
 While flow measurement ensure proper sealing of socket to avoid false air inside the system
 Ensure all blaster must be off while measuring oxygen at kiln inlet.
 Close the socket properly to avoid false air into system.
 Inform responsible mechanical engineer for any air leakage or spillage at site

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

B-03.2_Register - Standard Department: Production Page No. 230


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 231


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-022 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning and inspection of Solid flow meter
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Falling object
5.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 232


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Compressed air pipe for foreign material cleaning

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Inform CCR prior to start cleaning or inspection job.


 Isolate the Solid flow meter feeding air slide blower by applying emergency/Local stop button.
 Wait for two minutes for setting the aerated material.
 Close the compressed air valves for pneumatic gate.
 Open the inspection door and open pneumatic gate solenoid value.
 Clean the foreign material with the help of compressed air.
 Close the inspection door.
 Inform CCR to run the system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 233


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-022 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning and inspection of Solid flow meter
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Falling object
5.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the
precautions and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 234


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Compressed air pipe for foreign material cleaning

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Inform CCR prior to start cleaning or inspection job.


 Isolate the Solid flow meter feeding air slide blower by applying emergency/Local stop button.
 Wait for two minutes for setting the aerated material.
 Close the compressed air valves for pneumatic gate.
 Open the inspection door and open pneumatic gate solenoid value.
 Clean the foreign material with the help of compressed air.
 Close the inspection door.
 Inform CCR to run the system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 235


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-024 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Bag filter hopper cleaning
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 236


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 2 No’s


 Spade with wooden handle 2 No’s
 Crow Bar, 1.5 meters long & 15 mm dia 2 No’s
 Hammer with wooden handle, 2 Kgs 2 No’s

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Inform to CCR before cleaning starts.


 Ensure bag filter fan and RAL is running if material is not set.
 Open the inspection/manhole door of the hopper (If available).
 Remove all possible set material by crow bar and hammer from outside.
 Only residual material to be removed manually by labor.
 Ensure proper ventilation inside hopper before starting the job.
 Use proper working platform.
 Do the hopper cleaning.
 Remove cleaning tools from work place after completion of job.
 Check inside the hopper from outside.
 Close the hopper inspection/manhole door (If available).
 Inform CCR to run the system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 237


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-025 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for hopper cleaning from outside
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 238


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 2 No’s


 Spade with wooden handle 2 No’s
 Electric Chipper 1 No’s
 Crow Bar, 1.5 meters long & 15 mm dia 2 No’s
 Hammer with wooden handle 2 No’s

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Inform CCR prior to start cleaning job.


 Stop the respective feeding system by applying emergency/ Local stop.
 Try to Hammer/Dig the hopper from outside.(If available then run the Blasters)
 Try to run the next group after the hopper in local mode taking permission from CCR
 Check the material flow.
 Keep an idle person next to the Emergency stop/local stop Panel.
 Maintain a proper distance while hopper cleaning.
 Do the hopper cleaning.
 After cleaning Inform CCR to run feeding system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 239


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-026 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Screw conveyor jam removal job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts..
4.Falling object

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 240


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hammer with wooden handle 2 No’s


 Hand shovel with handle 2 No’s

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Inform CCR prior to start cleaning/inspection job.


 Isolate the screw conveyor locally by applying emergency/Local stop.
 Open discharge door.
 Try to clean set material through manually.
 After cleaning close the inspection door.
 Remove the Isolation of conveyor.
 Run the conveyor locally by taking CCR permission.
 Stop the conveyor.
 Informed to CCR for clearance.
 Remove cleaning tools and scrap materials from work place after completion of job

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 241


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-027 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Roller press reject handling through reject bin
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Falling object
5.Accidental start of gas /material circuit

Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 242
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

NOT APPLICABLE

07. Manpower Requirements: 05

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Place the tractor or truck under the reject bin discharge chute.
 Back horn should blow while reversing the truck& reversing should be guided by site attendant.
 Truck should be parked on flat horizontal surface & wheel choke should be fixed.
 Ask CCR to open the reject bin slide gate & emptied out the bin into truck.
 Ask CCR to close the reject bin slide gate.
 Remove the truck from bin discharge chute.
 Empty out the material at designated place.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 243


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-CM-028 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.03.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Belt Conveyor discharge chute cleaning job.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipment/parts.
4.Exposure to high temperature.
5.Falling object
6.Electric shock
7.Accidental start of gas /material circuit
8.Power failure
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3 Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

B-03.2_Register - Standard Department: Production Page No. 244


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
05. Responsibility: HOD

06. Tools & Tackles:


 Electric Chipper with chisel 1 No
 Crow Bar, 2 Nos, 1.5 meters Long, 16 MM dia
 Hammer with wooden handle 2 Nos

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step Procedure:

 Inform CCR prior to start chute cleaning job.


 Stop the respective feeding system by applying emergency/ Local stop.
 Try to Hammer/Dig the discharge chute from outside.
 Check the material flow.
 Open inspection door.
 Try to clean it through crow bar & Hammer.
 Use electric chipper if coating piece is big.
 Close the inspection door.
 Inform CCR to run feeding system.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 245


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-001 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Synthetic Gypsum Plant circuit inspection during plant Starting/Running
condition.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 246


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: NIL

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check entire plant circuit in all respect.


 Inform to CCR to run the group.
 Keep in touch with CCR while starting the plant.
 Again check the plant circuit after starting the plant.
 Inform to CCR for any abnormality at site.
 Check plant circuit JPF i.e. suction, purging, compressed air pressure etc.
 Do not work in improper position.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 247


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-002 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for House Keeping in Synthetic Gypsum Plant circuit.
Permit to Work Requirements: No
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 248


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No
 Basket MS 2 No

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Identify the area where house keeping is required.


 Do not allow to work in upper & down stream from work place.
 Check opening regarding falling object.
 Check machine guarding is proper if house keeping is being carried in near by area.
 Ensure that house keeping to be carried out in presence of plant Attendant/Supervisor.
 If acid spilled then add sodium carbonate/ lime to neutralize the acid. Absorb neutralize material into dry sand.
 Dispose of cleaned material at safe place.
 Remove cleaning tools at work place after completing of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 249


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-003 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SO Work Instruction for Sulphuric Acid unloading into service tank from acid tanker.P:
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1 Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Truck moving or sliping while unloading.
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Acid burn

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 250


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Unloading hose pipe


 Clamp coupler

07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check service tank have sufficient space for acid unloading.


 Park the acid tanker at designated place.
 Back horn should blow while reversing the tanker & reversing should be guided by site attendant.
 Tanker should be parked on flat horizontal surface & wheel choke should be fixed while unloading or waiting for his
queue
 Connect hose pipe one end to service tank pipe & other end to tanker pipe.
 Open the tanker valve & emptied out entire tanker into service tank.
 Close the tanker & service tank valve.
 Remove the tanker from unloading area.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 251


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-004 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP Work Instruction for Sulphuric Acid transportation into acid storage tank from service tank
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1 Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Acid burn.
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3.Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles: Nil


B-03.2_Register - Standard Department: Production Page No. 252
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check storage tank have sufficient space for acid unloading.


 Open the acid storage tank inlet valve.
 Start the connected acid pump.
 Stop the acid pump when service tank gets empty.
 Close the inlet valve of acid storage tank.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 253


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-005 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for Sulphuric Acid transportation from acid storage tank to mixer.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1. Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles: Nil

B-03.2_Register - Standard Department: Production Page No. 254


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
07. Manpower Requirements: 03

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check mixer is in operation.


 Open the acid storage tank outlet valve.
 Start the connected acid pump.
 Check the acid pipe line leakage if any.
 Set the required flow rate.
 Stop acid pump when mixer is stop.
 Close the acid storage tank outlet valve.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 255


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-006 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for raw meal dust transport to 50 ton bin from dense phase system.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

RM: Raw Mills

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 256


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 1 No


 Spade with wooden handle 1 No

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Check 50 ton bin & dense phase circuit in all respect.


 Check that 50 ton bin has sufficient space to dust transport.
 Check availability of compressed air for dense phase as well as JPF purging.
 Check all seal air pressures of dense phase are normal.
 Start the dense phase group.
 Keep in touch with CCR while starting the plant.
 Again check the plant circuit after starting the plant.
 Inform to CCR for any abnormality at site.
 Check plant circuit JPF i.e. suction, purging, compressed air pressure etc.
 Stop the dense phase system when 50 ton bin gets full.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 257


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-007 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning of mixer.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure of dust
5.Accidental start of mixer
6.Spillage of liquor
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3.Skin damage due to spillage of liquor.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD


B-03.2_Register - Standard Department: Production Page No. 258
Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles: Nil

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Empty out the mixer by running without material.


 Check mixer is not in operation & isolation properly carried out for maintenance.
 Check scrubbing fan for chimney is on for mixer ventilation.
 Obtained the work permit from authority for maintenance work
 Open the mixer manhole covers.
 Wash the mixer with clean water.
 Clean the residual material after washing with water.
 Clean the paddle bolts & shaft.
 Check paddles conditions, paddle bolts & shaft condition.
 Fix the new paddle & bolts if required.
 Tightened the paddle bolts.
 Close the mixer manhole covers.
 Close the work permit.
 Remove the tools & tackles at work place.
 Remove the isolation.
 Take the mixer trial run in local mode from site & take into operation if trial run is satisfactory.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 259


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-009 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for cleaning and inspection of rotary feeder.
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Spillage of liquor
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3.Skin damage

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

B-03.2_Register - Standard Department: Production Page No. 260


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
06. Tools & Tackles:

 Hand shovel with handle 2 No’s


 Hammer with wooden handle 2 No’s
 Crow Bar, 1.5 meters long & 15 mm dia 2 No’s

07. Manpower Requirements: 02

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Isolate the rotary feeder locally before cleaning & inform to CCR and apply emergency stop/Local stop.
 Open rotary feeder door.
 Try to clean set material through crow bar.
 After cleaning close the inspection door.
 Remove the Isolation of rotary feeder.
 Run the feeder locally by taking CCR permission.
 Stop the RAL if it is OK.
 Inform to CCR for clearance.
 Remove cleaning tools from work place after completion of job.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 261


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas

Classification: Standard Operating Procedure Page.: 2 Nos


SOP No.: ACL-WI-SG-010 Rev. No. 00
Originating Department: Production Revised Date of Issue: 01.10.2018
Prepared By: (Team
Anil K Chordia, S P Gautam, Manish Ranjan, S S Singh
Members)
Approved By:
V Saxena
Plant Head/ HOD
SOP: Work Instruction for handling of huge spillage of Sulphuric Acid from acid storage tank
Permit to Work Requirements: Yes
Mandatory PPEs: Safety Helmet, Safety goggles, Nose Mask, Reflective jacket, Safety Shoes, Ear plugs
Related Hazards:

1.Exposure of Dust
2.Slip /Trip /Fall from stairs
3.Caught in under and between the equipement/parts.
4.Exposure to high temperature.
5.Acid spillage
Consequences of the deviation:

1. Respiratory Problems
2. Injury fracture due to hit of material /slip and trip
3. Skin damage.

01. Purpose: The Purpose of this SOP is to comply with applicable regulatory requirements and to identify the precautions
and general safety rules that should be followed when doing the Job.

02. Scope: This SOP applies to all persons associated with ACL (employees, contractors, workmen)

03. Abbreviation:

SOP: Standard Operating Procedure

HOD: Head of department

ACL: Ambuja Cements limited

PPE: Personal Protective Equipment

04. Accountability: Section In-charge/ Engineer/Shift manager/Patroller/Attendant

05. Responsibility: HOD

06. Tools & Tackles: Nil

B-03.2_Register - Standard Department: Production Page No. 262


Operating Procedure
Ambuja Cements Limited
Unit- Rabriyawas
07. Manpower Requirements: 04

08. Results & Acceptance: Working person will not get injured during feeding

09. Frequency of Realization: As per requirement

10. Step by Step Procedure:

 Barricade the acid spillage area and evacuate the working personnel.
 Check the empty level of standby acid tank from CCR Level Sensor.
 Start the connected acid pump from CCR situated in the sump area of dyke.
 Check the CCR level Sensor of acid tank ensuring that acid is going to tank.
 Stop the acid pump when sump in dyke area gets emptied.
 Add the Lime dust to neutralize the remaining acid in the dyke area.
 Leave it the mixture for 1-2 Hrs for completion of neutralization.
 Strict Supervision required while removing the soaked lime dust.
 Shift the soaked lime dust to designated place.

11. Communications:

Awareness information which can inspire work men towards behavioral safety to achieve zero harm should be given by
TBT, Monthly safety meetings etc.

12. Amendment Details

Date Rev Change Reason - Change Changed by

B-03.2_Register - Standard Department: Production Page No. 263


Operating Procedure