Cleaning at Kiln Take Up Pulley SOP

Issue No:MTHP/SA/KILN/SOP/001
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 1
TITLE : Cleaning at AC-7&AC-8/A1&A2 including rollers

A) HIRA : Maximum Risk rating :
100
Risk level : 2
B) Equipment's: 1. A1/A2 & AC7/AC8 charging belt
2. Pocking rod
3. Spade (Shovel)
4. Collecting pan
C) Safety precautions
1.Use CO canister mask, ear plug, safety goggles & hand gloves.
2.Ensure walk way, platform & ladder are safe & cleaned.
3.CO meter must be at site.and activity must be done if CO is less than 50 ppm.
4.While going to kiln top person must register his entry in the Kiln Top Entry Book.
5.Ensure proper tool handling practice with PPE's
6.Tools may hit to the body & cause cut injury or fracture.
Description
Desired Condition/Range
N/A/E
Check CO concentration by CO meter near the job location before doing the
job.
< 50 ppm
If CO concentration is more than 50 ppm, then leave the job.
> 50 ppm
Sr. No.
Action By
PRE START-UP CHECKS

1
1-A
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Ensure kIln's cone distributor's water sealing is proper.
OK
Kiln top operator
Ensure kiln's top bag filter is working to avoid dust exposue
OK
Kiln top operator
Ensure dump pipe/line in which the material to be dumped is cleaned
OK
company
Mukadam/cleani
ng contactor
Area Cleaned
company
Mukadam/cleani
ng contactor
Structure
LOTO done
OK
35-60 Amp/ 20-35 Amp
CHECKS DURING CLEANING AT A1/A2 & AC7/AC8 INCLUDING ROLLERS
Collect dust & lime stone/fuel by spade in the collecting pan & pour it into dump
pipe/line so that it would collect in the kiln bottom's dust collecting bin.While
performing this job there is a possibility of dust exposure to body. Also eye
irritation may take place due to dust exposer.
If contractor's worker found any equipment or conveying belt's structure has

deteoriated, then inform to shift incharge or operator
If jaming found between running charging belt & its roller i.e. A1/A2 or
AC7/AC8, then stop the material charging & stop A1 & AC7 or A2 & AC8 belt of
which roller's found jammed & LOTO done.
After removing jamming, remove LOTO & start the material charging on A1 &
AC7 or A2 & AC8 belt with a proper communication between kiln top operator &
PBL operator.
INPROCESS CHECKS
Monitor A1/A2 & AC-7/AC-8 charging belt drive load
company
Mukadam/cleani
ng contactor
Kiln top
operator/PBL
operator
Kiln top
operator/PBL
operator
Kiln top operator
Action Confirm
Back
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 1
TITLE : Cleaning of A1/A2 outlet hoppers

80
Risk level : 2
2. Pocking rod
3. Spaner
4. Torch for illumination
5. Hammer
6. Hose pipe for water spray
Description
N/A/E
job.
< 50 ppm
> 50 ppm
OK
Kiln top operator
LOTO done
Kiln top operator
OK
Kiln top operator
Sr. No.
Action By
PRE START-UP CHECKS

1
1-A
2
3
4

Ensure raw material charging is stopped on a respective belt with a proper
communication between kiln top operator & PBL operator & LOTO done for A1
& AC7 or A2 & AC8 belt.
Ensure instrument air supply valve is closed for trolly's diverting plate control
valve of LK-5 or LK-6
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
OK
Kiln top operator
OK
company
Mukadam/cleani
ng contactor
LOTO done
Kiln top
operator/PBL
operator
CHECKS DURING CLEANING OF A1/A2 OUTLET HOPPER

1
First stop the material charging & stop A1 & AC7 or A2 & AC8 belt of which
hopper found jammed & LOTO done.
Now open the A1 or A2 outlet hopper's window by shift fitter & check inside
jamming of the material with the help of illumination torch. While performing
this job there is a possibility of dust & heat exposure to body and also tool may
hit to body part & cause injury.So please take care of it.
Jamming found
Kiln top operator
If jamming found try to clear itby pocking rod. While performing this job there is
a possibility of dust exposure to body and also tool may hit to body part &
cause injury.So please take care of it.
Jamming found
Kiln top operator
If jamming found hard then carefully spray water on it with the hose pipe.
Remove lumps/jamming
Kiln top operator
Jamming removed
Kiln top operator
LOTO removed
Kiln top
operator/PBL
operator
40-70 % filled
Kiln top operator
35-60 Amp/ 20-35 Amp
Kiln top operator
1
2
After removing jamming, close the A1 or A2 outlet hopper's window by shift

fitter & open instrument air supply valve for trolly's diverting plate control valve
of LK-5 or LK-6
Now after removing LOTO start the material charging on A1 & AC7 or A2 &
AC8 belt with a proper communication between kiln top operator & PBL
operator
INPROCESS CHECKS
Monitor Charging bin level of every kiln & ensure whether raw material is going
on selected charging bin or it is going to other kiln's charging bin.
Action Confirm
Back
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 2
TITLE : All kiln's gas valve checking job

Risk level : 2
Back
1.Carrousal
2.Escorgot
3.Star discharger
4.Discharge Apron Conveyor
5.Pocking rod
6.Hammer
7.Air blower
8.Torch for illumination inside the kiln
9.spaner
1.Use CO canister mask, safety goggles, heat resistant hand gloves and gum boot.
2.Ensure CO is less than 50 ppm by CO meter, before entering in kiln.
3.Ensure area below the job location is barricated.
4.Ensure walk way, ladder and platform are safe and cleaned.
5.Ensure proper tool handling practice with PPE's.
6.Ensure kiln top temperature should be less than 100 Deg.C
Description
Sr. No.
N/A/E
Action By
drive stopped & LOTO done
Disch.Operator
Disch.Operator
PRE START-UP CHECKS

1
Ensure kiln's discharge is stopped by stopping respective air blower, escorgot,

carrousal, star discharger & discharge apron conveyor & LOTO done.
Ensure kiln's gas valve is closed
OK
Ensure railing or support is safe & in good condition for using safety belt.
OK
4
5
All Kiln's bottom bag filters must be working to avoid dust exposer
Ensure top temperature of kiln should be less than 100 Deg.C
Check CO concentration by CO meter near the job location before starting the
job.
If CO concentration is more then 50 ppm at a particular point the go for another
kiln's level checking.
CHECKS DURING KILN GAS VALVE CHECKING JOB
Working
OK
N
N
Contractor's
supervisor
Disch.Operator
Kiln top operator
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
OK
Contractor's
supervisor
6
6-A
Shift all the cleaning equipents & other tools at gas valve platform area. Before
starting job wear safety belt & fix its hook at suitable railing or support.
Now open the gas valve's window & check CO content by CO meter.
CO < 50 ppm
2-A
If CO is more than 50 ppm then close the window and leave the job.
CO > 50 ppm
Jamming found
Contractor's
worker
OK
Contractor's
worker
Gas valve checking
Contractor's
worker
3
4
If CO content is permissible, then check inside jamming. If jamming found, then

clean it with the help of pocking rod or by hammering.
After removing jamming, operate the gas valve manualy. If it founds jam, then
rouse the gas valve with the help of oiling/greasing or hammering
Now check the gas valve disc thickness, check whether there is a gap between
gas valve's disc outer circumfrence & gas line internal circumfrence or not,
check gas valve opening & closing direction arrow, check hole in the gas valve
disc or any other damage.
Contractor's
supervisor
Contractor's
supervisor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 2 of 2
TITLE : All kiln's gas valve checking job

Risk level : 2
64
Sr. No.
Description
N/A/E
Action By
If any abnomality found, informed the shift incharge or operator & call
maintenance team to rectify the problem
Gas valve damage
Contractor's
worker
After the clearance from maintenace dept. close the gas valve's checking
window.
Gas valve checked
Contractor's
worker/ SAMG
Engineer
Now open the gas valve & start kiln's discharge is by starting respective air
blower, escorgot, carrousal, star discharger & discharge apron conveyor.
drive started & LOTO

removed
Disch.Operator
OK
OK
N
N
37- 40% CO2
Kiln operator
Kiln operator
Kiln
operator/shift
incharge
1
2
INPROCESS CHECKS
Monitor process parameter of kiln as per SOP
Monitor electrical load of all rotating drives of kiln for normal operation
Moniter kiln's individual & total gas quality on DCS.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 1
TITLE : cleaning at take up pulley area of AC-7/AC-8 & A-1/A-2

48
Risk level : 1
Back
1. A1/A2 & AC7/AC8 charging belt

2. Pocking rod
3. Spade (Shovel)
4. Collecting pan
Description
N/A/E
job.
< 50 ppm
> 50 ppm
Sr. No.
Action By
PRE START-UP CHECKS

1
1-A
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
OK
Kiln top operator
OK
Kiln top operator
OK
company
Mukadam/cleani
ng contactor
Area Cleaned
company
Mukadam/cleani
ng contactor
Structure
company
Mukadam/cleani
ng contactor
40-70 % filled
Kiln top operator
35-60 Amp/ 20-35 Amp
Kiln top operator
CHECKS DURING CLEANING AT TAKE UP PULLY AREA OF A1/A2 &

AC7/AC8
Collect dust & lime stone/fuel by spade in the collecting pan placed on the kiln
deck & pour it into dump pipe/line so that it would collect in the kiln bottom's
dust collecting bin.While performing this job there is a possibility of dust & heat
exposure to body and also hot quick lime may fall on workers. Also eye

1
2
INPROCESS CHECKS
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 2
TITLE : All kiln's top deck plate cleaning

Risk level : 2
Back
1. Spade (Shovel)
2. Collecting pan
1.Use CO canister mask, ear plug, safety goggles & heat resistant hand gloves.
5.Full body protection suite.
Sr. No.
2-A
Description
N/A/E
Action By
Air blower stopped & LOTO

done
Disch.Operator/
Kiln top operator
job.
< 50 ppm

> 50 ppm
PRE START-UP CHECKS

Stop respective kiln's Air blower one by one ( in case of gas coming out from
the level checking nipple), close its gas valve & if required also close kiln's
charging & discharge. Also check the direction of air.
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Ensure kiln's top tempreture must be below 100 Deg.C
< 100 Deg.C
Kiln top operator
OK
Kiln top operator
Ensure top pressure controlling control valve & manual valve is in open
condition.
open
Kiln top operator
Ensure kiln top deck is safe & cleaned.
OK
company
Mukadam/cleani
ng contactor
OK
Kiln top operator
OK
company
Mukadam/cleani
ng contactor
CHECKS DURING KILN TOP DECK PLATE CLEANING JOB

1
Stand on kiln's top deck plate after wearing full body protection suite because
during deck cleaning if laen gas compressor trip, then hot cone sealing water
may spread on body & cause burn injury.
OK
company
Mukadam/cleani
ng contactor
Now collect dust & lime stone/fuel by spade in the collecting pan near the take
up pulley area & pour it into dump pipe/line so that it would collect in the kiln
bottom's dust collecting bin.While performing this job there is a possibility of
dust & heat exposure to body and also hot quick lime may fall on workers. Also
eye irritation may take place due to dust exposer.
OK
company
Mukadam/cleani
ng contactor

Structure
company
Mukadam/cleani
ng contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
64
Sr. No.
Description
Rev. Date :
Page
: 2 of 2

Risk level : 2
After cleaning job done, open the gas valve, start its air blower & start kiln's
charging & discharge with proper communication with kiln top operator &
contractor's worker.
N/A/E
Action By

removed
Disch.Operator/
Kiln top operator
< 100 Deg.C
Kiln top operator
INPROCESS CHECKS
1
Monitor kiln top temperature strictly.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 1
TITLE : All Trolly divert'g plate checking job

Risk level : 2
Back
Description
N/A/E
Action By
job.
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
Sr. No.
PRE START-UP CHECKS
1
1-A
2
OK
Kiln top operator
OK
Kiln top operator
Ensure material charging is stopped on A1/A2 or AC7/AC8 & also A1/A2 or

AC7/AC8 is stopped with proper communication between PBL & KILN top
operator and LOTO done
LOTO done
Kiln top
operator/PBL
operator
Ensure instrument air supply valve is closed for trolly's diverting plate control
valve.
OK
Kiln top operator
OK
Kiln top operator
CHECKS DURING KILN'S TROLLY DIVERTING PLATE CHECKING JOB

1
Approch for proper location with the support of AC-7/AC-8 belt conveyor or
near by related supports.
Now check the diverting plate thickness, check whether there is a gap between
trolly diverting plate or not, check hole in the trolly's diverting or any other
damage.
Trolly diverting plate

checked
Kiln top operator
Trolly diverting plate

checked
Kiln top operator
OK
Kiln top operator
OK
Kiln top
operator/Shift
incharge
After checking, open the instrument air supply valve for trolly's diverting plate's
control valve. Now remove LOTO & start the material charging on A1 & AC7 or
A2 & AC8 belt with a proper communication between kiln top operator & PBL
operator
INPROCESS CHECKS
Monitor no one start A1/A2 or AC-7/AC-8 charging belt during checking strictly
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 1
TITLE : All charging bin divert'g plate checking.

Risk level : 2
Back
Description
N/A/E
Action By
job.
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
Sr. No.
PRE START-UP CHECKS
1
1-A
2
OK
Kiln top operator
OK
Kiln top operator
LOTO done
Kiln top
operator/PBL
operator
CHECKS DURING KILN'S CHARGING BIN DIVERTING PLATE CHECKING

JOB
1
near by related supports.If required stop charging & also stop AC-7/AC-8 belt
with proper communication between PBL & KILN top operator & LOTO done
Now check respective kiln's charging bin's diverting plate thickness, check
Charging bin diverting plate
whether there is a gap between charging bin's diverting plate or not, check hole
checked
in the charging bin's diverting plate or any other damage.
Kiln top operator

checked
Kiln top operator
After checking, remove LOTO of AC-7/AC-8 belt if done & start the material
charging on AC7/AC8 belt with a proper communication between kiln top
operator & PBL operator
OK
Kiln top
operator/PBL
operator
OK
Kiln top
operator/Shift
incharge
INPROCESS CHECKS
1
Monitor no one start AC-7/AC-8 charging belt during checking strictly
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 1
TITLE : Kiln Box up and start up.

32
Risk level : 1
1.Carrousal
B) Equipment's:
2.Escorgot
3.Star discharger
5.Charging Apron Conveyor
6.Star feeder
7.Cone distributor
8.Hammer for hopper valve operation
9.Air blower
Back
1.Use dust mask, safety goggles, Hand gloves and Gum boot
2.Ensure walk way and platform are safe and cleaned
3.Hopper valve must be roused and easily operatable.
4.Ensure Discharge temperature should be 50-75 Deg.C
Description
Sr. No.
N/A/E
Action By
Ok
Kiln
operator/Shift
incharge
37-40 %
Kiln operator
OK
Working
Kiln
operator/Shift
incharge
Disch.Operator
PRE START-UP CHECKS

1
Ensure no maintenance job is given for any drive of kiln during start up.
Ensure respective kiln gas quality is within the prescribed limit before box up.
Ensure Lime silo level is full as well as other kilns are working
CHECKS DURING KILN BOX UP
Stop kiln's discharge by stopping escorgot, carrousal, star discharger &

discharge apron conveyor & LOTO done
Disch.Operator
Now stop air flow by stopping respective air blower of kiln and locked out and
then close the gas valve of kiln. Provide LOTO on push button of air blower.
Disch.Operator
drive stopped
Kiln top operator
OK
Disch.attendant
After maintaining prescribed kiln level, stop kiln's charging by stopping CAC,
Star Feeder & cone distributor
CHECKS DURING KILN START UP
Ensure kiln's bottam hooper valve & both door must be in close condition &
check the washer & scrubber inlet sea water flow.
After ensuring that no maintenance job is given for any drive of kiln, open the
gas valve of kiln & start the specific air blower

removed
Disch.Operator
After that start the kiln's discharge by starting escorgot, carrousal, star
discharger & discharge apron conveyor.

removed
Disch.Operator
After that start the kiln's charging by starting CAC, Star Feeder & cone
distributor
drive started
Kiln top operator
OK
OK
N
N
Kiln operator
Kiln operator
1
2
INPROCESS CHECKS
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
48
Rev. Date :
Page
: 1 of 1
TITLE : Kiln Air blower change over job.

Risk level : 1
Back
1.Air blower
2.Hammer/spaner for valve operation
3.Lock pin for blower's delivery valve
1.Use dust mask, cover face with cotton cloth, safety goggles, ear plug & hand gloves
3.Air blower delivery valve must be roused and easily operatable.
4.Fall due to conjested area near air blower interconnection valve.
Description
Sr. No.
N/A/E
Action By
Emergency switch ON
Disch.Operator
Area cleaned
company
Mukadam/cleani
ng contactor
Air flow indicator
instrument
person
Working
Disch.Operator
OK
Disch.Operator
PRE START-UP CHECKS

1
Ensure emergency off switch of specific airblower must be in on condition.
Ensure Air blower area & walkway is cleaned
3
4
5
Ensure Air Flow indicator is working properly. If there is a doubt in flow indicator
by observing kiln's parameter, then call instrument person to check it.After the
clearance from instrument department if problem remains, then go for further
steps.
Ensure air blower delivery header interconection valve must be in open
condition which is being started.
CHECKS DURING KILN'S AIR BLOWER CHANGE OVER JOB
First remove the air blower's delivery valve lock pin which is being started &
open the delivery valve in full condition. Now Start the air blower. While
performing this job hammer or spaner may slip and cause cut injury or
fracuture. Also there is a possibility of dust exposure & eye irritation to body.
OK
Disch.attendant/
Disch.Operator
Now stop the airblower which is being stopped & close the air blower delivery
valve fully & lock its delivery valve with lock pin.
OK
Disch.attendant/
Disch.Operator
Now adjust the air flow by increasing or decreasing the delivery valve of air
blower which is being started with proper communication with the operator/shift
incharge.
Airflow
Disch.attendant/
Disch.Operator
After that switch off the emergency switchof air blower which is being stopped.
OK
Disch.attendant/
Disch.Operator
INPROCESS CHECKS
Monitor process parameter of kiln like air flow and back pressure
Monitor air blower's drive load
Monitor viberation or abnormal sound from the air blower and if found informed
to shift incharge or operator.
OK
40-75 Amp
No viberation or abnormal
sound
N
N
1
2
3
Kiln operator
Kiln operator
Disch.attendant/
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 2
TITLE : Individual kiln discharge material checking job.

32
Risk level : 1
Back
1. Old & New Main Discharge Apron conveyor

2. LK-1, LK-10, LK-2 & 8, LK-3 & 9, LK-4 & 7 and LK-5 & 6
discharge system diverting plate.
3. Both bottom silo belt
4. Both cross silo belt
5. Bottom silo belt's bag filter
6. All kiln's bottom bag filter
7. Spade (Shovel)
1.Use dust mask, cover face with cotton cloth, safety goggles, ear plug & heat resistant hand gloves.
2.Ensure walk way, steps and platform are safe and cleaned.
3.Ensure no person is doing maintenance job near Bottom silo belt & Cross silo belt.
5.Hot material may hit to the body & cause burn injury.
Sr. No.
1
2
2-A
3
4
5
6
7
8
1
1-A
Description
PRE START-UP CHECKS

Ensure spare system is available & ready to start.
Ready to start
Ensure no person is doing maintenance job near Main discharge apron
No person should be present
conveyor, bottom silo belt & cross silo belt.
If person is doing cleaning job near the discharge system, then stop them &
People doing job
start the drive after informing them.
All Kiln's bottom bag filters, bottom silo bag filter & cross silo bag filter must be
Working
working to avoid dust exposer
Ensure Main discharge apron conveyor to Bottom silo belt's hopper as well as
Hopper clean
bottom silo belt to cross silo belt's hopper is cleaned
Ensure spare system bottom silo belt's pully is cleaned & free from any
pully cleaned
jamming.
If pully is not cleaned, then first clean it before starting the spare system
pully not cleaned
Check pull chord tripping of spare bottom silo belt
Pull chord tripping
Check the bottom temperature of kilns to facilate the job
80-120 Deg.C
CHECKS DURING KILN DISCHARGE MATERIAL CHECKING JOB
First start the spare cross silo belt, then spare bottom silo belt & then spare
main discharge apron conveyor and monitor the idle drive's load for 3-5 min.
15-20 Amp / 20-25 Amp
Also check the interlocking of discharge system.
If there is a problem in the interlocking of the discharge system, then inform to
interlocking fails
shift incharge or operator and call the Electrical person.
N/A/E
Action By
Disch.Operator
Disch.attendant
Disch.Operator
Disch.Operator
Lumps
attendant
Disch.attendant
A
N
N
Disch.attendant
Disch.Operator
Kiln operator
Disch.Operator
Disch.Operator
Disch.Operator
Now divert the material of the kiln for which the sample to be collected w.r.t the
running spare system one by one.While performing these job there is a
possibility of dust & heat exposure to body. So take care of it.
Individual kiln' discharge

material
Check material condition of individual kiln on spare running bottom silo beltl.It
should be Grey or Creamish
Grey/Cream
Kiln operator/
Shift incharge
Brownish
Kiln operator
Blackish
Kiln operator
3-A
3-B
If material found brownish then

1.Increase air flow and control discharge temperature at about 50-100 Deg.C
2.Increase the residence time by increasing Escargot discharge OFF timer by
If material found blackish then
1.Decrease air flow and control discharge temperature at about 50-100 Deg.C
2.Decrease the residence time by increasing Escargot discharge ON timer by
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
32
Sr. No.
Description
4
4-A
5
5-A
6-A
7-A
8-A
9
1
2
3
1
2
Rev. Date :
Page
: 2 of 2
TITLE : Individual kiln discharge material checking job.

Risk level : 1
Monitor dust content in the discharge material

If dust content observed then increase discharge rate and so reduce residence
time in kiln.
Check the physical condition of discharge material present on bottom silo belt
w.r.t.Temp.It should be worm or cold
If temperature of material is hot or red hot then:
1.Increase air flow by 1000-1500 CFM and monitor discharge temp.
2.Increase residence time by reducing discharge rate
Check lumps present in discharge material

If lumps present, then:
1. Remove lumps as per SOP- MTHP/SA/KILN/SOP/033
2. Increase the discharge temp. by reducing air flow & increase the discharge
rate of kiln.
3. If required decrease the fuel ration by 0.5 to 1 kg after discussing with
sectional incharge
Check unburnt fuel present in discharge material
If fuel particles found high/very high, then
1. Check for channelling due to lumps or arching
2. Check cone distributor is working or not, if not working then informed shift in
charge & operator and attend it.
3. If required decrease the fuel ration by 0.5 to 1 kg after discussing with
sectional incharge
Check unburnt limestone present in discharge material
If unburnt limestone found high/very high, then
Collect sample of quick lime from spare running bottom silo belt & spray water
on collected sample carefully to check the quick lime quality.
INPROCESS CHECKS
Monitor spare discharge system's drive load.
Monitor the interlocking of the discharge system
Monitor discharge tempreture of kiln.
N/A/E
Action By
No dust content
Kiln operator/
Shift incharge
High/Moderate dust content
Kiln operator
Worm/Cold temp.
Kiln operator/
Shift incharge
Red hot/Hot
Kiln
operator/Disch.
Operator
No lumps should be present
Kiln operator/
Shift incharge
High/Very high lumps

present
Kiln operator/
Shift incharge
No/few fuel particles should

be present
Kiln operator/
Shift incharge
High/Very high fuel particles

is present
Kiln operator/
Shift incharge
No/few unburnt limestone

should be present
Kiln operator/
Shift incharge
High/Very high unburnt

limestone is present
Kiln operator/
Shift incharge
OK
Kiln operator/
Shift incharge
15-20 Amp/20-25 Amp

interlocking
80-120 Deg.C
OK
OK
N
N
N
N
N
Disch.Operator
Disch.Operator
Kiln operator
Kiln operator
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
32
Rev. Date :
Page
: 1 of 1
TITLE : All kiln door shed cleaning.

Risk level : 1
Back
1. Scrapper (having long handle)

3. Spade (Shovel)
4. Collecting pan
1.Use dust mask, ear plug, safety goggles & hand gloves.
Description
Sr. No.
N/A/E
Area barrication
Action By
PRE START-UP CHECKS

company
Mukadam/cleani
ng contactor
Kiln top
operator/Shift
incharge
company
Mukadam/cleani
ng contactor
Ensure area below the job location is barricated
Ensure no other cleaning activity is going on kiln top so that dust or lime stone
would not fall on the person who is going to perform the job.
OK
Ensure scaffolding is prepared for job location & scaffolding has certified by the
autorized person
OK
Ensure kiln's top & bottom bag filter is working to avoid dust exposue
OK
Kiln top operator
OK
company
Mukadam/cleani
ng contactor
Area Cleaned
company
Mukadam/cleani
ng contactor
Structure
Barrication removed
ok
ok
CHECKS DURING KILN DOOR SHED CLEANING JOB

1
Remove dust & lime stone from the kiln door's shed by scrapper.
Now collect dust & lime stone/fuel by spade in the collecting pan & pour it into a
specified place or in tractor.While performing this job there is a possibility of
dust exposure to body and tools may hit to body cause cut injury. Also eye
If contractor's worker found that structure has deteoriated, then inform to shift
incharge or operator
After cleaning remove the barrication
1
2
INPROCESS CHECKS
Activity should be done under the inspection of company Mukadam/cleaning
contactor
Area to be barricated where the cleaning job is being done
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
company
Mukadam/cleani
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
80
Rev. Date :
Page
: 1 of 2
TITLE : All kiln walkway cleaning job

Risk level : 2
Back
1.Carrousal
2.Escorgot
3.Star discharger
5.Main discharge system
6.Pocking rod
7.Hammer
8.Air blower
1.Use dust mask, cover face with cotton cloth, safety goggles, heat resistant hand gloves and gum boot.
2.Sudden release of hot material/powder due to material sliding.
Description
Sr. No.
N/A/E
Action By
Electical
engineer
PRE START-UP CHECKS

1
Ensure kiln's discharge is stopped by stopping escorgot, carrousal & star

discharger & fuse is removed by electrical dept.
After stopping kiln's discharge, air blower must be in running condition to

escape residual CO at bottom of Kiln and to reduce discharge temp. untill it
reaches to prescribed limit
25-50ppm/50-60 Deg.C
Disch.Operator
Ensure air flow is stopped by stopping respective air blower of kiln and locked
out and then close the gas valve of kiln. Provide LOTO on push button
Push button locked out
Disch.Operator

Working
OK
OK
N
N
N
N
Disch.Operator
Disch.Operator
Kiln operator
Disch.Operator
CO < 50 ppm
Disch.attendant
4
5
6
7
1
1-A
2
3
4
Ensure Escorgot,Carrousal are stopped and LOTO done.

Ensure Discharge temperature of kiln should be 50-60 Deg.C
Ensure discharge apron conveyor must be in running condtion.
CHECKS DURING WALKWAY CLEANING JOB
Open the both kiln door slowly, chances of suddenly release of hot
material/Powder. Open the door by standing back side of it and check CO
content by CO meter.
If CO is more than 50 ppm then close the door and start air blower for 10-15
min.
while entering in the kiln its door to be locked with the chain & key must be kept
with the person who is entering in the kiln.
Open hopper valve & empty out hopper slowly.Ensure discharge apron
conveyer should not get overload.
First remove lumps near door by using pocking rod and shovol.Ensure area
below must be barricated.
CO > 50 ppm
Disch.Operator
Ok
Disch.attendant
4-6 amp.
Disch.attendant
OK
Disch.attendant
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
80
Sr. No.
Description
Rev. Date :
Page
: 2 of 2
TITLE : All kiln walkway cleaning job

Risk level : 2
while entering in the kiln check walkway of kiln, if dust and material observed
then clean it by using shovel.
After that clean the material or lumps placed on walkway & put it into bottam
hopper. Be ensure that continuous cleaning activity done inside the kiln should
not be more than 10-15 mins because continuous exposure will increase heat
to body.
If lumps observed on walkway then break the lumps by pocking rod. Take care
as area is confined and person can fall.,So exposure should be 10-15 min.
only. Also check lumps near carrousal knife as well as in carrousal discharge
hopper, if found, then try to break it with the pocking rod.
N/A/E
Action By
Use PPE's
Disch.attendant
Use PPE's
Disch.attendant
No lumps
Disch.attendant
50-60 Deg.C
Disch.Operator
After some time if person working inside the kiln feels more heat, then stop the
cleaing activity, close both the doors, bottam hopper then open the gas valve of
kiln & start the specific airblower for cooling.
After sufficient cooling, start the cleaning activity again by following all the
previous steps and after completing the cleaning job handover the kiln for
preventive maintenance or checking job if required.
walkway cleaned
Disch.attendant
10
After the clearance from maintenace dept. close both the kiln's doors, bottam
hopper then open the gas valve of kiln, start the specific airblower.
walkway cleaned
Disch.attendant
11
After that start the kiln's discharge by starting escorgot, carrousal & star
discharger after fuse insertization by electrical dept.
OK
Electical
engineer
OK
OK
N
N
Kiln operator
Kiln operator
1
2
INPROCESS CHECKS
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : Lumps removal from MDC & bottam silo belt outlet hopper.
64
Risk level : 2
1.
Old
&
New
Main
Discharge Apron conveyor
B) Equipment's:
5. Pocking Rod
6. Collecting pan
7. Bottom silo belt's bag filter & Cross silo belt's bag filter
8. Hammer
9. All kiln bottom bag filters
10. If required hose pipe for water spray.
11. Spaner
Description
Sr. No.
N/A/E
Ready to start
Disch.Operator
Disch.attendant
People doing job
Disch.Operator
Working
Disch.Operator
Action By
PRE START-UP CHECKS

1
Ensure no person is doing cleaning or maintenance job near spare Main

Discharge Apron conveyor, Bottom silo belt & Cross silo belt.
2-A
3
CHECKS DURING LUMPS REMOVAL FROM MDAC OUTLET HOPPER
If the running Bottom Silo Belt or MDAC indicates high load, then first stop the
running discharge system immediately & LOTO to be done for this system.
After that start the spare cross silo belt, then spare bottom silo belt & then
spare main discharge apron conveyor and monitor the idle drive's load for 1-2
min. Also check the interlocking of spare discharge system.
LOTO DONE &

1520 Amp / 20-25 Amp
Disch.Operator
1-A

interlocking fails
Disch.Operator
Now change the all kiln's discharge diverting plate w.r.t the available spare
system one by one as well as change the kiln bottom bag filter's delivery line's
diverting valve strictly.While performing these job there is a possibility of dust &
heat exposure to body. So take care of it.
kiln's discharge diverting

plate must be diverted
Disch.attendant
2-A
Sometimes diveting plate got jammed so hammer or pocking rod to be used to

remove the jamming, please take care while performing this job.Tools may hit
to the body parts and cause injury.

plate got jammed
Disch.attendant
Discharge started
Disch.Operator
After that change the interlocking of all kiln's discharge with the available
system by placing the knob of selector switch & start the kiln's discharge one
by one.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
Sr. No.
4
5
7-A
8
9
10
CHEMICALS' DIVISION
Rev. Date :
Page
: 2 of 2
TITLE : Lumps removal from MDC & bottam silo belt outlet hopper.
64
Risk level : 2
Description
Now open the window of previously working MDC outlet hopper by shift fitter for
checking inside lumps or jamming.
If lumps found then try to break it by pocking rod, while performing this job
there is a possibility of dust & heat exposure to body and also tool may hit to
body part & cause cut injury so please take care of it.
If lumps found hard then carefully spray water on lumps with the hose
pipe.During this operation lumps may break and heat will generate and burn
injury can happen.So use face shield.Also hot lumps may hit to the body
Then start the discharge system with proper communication between discharge
attendant and discharge operator just for trial purpose.
If Bottom Silo Belt or MDAC still indicates high load, repeat the above
procedure till the load gets normal.
If foreign material found or any damage found inside the hopper, then inform
maintenance engineer or shift fitter to remove it.
After the clearance from Maintenance team start the discharge system for idle
trial & run for 3-5 min.
If idle trial found ok, then close the MDAC outlet hopper's window by shift fitter
& run the previous working discharge system for 10-15 min in idle condition so
that the material will be emptied out & it will be available.
N/A/E
Action By
LOTO
Disch.Operator
Disch.attendant
Disch.attendant
15-20 Amp / 20-25 Amp
Disch.attendant/
Disch.Operator
> 20 amp / > 25 amp
Disch.attendant/
Disch.Operator
foreign material/damage
found
SAMG Area
Engineer
15-20 Amp / 20-25 Amp
SAMG Engineer
15-20 Amp / 20-25 Amp
Disch.Operator
Disch.Operator
interlocking fails
Disch.Operator

Disch.attendant

plate got jammed
Disch.attendant
Discharge started
Disch.Operator
LOTO
Disch.Operator
Disch.attendant
Disch.attendant
15-20 Amp / 20-25 Amp
Disch.attendant/
Disch.Operator
> 20 amp / > 25 amp
Disch.attendant/
Disch.Operator
found
SAMG Area
Engineer
15-20 Amp / 20-25 Amp
SAMG Engineer
15-20 Amp / 20-25 Amp
Disch.Operator
15-20 Amp / 20-25 Amp

interlocking
N
N
Disch.Operator
Disch.Operator
80-120 Deg.C
Kiln operator
CHECKS DURING LUMPS REMOVAL FROM BOTTOM SILO BELT OUTLET

HOPPER
1-A
2
2-A
4
5
7
7-A
8
9
10
1
2
3
If the running Bottom Silo Belt or Cross silo belt indicates high load, then first
stop the running discharge system immediately & LOTO to be done for this
LOTO DONE &
15system. After that start the spare cross silo belt, then spare bottom silo belt &
20 Amp / 20-25 Amp
then spare main discharge apron conveyor and monitor the idle drive's load for
1-2 min. Also check the interlocking of spare discharge system.
by one.
Now open the window of previously working Bottom silo belt outlet hopper by
shift fitter for checking inside lumps or jamming.
part.so please take care of it.
If Bottom Silo Belt or Cross silo belt still indicates high load, repeat the above
If idle trial found ok, then close the BSB outlet hopper's window by shift fitter &
run the previous working discharge system for 10-15 min in idle condition so
INPROCESS CHECKS
Monitor discharge system's drive load.
Monitor Kiln discharge temp. it should be 80-120 Deg.C.If discharge temp. is
below 80 Deg.C , then there is chance of lumps formation.In such case
increase Escorgot ON timer & monitor discharge temp.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
32
Rev. Date :
Page
: 1 of 2
TITLE : All kiln discharge sample collecting job

Risk level : 1
Back

7. Spade (Shovel)
8. Air tight metallic containers for individual kiln
Sr. No.
1
2
2-A
3
4
5
6
7
8
1
1-A
Description
PRE START-UP CHECKS

Ready to start
People doing job
Working
Hopper clean
pully cleaned
jamming.
pully not cleaned
Check pull chord tripping of spare bottom silo belt
Pull chord tripping
Check the bottom temperature of kilns to facilate the job
80-120 Deg.C
CHECKS DURING QUICK LIME SAMPLING JOB
15-20 Amp / 20-25 Amp
interlocking fails
N/A/E
Action By
Disch.Operator
Disch.attendant
Disch.Operator
Disch.Operator
Lumps
attendant
Disch.attendant
A
N
N
Disch.attendant
Disch.Operator
Kiln operator
Disch.Operator
Disch.Operator
Now divert the material of the kiln for which the sample to be collected w.r.t the
running spare system one by one.While performing these job there is a

material
Disch.Operator
Collect the samples from the bottom silo belt in the empty container of
appropriate kiln after ensuring that only the material of desired kiln is coming.

material
sample boy
Sampling & preparation to be done as quickly as possible in order to avoid the

material coming in the contact with air.

material
sample boy
The sample quanity should not be less than 3.0 kg in weight per kiln

material
sample boy
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
32
Sr. No.
Description
1
2
3
Rev. Date :
Page
: 2 of 2
TITLE : All kiln discharge sample collecting job

Risk level : 1
The collected sample should comprise of material size 8010 mm

The samples should be crushed futher to -12 mm size & by repetaed through
mixing and quartering a final sample of 500 gms is obtained. This sample is to
be further pulverised and put in airtight container immediately as it can absorb
moisture rapidly due to its larger surface area.
NOTE Futher analysis is carried out by Central Lab as per their SOP
INPROCESS CHECKS
Monitor spare discharge system's drive load.
N/A/E
Action By

material
sample boy
OK
sample boycentral lab
15-20 Amp
interlocking
80-120 Deg.C
N
N
N
Disch.Operator
Disch.Operator
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 1
TITLE : All bag filter bottam tank cleaning.

Risk level : 2
Back
1. Tractor or dumper must be available

3. Pocking Rod or hammer
1.Use dust mask, gum boot, safety goggles, ear plug & hand gloves.
2.Ensure walk way and platform are safe and cleaned.
3.Ensure escape route is safe ,cleaned and must be known to working person.
Description
Sr. No.
N/A/E
Action By
PRE START-UP CHECKS

1
Ensure right position of tractor under the bottom drain valve of cleaning tank.
OK
Cleaning
contactor
Ensure cleaning tools must be in good condition & should be in desired angle
shape.
OK
Cleaning
contactor
Ensure surrounding area bag filter is working properly to avoid dust exposure
OK
Disch.Operator
Wherever required arrange scaffolding to perform the job.
OK
Shift incharge
OK
Cleaning
contactor
Jamming found
Cleaning
contactor
Jamming found
Cleaning
contactor
Jamming found
Cleaning
contactor
Jamming found
Cleaning
contactor
ok
company
Mukadam/cleani
ng contactor
CHECKS DURING BAG FILTER BOTTOM TANK CLEANING JOB

Open bottom valve of dedusting tank gradually and dumper/tractor must be
available at the bottom of tank.
If material is not sliding, then hammering to be done at the bottom of the tank.
While performing this job there is a possibility of dust exposure to body and tool
may slip & hit to body part & cause injury.So please take care of it. Also eye
If jamming is not removed by hammering, then apply water with the hose pipe
from the top of the tank to remove jamming.
If jamming is not removed by applying water, then prepare scaffolding to
approach to tank's bottom valve & keep appropriate distance from the tank
bottom to avoid any abnormal condition. Now after wearing safety belt stand on
the scaffolding & clean the jamming by angle shaped pocking rod having long
handle as shown in attached picture. While pocking dont put face in the
bottom of the tank.There is chances of suddenly sliding of material from tank.
If still material is not slidding from the tank, informed to shift incharge or higher
authority about this abnormality & leave the job after barrication of the job
location
INPROCESS CHECKS

contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
64
Rev. Date :
Page
: 1 of 2
TITLE : All kiln gas checking job.

Risk level : 2
Back
B) Equipment's:
1.Orsat apparatus
1.Use dust mask, safety goggles, ear plug & hand gloves.
4.Apparatus may fall & glass may hit to body & cause cut injury.
Sr. No.
Description
PRE START-UP CHECKS

Ensure All kilns are working under slightly pressure.
Ensure fuel should be in dry condition
Ensure there is no leakage from the gas line of the kiln. If there is any leakage,
then first attend it befoe deciding on any corrective action.
Ensure Limestone & fuel characteristics are normal
Ensure kiln level is within prescribed limit.
Ensure kiln top temperature is within prescribed limit.
N/A/E
Action By
15-20 mm WC
Dry fuel
No leakage
Ok
11-14 ft empty from the top
100-150 Deg.C
Kiln operator
PBL
operator/Shift
incharge
Kiln
operator/Shift
incharge
PBL
operator/Shift
incharge
Kiln Top
operator
Kiln Top
operator
37- 40% CO2
Kiln operator
< 37% CO2
Kiln operator
CHECKS DURING KILN GAS CHECKING JOB

1
1-A
To carry CO2 gas measurment put orsat apparatus at proper stand & make
individual CO2 gas measurment one by one with right procedure.
If CO2 gas quality is less than the prescribed value then check kiln level. It
should be 11-14 ft empty from the kiln top. If the kiln level is empty more than
14 ft from the top , then there may be a possibility of breakdown in charging
system.In this case stop the kiln discharge unless the kiln level becomes 14 ft
empty from the top.
1-B
If CO2 gas quality is less than the prescribed value then check kiln level. It
should be 11-14 ft empty from the kiln top. If the kiln level is empty less than 11
ft from the top , then .incresae the kiln discharge unless the kiln level becomes
11 ft empty from the top.Also check cone distributor water sealing in this case.
< 37% CO2
Kiln operator
1-C
Check limestone & fuel quality which is to be fed. If it found poor, then restore
material quality.
< 37% CO2
PBL
operator/Shift
incharge
1-D
Adjust the air flow if it found too excess. Excess air flow can be identified by
checking % O2. It should be 0.5 to 1.0 % O2.
< 37% CO2
Kiln operator
1-E
If there is any doubt about PBL upset, then go for material test.
< 37% CO2
PBL
operator/Shift
incharge
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
64
Sr. No.
Description
Rev. Date :
Page
: 2 of 2
TITLE : All kiln gas checking job.

Risk level : 2
N/A/E
Action By
< 37% CO2
Sectional
incharge
< 37% CO2
Check cone distributor malfuctioning.It should be working properly.
< 37% CO2
Adjust fuel ratio as per requirement. For this ref. fuel ratio changing SOP.
< 37% CO2
Check limestone screen. If it found damaged, then attend it befoe deciding on

any corrective action.
< 37% CO2
PBL
operator/Shift
incharge
1-F
If lumps found during kiln checking then adjust kiln discharge rate as per SOP
No. MTHP/SA/KILN/SOP/034
1-G
Check kiln's washer & scrubber big & baby seal pot. If it found empty or
jammed, then first attend it befoe deciding on any corrective action.
1-H
1-I
1-J
Sectional
incharge
Kiln Top
operator
Sectional
incharge
INPROCESS CHECKS
1
Moniter kiln's individual & total gas quality on DCS. If any deviation found, call
the instrument person to attend it immediately.
37- 40% CO2
Kiln
operator/shift
incharge
Kiln operator has to check the gas quality with Orsat apparatus in every four
hour for individual kiln. If process required, sometimes he has to check the gas
quality of a particular kiln in every two hour which is having the low kiln gas
quality.
Every 4 hours
Kiln operator
Sometime when process required CO2 gas measurment will be done at kiln top
from the chimney's tapping.First clean the nipple then make CO2 gas
measurment job with right procedure. While performing this job operator must
wear kenaster CO mask & do the job if CO content is less than 50 ppm.
CO < 50 ppm/
40% CO2
Kiln operator
There is a possibility of Orsat apparatus sample tube leakage/damage. In this

case attend it immediately
Sometime Orsat apparatus reagent become dilute. So to overcome with this
problem change the reagent once in a week.
Orsat apparatus should be

ok
Orsat apparatus should be
ok
Kiln operator
4
5
6
Check the type of fuel present on 'G' belt twice in a shift
Fuel
37-
N
N
Kiln operator
hydrator
operator/shift
incharge
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
80
Rev. Date :
Page
: 1 of 2
TITLE : Both MDC bottom area cleaning job

Risk level : 2
Back
1. Both Main discharge apron conveyor

5. Bottom silo Bag filter & Cross silo Bag filter
6. Collecting pan
7. Spade
3.Ensure no person is doing maintenance job near MDC, bottom silo belt & cross silo belt.
Description
Sr. No.
N/A/E
Action By
Ready to start
Disch.Operator
Disch.attendant
People doing job
Disch.Operator
Working
Disch.Operator
Hopper clean
Lumps
attendant
pully cleaned
Disch.attendant
pully not cleaned
Disch.attendant
15-20 Amp / 20-25 Amp
Disch.Operator
PRE START-UP CHECKS

1

2-A
3
4
5
6
jamming.
CHECKS DURING BOTH MDC BOTTOM AREA CLEANING
1-A

interlocking fails
Disch.Operator
After that collect the dust & quick lime by spade in the collecting pan & pour
into spare running MDC or directly pour the material into the spare running
MDC.While performing this job there is a possibility of dust & heat exposure to
body and also hot quick lime may fall on workers. Also eye irritation may take
place due to dust exposer.
Area Cleaned
company
Mukadam/cleani
ng contactor
into running MDC which is on load or directly pour the material into the running
MDC.While performing this job there is a possibility of dust & heat exposure to
Area Cleaned
company
Mukadam/cleani
ng contactor
Run the spare discharge system for 10-15 min in idle condition so that the
material will be emptied out & it will be available.
20-25 Amp
Disch.Operator

Structure
company
Mukadam/cleani
ng contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
80
Sr. No.
Description
1
2
Rev. Date :
Page
: 2 of 2
TITLE : Both MDC bottom area cleaning job

Risk level : 2
INPROCESS CHECKS
N/A/E
Action By
15-20 Amp / 20-25 Amp

interlocking
N
N
Disch.Operator
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 2
TITLE : All discharge apron conveyor & S/D area cleaning.

32
Risk level : 1
Back
1. Both Main discharge apron conveyor

5. Bottom silo Bag filter & Cross silo Bag filter
6. Collecting pan
7. Spade
6.Ensure no contractor worker who is going to perform the job wears loose clothes due to rotating equipments.
Description
Sr. No.
N/A/E
Action By
Action Confirm
PRE START-UP CHECKS

1
Working
Disch.Operator
Ensure escape route is clear & known to working person
Cleaned
company
Mukadam/cleani
ng contactor
Ensure respective kiln's discharge apron conveyor is in running condition.
DAC is running
Disch.Operator
Area Cleaned
company
Mukadam/cleani
ng contactor
4-6 Amp
Disch.Operator
Equipment condition
company
Mukadam/cleani
ng contactor
CHECKS DURING DAC AREA CLEANING JOB
Collect the dust & quick lime by spade in the collecting pan & pour into running
DAC.While performing this job there is a possibility of dust & heat exposure to
Monitor the load of DAC while performing this job
If contractor's worker found any equipment damage, then inform to shift

Soda Ash/Kiln
Rev. No. : 00
CHEMICALS' DIVISION
TITLE : All discharge apron conveyor & S/D area cleaning.
Rev. Date :
Page
: 2 of 2
32
Sr. No.
Description
1
2
Risk level : 1
CHECKS DURING S/D AREA CLEANING JOB

Collect the dust & quick lime by spade in the collecting pan & put it into a
proper location.While performing this job there is a possibility of dust & heat
exposure to body and also hot quick lime may fall on workers. Also eye
INPROCESS CHECKS
Monitor the discharge apron conveyor's drive load.
Monitor the interlocking of discharge apron conveyor with MDC
N/A/E
Action By
Area Cleaned
company
Mukadam/cleani
ng contactor
4-6 Amp
interlocking
N
N
Disch.Operator
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 2
TITLE : Both bottam silo & cross silo belt area cleaning
64
Risk level : 2
Back

4. Cross silo belt's bag filter
5. Collecting pan
6. Spade
7. Hopper's skirt plate & packing
Description
Sr. No.
N/A/E
Action By
Ready to start
Disch.Operator
Disch.attendant
People doing job
Disch.Operator
PRE START-UP CHECKS

1
Ensure no person is doing maintenance job near Bottom silo belt & Cross silo
belt.
2-A
Ensure bottom silo belt to cross silo belt's hopper is cleaned
Working
Disch.Operator
Hopper clean
Lumps
attendant
jamming.
pully cleaned
Disch.attendant
pully not cleaned
Disch.attendant
CHECKS DURING BOTTOM SILO BELT AREA CLEANING

1
First start the spare cross silo belt, then spare bottom silo belt and monitor the
idle drive's load for 3-5 min. Also check the interlocking of both system.
15-20 Amp
Disch.Operator
1-A

interlocking fails
Disch.Operator
into spare running bottom silo belt or directly pour the material into the spare
running bottom silo belt.
Area Cleaned
company
Mukadam/cleani
ng contactor
into running bottom silo belt which is on load or directly pour the material into
the running bottom silo belt.While performing this job there is a possibility of
dust & heat exposure to body and also quick lime may return from the inclined
belt due to lack of friction on spare belt and also eye irritation may take place
due to dust exposer.
Area Cleaned
company
Mukadam/cleani
ng contactor
If contractor worker found that Bottom silo belt's hopper skirt plate or skirt
packing got damaged, then inform to shift incharge or operator
Skirt plate/Skirt packing
If contractor worker found any belt's structure has deteoriated, then inform to
shift incharge or operator
Structure
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 2 of 2
TITLE : Both bottam silo & cross silo belt area cleaning
Risk level : 2
64
Sr. No.
Description
N/A/E
Action By
15-20 Amp
Disch.Operator
Area Cleaned
company
Mukadam/cleani
ng contactor
Area Cleaned
company
Mukadam/cleani
ng contactor
Skirt plate/Skirt packing
Structure
15-20 Amp
interlocking
N
N
CHECKS DURING CROSS SILO BELT AREA CLEANING

1
First start the spare cross silo belt & monitor the idle drive's load for 1-2 min.
into spare running cross silo belt or directly pour the material into the spare
running cross silo belt.While performing this job there is a possibility of dust &
heat exposure to body and also quick lime may return from the inclined belt due
to lack of friction on spare belt and also eye irritation may take place due to
dust exposer.
4
5
1
2
into running cross silo belt which is on load or directly pour the material into the
running cross silo belt.While performing this job there is a possibility of dust &
heat exposure to body and also quick lime may return from the inclined belt due
to lack of friction on spare belt and also eye irritation may take place due to
dust exposer.
If contractor worker found that cross silo belt's hopper skirt plate or skirt
packing got damaged, then inform to shift incharge or operator
If contractor worker found any belt's structure has deteoriated, then inform to
shift incharge or operator
INPROCESS CHECKS
company
Mukadam/cleani
company
Mukadam/cleani
ng contactor
Disch.Operator
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : Discharge system change over job

32
Risk level : 1
B) Equipment's: 1. Old & New Main Discharge Apron conveyor
5. All Kiln Discharge Apron Conveyor except LK-4 & LK-5.
6. LK-4 & LK-5 Star discharger
7. Pocking Rod
8. Hammer
9. All kiln bottom bag filter's delivery line's diverting valve.
Back
3.Ensure no person is doing cleaning & maintenance job near Main Discharge Apron conveyor, Bottom silo belt & Cross silo belt.
4.Please take care while doing hammering or plate diverting job.
Description
Sr. No.
N/A/E
Action By
PRE START-UP CHECKS

1
Ready to start
Disch.Operator
Ensure no person is doing cleaning or maintenance job near Main Discharge

Apron conveyor, Bottom silo belt & Cross silo belt.
Disch.attendant
2-A
People doing job
Disch.Operator
Working
Hopper clean
Disch.Operator
Lumps
attendant
pully cleaned
Disch.attendant
15-20 Amp / 20-25 Amp
Disch.Operator
3
4
5
1-A
2
3-A
jamming.
CHECKS DURING DISCHARGE SYSTEM CHANGE OVER
After that stop all kiln's discharge
After that change the interlocking of all kiln's discharge apron conveyor with the
available system by placing the knob of selector switch & start the kiln's
discharge one by one.
interlocking fails
Disch.Operator
All kiln's discharge should

be stopped
Disch.Operator

Disch.attendant

plate got jammed
Disch.attendant
Discharge started
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
32
Sr. No.
Description
1
2
Rev. Date :
Page
: 2 of 2
TITLE : Discharge system change over job

Risk level : 1
Run the previous working discharge system for 10-15 min in idle condition so
INPROCESS CHECKS
N/A/E
Action By
20-25 Amp
Disch.Operator
15-20 Amp / 20-25 Amp

interlocking
N
N
Disch.Operator
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 2
TITLE :Lumps removal from carrusal knife & it's hopper.

80
Risk level : 2
Back
1.Carrousal
2.Escorgot
3.Star discharger
6.Pocking rod
7.Hose pipe for water spraying
8.Hammer
9.Air blower
1.Use dust mask, cover face with cotton cloth, safety goggles, Hand gloves and Gum boot
2.Sudden release of hot material/powder due to material sliding.
Sr. No.
Description
PRE START-UP CHECKS
Stop discharge of kiln by stopping Escargot to escape residual CO at bottom of
Kiln and to reduce discharge temp.by air blowing
N/A/E
Action By
25-50ppm/50-60 Deg.C
Disch.Operator
Ensure air flow is stopped by stopping Air blower and locked out and then close
the gas valve of kiln.Provide LOTO on push button
Disch.Operator
Ensure Escorgot,Carrousal are stopped and LOTO done.
Disch.Operator
Ensure water spraying hose pipe connected tightly with clamp
No leakage
Disch.attendant
5
6
7
Ensure Discharge temperature of kiln should be 50-60 Deg.C
Ensure discharge apron conveyor must be in running condtion.
CHECKS DURING LUMPS REMOVAL
min.
while entering in the kiln its door to be locked with the chain & key must be kept
with the person who is entering in the kiln.
Open hopper valve & empty out hopper slowly.Ensure discharge apron
conveyer should not get overload.
First remove lumps near door by using pocking rod and shawol.Ensure area
below must be barricated.
Working
OK
OK
N
N
N
Disch.Operator
Kiln operator
Disch.Operator
CO < 50 ppm
Disch.attendant
CO > 50 ppm
Disch.Operator
1
1-A
2
3
4
Ok
Disch.attendant
4-6 amp.
Disch.attendant
OK
Disch.attendant
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
A) HIRA : Maximum Risk rating : 80

Sr. No.
5
6
7
10
11
12
1
2
Rev. Date :
Page
: 2 of 2
TITLE :Lumps removal from carrusal knife & it's hopper.

Risk level : 2
Description
Check walk way of kiln, if dust and material observed then clean it by using
shawol.
Then enter in kiln and check for lumps near carrousal knife as well as in
carrousal discharge hopper.
If lumps observed then break the lumps by pocking. Take care as area is
confined and person can fall.Continuous exposure will increase heat to
body,So exposure should be 10-15 min. only.
If lumps found hard then spray water carefully on lumps. The lumps may break
into several piece during water spraying and can cause severe injury to man
who is doing the job.So keep sufficient distance from the lumps during water
spray for safe operation
If lumps get break,then stop the water & close both the door & open gas valve
& start specific airblower.
After 15 min. start the carussal only & observe it's load, if found normal start
the discharge of kiln. If still taking high load repeat the above procedure till
carrousal load gets normal.
Sometimes lumps get stuck up in carousal outlet hopper. Then open the
stardischarge inlet hopper's window by shift fitter & check inside material which
is jamming.
Break the lumps with pocking of rod(parai) than start stardischarge with proper
communication for removal it. If lumps found hard than spray water carefully
on lumps properly. If still taking high load repeat above procedure till
stardischarge load gets normal.
INPROCESS CHECKS
Monitor Carrousal and Escorgot load
N/A/E
Action By
Use PPE's
Disch.attendant
No lumps
Disch.attendant
No lumps
Disch.attendant
No lumps
Disch.attendant
No lumps
Disch.attendant
3-5 amp.
Disch.Operator
No lumps
Disch.attendant
No lumps
Disch.attendant
3-5 amp
80-120 Deg.C
N
N
Kiln operator
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : All Kiln checking job

Risk level : 2

64
B) Equipment's: 1.Carrousal
2.Escorgot
3.Star discharger
6.Pocking rod
7.Hose pipe for water spraying
8.Hammer for hopper valve operation
9.Air blower
Back
1.Use dust mask, cover face with cotton cloth, safety goggles, Hand gloves and Gum boot
2.Sudden release of hot material/powder during kiln door opening
Sr. No.
Description
PRE START-UP CHECKS
Stop discharge of kiln by stopping Escargot to escape residual CO at bottom of
Kiln by air blowing for 10 min.
N/A/E
Action By
25-50ppm
Disch.Operator
Ensure air flow is stopped by stopping Air blower and locked out and then close
the gas valve of kiln
Disch.Operator
Ensure Escorgot,Carrousal are stopped and locked out
Disch.Operator
Ensure water spraying hose pipe connected tightly with clamp
No leakage
Disch.attendant
CHECKS DURING KILN CHECKING
min.
Lock the door in open condition by chain and key must be with checking
person.
Open hopper valve & empty out hopper slowly.Ensure conveyer should not get
overloaded.
Check walk way of kiln, if dust and material observed then clean it by using
shawol.
Check condition of Escorgot,Carrousal, lip plate, Skirt plate for any damage.
Working
Disch.Operator
1
1-A
2
3
4
5
5-A
If any damage found inform shift in charge and operator.

Check material condition on escargot and carrousal.It should be Grey or
Creamish
CO < 50 ppm
Disch.attendant
CO > 50 ppm
Disch.Operator
Ok
Disch.attendant
15-20 amp.
Disch.attendant
Use PPE's
Disch.attendant
No damage
Disch.Operator
Damage
Disch.Operator
Grey/Cream
Disch.attendant
6-A
If material found brownish then

1.Increase air flow and control discharge temperature at about 50-100 Deg.C
2.Increase the residence time by increasing Escargot discharge OFF timer by
two min. and monitor the discharge condition
3.If required increase the fuel ration by 0.5 to 1 kg.
Brownish
Kiln operator
6-B
If material found blackish then

1.Decrease air flow and control discharge temperature at about 50-100 Deg.C
2.Decrease the residence time by increasing Escargot discharge ON timer by
5-10 sec.. and monitor the discharge condition
3.If required decrease the fuel ration by 0.5 to 1 kg.
Blackish
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Sr. No.
7
7-A
8
8-A
Description
Monitor dust content in material on Carrousel and Escargot

If dust content observed then increase discharge rate and so reduce residence
time in kiln.
Check the physical condition of material present on carrousel and escargot
w.r.t.Temp.It should be worm or cold
If temperature of material is hot or red hot then:
1.Increase air flow by 1000-1500 CFM and monitor discharge temp.
2.Increase residence time by reducing discharge rate
Check uniformity of temp. around material on escargot.
9-A
If temp. is non uniform then :

1.Check lumps on Escargot & Carrousel, if lumps observed try to break it with
the help of water spray and then remove it.
2.Check lip plate condition for any damage, if found damage informed to shift in
charge or operator & attend it.
3.If condition 1 & 2 found ok, then check for arching as per SOP in kiln.
10
Check for any lumps present in kiln
If lumps present, then:

1. Remove lumps as per SOP- MTHP/SA/KILN/SOP/033
10-A 2. Increase the discharge temp. by reducing air flow & increase the discharge
rate of kiln.
3. If required decrease the fuel ration by 0.5 to 1 kg.
11
Check unburnt fuel present in material on Carrousel & Escargot
If fuel particles found high/very high, then

11-A 2. Check cone distributor is working or not, if not working then informed shift in
3. If required decrease the fuel ration by 0.5 to 1 kg.
12
Check for any unburnt limestone present in kiln
If unburnt limestone found high/very high, then

12-A charge & operator and attend it.
3. If required increase the fuel ration by 0.5 to 1 kg.
4. Check Limestone size, screen condition & quality of limestone w.r.t
impurities
13
13-A
Rev. Date :
Page
: 2 of 2
TITLE : All Kiln checking job

Risk level : 2
A) HIRA : Maximum Risk rating : 64
Check for any lumps struck in moving part.

If lumps observed then remove it by pocking or try to break it by water spraying.
Take care of hot vapour which will going to generate after water spray on hot
lumps
N/A/E
Action By
Disch.attendant
No dust content
High/Moderate dust content
Kiln operator
Worm/Cold temp.
Disch.attendant
Red hot/Hot
Kiln operator
Temp. should be uniform
Disch.attendant
Non uniform temp.
Disch.Operator
Disch.attendant
High/Very high lumps

present
Disch.Operator
No/few fuel particles should

be present
Disch.Operator
High/Very high fuel particles

is present
Kiln operator
No/few unburnt limestone

should be present
Disch.Operator
High/Very high unburnt

limestone is present
Kiln operator
Disch.attendant
lumps present
Disch.attendant
14
Check for hopper valve is getting closed properly
valve must be fully closed
Disch.attendant
15
Check for kiln door packing rope, clamps & fittings
Ok
Disch.attendant
1
2
INPROCESS CHECKS
OK
OK
N
N
Kiln operator
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 1
TITLE : All kiln airfow adjustment by blower delievery & interconection v/v operation
48
Risk level : 1
B) Equipment's:
Back
1.Air blower
2.Hammer/spaner for valve operation
3.Lock pin for blower's delivery valve
1.Use dust mask, cover face with cotton cloth, safety goggles, ear plug & hand gloves
3.Air blower delivery valve must be roused and easily operatable.
4.Fall due to conjested area near air blower interconnection valve.
Description
N/A/E
Action By
Emergency switch ON
Disch.Operator
Area cleaned
company
Mukadam/cleani
ng contactor
Air flow indicator
instrument
person
Working
Disch.Operator
While increasing the airflow of a respective kiln first remove the air blower
delivery valve lock pin, then open the specific airblower delivery valve gradually
with proper communication with the operator/shift incharge.While performing
this job hammer or spaner may slip and cause cut injury/fracuture. Also there is
a possibility of dust exposure & eye irritation to body.
Airflow
Disch.attendant/
Disch.Operator
While decreasing the airflow of a respective kiln first remove the air blower
delivery valve lock pin, then close the specific airblower's delivery valve
gradually with proper communication with the operator/shift incharge.While
performing this job hammer or spaner may slip and cause cut injury/fracuture.
Also there is a possibility of dust exposure & eye irritation to body.
Airflow
Disch.attendant/
Disch.Operator
If required more airflow, then start another airblower into specific kiln if
possible. Be ensure specific airblower delivery header interconection valve
must be in open condition which is to be started. There is a possibity of fall due
to conjested area near air blower interconnection valve
Airflow
Disch.attendant/
Disch.Operator
Airflow
Disch.attendant/
Disch.Operator
OK
40-75 Amp
No viberation or abnormal
sound
N
N
Sr. No.
PRE START-UP CHECKS
1
Ensure emergency off switch of specific airblower must be in on condition.
Ensure Air blower area & walkway is cleaned
3
4
1
2
3
Ensure Air Flow indicator is working properly. If there is a doubt in flow indicator
by observing kiln's parameter, then call instrument person to check it.After the
clearance from instrument department if problem remains, then go for further
steps.
CHECKS DURING KILN AIRFOW ADJUSTMENT BY BLOWER DELIVERY &
INTERCONNECTION VALVE OPERATION
First fully open the delivery valve of air blower which is to be started & then
adjust the airflow by increasing or decreasing the delivery valve with proper
communication with the operator/shift incharge.
INPROCESS CHECKS
Monitor process parameter of kiln like air flow and back pressure
Monitor air blower's drive load
Monitor viberation or abnormal sound from the air blower and if found informed
to shift incharge or operator.
Kiln operator
Kiln operator
Disch.attendant/
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : All Star discharger internal jamming removal job

48
Risk level : 1
Back

2.Escorgot
3.Star discharger
5.Pocking Rod
6.Hammer
7.All kiln's bottom bag filter
8.Air Blower
9.Hose pipe for water spray
10.Torch for illumination
11.Spaner
1.Use dust mask, Face shield, safety goggles, Hand gloves & gum boot
4.Please take care while doing hammering or pocking.
Sr. No.
1
2
2-A
Description
PRE START-UP CHECKS
Ensure Star discharger is isolated by stopping kiln's respective Air
blower,Escorgot,carrousal and power off the Star dicharger & locked out and
also close the gas valve of respective kiln
Ensure kiln's discharge apron conveyor is in running condition.
If kiln's discharge apron conveyor is not running, informed to shift incharge or
operator and call the Electrical person.
Ensure no person is doing cleaning or maintenance job near the discharge
apron conveyor and star discharger of specific kiln.
CHECKS DURING STAR DISCHARGER JAMMING REMOVAL
Open the star discharger inlet hopper's window by shift fitter & check inside
jamming of the material with the help of illumination torch. The jamming may be
formed due to the reation of lime kiln bottom dust and leakage of cone sealing
water inside the kiln or it may be in lumps form. While performing this job there
is a possibility of dust & heat exposure to body and also tool may hit to body
part & cause injury.So please take care of it.
5
5-A
If jamming found try to clear it by pocking rod. While performing this job there is
a possibility of dust & heat exposure to body and also tool may hit to body part
& cause injury.So please take care of it.
Then start star discharger in forward or reverse direction with proper
communication between discharge attendant and discharge operator just for
trial purpose.
If star discharger still taking high load, repeat the above procedure till star
discharge load gets normal.
Sometime lumps/jamming does not remove easily by pocking rod. If it happens,

then open the side cover of star discharge with the help of maintenance people
& clean it properly by applying water or pocking rod.
If foreign material found or any damage found inside the star feeder, then
inform maintenance engineer or shift fitter to remove it.
N/A/E
Action By
Push button LOTO
Disch.Operator
DAC is running
Disch.Operator
DAC is not running
Disch.Operator
Working
Disch.Operator
Disch.attendant
Jamming found
Disch.attendant
Jamming found
Disch.attendant
Disch.attendant
Disch.attendant
4-5 Amp
Disch.attendant/
Disch.Operator
> 7 Amp
Disch.attendant/
Disch.Operator
found jamming
Disch.attendant
found
SAMG Area
Engineer
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

48
Risk level : 1
Sr. No.
Description
7
8
1
2
3
After the clearance from Maintenance/Electrial dept. start star discharger for
idle trial & run for 3-5 min.
If idle trial found ok, then close star discharger inlet hopper's window by shift
fitter & open the gas valve, start the Air blower, Escorgot, Carrousal of
respective kiln.
INPROCESS CHECKS
Monitor Star discharger load regularly
If star discharger trip frequently or more than two times then stop it and call
Maintenance or Electrical people to check it.
Rev. Date :
Page
: 2 of 2
N/A/E
Action By
4-5 Amp
SAMG/Electrical
Engineer
4-5 Amp
Disch.Operator
4-5 Amp
Disch.Operator
> 7 Amp
Disch.Operator
80-120 Deg.C
Kiln operator
Action Confirm
Soda Ash/Kiln

CHEMICALS' DIVISION
48

Risk level : 1
Description
Sr. No.
1
2
2-A
3
4
1
2
3
4
5
5-A
6
7
PRE START-UP CHECKS

Ensure kiln's discharge apron conveyor is in running condition.
CHECKS DURING STAR DISCHARGER JAMMING REMOVAL
Open the star discharger inlet hopper's window by shift fitter & check inside
jamming of the material with the help of illumination torch. The jamming may be
If jamming found try to clear it by pocking rod. While performing this job there is
a possibility of dust & heat exposure to body and also tool may hit to body part &
If lumps found then try to break it by pocking rod, while performing this job there
is a possibility of dust & heat exposure to body and also tool may hit to body part
trial purpose.
then open the side cover of star discharge with the help of maintenance people
If foreign material found or any damage found inside the star feeder, then inform
Soda Ash/Kiln
CHEMICALS' DIVISION

48
Risk level : 1
Sr. No.
Description
7
8
After the clearance from Maintenance/Electrial dept. start star discharger for idle
INPROCESS CHECKS
1
2
3

Rev. No. : 00
' DIVISION
Rev. Date :
Page
: 1 of 2
ernal jamming removal job

l : 1
Back
m boot
N/A/E
Action By
Push button LOTO

DAC is running
DAC is not running
Working
N
N
A
N
Disch.Operator
Disch.Operator
Disch.Operator
Disch.Operator
Disch.attendant
Jamming found
Disch.attendant
Jamming found
Disch.attendant
Disch.attendant
Disch.attendant
4-5 Amp
Disch.attendant/
Disch.Operator
> 7 Amp
Disch.attendant/
Disch.Operator
found jamming
Disch.attendant
found
SAMG Area
Engineer
Action Confirm
Rev. No. : 00
' DIVISION
Rev. Date :
Page
: 2 of 2
ernal jamming removal job

l : 1
N/A/E
4-5 Amp
4-5 Amp
Action By
SAMG/Electrical
Engineer
Disch.Operator
Action Confirm
4-5 Amp
> 7 Amp
80-120 Deg.C
N
A
N
Disch.Operator
Disch.Operator
Kiln operator
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 2
TITLE : All Kiln Level Checking Job by Rope or Level Rod

96
Risk level : 2
Back
1.Rope
2.Level Rod
Description
Sr. No.
N/A/E
Action By
Air blower stop & LOTO

done
Disch.Operator/
Kiln top operator
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
PRE START-UP CHECKS

1
2
2-A
Stop respective kiln's Air blower one by one (in case of level to be checked by
rope) & close its gas valve. Also check the direction of air.
job.
Ensure measuring nipple is cleaned & gas should not be coming out from it.
CO/CO2 gas
Kiln top operator
< 100 Deg.C
Kiln top operator
OK
Kiln top operator
condition.
open
Kiln top operator
OK
Kiln top operator
OK
Kiln top operator
In the opposite direction of

air
Kiln top operator
11-14 ft empty from top
Kiln top operator
Air blower start
Disch.Operator

air
Kiln top operator
CHECKS DURING LEVEL MEASUREMENT BY ROPE

1
2
3
Take wet rope with binding proper weight, then take the proper direction(in the
same direction of air) & put the rope into level measuring nipple gradually till it
touch inside material & mark/note down
Pull the rope outside and measure the level.While pulling the rope heat
exposre to body may take place, so please wear heat resistant hand gloves
strictly.
After level measurement open the respective kiln's gas valve & start its
respective air blower one by one.
CHECKS DURING LEVEL MEASUREMENT BY LEVEL ROD
Stand on platform above the level measuring nipple in the opposite direction of
air.
Put the rod into level measuring nipple gradually till it touch inside
material.Dont hold this rod more that 45-60sec. inside as it will become hot.
45-60 sec inside
Kiln top operator
Mark the level on rod and take out from the nipple.Measure the level by
substracting from total height of rod (21 ft.) and again substract 4 ft. as height
between deck and platform.
Kiln top operator
If the level rod does not touch material inside the kiln, then pull it out and check
the kiln level with the help of rope & also stop the kiln's discharge by stopping
respective drives to maintain kiln level.
> 16 ft empty from top
Kiln top operator
3-A
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
TITLE : All Kiln Level Checking Job by Rope or Level Rod

96
Risk level : 2
Sr. No.
Description
When prescribed kiln level achieved, then start the kiln discharge
Rev. Date :
Page
: 2 of 2
N/A/E
Action By
Kiln top operator
Kiln level indicator
Kiln top operator
Kiln top operator
INPROCESS CHECKS
1
Monitor kiln's high and low level indication.It should work properly. If it does not
work properly, then call the instrument person to check it.
Check kiln level in every one hour at kiln top
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
80
Rev. Date :
Page
: 1 of 1
TITLE : All kiln's ring platform cleaning job

Risk level : 2
Back

3. Spade (Shovel)
4. Collecting pan
3.CO meter must be at site and activity must be done if CO is less than 50 ppm
Description
Sr. No.
N/A/E
Action By
Area barrication
company
Mukadam/cleani
ng contactor
Kiln top operator
PRE START-UP CHECKS

1
job.
< 50 ppm
If CO concentration is more then 50 ppm, then leave the job.
> 50 ppm
1-A
company
Mukadam/cleani
ng contactor
Kiln top
operator/Shift
incharge
Kiln top
operator/Disch.
Operator
Contractor's
supervisor
OK
OK
OK
OK
Contractor's
supervisor
Area Cleaned
company
Mukadam/cleani
ng contactor
Structure
Barrication removed
ok
ok
CHECKS DURING KILN'S GASLINE FLOOR AREA CLEANING JOB

1
Shift all the cleaning equipents & other tools at kiln ring platform area. Before
Now collect dust, jamming material (removed from the gas line cleaning) & lime
stone/fuel by spade in the collecting pan & pour it into a specified place and
after that in tractor.While performing this job there is a possibility of dust
exposure to body and tools may hit to body cause cut injury. Also eye irritation
may take place due to dust exposer. While performing this job the person may
fall due to conjested area cause head/cut injury.So please take care of it.
1
2
INPROCESS CHECKS
contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
company
Mukadam/cleani
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
80
Rev. Date :
Page
: 1 of 2
TITLE : All kiln top pressure & temp. checking

Risk level : 2
Back
1.Manometer
2.Tapping cleaning rod
3.Connecting tubes for manometer legs and source
4.Thermometer
Sr. No.
Description
PRE START-UP CHECKS
Ensure kiln checking is completed and no kiln change over during pressure
drop measurement.
There should be no variation in Lean gas suction header.
Ensure measuring nipple is cleaned.
job.
N/A/E
Ok
Kiln operator
Ok
process house
shift engineer
Ok
Kiln operator
< 50 ppm
Kiln top operator
Action By
> 50 ppm
Kiln top operator
< 100 Deg.C
Kiln top operator
OK
Kiln top operator
OK
Kiln top operator
OK
Kiln top operator
Ensure manometer & thermometer is in good condition.
OK
Kiln top operator
OK
Kiln top operator
OK
Kiln operator
OK
Kiln operator
4-A
10
Note down the reading of top pressure & top temp. of individual kiln from DCS
panel.
CHECKS DURING KILN TOP PRESSURE & TEMPERATURE CHECKING
JOB
Clean the measuring nipple by tapping cleaning rod and ensure pressure is
coming at tapping.While performing this job there is a possibility of dust & heat
exposure to body and also person may fall due to conjested area & cause cut
injury/fracture.So please take care of it.
Now for a specfic kiln, connect the manometer tubes to measuring nipple and
after stabilising liquid level in manometer note the difference between high and
low level in manometer leg. Note down the reading & compare with the DCS
data.
If there is a difference between manometer reading & DCS reading, then call
instrument person to rectify the problem.
Not OK
Kiln operator
Now clean the temperature measuring nipple by tapping rod. While performing
this job there is a possibility of dust & heat exposure to body and also person
may fall due to conjested area & cause cut injury/fracture.So please take care
of it.
OK
Kiln operator
Now for a specfic kiln, insert the thermometer to measuring nipple and note
down the temperature reading & compare with the DCS data.
OK
Kiln operator
Not OK
Kiln operator
OK
Kiln operator
2-A
4-A
If there is a difference between thermometer reading & DCS reading, then call
instrument person to rectify the problem.
Similarly repeat above procedure for all kiln's top pressure & temperature
checking.
INPROCESS CHECKS
Ensure top pressure controlling control valve is working properly by operating it

manually by DCS panel.
OK
Kiln operator
Monitor kiln's process parameter strictly
OK
Shift incharge
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
40
Rev. Date :
Page
: 1 of 2
TITLE : All CAC & SF area cleaning job

Risk level : 1
Back
1. Spade (Shovel)
2. Collecting pan
Description
N/A/E
job.
< 50 ppm
> 50 ppm
Sr. No.
Action By
PRE START-UP CHECKS

1
1-A
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
OK
Kiln top operator
OK
Kiln top operator
OK
company
Mukadam/cleani
ng contactor

done
Disch.Operator/
Kiln top operator
OK
company
Mukadam/cleani
ng contactor
Structure
company
Mukadam/cleani
ng contactor
CHECKS DURING KILN'S CAC & SF AREA CLEANING JOB
Collect dust & lime stone/fuel by spade in the collecting pan near the take up
pulley area & pour it into dump pipe/line so that it would collect in the kiln
bottom's dust collecting bin.While performing this job there is a possibility of
dust & heat exposure to body and also hot quick lime may fall on workers. Also
eye irritation may take place due to dust exposer.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
40
Sr. No.
Description
Rev. Date :
Page
: 2 of 2
TITLE : All CAC & SF area cleaning job

Risk level : 1
After cleaning job done, open the gas valve, start its air blower & start kiln's
charging & discharge with proper communication with kiln top operator &
contractor's worker.
N/A/E
Action By

removed
Disch.Operator/
Kiln top operator
ok
company
Mukadam/cleani
ng contactor
INPROCESS CHECKS
1

contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 2
TITLE : All kiln's cone distributor water controlling job

80
Risk level : 2
Back
1. Spaner
2. Tapping cleaning rod
4.While going to kiln top person must register his entry in the Kiln Top Entry Book. .
5.Full body protection suite.
Sr. No.
2-A
Description
N/A/E
Action By

done
Disch.Operator/
Kiln top operator
job.
< 50 ppm
Kiln top operator

> 50 ppm
Kiln top operator
< 100 Deg.C
Kiln top operator
open
Kiln top operator
OK
Kiln top operator
OK
Kiln top operator
OK
Kiln top operator
Channel overflow
Kiln top operator
Channel having less water

flow or empty
Kiln top operator
PRE START-UP CHECKS

condition.

CHECKS DURING KILN'S CONE DISTRIBUTOR WATER CONTROLLING
JOB
Stand on kiln's top deck plate after wearing full body protection suite because
during deck cleaning if laen gas compressor trip, then hot cone sealing water
may spread on body & cause burn injury.
If cone sealing's water outlet channel found overflow, then control the water
intet valve & check. While performing this job there is a possibility of dust
exposure to body. Also eye irritation may take place due to dust exposer. While
performing this job the person may fall due to conjested area And cause head
injury or cut injury or fracture.So please take care of it.
If it is observed that the cone sealing's water outlet channel having less water
flow or found empty, then open the consealing valve more & check. If water is
not coming, then hammer the inlet line slowly slowly to clean it.While
performing this job there is a possibility of dust exposure to body. Also eye
irritation may take place due to dust exposer. While performing this job the
person may fall due to conjested area And cause head injury or cut injury or
fracture.So please take care of it.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 2 of 2

Risk level : 2
64
Sr. No.
Description
If after hammering the inlet line is still jammed, then informed to shift incharge.
Issue safety work permit to clean the cone sealing line as per JSA no.
MTHP/SA/KILN/JSA/014
After controlling water flow or cleaning inlet line, open the gas valve, start its air
blower & start kiln's charging & discharge with proper communication with kiln
top operator & contractor's worker.
N/A/E
Action By
inlet line jammed
Kiln top operator
Ok
Kiln shift
incharge

removed
Disch.Operator/
Kiln top operator
< 100 Deg.C
Kiln top operator
INPROCESS CHECKS
1
Monitor kiln top temperature strictly.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
80
Rev. Date :
Page
: 1 of 1
TITLE : All kiln gas valve platform area cleaning job

Risk level : 2
Back

3. Spade (Shovel)
4. Collecting pan
Description
Sr. No.
N/A/E
Area barrication
Action By
PRE START-UP CHECKS

1
OK
OK
OK
company
Mukadam/cleani
ng contactor
Kiln top
operator/Shift
incharge
Kiln top
operator/Disch.
Operator
Contractor's
supervisor

1
Shift all the cleaning equipents & other tools at gas valve platform area. Before
OK
Contractor's
supervisor
Area Cleaned
company
Mukadam/cleani
ng contactor
Structure
Barrication removed
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
INPROCESS CHECKS
1

contactor
ok
ok
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
B) Equipment's:
Rev. Date :
Page
: 1 of 1
TITLE : All kiln's bagfilter presuure drop checking job

80
Risk level : 2
Back
1.Manometer
Description
Sr. No.
N/A/E
Action By
PRE START-UP CHECKS

1
Ensure Bag filter is working and its dust collecting tanks are empty.
Ok
Kiln operator
Check leakage if any in upstream and downstream of Bag filter.
Ok
process house
shift engineer
Ok
Kiln operator
job.
< 50 ppm
Kiln operator
> 50 ppm
Kiln operator
Kiln top
operator
Kiln top
operator/Disch.
4-A
5
OK
OK
Ensure manometer is in good condition.
OK
Kiln operator
Ensure pressure drop calculation format is ready.
OK
Kiln
operator/Shift
incharge
OK
Kiln operator
OK
OK
OK
N
N
N
Kiln operator
Kiln operator
Kiln operator
OK
Kiln operator
CHECKS DURING KILN PRESSURE DROP CHECKING JOB

1
2
3
4
5
Check suction at Bag filter blower.(Between Blower and Bag filter).Note down
as P1
Check suction at Bag filter.(At Bag house).Note down as P2
Check suction between Bag filter and source.Note down as P3
Check suction at source.Note down as P4
Calculate drop as per given farmulae :
Drop between BF&Blower = P1-P2, Drop across BF= P1-P3,Drop between BF
and source =P3-P4 (all reading are inch. Of WC)
INPROCESS CHECKS
Monitor Bag filter blower load it should be between as per standerd.Standard

load are as per log sheet.
Operat
Shift In chatge
or
Ensure that dust is conteniouly discharging through dicharge pipe and Star
discharger working with normal load (5-7 amp.)
Operat
Shift In chatge
or
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
B) Equipment's:
80
Rev. Date :
Page
: 1 of 1
TITLE : All kiln pressure drop checking

Risk level : 2
Back
1.Manometer
4.While going to kiln top person must register his entry in the Kiln Top Entry Book. ok.
Description
Sr. No.
PRE START-UP CHECKS

drop measurement.
N/A/E
Ok
Kiln operator
Ok
process house
shift engineer
Action By
Ok
Kiln operator
job.
< 50 ppm
Kiln operator
> 50 ppm
Kiln operator
Kiln top
operator
Kiln top
operator
4-A
5
< 100 Deg.C
OK
OK
Kiln operator
OK
Kiln top
operator/Disch.
Kiln operator
Ensure manometer is in good condition.
OK
10
Note down the reading of top pressure of individual kiln from DCS panel.
OK
Kiln operator
11
Ensure pressure drop calculation format is ready.
OK
Kiln
operator/Shift
incharge
CHECKS DURING KILN PRESSURE DROP CHECKING JOB

1
Clean the measuring nipple tapping at Gas line,Scruber gas inlet & outlet and
washer gas inlet & outlet.
OK
Kiln operator
Now for a specfic kiln, connect the manometer tubes to measuring nipple at kiln
top pressure control valve and after stabilising liquid level in manometer note the
difference between high and low level in manometer leg. This will be P1 Inch of
WC. Ensure area is cleaned and check condition of platform and railing is good
before starting the job. While performing this job there is a possibility of dust &
heat exposure to body and also person may fall due to conjested area & cause
cut injury/fracture.So please take care of it
OK
Kiln operator
Now for a specfic kiln, connect the manometer tubes to measuring nipple at
Washer gas inlet tapping and after stabilising liquid level in manometer note the
difference between high and low level in manometer leg. This will be P2 Inch of
WC. Ensure area is cleaned and check condition of platform and railing is good
OK
Kiln operator
Washer gas outlet tapping and after stabilising liquid level in manometer note
the difference between high and low level in manometer leg. This will be P3 Inch
of WC. The same reading will give the Scrubber gas inlet pressure reading.
Ensure area is cleaned and check condition of platform and railing is good
OK
Kiln operator
Scrubber gas outlet before gas valve tapping and after stabilising liquid level in
manometer note the difference between high and low level in manometer leg.
This will be P4 Inch of WC. Ensure area is cleaned and check condition of
platform and railing is good before starting the job. While performing this job
there is a possibility of dust & heat exposure to body and also person may fall
due to conjested area & cause cut injury/fracture.So please take care of it
OK
Kiln operator
Scrubber gas outlet after gas valve tapping and after stabilising liquid level in
OK
Kiln operator
scruber gas outlet tapping (at gas line) and after stabilising liquid level in
OK
Kiln operator
Now calculate pressure drop as per given formulae :

Drop at Washer= P2-P3, Drop at Scruber = P6-P3,
Gas valve=P5-P4, Drop across kiln = P1-P6
OK
Kiln operator
OK
Kiln operator
200-300 gpm
Shift incharge
Drop at
INPROCESS CHECKS
1
Ensure top pressure controlling control valve is working properly by operating it

manually by DCS panel.
Monitor the water flow in individual kiln's washer & scrubber.
Monitor all kilns are working under slightly pressure.
Monitor Polisher tank level and continuous make up water supply into tank.
15-20 mm WC
Shift incharge
Tank level must be

maintained 75-100 %
Shift incharge
Check all kiln's washer & scrubber seal pot. It should not be jammed and water
must be overflow continuously.
OK
Shift incharge
Monitor kiln's process parameter strictly
OK
Shift incharge
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
32
Rev. Date :
Page
: 1 of 1
TITLE : All kiln's gasline floor area cleaning job

Risk level : 1
Back

3. Spade (Shovel)
4. Collecting pan
Description
Sr. No.
N/A/E
Area barrication
Action By
PRE START-UP CHECKS

company
Mukadam/cleani
ng contactor
Kiln top
operator/Shift
incharge
Kiln top
operator/Disch.
Operator
OK
OK
OK
Contractor's
supervisor
Area Cleaned
company
Mukadam/cleani
ng contactor
Structure
Barrication removed
ok
ok

1
Shift all the cleaning equipents & other tools at gas line platform area.
1
2
INPROCESS CHECKS
contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
company
Mukadam/cleani
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : All washer & scrubber pump change over job.

48
Risk level : 1
B) Equipment's: 1.Spaner
2.Both washer pump
3.Both scrubber pump
4.All kiln's washer & scrubber
5.Wheel spaner
1.Use dust mask, safety goggles, Hand gloves & gum boot
3.Ensure no person is doing maintenance job on equipment.
4.Please take care while hammering or operating valve.
Description
Sr. No.
1
PRE START-UP CHECKS

Ensure spare pump is available.
Note down the water flow in individual kiln's washer & scrubber.
Ensure Electric power is available for the pump which is being started
3-A
If power is not available, then call Electrical person

CHECKS DURING WASHER & SCRUBBER PUMP CHANGE OVER JOB
Open suction & vent valve of pump which is being started.While performing
this job the person may fall due to conjested area also tool may slip from the
hand & may hit to body part cause fracture or injury
Switch on the pump which is being started by pressing electric switch
3
4
5
Close the delivery valve 25% of pump (which is going to stop)

Open the delivery valve 25% of pump (which is going to start)
Open the delivery valve 50% of pump & close the vent valve after proper vent
(which is going to start).
N/A/E
Action By
Disch.Operator
Kiln
operator/Shift
incharge
OK
200-300 gpm
Electric power available
Electric power not available
OK
Disch.Operator
Disch.Operator
Electrical
incharge
Power ON
Disch.Operator
95-120 Amp
80-90 Amp
95-110 Amp
N
N
N
Disch.Operator
Disch.Operator
Disch.Operator
95-110 Amp
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
TITLE : All washer & scrubber pump change over job.

48
Risk level : 1
Sr. No.
Description
7
8
9
Close the delivery valve 100% of pump (which is going to stop).
Monitor the water flow in individual kiln's washer & scrubber during pump
change over.
Monitor viberation & abnormal sound from the pump which is going to start &
the pump which is going to stop. If viberation & abnormal sound found,
informed to shift incharge or operator for further action
Back
N/A/E
Action By
75-80 Amp
Disch.Operator
Disch.Operator
Disch.Operator
100-120 Amp
200-300 gpm
Kiln operator
Kiln
operator/Shift
incharge
Viberatio & abnormal sound
Disch.Operator
Open the delivery valve 100% of pump (which is going to start). Be ensure that
100-120 Amp/
seawater flow in each kiln's washer & scrubber is the same as before starting
300 gpm
the job.
Switch off the pump (which is being stopped) by pressing electric switch &
OK
close the suction & delivery valve of pump (which is going to stop)
INPROCESS CHECKS
Monitor washer or scrubber pump load
Rev. Date :
Page
: 2 of 2
200-
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
96
Rev. Date :
Page
: 1 of 2
TITLE : All Ventury pump change over job.

Risk level : 2
Back
1.Spaner
2.Both ventury pump
3.All ventury
4.Wheel spaner
Description
Sr. No.
1
PRE START-UP CHECKS

2-A

CHECKS DURING VENTURY PUMP CHANGE OVER JOB
3
4
5

N/A/E
Action By
OK
Disch.Operator
Disch.Operator
Electrical
incharge
OK
Disch.Operator
Power ON
Disch.Operator
130-140 Amp
105-115 Amp
120-135 Amp
N
N
N
Disch.Operator
Disch.Operator
Disch.Operator
120-135 Amp
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 2 of 2
TITLE : All Ventury pump change over job.

Risk level : 2
96
Sr. No.
Description
N/A/E
Action By
100-105 Amp
Disch.Operator
Open the delivery valve 100% of pump (which is going to start).
140-150 Amp
Disch.Operator
Power off the pump (which is being stopped) by pressing electric switch &
OK
Disch.Operator
140-150 Amp
Kiln operator
Kiln
operator/Shift
incharge
INPROCESS CHECKS
Monitor ventury pump load
Monitor totol water flow to ventury.
1600-2000 gpm
Viberation & abnormal

sound
Disch.Operator
tank level must be

maintained 75-100 %
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
80
Rev. Date :
Page
: 1 of 1
TITLE : All Ventury pressure drop checking job

Risk level : 2
Back
1.Manometer
3.Connecting tubes for manometer legs and source tapping
3.CO meter must be at site and activity must be done if CO is less than 50 ppm.
Sr. No.
Description
PRE START-UP CHECKS
drop measurement.
Desired Condition/Range N/A/E
Action By
Ok
Kiln operator
Ok
process house
shift engineer
Note down the total gas flow at process house and Bicarb, Lean gas and Mix
gas suction header.Inform process house and Kiln shift incharge regarding
this activity.
Ok
kiln shift
incharge
Ok
Kiln operator
Ensure total water flow to ventury is within prescribed limit
1600-2000 gpm
Kiln operator
CHECKS DURING VENTURY PRESSURE DROP CHECKING JOB

1
Clean the gas inlet and outlet tapping of venturi and ensure suction is coming
at tapping.
Pressure drop
Kiln operator
Connect manometer tubes to venturi gas inlet tapping and after stabilising
liquid level in manometer note the difference between high and low level in
manometer leg.This will be P1 Inch of WC
Pressure drop
Kiln operator
Then Connect manometer tubes to venturi gas outlet tapping and after
stabilising liquid level in manometer note the difference between high and low
level in manometer leg.This will be P2 Inch of WC
Pressure drop
Kiln operator
Now calculate difference between P2 and P1 this will give you pressure drop
across venturi in terms of Inch of WC
Pressure drop
Kiln operator
Similarly repeat above procedure for all venturi.
Pressure drop
Kiln operator
1
2
INPROCESS CHECKS
Monitor total water flow rate to ventury
Monitor Venturi pump load.
1600-2000 gpm
145-155 Amp
N
N
Kiln operator
Kiln operator
tank level must be

maintained 75-100 %
Kiln operator
Monitor quality and quantity of ventury outlet water physically.It
should be clear.
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : Lumps removal from S/D inlet & outlet hopper.

84
Risk level : 2
Back

2.Escorgot
3.Star discharger
5.Pocking Rod
6.Hammer
7.All kiln's bottom bag filter
8.Air Blower
11.Spaner
Sr. No.
1
2
2-A
3
4
4
4-A
Description
PRE START-UP CHECKS
blower,Escorgot,carrousal and power off the Star dicharger & locked out and
also close the gas valve of respective kiln
Ensure kiln's discharge apron conveyor is in running condition in case of
Lumps removal from S/D inlet hopper.
operator and call the Electrical person.
N/A/E
Action By
Push button LOTO
Disch.Operator
DAC is running
Disch.Operator
Disch.Operator
DAC is not running
Working
CHECKS DURING LUMPS REMOVAL FROM STAR DISCHARGER INLET
HOPPER
Open the star discharger inlet hopper's window by shift fitter & check lumps
inside with the help of illumination torch.While performing this job there is a
found jamming
possibility of dust & heat exposure to body and also tool may hit to body part &
cause injury.So please take care of it.
4-5 Amp
trial purpose.
> 7 Amp

then open the side cover of stardischarge & clean it properly by applying water
or pocking rod.
If foreign material found or any damage found inside the star discharger, then
Disch.Operator
Disch.attendant
Disch.attendant
Disch.attendant
Disch.attendant
Disch.attendant/
Disch.Operator
Disch.attendant/
Disch.Operator
found jamming
Disch.attendant
found
SAMG Area
Engineer
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
TITLE : Lumps removal from S/D inlet & outlet hopper.

84
Risk level : 2
Sr. No.
Description
Rev. Date :
Page
: 2 of 2
N/A/E
Action By
4-5 Amp
SAMG/Electrical
Engineer
4-5 Amp
Disch.Operator
found jamming
Disch.attendant
After the clearance from Maintenance/Electrial dept. start star discharger for
idle trial & run for 3-5 min.
fitter & open the gas valve, start the Air blower, Escorgot, Carrousal of
respective kiln.
CHECKS DURING LUMPS REMOVAL FROM STAR DISCHARGER OUTLET
HOPPER
If DAC of a specfic kiln indicates high load, then stop Star discharger & DAC &
LOTO done. After that open the star discharger outlet hopper's window by shift
fitter & check lumps inside with the help of illumination torch.While performing
this job there is a possibility of dust & heat exposure to body and also tool may
hit to body part & cause injury.So please take care of it.
Disch.attendant
Disch.attendant

trial purpose.
4-5 Amp
Disch.attendant/
Disch.Operator
After that start DAC. If idle trial found ok, then close star discharger outlet
hopper's window by shift fitter & open the gas valve, start the Air blower,
Escorgot, Carrousal of respective kiln.
4-5 Amp
Disch.attendant/
Disch.Operator
4-5 Amp
Disch.Operator
> 7 Amp
Disch.Operator
80-120 Deg.C
Kiln operator
1
2
3
INPROCESS CHECKS
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : All kiln discharge apron conveyor jamming removal at diverting plate & hopper
64
Risk level : 2
1.
Old
&
New
Main Discharge Apron conveyor
B) Equipment's:
5. All Kiln Discharge Apron Conveyor except LK-4 & LK-5.
6. LK-4 & LK-5 Star discharger
7. Pocking Rod
8. Hammer
9. All kiln bottom bag filter's delivery line's diverting valve
11. Spaner
Back
1.Use dust mask, Face shield, safety goggles, ear plug & heat resistant hand gloves.
4.Please take care while doing hammering or plate diverting job.
Description
Sr. No.
N/A/E
Ready to start
Disch.Operator
Disch.attendant
People doing job
Disch.Operator
Disch.Operator
Lumps
attendant
Action By
PRE START-UP CHECKS

1
Ensure no person is doing cleaning or maintenance job near Main

2-A
3
4
5
6
1
2
If person is doing cleaning job near the discharge system, then stop them
& start the drive after informing them.
Ensure Main discharge apron conveyor to Bottom silo belt's hopper as well
as bottom silo belt to cross silo belt's hopper is cleaned
jamming.
Ensure DAC of two adjacent kiln having the common discharge's diverting
plate must be stopped & LOTO done
CHECKS DURING KILN'S DISCHARGE APRON CONVEYOR JAMMING
REMOVAL AT DIVERTING PLATE & HOPPER
If DAC of a specfic kiln indicates high load, then stop kiln's discharge by
stopping all the related drives & LOTO done for DAC.
First start the spare cross silo belt, then spare bottom silo belt & then
spare main discharge apron conveyor and monitor the idle drive's load for
3-5 min. Also check the interlocking of discharge system.
If there is a problem in the interlocking of the discharge system, then
inform to shift incharge or operator and call the Electrical person.
Working
Hopper clean
pully cleaned
Disch.attendant
DAC stopped
Disch.Operator
> 6 Amp
Disch.attendant
15-20 Amp / 20-25 Amp
Disch.Operator
interlocking fails
Disch.Operator
After that stop all kiln's discharge
All kiln's discharge should

be stopped
Disch.Operator
system one by one as well as change the kiln bottom bag filter's delivery
line's diverting valve strictly.While performing these job there is a

Disch.attendant
4-A
Sometimes diveting plate got jammed so hammer or pocking rod to be

used to remove the jamming, please take care while performing this
job.Tools may hit to the body parts and cause injury.

plate got jammed
Disch.attendant
After that change the interlocking of all kiln's discharge apron conveyor
with the available system by placing the knob of selector switch .
interlocking
Disch.Operator
2-A
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : All kiln discharge apron conveyor jamming removal at diverting plate & hopper
80
Risk level : 2
Sr. No.
Description
N/A/E
Action By
Now start all kiln's discharge one by one except the discharge of two
adjacent kiln which is having the common discharge's diverting plate. DAC
of these two kiln's must be stopped & LOTO done
Discharge started
Disch.Operator
Now open the discharge apron conveyor's outlet window of respective kiln
by the shift fitter & check lumps inside with the help of illumination torch.
Lumps may stuck up in the hopper's outlet or in the diverting plate.While
performing this job there is a possibility of dust & heat exposure to body
and also tool may hit to body part & cause injury.So please take care of it.
found jamming
Disch.attendant
Disch.attendant
Disch.attendant
4-5 Amp
Disch.attendant/
Disch.Operator
15-20 Amp / 20-25 Amp

interlocking
4-5 Amp
N
N
N
Disch.Operator
Disch.Operator
Disch.Operator
80-120 Deg.C
Kiln operator
10
1
2
3
4
there is a possibility of dust & heat exposure to body and also tool may hit
to body part & cause cut injury so please take care of it.
pipe.During this operation lumps may break and heat will generate and
burn injury can happen.So use face shield.Also hot lumps may hit to the
body part.so please take care of it.
After lumps removal, start the discharge of two adjacent kiln which is
having the common discharge's diverting plate with proper communication
between discharge attendant and discharge operator.
INPROCESS CHECKS
Monitor DAC drive's load
Monitor Kiln discharge temp. it should be 80-120 Deg.C.If discharge temp.
is below 80 Deg.C , then there is chance of lumps formation.In such case
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 1
TITLE : Kiln area including all drain channel cleaning

32
Risk level : 1
Back
1. Collecting pan
2. Spade
4. Tractor for collecting material
5. Wheel stopper for tractor
1.Use dust mask, safety goggles, ear plug, gum boot & hand gloves.
Description
Sr. No.
N/A/E
Area barricated
Ok
material cleaned
company
Mukadam/cleani
ng contactor
ok
company
Mukadam/cleani
ng contactor
ok
company
Mukadam/cleani
ng contactor
material gate pass
shift incharge
ok
company
Mukadam/cleani
ng contactor
Action By
PRE START-UP CHECKS

1
Ensure area is barricated with danger tape where the cleaning job is being
done
Ensure walk way and platform are safe and cleaned.
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor

1
First collect the scrap or other material placed above the drain cover into a
collecting pan & dump it into a specified place or in tractor.
Now open the drain covers of drain channel one by one for a specific area
where cleaning to be done. While performing this job there is a possibility of
dust exposure to body and also cut injury due to sharp edge of drain cover &
muscle pull sprain due to heavy weight of drain cover may take place.
After that collect the material placed in the drain channel by spade into a
collecting pan & dump it into a specified place or in tractor.The wheel stopper
must be placed in the tractor's wheel & also its key must be removed & kept
with the tractor's driver.Also tractor's reverse horn must be on while performing
this job.
After that tractor's driver would shift the garbage or material to a suitable
location.For material shifting one material gate pass should be signed by the
shift incharge for one trip at a time & gate pass to be handovered to tractor's
driver.
After that wash the drain channel with sea water completely.While performing
this job there is a possibility that drain channel's surrounding area become
slipery & person doing this cleaning job may slip which would lead to fracture or
injury. So take care of it.
After cleaning of drain channel placed the drain cover over drain channel one
by one.
drain cover provided
When surrounding area near drain's channel becomes dry, de-barricated the
area.
barrication removed
ok
ok
1
2
INPROCESS CHECKS
contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
company
Mukadam/cleani
ng contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 1
TITLE : Kiln Top BF-3 unloading by bulker

Risk level : 2
Back
1. Bluker or Tractor must be available

2. Pocking Rod
3. Hammer
1.Use dust mask, gum boot, safety goggles, ear plug & hand gloves.
3.Ensure escape route is safe ,cleaned and must be known to working person.
Description
Sr. No.
N/A/E
Action By
PRE START-UP CHECKS

Cleaning
contactor
Ensure right position of tractor under the bottom drain valve of cleaning tank.
OK
Ensure cleaning tools must be in good condition & should be in desired angle
shape.
OK
Cleaning
contactor
Ensure surrounding area bag filter is working properly to avoid dust exposure
OK
Disch.Operator
CHECKS DURING KILN TOP BF-3 UNLOADING BY BULKER

First ensure the right position of bulker under the bottam drain valve of bottam
tank & adjust with telescopic spoud properly.
Now open the bottam drain valve & start the bag filter's star dischager from
panel. If material is not sliding, then hammering to be done at the bottom of the
tank. While performing this job there is a possibility of dust exposure to body
and tool may slip & hit to body part & cause injury.So please take care of it.
Also eye irritation may take place due to dust exposer.
If material not sliding after hammering, then first stop the bag filter's star
discharger. Now open the side window plate. While opening the window face
should not be infront of it. First only loose the bolt and if no material is coming
from it, open all bolts except one so that in emergency condition, window can
be closed immediately.
OK
Cleaning
contactor
OK
Cleaning
contactor
OK
Cleaning
contactor
OK
Cleaning
contactor
Now try to clear the jamming by angle shaped pocking rod which having long
handle as shown in attached picture. While pocking dont put face in the
window.There is chances of suddenly sliding of material from tank.
4
After cleaning hopper outlet by pocking rod,close the side window plate & start
the star discharger again.
OK
Cleaning
contactor
Now observe the bulker level from another mainhole with help of cliner &
proper communication for fillup the bulker. Than close the bottam valve &
stardischarge from panel & remove the telescopic spoud properly from bulker.
Jamming found
Cleaning
contactor
When bluker is not available, bag filter unloading will be carried out by tractor
or dumper.
OK
Cleaning
contactor
ok
company
Mukadam/cleani
ng contactor
INPROCESS CHECKS
1

contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 1
TITLE : Lime dust & lumps removal from all place in tractor
48
Risk level : 1
Back
1. Collecting pan
2. Spade
4. Tractor for collecting material
5. Wheel stopper for tractor
1.Use dust mask, safety goggles, ear plug, gum boot & heat resistance hand gloves.
Description
Sr. No.
N/A/E
Area barricated
Ok
Action By
PRE START-UP CHECKS

1
Ensure area is barricated with danger tape where the cleaning job is being
done
Ensure walk way and platform are safe and cleaned.
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
First collect the lime dust from surrounding area by spade into a collecting pan
& dump it into a specified place or in tractor. The wheel stopper must be placed
in the tractor's wheel & also its key must be removed & kept with the tractor's
driver.Also tractor's reverse horn must be on while performing this job.
material cleaned
company
Mukadam/cleani
ng contactor
Now remove all lumps from bottom side area of bottom silo belts with help of
spade & collect the lumps into a collecting pan & dump it into a specified place
or in tractor. The wheel stopper must be placed in the tractor's wheel & also its
key must be removed & kept with the tractor's driver.Also tractor's reverse horn
must be on while performing this job. from surrounding area than collect at one
place.
ok
company
Mukadam/cleani
ng contactor
While performing this job there is a possibility of dust & heat exposure to body
and also quick lime may return from the inclined belt due to lack of friction on
spare belt and also eye irritation may take place due to dust exposer.
Use PPE's
company
Mukadam/cleani
ng contactor
material gate pass
shift incharge
ok
ok
1
2
After that tractor's driver would shift the lime dust or lumps to a suitable
location.For material shifting one material gate pass should be signed by the
shift incharge for one trip at a time & gate pass to be handovered to tractor's
driver.
INPROCESS CHECKS
contactor
company
Mukadam/cleani
company
Mukadam/cleani
ng contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 1
TITLE : Charging system manual operation during DCS failure

80
Risk level : 2
Back

2. Torch for illumination
3. Hammer
4. Pocking rod
Description
N/A/E
Action By
job.
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
Sr. No.
PRE START-UP CHECKS
1
1-A
2
OK
Kiln top operator
OK
Kiln top operator
Ok
Kiln top
operator/PBL
operator

air
Kiln top operator
CHECKS DURING CHARGING SYSTEM MANUAL OPERATION DURING

DCS FAILURE
1
First stop the material charging & stop A1 & AC7 or A2 & AC8 belt with a
proper communication between kiln top operator & PBL operator.
Now check individual kiln level by standing on platform above the level
measuring nipple in the opposite direction of air.
Now start material charging on AC7 or AC8 belt in control rate & with a proper
communication between kiln top operator & PBL operator.
Charging started
Kiln top
operator/PBL
operator
In manual operation give priority in charging to kiln which having low kiln level
& keep diverting plate to a respective charging bin untill bin level maintain 70%
by physical observation with the help of torch.
Charging started
Kiln top operator
Follow this process untill the DCS system get normal.
OK
Kiln top operator
40-70 % filled
Kiln top operator
INPROCESS CHECKS
Monitor individual kiln level regularly
Monitor kiln's high and low level indication.It should work properly. If it does not
work properly, then call the instrument person to check it.
35-60 Amp/ 20-35 Amp
Kiln top operator
11-14 ft empty from the top
Kiln top operator
Kiln level indicator
Kiln top operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : Lumps removal from cross silo belt outlet hopper.

64
Risk level : 2
1.
Old
&
New
Main
Discharge
Apron conveyor
B) Equipment's:
5. Pocking Rod
6. Collecting pan
8. Hammer
10. If required hose pipe for water spray.
11. Spaner
3.Ensure no person is doing maintenance job near MDAC, Bottom silo belt & Cross silo belt.
Description
Sr. No.
N/A/E
Action By
PRE START-UP CHECKS

1

2-A
3
All Kiln's bottom bag filters must be working to avoid dust exposer.
Ready to start
Disch.Operator
Disch.attendant
People doing job
Disch.Operator
Working
Disch.Operator
LOTO DONE &

1520 Amp / 20-25 Amp
Disch.Operator
CHECKS DURING LUMPS REMOVAL FROM CROSS SILO BELT'S OUTLET

HOPPER
1-A
2
2-A
If the running Cross Silo Belt or Bottom Silo Belt indicates indicates high load,
then first stop the running discharge system immediately & LOTO to be done
for this system. After that start the spare cross silo belt, then spare bottom silo
belt & then spare main discharge apron conveyor and monitor the idle drive's
load for 1-2 min. Also check the interlocking of spare discharge system.
by one.
interlocking fails
Disch.Operator

Disch.attendant

plate got jammed
Disch.attendant
Discharge started
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
TITLE : Lumps removal from cross silo belt outlet hopper.

80
Risk level : 2
Sr. No.
Description
4
5
Now open the window of previously working Cross silo belt's outlet hopper by
shift fitter for checking inside lumps or jamming.
7-A
If Cross Silo Belt or Bottom Silo Belt still indicates high load, repeat the above
8
9
10
1
2
3
If idle trial found ok, then run the previous working discharge system for 10-15
min in idle condition so that the material will be emptied out & it will be
available.
INPROCESS CHECKS
Rev. Date :
Page
: 2 of 2
N/A/E
Action By
LOTO
Disch.Operator
Disch.attendant
Disch.attendant
15-20 Amp / 20-25 Amp
Disch.attendant/
Disch.Operator
> 20 amp / > 25 amp
Disch.attendant/
Disch.Operator
found
SAMG Area
Engineer
15-20 Amp / 20-25 Amp
SAMG Engineer
15-20 Amp / 20-25 Amp
Disch.Operator
15-20 Amp / 20-25 Amp

interlocking
N
N
Disch.Operator
Disch.Operator
80-120 Deg.C
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
Rev. Date :
Page
: 1 of 2
TITLE : Removel of foreign material from MDAC & Bottom silo belt.
64
Risk level : 2

5. Pocking Rod
7. Hammer
9. Spaner
3.Ensure no person is doing maintenance job near MDAC, Bottom silo belt & Cross silo belt.
Description
Sr. No.
N/A/E
Action By
Ready to start
Disch.Operator
Disch.attendant
People doing job
Disch.Operator
Working
Disch.Operator
LOTO DONE &

1520 Amp / 20-25 Amp
Disch.Operator
interlocking fails
Disch.Operator
PRE START-UP CHECKS

1

2-A
3
1-A
CHECKS DURING FOREIGN MATERIAL REMOVAL FROM MDAC &
BOTTOM SILO BELT
If the running Bottom Silo Belt or MDAC indicates high load, then first stop the
running discharge system immediately by push button or by operating pull
chord & LOTO to be done for this system. After that start the spare cross silo
belt, then spare bottom silo belt & then spare main discharge apron conveyor
and monitor the idle drive's load for 1-2 min. Also check the interlocking of
spare discharge system.

Disch.attendant
2-A


plate got jammed
Disch.attendant
by one.
Discharge started
Disch.Operator
If foreign material found or any damage found on MDAC or Bottom Silo Belt,
then removed it or informed to maintenance engineer or shift fitter in case of
equipment damage.
foreign material found
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 2 of 2
TITLE : Removel of foreign material from MDAC & Bottom silo belt.
64
Risk level : 2
Description
N/A/E
Action By
If it is observed that foreign material got stuck up into the outlet hopper of
MDAC or Bottom Silo Belt, then open the outlet hopper's window of previously
working MDAC or Bottom Silo Belt & inform to maintenance engineer or shift
fitter to remove it.
foreign material found
Disch.attendant/
Disch.Operator
15-20 Amp / 20-25 Amp
SAMG Engineer
If idle trial found ok, then close the outlet hopper's window & run the previous
working discharge system for 10-15 min in idle condition so that the material
will be emptied out & it will be available.
15-20 Amp / 20-25 Amp
Disch.Operator
15-20 Amp / 20-25 Amp

interlocking
80-120 Deg.C
N
N
N
Disch.Operator
Disch.Operator
Kiln operator
Sr. No.
1
2
3
INPROCESS CHECKS
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : All cone disrtibuter inspection window cleaning job

80
Risk level : 2
Back

B) Equipment's: 1.Star feeder
3.Pocking Rod
4.Hammer
5.kiln Top bag filter
6.Air Blower
8.Spaner
1.Use CO canister mask, face shield, safety goggles, ear plug heat resistant hand gloves.
3.Ensure no person is doing maintenance job near cone distributor of specific kiln.
Sr. No.
1
2
2-A
Description
PRE START-UP CHECKS
Ensure Star feeder is isolated by stopping kiln's respective Air blower, Charging
apron conveyor and power off the Star feeder & LOTO done.Also close the gas
valve of respective kiln.
job.
N/A/E
Action By
Push button LOTO
Kiln Top
operator
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
Working
Kiln Top
operator
Kiln Top
operator
All Kiln's Top bag filters must be working to avoid dust exposer
Ensure no person is doing maintenance job near cone distributor of specific

kiln.
< 100 Deg.C
Kiln top operator
OK
Kiln top operator
Kiln top
operator/Disch.
Operator
CHECKS DURING CLEANING JOB FROM STAR FEEDER OUTLET

HOPPER
If Star feeder of a specfic kiln indicates high load, then stop CAC, Star feeder,
Cone distributor & Air blower of respective kiln & LOTO done. Now open the
cone distributor's inspection window by shift fitter & check jamming inside with
the help of illumination torch.While performing this job there is a possibility of
jamming found &
suction
dust & heat exposure to body and also tool may hit to body part & cause
-1 to -3 mm WC
injury.So please take care of it. if CO2/CO is coming from the hopper's window,
then adjust gas valve of respective kiln so that the kiln will work under slight
suction.
If jamming found then try to break it by pocking rod, while performing this job
Remove jamming
Kiln top operator
If jamming found hard then carefully spray water on it with the hose pipe.During
this operation heat will generate and burn injury can happen.So use face
shield.Also hot limestone/jamming may hit to the body part.so please take care
of it.
Remove jamming
Kiln top operator
If jamming removed, then start cone distributor & star feeder with proper
communication between kiln top operator just for trial purpose.
4-6 Amp
Kiln top operator
4-A
5
6
7
If star feeder still taking high load, repeat the above procedure till star feeder
load gets normal.
Sometime jamming does not remove easily by pocking rod. If it happens, then
open the side cover of star feeder with the help of maintenance person & clean
If foreign material found or any damage found inside the cone distributor, then
After the clearance from Maintenance/Electrial dept. start cone distributor &
star feeder for idle trial & run for 3-5 min.
> 7 Amp
Kiln top operator
found jamming
Kiln top operator
found
SAMG Area
Engineer
4-5 Amp
SAMG/Electrical
Engineer
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
TITLE : All cone disrtibuter inspection window cleaning job

80
Risk level : 2
Sr. No.
Description
8
8-A
If idle trial found ok, then open the gas valve & start the Air blower, Charging
apron conveyor of respective kiln.
During the cleaning job, Check the kiln level also and if it is found below the
prescribed limit, then stop the kiln discharge to maintain the kiln level.
Rev. Date :
Page
: 2 of 2
N/A/E
Action By
4-5 Amp
Kiln top operator
Disch.Operator
4-5 Amp
Kiln top operator
> 7 Amp
Kiln top operator
suction -1 to -3 mm WC
Disch.Operator
INPROCESS CHECKS
1
2
3
Monitor Star feeder load regularly

If star feeder trip frequently or more than two times then stop it and call
Ensure respective kiln is in under slightly suction only so that total kiln gas
quality will not decrease rapidly.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 2
TITLE : All kiln star feeder inlet & outlet hopper cleaning
80
Risk level : 2
Back
B) Equipment's:
1.Star feeder
3.Pocking Rod
4.Hammer
6.Air Blower
8.Spaner
1.Use CO canister mask, face shield, safety goggles, ear plug heat resistant hand gloves.
3.Ensure no person is doing maintenance job near cone distributor of specific kiln.
Description
N/A/E
Action By
Push button LOTO
Kiln Top
operator
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
Ensure kiln's cone distributor is in running condition in case of cleaning job to

be done for star feeder inlet hopper.
CAC is running
Kiln Top
operator
3-A
If kiln's cone distributor is not running, informed to shift incharge or operator

and call the Maintenance or Electrical person.
CAC is not running
Kiln Top
operator
Working
Sr. No.
1
2
2-A
PRE START-UP CHECKS

Ensure Star feeder is isolated by stopping kiln's respective Air blower, Charging
apron conveyor and power off the Star feeder & LOTO done.Also close the gas
valve of respective kiln.
job.
Kiln Top
operator
Kiln Top
operator
Ensure no person is doing maintenance job near cone distributor of specific

kiln.
< 100 Deg.C
Kiln top operator
OK
Kiln top operator
CHECKS DURING CLEANING JOB FROM STAR FEEDER INLET HOPPER

1
If CAC of a respective kiln is taking high load, then stop the kiln's respective Air
blower, Charging apron conveyor, Star feeder & LOTO done
LOTO done
Kiln top
operator/Disch.
Operator
Now open the star feeder inlet hopper's window by shift fitter & check jamming
inside with the help of illumination torch.While performing this job there is a
possibility of dust & heat exposure to body and also tool may hit to body part &
cause injury.So please take care of it. if CO2/CO is coming from the hopper's
window, then adjust gas valve of respective kiln so that the kiln will work under
slight suction.
jamming found &

suction
-1 to -3 mm WC
Kiln top
operator/Disch.
Operator
Remove jamming
Kiln top operator
of it.
Remove jamming
Kiln top operator
Then start star feeder in forward or reverse direction with proper communication
between kiln top operator just for trial purpose.
4-6 Amp
Kiln top operator
load gets normal.
> 7 Amp
Kiln top operator
found jamming
Kiln top operator
found
SAMG Area
Engineer
5-A
it properly by applying water or pocking rod.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
TITLE : All kiln star feeder inlet & outlet hopper cleaning
80
Risk level : 2
Sr. No.
Description
8
9
9-A
After the clearance from Maintenance/Electrial dept. start star feeder for idle
4-5 Amp
4-5 Amp
CHECKS DURING CLEANING JOB FROM STAR FEEDER OUTLET
HOPPER
If Star feeder of a specfic kiln indicates high load, then stop CAC, Star feeder,
Cone distributor & Air blower of respective kiln & LOTO done. Now open the
star feeder outlet hopper's window by shift fitter & check jamming inside with
jamming found &
suction
dust & heat exposure to body and also tool may hit to body part & cause
-1 to -3 mm WC
injury.So please take care of it. if CO2/CO is coming from the hopper's window,
then adjust gas valve of respective kiln so that the kiln will work under slight
suction.
Rev. Date :
Page
: 2 of 2
N/A/E
Action By
SAMG/Electrical
Engineer
Kiln top operator
Disch.Operator
Kiln top
operator/Disch.
Operator
Remove jamming
Kiln top operator
of it.
Remove jamming
Kiln top operator
Then start star feeder in forward or reverse direction with proper communication
between kiln top operator just for trial purpose.
4-6 Amp
Kiln top operator
4-A
5
6
7
8
8-A
load gets normal.
After the clearance from Maintenance/Electrial dept. start star feeder for idle
> 7 Amp
Kiln top operator
found jamming
Kiln top operator
found
4-5 Amp
SAMG Area
Engineer
SAMG/Electrical
Engineer
4-5 Amp
Kiln top operator
Disch.Operator
4-5 Amp
Kiln top operator
> 7 Amp
Kiln top operator
suction -1 to -3 mm WC
Disch.Operator
INPROCESS CHECKS
1
2
3
Monitor Star feeder load regularly

If star feeder trip frequently or more than two times then stop it and call
Ensure respective kiln is in under slightly suction only so that total kiln gas
quality will not decrease rapidly.
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 1
TITLE : All kiln charging bin (bottom) hammering job

64
Risk level : 2
B) Equipment's: 1.Charging Apron Conveyor
2.Star feeder
3.Cone distributor
4.Pocking Rod
5.Hammer
Back
1.Use CO canister mask, safety goggles, ear plug heat resistant hand gloves.
Description
Sr. No.
1
1-A
PRE START-UP CHECKS

job.
Ensure respective kiln's cone distributor, star feeder & CAC is in running
condition.
N/A/E
Action By
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
Ok
Working
OK
Kiln top operator
Kiln Top
operator
Kiln Top
operator
CHECKS DURING KILN CHARGING BIN HAMMERING JOB
If material placed in the charing bin does not slide to charging bin, then
hammering to be done with hammer or pocking rod. While performing this job
there is a possibility of dust exposure to body and also tool may slip from the
Ok
Kiln top
operator/Disch.
Operator
When material starts sliding to CAC, then stop the activity
Ok
Kiln top operator
4-6 Amp
Kiln top operator
40-70 % fill
Kiln top operator
INPROCESS CHECKS
1
Monitor Charging apron conveyor's drive load.
Monitor Charging bin level
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 1
TITLE : All Diverting plate & hopper cleaning due to jamming in rainy season
64
Risk level : 2
2. Pocking Rod
3. Hammer
4. All kiln's top bag filter
5. Spade
7. Collecting pan
Back
1.Use CO canister mask, ear plug, safety goggles, gum boot & hand gloves.
Description
N/A/E
Action By
job.
< 50 ppm
Kiln top operator
> 50 ppm
Kiln top operator
Sr. No.
PRE START-UP CHECKS
1
1-A
2
OK
Kiln top operator
OK
Kiln top operator
LOTO done
Kiln top
operator/PBL
operator
Jamming found
Kiln top operator
CHECKS DURING KILN'S CHARGING BIN DIVERTING PLATE & HOPPER

CLEANING JOB DUE TO JAMMING IN RAINY SEASON
1
near by related supports.If required stop charging & also stop AC-7/AC-8 belt
with proper communication between PBL & KILN top operator & LOTO done
Now check respective kiln charging bin's diverting plate with the help of torch. If
jamming found try to clear it with the help of pocking rod/hammer or spade &
collect the material in the collecting pan & pour it into dump pipe/line so that it
would collect in the kiln bottom's dust collecting bin. While performing this job
body part & cause injury.So please take care of it.
Also check whether there is a gap between charging bin's diverting plate or not, Charging bin diverting plate
check hole in the charging bin's diverting plate or any other damage.
checked
Kiln top operator

checked
Kiln top operator
After removing jamming, remove LOTO of AC-7/AC-8 belt if done & start the
material charging on AC7/AC8 belt with a proper communication between kiln
top operator & PBL operator
OK
Kiln top
operator/PBL
operator
OK
Kiln top
operator/Shift
incharge
INPROCESS CHECKS
1
Monitor no one start AC-7/AC-8 charging belt during checking strictly
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 1 of 1
TITLE : Gas quality checking job at ventury outlet & compressor inlet/outlet
48
Risk level : 1
B) Equipment's:
Back
1.Orsat apparatus
2.Small Vaccum pump
1.Use dust mask, safety goggles, ear plug & hand gloves.
4.Apparatus may fall & glass may hit to body & cause cut injury.
Description
Sr. No.
PRE START-UP CHECKS

drop measurement.
Desired Condition/Range N/A/E
Ok
Action By
Kiln operator
Ok
process house
shift incharge
Note down the total gas flow at process house and Bicarb, Lean gas and Mix
gas suction header.Inform process house and Kiln shift incharge regarding
this activity.
Ok
kiln shift
incharge
Ok
11-14 ft empty from the

top
Central lab
tester
Kiln Top
operator
Kiln Top
operator
Kiln operator
kiln shift
incharge
kiln shift
incharge/Electri
cal Engineer
kiln shift
incharge/Electri
cal Engineer
Ensure all kiln level is within prescribed limit.
Ensure kiln top temperature is within prescribed limit.
100-150 Deg.C
Ensure All kilns are working under slightly pressure.
15-20 mm WC
Ensure mobile vacuum pump is available at site.
Ok
Ensure electric extension board is available at site for power supply to mobile
vaccum pump.
Ok
10
Ensure electric power is available for vacuum pump
Ok
Ok
Central lab
tester
CHECKS DURING GAS QUALITY CHECKING JOB DURING VENTURY

INLET & COMPRESSOR INLET/OUTLET
1
Clean tapping of ventury gas outlet and ensure suction is coming at tapping.
Now connect one end of vacuum pump to Ventury gas outlet's tapping & other
end to Orsat apparatus & check Kiln gas quality.
37- 40% CO2
Central lab
tester
Now connect one end of vacuum pump to Compressor gas inlet's tapping &
other end to Orsat apparatus & check Kiln gas quality.
37- 40% CO2
Central lab
tester
Now connect one end of vacuum pump to Compressor gas outlet's tapping &
other end to Orsat apparatus & check Kiln gas quality.
37- 40% CO2
Central lab
tester
INPROCESS CHECKS
1
Moniter kiln's individual & total gas quality on DCS. If any deviation found, call
the instrument person to attend it immediately.
37- 40% CO2
Kiln
operator/shift
incharge
There is a possibility of Orsat apparatus sample tube leakage/damage. In this

case attend it immediately
Orsat apparatus should

be ok
Central lab
tester
Adjust the air flow if it found too excess. Excess air flow can be identified by
checking % O2. It should be 0.5 to 1.0 % O2.
< 37% CO2
Kiln operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 1
TITLE : Kiln de-arching job.

Risk level : 2
Back
1.Lime Kiln
2.CAC
3.Star Feeder
4.Cone Distributer
5.Escargot
6.Carrousal
7.Star Discharger
8.DAC
9.Air blower
1.Use CO canister mask, safety goggles, heat resistance hand gloves & gum boot
3.Ensure no person is inside the kiln.
Description
N/A/E
Action By
Ensure kiln must be isolated by slip blank in scrubber gas outlet to gas header.
OK
Shift incharge/
Kiln operator
OK
Shift incharge/
instrument
engineer
Fuse removed & LOTO done
Shift incharge/
Electrical
engineer
40-50 Deg.C
Disch.Operator
OK
Shift incharge/
Kiln operator
Sr. No.
PRE START-UP CHECKS
1
Ensure rediation source of adjecent kiln must be removed and isolated.

2
Ensure kiln's top drives & air blower must be de-energised and LOTO done.
The temperature of kiln top must be brought down to 40 - 50 Deg.C by blowing

air inside lime kiln and kiln shell temp. must be 40 Deg.C
5
6
Ensure 30" dia. De-arching window (both) & offtake window must be opened at
kiln top.
Ensure safety belt must be used while inspection of arching.
OK
Ensure pedestal fan and flood light must be connected to a ELCB and Fan
must be covered with net.
OK
Ensure area near de-arching window and ring platform must be cleaned.
OK
Ensure walk way near de-arching window must be provided with side railling
and net.
OK
10
Ensure hose pipe is leak proof and standard fittings and connection must be
done.
OK
Electrical
engineer
company
Mukadam/cleani
ng contactor
Maintenance
engineer/
Cleaning
contractor
company
Mukadam/cleani
ng contactor
CHECKS DURING KILN EMPTYING ACTIVITY FOR DE-ARCHING JOB

1
When kiln has emptied out, open both the de-arching window & Check the
extent of arching in the kiln.
OK
company
Mukadam/cleani
ng contactor
After inspection of arching, spray water properly on arching inside the kiln from
de arching window. After that de-arching windows must be closed and bolted by
the responsible person in the team. While performing this job there is a
possibility of dust & heat exposure to body.
OK
Kiln top operator
Now start air blower in the kiln for approx. 2-3 hrs after energisation of it. While
air blowing is on ensure no person is standing near de-acrhing window and on
ring platform.
OK
Disch.Operator
Now stop the airblower & LOTO to be done. Than remove the material from
bottom side by starting discharge system of kiln. Be ensure due to powdery
material discharge system can be overload & dust exposure may occur during
this operation.
LOTO DONE
Kiln operator
Again repetition of dearching job sequence till removal all arching inside kiln &
removal material from bottam side of kiln with discharge system in control.
OK
Kiln operator/
contractor
person
OK
OK
N
N
Kiln operator
Kiln operator
1
2
INPROCESS CHECKS
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 2
TITLE : Kiln emptying activity for de-arching job

Risk level : 2
Back
1.Lime Kiln
2.CAC
3.Star Feeder
4.Cone Distributer
5.Escargot
6.Carrousal
7.Star Discharger
8.DAC
9.Air blower
4.Ensure CO meter is available while working at Kiln top as during emptying CO gas concentration will increase.
Description
Sr. No.
N/A/E
Action By
OK
Shift incharge/
sectional
incharge
PRE START-UP CHECKS

1
Inform all the concern persons like PBL operator, Kiln top operator, Kiln
operator etc. about kiln to be emptied out.
CHECKS DURING KILN EMPTYING ACTIVITY FOR DE-ARCHING JOB
Stop charging the kiln.
OK
Kiln top operator
Take 20 T only lime stone in charging bin.
OK
Kiln top operator
Charge lime stone gradually only to bring down the top temperature. Charge 15 20 T lime stone to maintain the top temperature
50-60 Deg.C
Kiln top operator
Check the gas quality in every two hours. When CO2 gas quality reach at 34%,
open the top pressure control & manually valve fully open & control the gas
valve to maintain kiln top presssure.
OK
Kiln operator
After 6-12 hrs. of discharging, when CO2 gas reach at 30% stop discharge &
also its air blower, close the gas valve & cutoff the gas line by providing slip
blank at scrubber outlet gas line, then open 30"dia manhole at kiln top. Be
ensure communication must be proper with processhouse & kiln shift in charge.
OK
Kiln operator/
contractor
person
Now again start air blower and start discharge. As the kiln gets emptied out
blower load will increases so reduce the blower delivery valve accordingly &
maintain blower load 70 - 75 amps.
OK
Disch.Operator
Monitor the back pressure of the Kiln when it becomes zero, stop the blower,
escargot & carrousal and open the kiln's door to ensure that kiln is emptied out.
OK
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 2 of 2
TITLE : Kiln emptying activity for de-arching job

Risk level : 2
64
Sr. No.
Description
N/A/E
Action By
Close the door and start escargot, carrousal & air blower with 65 amp load and
keep it working for 24 hrs to cool the kiln & maintain top temp. within prescribed
limit
50-60 Deg.C
Disch.Operator
If top temp. is more than the prescribed limit, then continue the cooling by air
blower untill top temp. reached the desired value
> 70 Deg.C
Disch.Operator
Stop sea water to washer & scrubber.
OK
Disch.Operator
1
2
INPROCESS CHECKS
OK
OK
N
N
Kiln operator
Kiln operator
8-A
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
80
Rev. Date :
Page
: 1 of 1
TITLE : Leveling of kiln cone distributor

Risk level : 1
Back
1.Lime Kiln
2.CAC
3.Star Feeder
4.Cone Distributer
5.Escargot
6.Carrousal
7.Star Discharger
8.DAC
9.Air blower
Description
Sr. No.
N/A/E
Action By
PRE START-UP CHECKS

Shift incharge/
sectional
incharge
Instrument
engineer
Electrical
engineer
company
Mukadam/cleani
ng contactor
Maintenance
engineer/
Cleaning
contractor
Ensure kiln's top drives, bottom drives & air blower is isolated from process,
maintenance, electrical side.
fuse removed & LOTO done
Ensure nucleonic source of respective as well as adjacent kiln is removed &

isolated.
OK
Ensure pedestal fan and flood light must be connected to a ELCB and Fan
must be covered with net.
OK
Ensure area near de-arching window and ring platform must be cleaned.
OK
Ensure walk way near de-arching window must be provided with side railling
and net.
OK
OK
kiln top operator
Ensure cone sealing water is stopped.
OK
Kiln top operator
Ensure safe approch provided by providing fixed ladder to enter inside kiln.
OK
Checklist and procedure for confined space entry must be followed.
OK
10
Ensure instrument cylinder is provided for diverting plate's of charging bin of

respective kiln.
OK
Instrument
engineer
company
Mukadam/cleani
ng contactor
Shift incharge/
kiln operator
Shift incharge/
sectional
incharge
CHECKS DURING LEVELING OF CONE DISTRIBUTOR

1
After completing stacking of wood & lime stone inside the kiln, close both kiln's
door.
OK
Now Insert the fuse of following kiln top drives. Cone distributor, Star feeder &
Charging apron conveyor
OK
Now charge 4 ton coke only in the kiln.
OK
After that charge 24 ton Lime stone only in the kiln.
OK
After that charge 70 ton of Lime stone with 2 % higher than normal ratio of
coke.
OK
After that charge 70 ton of Lime stone with 1 % higher than normal ratio of
coke.
OK
Now charge 210 Tones of Lime stone with normal coke ratio.
OK
Then open the de-arching or inspection windows. Now after removing the net
check the kiln level from de-arching window .
Ok
Before entering in the kiln ensure level should be 12-15 ft.empty from
inspection window.
Ok
9-A
If kiln level is more than the prescribed limit, then close the de-arching window
& start the top drive to maintain the desired kiln level
10
Now provide ladder inside the kiln from the de-arching window. Before entering
in the kiln ensure that ladder is fixed with the support.
Ok
11
Now levelling inside the lime kiln by using spike and shovel.Leveling should be
horizhontal and equal at all sides of kiln
Ok
12
After leveling, close the de-arching window & start kiln top drives after fuse
insertisation. Now start charging of the kiln.
Ok
13
Now again remove the fuse of top drives & open the de-arching window.Now
Inspect the level distribution in the kiln after charging .Equal level should be at
all four side of kiln.
Ok
14
Inspection of level distribution in the kiln during charging from inspection

window.Charging material should not go toward off take of kiln
Ok
15
If improper distribution observed then cut cone distributer outlet hopper and
check required distribution.and set the level by trial and error method.
Ok
> 17 ft empty from the

arching window
de-
Kiln top
operator/PBL
operator
Kiln top
operator/PBL
operator
Kiln top
operator/PBL
operator
Kiln top
operator/PBL
operator
Kiln top
operator/PBL
operator
Kiln top
operator/PBL
operator
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
kiln top operator
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Action Confirm
16
Repeat the Job sequence till the required cup shape of lime stone distribution
is formed
INPROCESS CHECKS
This activity must be done in the presence of authorised person only & person
must be trained and one supervisor must stand all the time during course of
slow firing
Monitor cone distributor load.
Ok
company
Mukadam/cleani
ng contactor
Ok
Shift incharge/
sectional
incharge
4-5 Amp
kiln top operator
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
96
Rev. Date :
Page
: 1 of 1
TITLE : Stacking of wood and limestone in lime kiln

Risk level : 2
Back
1.Lime Kiln
2.CAC
3.Star Feeder
4.Cone Distributer
5.Escargot
6.Carrousal
7.Star Discharger
8.DAC
9.Air blower
5.Ensure no heat/fire source is present near diesel oil cane.
Description
Sr. No.
N/A/E
Action By
PRE START-UP CHECKS

Shift incharge/
sectional
incharge
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Shift incharge/
sectional
incharge
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
OK
Lock the door in open condition by chain and key must be with responsible
person.
Ok
Make auxiliary arrangement of wood & fire bricks at site.
Ok
Scaffolding to be provided from ground floor to Kiln door & it should be certified
by authorised person.
OK
Ensure Escargot fixed plate is cleaned
Ok
Ensure kiln walkway is cleaned.
Ok
Ensure no cleaning activity is going on at kiln top so that dust or lime stone
would not fall on working person at kiln discharge area
Ok
Ensure kiln's bottom bag filter is working to avoid dust exposue
OK
Disch.Operator
Ensure flood light to be provided inside the kiln & it should be connected to a
ELCB.
OK
Shift
incharge/Electri
cal engineer
10
Ensure cone sealing water is stopped during slow firing job
OK
Kiln top operator
11
Ensurev Net has been provided inside the kiln so that if brick lining break, it
would not damage stacking
OK
Civil dept.
12
Fire extingusher,Sand bucket and water hose pipe should be ready at site.
OK
Shift incharge/
Kiln operator
13
Ensure nucleonic source of kiln is removed & isolated.
OK
Instrument
engineer
Ok
company
Mukadam/cleani
ng contactor
Ok
company
Mukadam/cleani
ng contactor
CHECKS DURING STACKING OF WOOD & LIMESTONE IN KILN

After providing scaffolding, shift fire bricks & wood to the site with the help of
scaffolding. Person standing on scaffolding must wear safety belt while doing
the job.
Now Marking to be done on Escargot by chalk into eight segment as shown in
figure:
8
3
5
Stack flat type Lime stone at marking No. 1, 3, 5 and 7 upped the top cap of
escargot
Ok
Stack Oil coated fire wood at marking No. 2, 4, 6
Ok
Keep the portion of marking No. 8 opened for wood stacking into the kilns upto
9' to 10' ft height from the Escargot.
Ok
After stacking the wood upto 9'-10' ft height, fill up portion No. 8 with oil coated
wood at last after removing of men from inside.
Ok
When stacking completed, inform to shift in-charge/sectional in-charge
Ok
Ok
Ok
INPROCESS CHECKS
slow firing
While handing over wooden piece ensure sharp edges should not injured coworker body part.
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Shift incharge/
sectional
incharge
company
Mukadam/cleani
ng contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
64
Rev. Date :
Page
: 1 of 1
TITLE : Kiln slow firing job

Risk level : 2
Back
1.Lime Kiln
2.CAC
3.Star Feeder
4.Cone Distributer
5.Escargot
6.Carrousal
7.Star Discharger
8.DAC
9.Air blower
10.Ignition equipment
5.Ensure no heat/fire source is present near diesel oil cane.
6.Person must wear fire protection suite while firing and adding wood pieces inside the kiln.
Description
Sr. No.
N/A/E
Action By
PRE START-UP CHECKS

Shift incharge/
sectional
incharge
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Shift incharge/
sectional
incharge
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
OK
Lock the door in open condition by chain and key must be with responsible
person.
Ok
Make auxiliary arrangement of wood & lime stone at site.
Ok
Scaffolding to be provided from ground floor to Kiln door & it should be certified
by authorised person.
OK
Ensure Escargot fixed plate is cleaned
Ok
Ensure kiln walkway is cleaned.
Ok
Ensure no cleaning activity is going on at kiln top so that dust or lime stone
would not fall on working person at kiln discharge area
Ok
Ensure kiln's bottom bag filter is working to avoid dust exposue
OK
Disch.Operator
Ensure flood light to be provided inside the kiln & it should be connected to a
ELCB.
OK
Shift
incharge/Electri
cal engineer
10
Ensure cone sealing water is stopped during slow firing job
OK
Kiln top operator
11
Ensure kiln top both chimney valve is in open condition.
OK
Kiln top operator
12
Ensure 30" dia. De-arching window (both), manhole & offtake window must be
in closed condition.
OK
Shift incharge/
Kiln operator
13
Ensure thermoclouple provided to chimey for continious monitering of top temp.
OK
Shift incharge/
Kiln operator
14
Fire extingusher,Sand bucket and water hose pipe should be ready at site.
OK
Shift incharge/
Kiln operator
15
Ensure nucleonic source of kiln is removed & isolated.
OK
Instrument
engineer
Ok
CHECKS DURING KILN SLOW FIRING JOB

After providing scaffolding, shift fire bricks & lime stone to the site with the help
of scaffolding. Person standing on scaffolding must wear safety belt while
doing the job.
Now Shifting and laying of fire bricks on escargot fix plate.
Ok
Now stack the wood inside lime kiln. The wood should be stacked by two
person on the escargot table under the supervision of trained & experienced
person.
Ok
Now after completing stacking, spray diesel over wood carefully.
Ok
100-150 Deg.C
Ok
1
2
INPROCESS CHECKS
Monitor kiln top temperature regularly.
slow firing
Person must wear fire protection suite while firing and adding wood pieces
inside the kiln.
Ok
While handing over wooden piece ensure sharp edges should not injured coworker body part.
Ok
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Kiln operator
Shift incharge/
sectional
incharge
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
72
Rev. Date :
Page
: 1 of 2
TITLE : Kiln top deck cleaning during ovehauling job

Risk level : 2
Back
1. Spade (Shovel)
2. Pocking rod
Description
N/A/E
job.
< 50 ppm

> 50 ppm
Sr. No.
Action By
PRE START-UP CHECKS

1
1-A
company
Mukadam/cleani
ng contactor
company
Mukadam/cleani
ng contactor
Kiln
operator/Shift
incharge
Ensure kiln's both door is closed & no one is inside the kiln.
OK
Ensure other kIln's cone distributor's water sealing is proper.
OK
Kiln top operator
OK
company
Mukadam/cleani
ng contactor
OK
Kiln top operator
Wherever required prepare scaffolding to perform the job
OK
company
Mukadam/cleani
ng contactor
CHECKS DURING KILN TOP DECK PLATE CLEANING JOB

1
After removing the assembly of cone distributor for overhauling job, stand on
kiln's top deck plate after wearing safety belt
OK
company
Mukadam/cleani
ng contactor
Now open the cone distributor's inspection window & check jamming inside with
dust & heat exposure to body and also tool may hit to body part & cause injury.
OK
company
Mukadam/cleani
ng contactor
Remove jamming
company
Mukadam/cleani
ng contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
Rev. Date :
Page
: 2 of 2
TITLE : Kiln top deck cleaning during ovehauling job

Risk level : 2
72
Sr. No.
Description
of it.
Now after cutting the deck plate, if jamming found on the inside shell of the kiln,
then prepare scaffolding if required to remove the jamming with the pocking
rod.
N/A/E
Action By
Remove jamming
company
Mukadam/cleani
ng contactor
Remove jamming
company
Mukadam/cleani
ng contactor
ok
company
Mukadam/cleani
ng contactor
INPROCESS CHECKS
1

contactor
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION

B) Equipment's:
48
Rev. Date :
Page
: 1 of 2
TITLE : All cone sealing pump change over job.

Risk level : 1
Back
1.Spaner
2.Both cone sealing pump
Description
Sr. No.
1
PRE START-UP CHECKS

2-A

CHECKS DURING CONE SEALING PUMP CHANGE OVER JOB
3
4
5

N/A/E
Action By
OK
Disch.Operator
Disch.Operator
Electrical
incharge
OK
Disch.Operator
Power ON
Disch.Operator
OK
OK
OK
N
N
N
Disch.Operator
Disch.Operator
Disch.Operator
OK
Disch.Operator
Action Confirm
Rev. No. : 00
Soda Ash/Kiln
CHEMICALS' DIVISION
96
Sr. No.
Description
7
8
9
1
2
Rev. Date :
Page
: 2 of 2
TITLE : All cone sealing pump change over job.

Risk level : 2

Open the delivery valve 100% of pump (which is going to start). Be ensure that
seawater flow in each kiln's washer & scrubber is the same as before starting
the job.
Switch off the pump (which is being stopped) by pressing electric switch &
INPROCESS CHECKS
Monitor cone distributor water seal of individual kiln after pump change over
job.
N/A/E
Action By
OK
Disch.Operator
OK
Disch.Operator
OK
Disch.Operator
OK
Kiln operator
Viberatio & abnormal sound
Disch.Operator
Action Confirm

Cleaning at Kiln Take Up Pulley SOP

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Cleaning at Kiln Take Up Pulley SOP

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Issue No:MTHP/SA/KILN/SOP/001

TITLE : Cleaning at AC-7&AC-8/A1&A2 including rollers

If CO concentration is more than 50 ppm, then leave the job.

PRE START-UP CHECKS

Ensure kIln's cone distributor's water sealing is proper.

Kiln top operator

Ensure kiln's top bag filter is working to avoid dust exposue

Kiln top operator

Ensure dump pipe/line in which the material to be dumped is cleaned

35-60 Amp/ 20-35 Amp

CHECKS DURING CLEANING AT A1/A2 & AC7/AC8 INCLUDING ROLLERS

If contractor's worker found any equipment or conveying belt's structure has

Kiln top operator

TITLE : Cleaning of A1/A2 outlet hoppers

If CO concentration is more than 50 ppm, then leave the job.

Kiln top operator

Kiln top operator

Kiln top operator

PRE START-UP CHECKS

Ensure kIln's cone distributor's water sealing is proper.

Ensure kiln's top bag filter is working to avoid dust exposue

Kiln top operator

Ensure dump pipe/line in which the material to be dumped is cleaned

CHECKS DURING CLEANING OF A1/A2 OUTLET HOPPER

Kiln top operator

Kiln top operator

Kiln top operator

Kiln top operator

Kiln top operator

35-60 Amp/ 20-35 Amp

Kiln top operator

After removing jamming, close the A1 or A2 outlet hopper's window by shift

A) HIRA : Maximum Risk rating :

TITLE : All kiln's gas valve checking job

drive stopped & LOTO done

PRE START-UP CHECKS

Ensure kiln's discharge is stopped by stopping respective air blower, escorgot,

Ensure kiln's gas valve is closed

Kiln top operator

Kiln top operator

Gas valve checking

If CO content is permissible, then check inside jamming. If jamming found, then

TITLE : All kiln's gas valve checking job

A) HIRA : Maximum Risk rating :

Gas valve damage

Gas valve checked

drive started & LOTO

37- 40% CO2

Moniter kiln's individual & total gas quality on DCS.

A) HIRA : Maximum Risk rating :

TITLE : cleaning at take up pulley area of AC-7/AC-8 & A-1/A-2

1. A1/A2 & AC7/AC8 charging belt

If CO concentration is more than 50 ppm, then leave the job.

PRE START-UP CHECKS

Ensure kIln's cone distributor's water sealing is proper.

Kiln top operator

Ensure kiln's top bag filter is working to avoid dust exposue

Kiln top operator

Ensure dump pipe/line in which the material to be dumped is cleaned

Kiln top operator

35-60 Amp/ 20-35 Amp

Kiln top operator