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UNITED CEMENTS PVT.

LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For
Doc.No. UCPL/ME/SOP/001
Operation & Maintenance Rev.No: 00
of Lime Stone Crushers
Approved By: HOD -MECHANICAL Issued By:
Date: 19.08.2018 Date:

Revision History

Page(s)/Section(s)
Date of Revision Revision Explanation
Revised

Effective Date: 25/08/2018

Prepared By: Vinod Kumar Verma Date: - 18.08.2018

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UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For
Doc.No. UCPL/ME/SOP/001
Operation & Maintenance Rev.No: 00
of Lime Stone Crushers
Approved By: HOD -MECHANICAL Issued By:
Date: 19.08.2018 Date:

TABLE OF CONTENTS

1. Purpose
2. Scope
3. Abbreviations
4. Responsibility
5. Procedure

a) Operation of Crusher
b) Maintenance of Crusher

6. Health & Safety Warning


7. Applicability
8. Data and Records

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UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For
Doc.No. UCPL/ME/SOP/001
Operation & Maintenance Rev.No: 00
of Lime Stone Crushers
Approved By: HOD -MECHANICAL Issued By:
Date: 19.08.2018 Date:

1. PURPOSE: -
To establish a system for operation and maintenance of Lime Stone
Crusher to reduce the idle running and maximize the utilization of system & for proper
operation of dust control units.

2. SCOPE: -
Applicable to Lime Stone Crushers –
 Single Rotor Impact Crusher &
 Hammer Crusher

3. ABRIVIATIONS: -

HOD – Head of Department


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

4. RESPONSIBILITY: -

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


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

5. PROCEDURE: -

a) OPERATION OF CRUSHER: -

I. Before start of crusher all the operative staff should be instructed to check
the circuit and to give feedback regarding the condition of the same.
II. Crusher Operator will check the logbook and Interact with control room
regarding the crusher operation.
III. Crusher Operator will ask to control room for checking the condition of the
equipment and give clearance to him for start of the crusher group.
IV. After start of the crusher circuit crusher operator will give instruction to
operatives to keep watch on the crusher and regulate the crusher apron
feeder according to the material Quality / size of Boulders.

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UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For
Doc.No. UCPL/ME/SOP/001
Operation & Maintenance Rev.No: 00
of Lime Stone Crushers
Approved By: HOD -MECHANICAL Issued By:
Date: 19.08.2018 Date:

V. The operator should be in contact with the quality department and stop idle
running of the crusher during non availability of the dumpers for long
duration and regulate the apron feeder speed for optimum utilization of the
crusher.
VI. In case of breakdown / jamming in crusher or any problem, operator will
stop the crusher and inform to control room to take action accordingly.
VII. In case of jamming in crusher, operator will perform the cleaning jam only
after proper Isolation of the power supply by issue of work permit. Jamming
of the crusher rotor by proper wedging .Operator and other workman will
take all the precaution and safety measures.
VIII. Crusher operator will place the safety display board “Crusher is not in
operation” in front of truck tippler area, to stop the dumper unloading until
the jam is cleared.

b) MAINTENANCE OF CRUSHER: -

I. Before any maintenance power supply is isolated by work permit system


and “LC” from all concerned departments.
II. Ensure that all the members are well aware with the nature of the job and
safety measures required during the work.
III. No one should be allowed without PPE’S in the crusher area.
IV. Working area should be barricaded to avoid entry of any outside person in
the area.
V. At the time of Maintenance job in Crusher / Apron Conveyor etc. Operator
and other workman will take all the precaution and safety measures.
VI. During the job in crusher, rotor should be jammed by proper wedging.
VII. After completion of the job remove all the lifting devices & wedges properly,
with all care.
VIII. Close the housing etc and after tightening the bolts, clearance may be
given for removing the electrical isolation.

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UNITED CEMENTS PVT. LIMITED
STANDARD OPERATING PROCEDURE (SOP)
For
Doc.No. UCPL/ME/SOP/001
Operation & Maintenance Rev.No: 00
of Lime Stone Crushers
Approved By: HOD -MECHANICAL Issued By:
Date: 19.08.2018 Date:

6. HEALTH & SAFETY WARNING

 All the operatives should use the PPE’S i.e. ear muffs, safety helmet
etc as per the requirement of working area.
 All the operatives should be aware of using the tools & tackles.
 Cutting, welding & grinding activities should be carried out with its
safety devices.
 Working area should be clean before & after the work.

7. APPLICABILITY: -

The procedure is applicable for following activities----


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

8. DATA AND RECORD: -

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


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

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