SOP - 02 - Poking Activity

STANDARD OPERATING PROCEDURE
SOP No. MEC-OPR-SOP-2 Effective Date 27.07.2021 REVISION No 00

SOP DESCRIPTION POKING ACTIVITY Section OPERATION
DEPARTMENT LIME KILN PLANT Page 1 of 8
Step Activity Associated Responsibility

Process / tools / PPEs (HOW) Remarks / Reference
No. (WHAT) Requirements/Hazards/Impacts (WHO)
SAFETY: a) Safety instruction on Poking activity to be given
a) Incident caused (if any) due to lack of to all the operators & firemen on site, regarding
knowledge about Poking activity. the hazards and risks. All the operators &
firemen to be trained about Do’s & Don’ts of the
b) Injury case (if any) due to non-use of activity.
proper and adequate safety appliance.
b) All the Poking activity operators & firemen to
c) Incident (if any) due to lack of be trained about consequences of non-use of
awareness of emergency situation in proper and adequate safety appliance during
working area/ Six Directional Hazards work. Use of proper PPEs (hand gloves, safety
(East, west, north, south, above & helmet, visor, safety shoes, safety goggles, FR
below). jacket, nose mask, etc).
Before starting the
c) All the operators & firemen to be informed
1.
Poking activity Shift Incharge
about various emergency conditions / Six
(Toolbox talk) (MEC)
Directional hazard which may arise during
executing the job and how to respond during
emergency condition.
ENVIRONMENT: a) Information on all aspects of poking activity to

a) Possible environmental Aspects of be given to all the operators & firemen on site.
Poking activity.
b) Information about impacts of aspects during
b) Possible Impacts of aspects on poking activity to be given to all the operators &
environment during Poking activity. firemen on site.
c) Possible occupational diseases caused

due to lack of knowledge/ non-use of c) Information of possible occupational diseases
PREPARED BY APPROVED BY
Name and Designation: Mr. Rajeev Kumar (Site Incharge) Name and Designation: Mr. Rajeev Kumar (Manager)
Signature : Signature:

proper PPEs. caused due to non-use of proper PPEs and
benefits of using proper PPE to be given to all
d) Environmental norms to be poking operators & firemen.
maintained:
i) Air quality (work zone): d) Information of Environmental norms to be given
< 2000 µg/m3. to all poking operators & firemen and steps to be
ii) PGP gas exposure taken to control pollution/PGP gas exposure
during Poking activity.
QUALITY:
a) Poking rod (Length- 3.5 to 4.2 mtr, Dia -
24/25mm) a) Check the condition of poking rod whether
b) in working condition /not working condition
b) 5 kg hammer for hammering before stating the job. Length of the rod should
be as per requirement of PG bed.
c) Man cooling fan for poking activity.
c) Check the condition of 5 K.G hammer handle to
d) Hook for holding the poking rod. be used for hammering.
d) Check the condition of man cooler fan (should

be in working condition).
e) Check the condition of hook (should not be in

damage condition).

2. Poking activity SAFETY: Operator a) While shifting, man cooler fan should be
handled carefully & eyesight should be on
Shifting of man footstep at working platform.
2.1 Hazard Risk
cooler fan towards a) Slip & Trip a) Injury potential such as
b) During shifting of man cooler fan care
poke hole fracture and bruises
should be taken. Two persons should be
b) Toppling of fan on b) Cuts and bruises engaged for shifting of fan. Always use
workman safety helmet, safety shoes, hand gloves,
c) Exposure to c) Headache/ vomiting/ safety goggles, nose mask & Fire-
Producer gas unconsciousness/fatality Retardant jacket.
c) Man cooler fan should be switched off

before shifting.
d) Calibrated CO Detector should be

available during working on Poke hole
platform/Shifting of man cooler fan.
ENVIRONMENT: No Hazard
QUALITY: a) During shifting please ensure that position

a) Proper positioning of man cooler fan of fan should be towards poke hole.

b) There should be a distance of min. 1mtr

between the poke hole and the fan so that
the worker does not have difficulty in
working.

2.2 Shifting of poking SAFETY: Operator a) While shifting, rod should be handled
rod from stand to Hazard Risk carefully.
a) Slip & Trip a) Injury/fracture.
workplace b) Special care should be taken during
b) Hit by Poking rod b) Injury
while working Poking activity as the rod may hit the
c) Exposure to c) Headache/ vomiting/ fellow workmen or self.
Producer gas unconsciousness//fatality
c) Always use calibrated CO detector during
work
ENVIRONMENT: No Hazard
QUALITY:
a) Proper positioning of poking rod. a) Never lift the rod alone. Minimum two
fireman should be available for handling
the rod.
b) Place the rod near the poke hole in vertical

position so that the rod can be easily
inserted into the poke hole.
c) Always use a poking rod with handle and

check the handle thoroughly.

2.3 Removal of Poke SAFETY: Operator a) While opening the Poke hole, keep your
Hole cap Hazard Risk face away from it. Always maintain
a) Exposure to a) Headache/ vomiting/ distance while removal of Poke hole cap to
Producer gas unconsciousness//fatality avoid hot gas & fumes.
b) Fire b) Serious burn injury
b) Always use safety helmet, safety shoes,
c) Eye injury helmet visor/ safety goggles, hand gloves,
c) Coal fines particles
nose mask, FR jacket, FR hand gloves, etc.
during cap removal activity.
c) If the fire comes out after removing the

poke hole cap, do the leveling work first.

d) Always use calibrated CO detector.
e) Always keep the man cooler fan in front of

the poke hole and work from the opposite
direction to avoid gas & fumes.
ENVIRONMENT:
Aspect Impact
a) SPM of air quality a) Air pollution a) While removing the poke hole cap, always
(work zone) < 2000 keep the fan in front of the poke hole so
µg/m3 that the gas released from the Poke hole
can move away from the working area.
QUALITY:
a) Proper opening of poke hole a) After removing the cap from the poke
hole, place the cap next to the poke hole so
that poke hole can be closed quickly after
work.

2.4 Inserting Poking SAFETY: Operator a) Poking rod should be handled carefully
rod in Poke hole Hazard Risk while poking & eyesight should be on the
a) Slip & Trip a) Injury/fracture. poke hole.
b) Mishandling of rod b) Injury
while working b) Always hold the rod properly so that it
c) Exposure to c) Headache/ vomiting/ does not fall on the body. The workmen

Producer gas unconsciousness//fatality should always use safety shoes, safety
helmet, helmet visor/ safety goggles, hand
gloves, nose mask & fire-retardant jacket.
c) Always use Calibrated CO detector during

work.
ENVIRONMENT:
Aspect Impact
a) SPM of air quality a) Air pollution a) When inserting the rod, always keep the
(work zone) < 2000 fan in front of the poke hole so that the gas
µg/m3 released from the poke hole can move
away from the working area.
QUALITY: a) During poking, rod should be inserted in

a) Proper insertion of Poking rod. the poke hole at least thrice. (i.e. in the
center, left side and right side of poke
hole)
DO’S & DON’TS:

Sl. No. DO’S Responsibility (WHO)

1 Toolbox talk to be conducted by shift incharge with PG plant operators & firemen before starting the job. Shift Incharge (MEC)
Use of proper PPEs like safety helmet, safety shoes, helmet visor/ safety goggles, FR jacket, FR hand gloves, nose mask,
2. Shift Incharge(MEC)
etc.
3. Lifting & Shifting of material should be done carefully. Operator
4. During shifting of man cooler fan please ensure that fan should be faced towards poke hole. Operator
5. Always hold the rod properly so that it does not fall on the body. Operator
6. Use proper tools and tackles for poking activity Operator
7. While poking, rod gets red hot. Always use FR hand gloves, pliers & asbestos cloth (if required) for lifting the rod Operator
8. While pulling out the rod, always keep the fan in front of the poke hole to keep out the emitted gas from working area. Operator
9. Always ensure the working of installed CO detector on Poke hole platform. Use calibrated CO detector during poking activity Shift Incharge (MEC)
If anyone feels headache or vomiting, then he should immediately inform his colleague & leave the workplace. He
10. Operator
should move to open area & inform his Shift Incharge.
Sl. No. DON’TS Responsibility (WHO)

1. Do not lift the Poking rod alone. Minimum two fireman should be available for handling the rod. Operator
2. When a fireman drives a hammer, there should be no one in the vicinity of swing of hammer. Operator
While closing the Poke hole, keep your face away from it. Always maintain distance while placing the Poke hole cap to
3. Operator
avoid hot gas & fumes.

SOP - 02 - Poking Activity

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STANDARD OPERATING PROCEDURE

SOP No. MEC-OPR-SOP-2 Effective Date 27.07.2021 REVISION No 00

DEPARTMENT LIME KILN PLANT Page 1 of 8

Step Activity Associated Responsibility

ENVIRONMENT: a) Information on all aspects of poking activity to

c) Possible occupational diseases caused

DEPARTMENT LIME KILN PLANT Page 2 of 8

Step Activity Associated Responsibility

d) Check the condition of man cooler fan (should

e) Check the condition of hook (should not be in

DEPARTMENT LIME KILN PLANT Page 3 of 8

Step Activity Associated Responsibility

c) Man cooler fan should be switched off

d) Calibrated CO Detector should be

QUALITY: a) During shifting please ensure that position

DEPARTMENT LIME KILN PLANT Page 4 of 8

Step Activity Associated Responsibility

b) There should be a distance of min. 1mtr

Step Activity Associated Responsibility

b) Place the rod near the poke hole in vertical

DEPARTMENT LIME KILN PLANT Page 5 of 8

Step Activity Associated Responsibility

c) Always use a poking rod with handle and

Step Activity Associated Responsibility

c) If the fire comes out after removing the

DEPARTMENT LIME KILN PLANT Page 6 of 8

Step Activity Associated Responsibility

e) Always keep the man cooler fan in front of

Step Activity Associated Responsibility

DEPARTMENT LIME KILN PLANT Page 7 of 8

Step Activity Associated Responsibility

c) Always use Calibrated CO detector during

QUALITY: a) During poking, rod should be inserted in

DO’S & DON’TS:

DEPARTMENT LIME KILN PLANT Page 8 of 8

Sl. No. DO’S Responsibility (WHO)

Sl. No. DON’TS Responsibility (WHO)

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