How to ensure safety for cyclone

lining works
Refractory
PR RFR P07 27 V1.0 1/6

Introduction
ƒ The purpose of this guideline is to recognize the specific hazards related to cyclone lining work and to
outline the necessary requirements for this type of work.
ƒ The following risks need to be addressed:
ƒ burn and dust inhalation during inspection
ƒ Inhalation of dust and dust in eyes during de-bricking and demolishing of castable in confined
space.
ƒ Refractory, coating & concrete panels (corroded anchors) may fall.
ƒ Air blasters, air lancing nozzles
ƒ Radioactive level detection
ƒ Work at height, trip and slips.
ƒ Confined space
ƒ Blocked escape routes
ƒ Such hazards can be eliminated or controlled by appropriate prevention measures, but sometimes, not
completely.
ƒ This guideline is applicable to all the employees and contractors of Lafarge.

Prerequisites
ƒ Before kiln stops, extensive automatic and/or manual cleaning has to be performed (air blasting, Cardox
shot, Woma guns…)
ƒ Gas temperature inside the cyclones and risers are to be brought down to reduce heat stress, according
to local regulations (about less than 50 deg C), before the inspection starts.
ƒ Hanging or loose coating and refractory are to be cleaned from outside using the access holes and
manhole doors. When it is not possible, contractor alpinists should be hired to clean downwards
ƒ The appropriate work permit must be obtained before scaffolding activities are allowed inside the
confined area
ƒ Scaffolding inside the cyclone and risers is carried out by a recognised contractor or trained workers, who
is well aware of our work at height guideline and scaffolding guideline. Provisions should be made to
allow heavy blocks to fall down on to the platform (re-enforced platform at work level).
ƒ Demolition workers should be registered and certified by the employer.

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report or not and to freely distribute it to all of its current and future subsidiaries worldwide in any form, whether paper, electronic or digital, including via Procedure Template developed by
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divulged and/or appropriated in whole or in part for personal use or for use by a third party without prior consent from the Production & Process Department,
except for reproduction by or for affiliated Lafarge companies.
 How to ensure safety for cyclone
lining works
Refractory
PR RFR P07 27 V1.0 2/6

Basic rules

1. General
ƒ Ensure that personal protective equipment are worn, including a dust, fumes mask (P3 type) and safety
harness.

1.1 Lock-out procedure:

Before beginning of inspection, cleaning, scaffolding, demolition and refractory installation work, ensure the
lock out procedure that involves:
ƒ 1. Electrical lock out
ƒ 2. Pneumatic lock out
ƒ 3. Mechanical lock out
ƒ 4. Release pressure from air blasters
ƒ 5. Stop Gamma radiation for level detection in cyclones!

1.2 Confined Space Regulation

Permit must be obtained prior to entry

1.3 Electrical Precaution

ƒ All equipments used within cyclones should be equipped with a constant pressure switch or control (also
called the dead man switch) that will shut-off the power when the pressure is released.
ƒ Be sure that the equipment is double insulated to reduce the risk of fire and electric shock.
ƒ Disconnect equipment from their power source before inserting or removing the bits. This is to ensure
inadvertent or accidental start-up.
ƒ Ensure no live wires are around the demolishing area
ƒ Conform to any local electrical regulations (such as the use of safety isolating transformers)

1.4 Lighting
ƒ Sufficient lighting must be provided to ensure a safe work environment.
 How to ensure safety for cyclone
lining works
Refractory
PR RFR P07 27 V1.0 3/6

2. Specific

2.1 Lock out

Electrical lock out
ƒ Stop and isolate the electrical power of pre-heater fan and put individual padlock in the isolation box.
ƒ Let the bag filter or EP fan running to maintain negative pressure inside the cyclones.
ƒ Adjust the preheater fan damper position and filter fan damper to get – 2 to - 5 mbar pressure at all
stages of preheater and lock the dampers electrically.
ƒ Isolate the power supply to all kiln feeding equipments up to the rotary feeder at the first stage riser.

Mechanical lock out

ƒ During inspection mechanically lock the flap damper below each cyclone in closed position

ƒ During coating and brick cleaning, release this mechanical lock but remove one small piece of feed pipe
in the bottom most cyclone feed pipes and close the entry to kiln inlet with a sliding gate made of ply
wood or steel plate. Cordon off the area with red tape.

ƒ Once cleaning in all stages is over, clean the debris and remove the red tape.
ƒ Reduce discharge height for safer removal of materials, as much as possible
ƒ Maintain escape ways and working areas clean at all times
ƒ During scaffolding and refractory installation, again isolate individual cyclones by locking the double flap
in closed position
ƒ In case the double flaps are removed for maintenance, install a sliding gate at the cyclone discharge.
 How to ensure safety for cyclone
lining works
Refractory
PR RFR P07 27 V1.0 4/6

Pneumatic lock
ƒ The air blasters/ air cannons and the cyclical cleaning equipment serving all the cyclones must be locked
out (air and power). The system must be purged off their gas or air charge. Purge valves may be left
open.

Isolation of Gamma Rays

ƒ In case the plant uses Gamma Rays level detector at the cyclone cones and other places, the source must
be switched off, isolated or removed prior to inspection.

Hanging coating and loose refractory cleaning

ƒ The hanging coating and loose refractory at cyclone roofs must be cleared before entering the cyclones
for scaffolding work.
ƒ Use the manhole doors and poke holes provided in the cyclones for this purpose. Provide inspection
openings in the roof to check the anchoring for corrosion.
ƒ If right access is not available, provide new access
 How to ensure safety for cyclone
lining works
Refractory
PR RFR P07 27 V1.0 5/6

2.2 Scaffolding work

ƒ Follow Lafarge WAH standards
ƒ Close the bottom level with a re-enforced platform of wooden planks

2.3 Demolition work

ƒ Select the proper demolition equipment for the job.
ƒ Check all bits to see that they are sharp. If not, sharpen according to the manufacturer’s
recommendations.
ƒ Ensure all clamps are tight, and couplings are properly bounded together.
ƒ When first starting the demolition equipment, always stand aside. Check for any abnormal wobbling and
vibration.
ƒ Do not allow anyone to stand in front or in line with the demolition equipment during this test.
ƒ Ensure no air leakage from air pipe. Whenever air leakage or damage of air pipe, first close air valve.
ƒ While working in confined space, the place is to be cleared free from materials lying there.
ƒ While dismantling refractory from roof, keep away from the falling debris
ƒ Cordon off the manhole area while transporting the broken refractory to the pre-heater floor

2.4 Brick lining work

ƒ Keep the work area clean, no loose material on the work platform
ƒ Do not over load the service platform with refractory.
ƒ Do not over crowd the platform with many workmen
ƒ Start the brick work from a metal flange or solid base
ƒ Any cutting of brick is to be carried out outside the cyclone
ƒ Weld the brick holders, well before the brick work starts.
ƒ Check anchors for proper welding
ƒ Simultaneous brickwork one above the other in vertical directions is only allowed if working areas are
isolated
ƒ Leave the escape route through manhole door free from brick or tools
 How to ensure safety for cyclone
lining works
Refractory
PR RFR P07 27 V1.0 6/6

2.5 Concrete work

ƒ Ensure proper ventilation in the cyclones while welding anchors (minimal dust during welding)
ƒ Check anchors if they are properly welded!
ƒ Operators used in gunning application must be well trained and approved by plant refractory champion.
ƒ Ensure proper communication between the person working inside cyclone and the person working
outside. Hands free walkie- talkie is recommended.
ƒ Ensure that the castable mixer machine is well protected from moving parts and dust emission
1 See procedures "How to ensure safety for castable mixing
"and "How to ensure safety for brick cutting"

2.6 Closing after work

ƒ Ensure no loose material is left inside the cyclone before scaffolding is removed
ƒ Ensure all shuttering materials are removed
ƒ Inspect the cyclone for foreign material after the removal of scaffolding
ƒ Free the double flap from mechanical lock
ƒ Conduct ball or brick drop test to ensure that the material path is free
ƒ Close manholes and inspection doors. Seal them properly
ƒ Restore all lock outs back in place.
ƒ Clean the pre-heater floor before hand over the cyclone for operation