Document no. PP/Q/OPN/WI/09 Rev no.

3 Date - 13 / 04 / 2022
Title : WORK INSTRUCTION FOR OPERATION OF ADDITIVE BALL MILL

1.0 Purpose : This work instruction has been prepared to establish safe and standard work
practices for operation of Additive Ball Mill.

2.0 Scope : This document is applicable in Additive Grinding Unit of Pellet Plant 1.

3.0 Responsibility & Authority :

Sl. Authority
Activity Responsibility
No
1 Inspection of Additive Ball Mill AO Wet Grinding Shift In charge
2 Additive Ball Mill Start up AO and CCR Engineer Wet Grinding Shift In charge
3 Checks required during operation AO and CCR Engineer Wet Grinding Shift In charge
4 Stopping procedure AO and CCR Engineer Wet Grinding Shift In charge
5 Filing and maintaining of records AO and CCR Engineer Wet Grinding Shift In charge

4.0 Abbreviation / Definition :

 ABM - Additive Ball mill

 AF - Additive Feed
 AO - Area Operator
 CCR - Centralized Control room
 COG - Carbon Monoxide Gas
 DP - Differential Pressure
 FCV - Flow Control Valve
 HP - High Pressure
 ID - Induced Draught
 LCS - Local Control Switch
 LP - Low Pressure
 LPM - Liters Per Minutes
 MG - Mixed Gas
 NG - Natural Gas
 Nm3/hr. - Newton m3 / hour
 RAV - Rotary Air Valve
 SI - Shift In-charge
 SOV - Shut Off Valve.

4.1 Procedure/ WI Category :A

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Document no. PP/Q/OPN/WI/09 Rev no. 3 Date - 13 / 04 / 2022
WI Category A B C D
Impact
Impact on Safety, Health & Legal High High Low Low
Impact on customer / Critical To Quality High Low High Low
5.0 Activities :

5.1 Standards references :

Tick mark the applicable
Sl. No Name of JSW Safety Standard ID Number of JSW Safety Standard
Std.( √ )
1 Confined Space Entry JSW/SAFETY/STANDARD/005

2 Working at Height JSW/SAFETY/ STANDARD /007

3 Lockout and Tag out (LOTO) JSW/SAFETY/STANDARD/009

4 Permit To Work (PTW) JSW/SAFETY/STANDARD/010

5 Electrical Safety JSW/SAFETY/STANDARD/015

6 Machine Guarding JSW/SAFETY/STANDARD/016

7 Personal Protective Equipment (PPE) JSW/SAFETY/STANDARD/018 √

8 Conveyor Safety JSW/SAFETY/STANDARD/021 √

9 Scaffolding Standard JSW/SAFETY/STANDARD/023

10 Lifting & Handling Standard JSW/SAFETY/STANDARD/---

5.2 Activities with Hazard : JSA table

Mandatory PPE’s : Helmet, Goggle, Safety Shoes.
Additional Job Specific PPE’s : Ear Muff

Job Safety Analysis -(JSA)

Sequence of Basic
Impact Potential Hazard
Job Steps/ Activities
5.2.1. ABM Start up:
5.2.1.1. Starting of Safety,
HAG Health 1.Accumulation
of gas in the HAG
Recommended
What could
safe jobs + Job Corrective action
go wrong
specific PPE’s
1.1. Start gas circuit 1.1. Blast 1.1. Keep safe distance
10 min. prior to inside HAG from HAG.
startup of HAG.
1.2. CCR Engineer will
1.2. Start Pilot close gas flow control
burner and wait till valve of HAG
excess gas burns
off before opening 1.3. Follow Fire and
Flow Control valve. Safety instructions to
minimize ignition
sources on site.

1.4. Implement
emergency evacuation
procedure

1.5. CCR Engineer to stop

Ball mill and Gas circuit
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immediately.

2.CO gas leakage 2.1. Ensure zero 2.1. CO gas 2.1. Move away from gas
ppm of COG in the leakage leakage area.
area with the help < 1200 ppm.
of Multi-gas meter. 2.2. Move victim (if any)
to fresh air immediately
2.2. Periodically and obtain medical
Gas line valve assistance.
checking
2.3. AO will inform the SI
and CCR Engineer about
the CO gas leakage.

2.4. CCR Engineer will

immediately close the
gas flow control valve of
HAG.

2.5. CCR Engineer to stop

Ball mill and Gas circuit
immediately.

2.6. Once the CO ppm

2.2. If CO gas reduces below 50 ppm,
leakage then the gas leakage is
>1200 ppm. to be arrested.
2.7. This is an emergency
situation and
PP/Q/OPN/WI/21 has to
be followed.

3. Sudden 3.1. Start the Main 3.1.Fire at 3.1. AO to inform CCR

temperature rise flame with a Bag filter Engineer to close flow
of Bag filter minimum opening house control valve of HAG.
of the flow control
valve 3.2. CCR Engineer to stop
Ball Mill and Gas circuit
3.2. When immediately.
operating in MG,
make sure NG line 3.3. The fire is to be
valve is 100% extinguished by using
closed. fire extinguisher / Fire
Hydrant Water.
3.3. Operate Flow
control valve in 3.4. In case fire is not
Auto mode for auto controlled by above
tripping of HAG if actions, immediately fire
bag filter inlet tender is to be called
temperature from Fire and safety
reaches services by SI.
98°C.

4. Back firing of 4.1. Maintain 4.1. Burn 4.1. Apply first aid to the
HAG negative pressure injury victim.
in VRM

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4.2. Keep safe
distance from HAG 4.2. After that, the victim
peeping hole and has to be taken to
inform CCR flow medical center.
control valve.
Environment

1. Hazard due to 1.1. Hearing 1.1. Hearing 1.1. Ear muffs to be worn
noise protection must be Loss. by operator working in
worn at all times the area of mill
while in the vicinity
of mill

2. Hazard due to 2.1. Hot surfaces to 2.1. Burn 2.1. Apply first aid to the
hot surfaces be marked at the injury victim.
hazard point with
Safety,
5.2.1.2. Starting of the pictogram ‘Hot 2.2. After that, the victim
Health
ABM Surface’ has to be taken to
medical center.
2.2. Wear
protective clothing
at all times with
long sleeves and
trousers.

3. Wear protective
hand gloves
Environment

5.3 Details of Activity :

Tools required : N.A.
Consumables : N.A.
Manpower required : 6
Time required : 30 min
Shut down required : No, Time: N.A.

5.3.1: Inspection of ABM:

5.3.1.1: Checks required for ABM start-up:
5.3.1.1.1 AO to check for mechanical and electrical healthiness of the equipment.
5.3.1.1.2 AO to check healthiness of bag filter purging system.
5.3.1.1.3 CCR ENGINEER to inform the SIC about the availability of MG and NG
usage for burner light up by checking pressure of MG and NG from DCS.
5.3.1.1.4 SIC to take decision regarding usage of MG or NG for HAG.
5.3.1.1.5 AO to check for healthiness of Raw Lime and Raw Coke Bins.
5.3.1.1.6 AO to check healthiness of Dilution air fan(secondary), Combustion air
fan(primary), LP & HP pump, Bag filter Hopper RAV, Cyclone RAV, ID fan,
Recirculation air fan, Classifier, Air slide blower emergency switches.
5.3.1.1.7 AO to check bag filter purging air valve is open.
5.3.1.1.8 AO/CCR ENGINEER to check Purging sequence, purging timing and purging
air pressure is above 5 bar.
5.3.1.1.9 AO to check tank level of Mill lubrication unit is approximately 80%.

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5.3.1.1.10 CCR Engineer to check if all ABM permissive are healthy in DCS.
5.3.1.1.11 CCR Engineer to maintain pressure before mill -2 to -3 mbar.
5.3.1.1.12 CCR ENGINEER to maintain temperature before mill 300°C to 350°C
depends on raw material moisture.
5.3.1.1.13 AO to check if Mill lubrication is running and Bearing lube pressure of 30
bar and Low pressure pump flow 20 - 25 LPM (Feed end) 30 - 40 LPM
(Discharge end) is maintained.
5.3.1.1.14 Gear box lubrication system is operating with gear box pump pressure to
be 2 to 3 bar.
5.3.1.1.15 CO to check oil temperature in the gearbox is in the acceptable range (60-
65oC).
5.3.1.1.16 AO to check service water flow to heat exchanger at Mill lubrication unit.
5.3.1.1.17 AO to check if Inching drive motor to gear box is disengaged.
5.3.1.1.18 AO to check for "Damper Open condition" of ID fan and "Damper closed
condition" of Recirculation Fan Damper before start-up of gas circuit.
5.3.1.1.19 AO to ensure opening of gas manual valves to 100 % located near the
burner for burner light up.
5.3.1.1.20 AO to check pneumatic air line for is open for SOV and FCV of HAG.
5.3.1.1.21 AO to check Bag filter hopper RAV for any leakage for material.
5.3.1.1.22 CCR Engineer to check operation mode to be ‘Main Drive’.

5.3.1.2: Burner permissive conditions:

5.3.1.2.1 During normal operation of plant, burner permissive will fail, if any of the
following conditions are met:
5.3.1.2.2 Combustion Air fan running indication not there.
5.3.1.2.3 Dilution Air fan running indication not there.
5.3.1.2.4 ABM outlet temperature rises above 170°C.
5.3.1.2.5 Bag filter outlet temperature rises above 98°C.
5.3.1.2.6 HAG core temperature rises above 1000°C.

5.3.2: Additive Ball mill start-up:

5.3.2.1 ABM start-up:
5.3.2.1.1 AO to start bag filter purging system from the field.
5.3.2.1.2 AO should give clearance and get the Product transport group started
from Control room in the following sequence: -
5.3.2.1.3 Ground Lime+ coke discharge Bag house fan.
5.3.2.1.4 Screw feeder.
5.3.2.1.5 Bag filter RAV.
5.3.2.1.6 Cyclone RAV 1 & 2.
5.3.2.1.7 AO should give clearance for gas circuit and CCR Engineer to start gas
circuit from Control room in the following sequence: -
5.3.2.1.8 De-dusting air fan.
5.3.2.1.9 Seal air fan.
5.3.2.1.10 Dynamic separator.
5.3.2.1.11 Recirculation Air fan.
5.3.2.1.12 Rejection air slide fan.
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5.3.2.1.13 Rejection Rotary valve.
5.3.2.1.14 Start combustion fan and dilution air fan to light up burner.
5.3.2.1.15 AO to open air line for pilot flame.
5.3.2.1.16 AO to make sure main gas line actuator is open and give clearance for
HAG startup to CCR Engineer.

5.3.2.2 HAG Startup in NG:

5.3.2.2.1 CCR ENGINEER to ensure that the burner start-up permissive is healthy, if
not check for the burner permissive conditions as mentioned in the
section 5.3.1.2.
5.3.2.2.2 AO to ensure NG pressure is within 0.80 bar to 0.90 bar.
5.3.2.2.3 Once the burner permissive is healthy, AO will ensure closing of the
Nitrogen gas manual valve & opens the manual valves of pilot burner gas
line & NG main gas line as per instruction from CCR ENGINEER.
5.3.2.2.4 CCR ENGINEER to adjust Combustion air fan rpm (~165 rpm) and dilution
air fan rpm (~500 rpm).
5.3.2.2.5 CCR ENGINEER to start HAG from DCS with a minimum opening of the
Flow Control Valve, only after taking clearance from AO.
5.3.2.2.6 Upon giving start command, the pilot burner will start initially on NG, if
the flame is stable & is sensed by the flame sensor, then only give
command to main flame, if the burner flame is not established/sensed by
the flame sensor within 5 sec. of giving the start command, then the pilot
burner solenoid will trip & cut off the gas supply to the pilot burner.
5.3.2.2.7 For restarting the burner, all the above steps need to be repeated.
5.3.2.2.8 CCR Engineer will further ensure that the burner operation is in AUTO
mode.
5.3.2.2.9 CCR Engineer & AO will ensure proper operation of the fuel gas control
valve of the burner as per DCS set point.

5.3.2.3 HAG Changeover from NG to MG:

5.3.2.3.1 CCR Engineer to stop HAG by closing FCV.
5.3.2.3.2 AO to close NG main valve.
5.3.2.3.3 AO to open vent valve and Nitrogen line valve.
5.3.2.3.4 AO to make sure O2 reading is zero in main gas line using multi gas meter.
5.3.2.3.5 AO to close Nitrogen line valve and vent valve.
5.3.2.3.6 AO to open MG main valve.

5.3.2.4 HAG Startup in MG:

5.3.2.4.1 CCR ENGINEER to ensure that the burner start-up permissive is healthy, if
not check for the burner permissive conditions as mentioned in the
section 5.3.2.
5.3.2.4.2 AO to ensure MG pressure is within 0.45 bar to 0.60 bar.
5.3.2.4.3 Once the burner permissive is healthy, AO will ensure closing of the
Nitrogen gas manual valve & opens the manual valves of pilot burner gas
line & MG main gas line as per instruction from CCR ENGINEER.
5.3.2.4.4 CCR ENGINEER to adjust Combustion air fan rpm (~165 rpm) and dilution
air fan rpm (~500 rpm).
5.3.2.4.5 CCR ENGINEER to start HAG from DCS with a minimum opening of the
Flow Control Valve, only after taking clearance from AO.
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5.3.2.4.6 Upon giving start command, the pilot burner will start initially on NG, if
the flame is stable & is sensed by the flame sensor, then only give
command to main flame, if the burner flame is not established/sensed by
the flame sensor within 5 sec. of giving the start command, then the pilot
burner solenoid will trip & cut off the gas supply to the pilot burner.
5.3.2.4.7 For restarting the burner, all the above steps need to be repeated.
5.3.2.4.8 CCR ENGINEER will further ensure that the burner operation is in AUTO
mode.
5.3.2.4.9 CCR & AO will ensure proper operation of the fuel gas control valve of the
burner as per DCS set point.
5.3.2.4.10 AO should give clearance for Main group and CCR Engineer to start Main
group from Control room in the following sequence:
5.3.2.4.11 Main motor Blower.
5.3.2.4.12 Bearing Lubrication.
5.3.2.4.13 Gearbox Lubrication.
5.3.2.4.14 Girth Gear Lubrication.
5.3.2.4.15 Ball mill main drive.

5.3.2.5 Additive Ball Mill Feed Circuit start up:

5.3.2.5.1 CCR Engineer to take clearance from AO and start Feed circuit in the
following sequence when bag filter inlet temperature reaches 85°C
5.3.2.5.2 Additive Feeder (AF-9).
5.3.2.5.3 Lime weigh feeder (AF-6).
5.3.2.5.4 Coke weigh feeder (AF-7).

5.3.3 Checks required during operation :

5.3.3.1. CCR Engineer to check mill for constant and uniform operation.AO to inspect mill
for abnormal operating noise.
5.3.3.2. AO to check periodically if all safety covers and protection devices are mounted
properly.
5.3.3.3. AO to inspect lubrication system for oil leaks and damage.
5.3.3.4. AO to check for any leakage of COG with the help of COG monitor.
5.3.3.5. CCR Engineer to check for a sudden rise in pad bearing temperatures.
5.3.3.6. CCR Engineer to maintain Ball mill current up to 130 amps, if current is <130
amps CCR Engineer will inform to SI for grinding media addition.
5.3.3.7. CCR ENGINEER to control mill feed in order to maintain Mill DP around 8 to 12
mbar.
5.3.3.8. CCR ENGINEER to maintain burner core temperature around 800°C.
5.3.3.9. CCR ENGINEER to maintain ABM discharge temperature around 105°C to 110°C,
bag house inlet temperature around 90°C and bag filter DP around 10-15 mbar.
5.3.3.10. CCR ENGINEER to check for any rise in Separator bearing vibration (Top and
bottom vibration to be below 10mm/s) and Separator bearing temperature (Top
bearing temperature <120°C and Bottom bearing temperature <135°C).
5.3.3.11. AO to also ensure the proper functioning of bag house so as to maintain clean
working environment. (Purging sequence and timing).
5.3.3.12. All important parameters and health of the equipment are regularly monitored
and recorded in control room.
5.3.3.13. AO to ensure that the lubrication unit is working normally.
5.3.3.14. AO to check the girth gear spray system storage barrel.
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5.3.3.15. All important parameters and health of the equipment are to be regularly
monitored in control room by CCR Engineer.

5.3.4 Stopping procedure:

5.3.4.1 CCR Engineer to switch off the HAG by closing FCV.
5.3.4.2 CCR Engineer to Stop the Mill feed.
5.3.4.3 CCR Engineer to ensure that ABM main motor stops after 10 minutes in ‘No feed’
logic.
5.3.4.4 CCR Engineer to make sure that mill lubrication is in operation.
5.3.4.5 CCR Engineer to stop the gas circuit is stopped after bag filter inlet temperature
reaches 40°C to 45°C.

5.3.5 Filling and maintaining of records.

Sl
Name Doc. No. Maintained by Retention Period
no.
1. Additive Log book PP/Q/Op/F/05 SI/AO 6 Months

6.0 IMS Document References :

1. PP/Q/OPN/WI/21: Work Instruction for Emergency Situation in case of Mixed Gas leakage
2. PP/O/OPN/HIRA/01: HIRA_Pellet Operation

7.0 Documents / Records :

Sl
Name Doc. No. Maintained by Retention Period
no.
1. Additive Log book PP/Q/Op/F/05 SI/AO 6 Months

8.0 Enclosures :

Schematic Diagram of Additive ball mill

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Area In charge Section Head Plant HOD

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