Ok Mill Operation And Maintenance Safety Instructions

INSTRUCTION MANUAL

OK mill Operation and maintenance

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70003294 2.0

Safety instructions

The text refers to the following instruction manuals etc.: OK mill for clinker; Operation and maintenance

70001089

Hydraulic installations

19871

VIGERSLEV ALLÉ 77 - 2500 VALBY - DENMARK ‹ 2040 AVENUE C - PA 18017-2188 BETHLEHEM – USA ‹ CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA

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Contents:

General information. ....................................................................................... 3 Visual inspection during operation. ................................................................. 4 Maintenance inside the mill. ............................................................................ 4 Handling of heavy parts................................................................................... 5 Hydraulic system. ............................................................................................ 6 Lubrication systems......................................................................................... 6

Edited by:

Approved by:

LRJe LuP

Translated by: MGN code:

B 400

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General information NOTE ! The present instruction manual is concerned with the situations which, according to the experience of FLS, are the most likely to occur. An exhaustive enumeration of all conceivable situations which may occur during the erection, operation and maintenance of the OK mill cannot be provided. Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual, and which the operator is/or feels unable to handle, we would recommend that FLS is contacted without undue delay for advice on appropriate action. Before any maintenance work is carried out, read this instruction, the safety instructions for the entire process module, the safety instructions for the entire cement plant and the cement mill maintenance instruction manual. The fact that the OK mill is a remotely operated machine integrated in a larger process module means that special procedures for safe maintenance must be worked out by the manager responsible for plant safety, taking into account the entire process module. Always ensure that workers carrying out maintenance work on the OK mill are skilled in the type of work they are performing and that they have been given the necessary instructions concerning the special precautions to be applied when working with large machinery. The mill is equipped with warning, prohibiting and mandatory signs which cover all normally occurring risks that could not be eliminated by conventional means, through the use of guards, rails etc. Safety precautions required when working with dangerous tools like disc grinders, welding machines, blowtorches etc. are foreseen to be part of normal site safety procedures and this aspect is outside the scope of the present instruction manual.

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Visual inspection during operation During operation, visual inspection must be restricted to safe areas. Never dismantle doors, guards or rails during operation. During operation, hot air or exhaust gases are utilized for heating the mill. Attention is drawn to the fact that temperatures of mill housing and air spouts can be very high. When entering the space for the gear unit below the mill during operation, be aware of the following. During operation, the air pressure inside the mill is lower than the atmospheric pressure, thereby preventing outflow of cement dust from the mill. However a small spillage rate of particles may occur at the location where the table enters the mill housing. Clean up the spillage on a regular basis. Goggles must be worn to prevent eye damage. The mill motor and feed system are noisy machines. Ear protection equipment must be used to prevent damage to hearing.

Maintenance inside the mill Prior to dismantling of any doors and guards, make sure that the following equipment has been stopped and interlocked to prevent starting: Mill main motor, mill fan, hydraulic system, all feeding equipment and heat generator, if any. The power supply for the above-mentioned equipment must be effectively locked by means of padlocks in the Motor Control Centre (MCC) to prevent inadvertent starting of the motors. The supervisor in charge of the maintenance team undertaking work inside the mill must keep the key for the lock. The padlocks must remain fitted until all personnel have left the mill and all doors and guards have been re-mounted. The manager responsible for plant safety must work out safe maintenance procedures to prevent inadvertent starting. Given the dusty environment inside the mill, anyone entering the mill must be wearing a face shield and goggles. If exhaust gases are utilized for heating the mill, it is essential to ensure that the mill is vented to normal O2, CO and CO2 level prior to entry into the mill. The mill must be vented while personnel are carrying out work inside the mill. In connection with entry into the mill, attention is drawn to the fact that cooling of the mill is a lengthy process, and that the temperatures of the surfaces inside the mill can be very high.

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When entering the mill, due caution is needed to step across the nozzle ring opening and the material built up between the air guide cone and the mill housing. There is a distinct risk of tripping; therefore, the manager in charge of plant safety aspects must notify the operating personnel of the attendant hazard. The interior of mill vertical mills often have hot accumulated material inside separator cone, feed sluice etc. this can dislodge and create dangerous situations; so proper inspection and precautions must be taken to avoid any hazard before entering the mill. When work is done inside the mill, one person must be assigned to perform surveillance function outside the mill, ensuring that any undetected gases will not cause suffocation of the persons working inside the mill. When it is necessary to do maintenance with the rollers in raised position, make sure that the rollers are locked mechanically in the upper position. This is done by mounting the Safety Clamp on top of the roller stopper shaft, lower the rollers so mechanical contact are achieved between roller stopper and Safety Clamp and roller stopper shaft. Changing of wear segments on the grinding rollers is done with the rollers in raised position. Removal of the segments will lead to imbalance of the roller. Undesirable turning of the roller must be prevented, see operation and maintenance instruction manual 70001089.

Handling of heavy parts During maintenance it may become necessary to handle heavy equipment. Handling of heavy parts may involve hazards but is foreseen to be a normal procedure for personnel carrying out maintenance work at a cement plant and this aspect is outside the scope of the present instruction manual Before handling heavy parts from the OK mill, read the operation and maintenance instruction manual 70001089.

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Hydraulic system Prior to performing any maintenance work on the hydraulic system, read the data and safety data sheet from the oil supplier. The hydraulic system is equipped with accumulators. Before dismantling any part of the system, make sure that the pressure in the entire hydraulic system has been reduced to zero bar. Before dismantling any part of the hydraulic system, make sure that the power supply has been turned off and locked out in the MCC. Following the reassembly of the system, a pressure test must be conducted as described in the general instruction manual 19871 for hydraulic systems.

Lubrication systems Prior to performing any maintenance work on the lubrication systems, read the data and safety data sheet from the lubricant supplier. Before dismantling any part of the lubrication systems, be sure that the power supply has been turned off and locked out in the MCC. Following the reassembly of the system, a pressure test must be conducted as described in the general instruction manual 19871 for hydraulic systems.

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