Document no. PP/Q/OPN/WI/31 Rev no.

2 Date - 13 /04 / 2022

Title : WORK INSTRUCTION FOR GCP DUST UNLOADING IN BALL MILL.

1.0 Purpose : Unloading of dust from Gas Cleaning plant to wet grinding ball mill by
Tanker through pneumatic conveying system
2.0 scope : This document is applicable in Ball Mill area of Pellet Plant 1.

3.0 Responsibility and Authority -

Sr. No Activity Responsibility Authority

1 Connecting Air hose & Dust Hose AO & shift In charge Wet Grinding Shift In charge
to tanker
2 Starting of Conveyor AO & shift In charge Wet Grinding Shift In charge
3 GCP Dust Pumping AO & lab person Wet Grinding Shift In charge
4 Filing and Maintaining of Shift In charge
AO and CCR Engineer
Records

4.0 Abbreviation / Definition –

 A/O : Area Operator

 CCR : Centralized control room
 DP : Differential Pressure
 MRSS : Main Receiving Sub- Station
 PSI :Pound per Square Inch
 S/I : Shift In-charge
 SPH :Slurry Pump

4.1 Procedure/ WI Category – C

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 -

Sl. No Name of JSW Safety Standard ID Number of JSW Safety Standard Tick mark the
applicable Std.( )
1 Safety Observation JSW/SAFETY/STANDARD/001
Document no. PP/Q/OPN/WI/31 Rev no. 2 Date - 13 /04 / 2022

2 Incident Investigation JSW/SAFETY/STANDARD/002

3 Contract Safety Management JSW/SAFETY/STANDARD/003

4 Road Safety JSW/SAFETY/STANDARD/004

5 Confined Space Entry JSW/SAFETY/STANDARD/005

6 Working at Height JSW/SAFETY/ STANDARD /007

7 Lockout and Tag out JSW/SAFETY/STANDARD/009

8 Permit To Work JSW/SAFETY/STANDARD/010

9 Electrical Safety JSW/SAFETY/STANDARD/015

10 Machine Guarding JSW/SAFETY/STANDARD/016

11 Personal Protective Equipment JSW/SAFETY/STANDARD/018 

12 Conveyor Safety JSW/SAFETY/STANDARD/021

13 Scaffolding Standard JSW/SAFETY/STANDARD/0 23

5.2 Activities with Hazard : JSA table

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

Job Safety Analysis -(JSA)

Sequence of Impact Potential Recommended safe What could Corrective action

Basic Job Hazard jobs go wrong
Steps/
Activities
5.2.1. Safety & 1.High pressure 1.1Make Sure air main 1.1In case of 1.1Drain air before
Connecting Air Health of air valve is fully closed puncture connecting to
hose & Dust pressurized tanker.
Hose to tanker air dust might 1.2. Area operator
injure worker should close air
main valve before
hose fixing.
Environment
Document no. PP/Q/OPN/WI/31 Rev no. 2 Date - 13 /04 / 2022

5.2.2 Starting Safety, 1.Come in 1.1 Safe distance from 1. 1 Worker 1.1Proper Training
of Conveyor Health contact with Conveyors hand might should be given on
running Belt stuck in belt conveyor safety
Conveyor conveyor idles
and pulley.

Environment 1. Atmospheric 1.1 Use dust mask 1.1 leakage of 1.1.1Use all PPE
air pollution dust might Properly.
containment
atmosphere
air and might
occur
Respiratory
problem

5.2.3 GCP Dust Safety, 1.Resperation 1.1Air pressure should 1.1Pressure 1.1.1Area operator
Pumping Health problem not be >2 bars regulator should check
might mal And should give
function clearance.
1.2.leakage of 1.2.1Use all PPE
dust might Properly.
containment
atmosphere
Environment

5.3 Detailed /Additional Activities –

 Checks required before unloading GCP dust tanker:

5.3.1 Connecting Air hose & Dust Hose to tanker:

5.3.1.1 Shift In charge & Area Operator will ensure ball mill or water circuit is running.
5.3.1.2 If in case ball mill is not running area in charge should inform control room
engineer to start water circuit and start WBC3/WBC4 belt in local.
5.3.1.3 Area Operator should help driver to park tanker at correct position for hose
connection and avoid road blockage.
5.3.1.4 Once GCP Tanker is parked Area operator should ensure that wheel stoppers are
placed below tires.
5.3.1.5 After wheel stoppers are placed area operator along with contract labors to fix
air hose & dust discharge hose.
Document no. PP/Q/OPN/WI/31 Rev no. 2 Date - 13 /04 / 2022

5.3.1.6 AO should ensure discharge hose pipe to be jam free before fixing it to the tanker
to avoid line jamming.
5.3.1.7 Water from air receiver tank should drain out manually and ensure no water in
airline to prevent line jamming in dust discharge hose and bunker by moisture.
5.3.1.8 Air receiver tank should have air pressure of 6-7 kg/cm2

5.3.2 Starting of Conveyor:

5.3.2.1 Area Operator should ensure RAV is running and dust bunker is empty or below
40 Percent.
5.3.2.2 Pressure control valve should open to receive 1.5 kg/cm2 air pressure for
conveying.

5.3.3 GCP Dust Pumping:

5.3.3.1 Once 1.5-2 kg/cm2 pressure is developed inside GCP Tanker, tanker discharge
valve should open. Water sprinkler at RAV to be opened to prevent dust spillage.
5.3.3.2 No one can climb (casual/worker/driver/helper) over GCP tanker in pellet plant in
case of any problem with tanker it should be return to GCP plant.
5.3.3.3 In case of jamming of pumping line or for bag filter cleaning work divert tanker to
Ball mill 2 direct pumping line to avoid any delay in the process.

 Checks required after unloading GCP dust tanker

5.3.3.4 Once tanker is empty GCP Tanker discharge valve to be closed and keep air hose
connected to clear dust hose line for 10 min
5.3.3.5 Once air hose and Dust Discharge hose is removed area operator should give
clearance to driver to remove stopper and to move the vehicle.
5.3.3.6 Area operator should inform shift in charge the time which tanker got empty and
the tonnage unloaded.

5.3.4 Filing and Maintaining of Records:

Sl Name of Record Record No. Maintained by Retention Period
no.
1 Area Operator Log Book PP/Q/OPN/F/01 CCR In charge 6 months
Document no. PP/Q/OPN/WI/31 Rev no. 2 Date - 13 /04 / 2022

2 Shift In charge log Book PP/Q/OPN/R/01 Shift In charge 6 months

6.0 IMS Document References:

1. PP/Q/OPN/S/04
2. PP/O/OPN/HIRA/01: HIRA Pellet Operation. SI.no: 37 & 38

7.0 Documentation and Records:

Sl Name of Record Record No. Maintained by Retention Period

no.
1 Wet Grinding CCR Log Book PP/Q/OPN/F/01 CCR In charge 1 year
2 Wet Grinding Shift In charge log Book PP/Q/OPN/R/01 Shift In charge 1 year
3. Wet Grinding Ball Mill Log Book PP/Q/OPN/F/02 Area Operator 1 year

8.0 Enclosure - NIL

Area In charge Section Head Plant HOD