CKSC Revised Version
CEMENT KNOWLEDGE SKILL CENTRE Production Department
1
Doc-Nr : Prod-PR-WI-000 Cleaning Pre-Heater Cyclone Chokes Page 1 of 5
1. Objective
To ensure that when a Cyclone choke is cleared, it is removed in a safe manner without injury to
people or damage to equipment.
2. Scope
• This instruction is applicable to Yanbu plant only.
• Legal and other requirements
• Permit to work from CCR to do live work in pre heater.
• Permit from CCR to access Aumund tunnels (clinker conveyors)
• Hard hat - to be worn at all times.
• Long Heat resistance gloves - to be worn when actively poking.
• Safety boots - to be worn at all times.
• Overall - to be worn at all times.
• Heat resisting coat - to be worn when actively poking.
• Eye protection – to be worn at all times.
• Balaklava - to be worn at all times
• Dust masks - to be worn at all times.
• Safety Shoes spats - during poking.
• Face shield to be worn during poking, using air lances.
• Isolate and depressurize the air blasters on the pre-heater
• Ensure that no vehicles are in the near vicinity of the pre heater, move the vehicles to a safe
distance.
• Ensure that there are no cutting and welding equipment on or near the pre heater.
NOTE: You must ensure that all PPE is in good condition. All substandard PPE must be changed for new
PPE. Equipment to be checked before and after every use.
3. Hazard/Risk
Injury due to unsafe use of equipment and accidents. Illnesses and increased exposure levels due to
lack of wearing prescribed protective clothing.
4. Responsibility
The adherence to this instruction is applicable to Production Manager; Shift Supervisors/Foreman;
CRO’s and Field Patrollers as well as any maintenance staff or any stand by personnel that are actively
part of the cyclone choke clearing operation. This includes all persons of a cleaning team.
5. Procedure
Activate choke alarm at CCR for pre heater cyclones. (Hazards - Kiln in over pressure; hot gases; Dust &
Toxic gases).
Stop the kiln. - (Beware of hazards as specified in 1. at all times).
Ensure that Kiln is not in over-pressure state.
CKSC Revised Version
CEMENT KNOWLEDGE SKILL CENTRE Production Department
1
Doc-Nr : Prod-PR-WI-000 Cleaning Pre-Heater Cyclone Chokes Page 2 of 5
• Instruct Safety to demarcate the area around the pre heater and all entrances with barrier tape.
• All other workers in the area are informed to evacuate.
• Instruct a worker to demarcate the area around the Kiln and Aumund pit or tunnel and ensure
that no person is in the Aumund pit or tunnel. (Specially Lab personal)
• All other workers in the area are informed to evacuate.
• Get necessary poking equipment as specified.
• Check wind direction when pre-heater is approached.
• Never approach the cyclone choke alone. Ensure that you are at least two persons and have
radio contact.
• Shift Team Leader/Foreman to ensure that only experienced persons attend to the choke. The
fewer people the better.
• Determine the extent of the choke by “feeling” how full the cyclone is by poking it from the top.
• Identify the choke position by opening the inspection holes from the bottom - working your
way up.
• Open an inspection hole partially, so that it can be closed quickly and easily in the event of a
flow of material. Where possible, bolted covers should remain loosely secured by one bolt.
• When the extent of the choke is established, call the Standby for Production immediately.
• Wait for the instruction of the Shift Team Leader/Foreman on duty before poking is started.
• An experienced worker will take the poking bar or air lance and approach the specified poking
hole which is already opened. (The difference between a poking bar and an air lance is that the
air lance will agitate the hot material and may cause the hot material to back fire out of the
hole.
• Constantly inspect the feed pipe to ensure that all the material will go into the kiln. (The aim is
to clear the blockage by getting all the material into the kiln)
• Always close the poking hole when moving to the next one.
• Insert the bar into the poking hole, when obstruction is felt - move bar up and down creating a
hammer action on the material build up.
• The kiln should be barred regularly according to the kiln stop procedure to ensure that there
are no build ups at the kiln inlet.
• Avoid damage to refractory lining by careless use of poking equipment. Do not attack the lining
instead of the buildup.
• As soon as the blockage is removed or cleared, move to a higher position and repeat the
previous action.
• Water may be used only if instructed to do so by the Production Manager only.
CKSC Revised Version
CEMENT KNOWLEDGE SKILL CENTRE Production Department
1
Doc-Nr : Prod-PR-WI-000 Cleaning Pre-Heater Cyclone Chokes Page 3 of 5
Cyclone choke clearingCyclone choke clearing
1 2 3
(1) Clear discharge pipe (2) Remove air lance from discharge pipe
1. Clear discharge
(3) Work from pipe
an access point in the lower section to clear build-up
2. Remove air lance from discharge pipe
3. Work from an access point in the lower section to clear build-up
Identify and locate the cyclone choke and its position.
Cyclone choke: symptoms
• Temperature splitting
No flow of hot material over the product thermocouple
Thermocouple cools down
Gas still flows through the top of the cyclone at normal temperature
• Gas / material temperature differential increases
Can be used to trigger an alarm
Gas temperature
Material (product)
temperature
CKSC Revised Version
CEMENT KNOWLEDGE SKILL CENTRE Production Department
1
Doc-Nr : Prod-PR-WI-000 Cleaning Pre-Heater Cyclone Chokes Page 4 of 5
Very important to take note of the following:
• Remove all material spillages as soon as possible.
• Be alert, aware and adhere to all the procedural requirements.
• In the unlikely event of an accident that you and or others could be involved in, DO NOT panic
– follow the emergency procedures.
Prohibitions:
1. Evacuate the Burners platform and Pre-heater area when the kiln is in over-pressure.
2. When inspection holes are opened in pre-heater area, make sure all workers are level or above
the hole, never under or on lower level.
3. Check wind direction for dust and never put any body parts (your head, hands & feet) in any
poking hole or poking doors.
4. Always wait for the instruction of the Shift Team Leader/Foreman before poking is started.
5. Make sure while you are poking that the poking bar is not under any body part that could be
injured if any material from the top could cause the bar in a sudden upwards direction.
6. If material suddenly spills out of a poking hole, immediately stand back to a safe position.
7. Don't use water on poking bar unless you are instructed to do so by the Production Manager.
8. Water on warm material could cause a steam explosion.
9. Never walk through warm material that was spilled - it could cause severe burns.
10. Demarcate spillages with barrier tape until the spillages can be removed.
11. Remove spillages as soon as possible.
MANUAL POKING METHOD
• Ensure that the correct PPE is ready and in good condition.
➢ Safety shoes
➢ Over – all
➢ Hard hat
➢ Gloves
➢ Full face visor
➢ Poking Jacket
➢ Poking gloves
➢ Respirator
CKSC Revised Version
CEMENT KNOWLEDGE SKILL CENTRE Production Department
1
Doc-Nr : Prod-PR-WI-000 Cleaning Pre-Heater Cyclone Chokes Page 5 of 5
• Get all the necessary tools and equipment ready.
➢ Air hoses
Air lances
➢ Big Shifting spanner
1x 4pd Hammer
• Ensure that there is RADIO or Cell phone communication with CCR.
• Only TWO persons needed to clean riser duct, of which ONE shall be a Field Patrollers.
• Ensure that all blasters are switched off.
• Inform the CRO and Shift Team Leader/Foreman that you are ready to start cleaning the riser
duct.
• Connect the air hose to air lance.
• Open the riser door, insert the air lance and then OPEN the air.
• Body positioning must not be over the air lance. A lump of coating may fall on to the air lance,
which will lead to serious injury.
Be aware at all times for falling material or hot rushes of gas and dust.
• NEVER open more than one door simultaneously.
• As soon as poking is finished, inform Shift Team Leader/Foreman and CCR.
