Doc. No.

ELECTRICAL STANDARD TEMPL/ELEC./SOP-04

Version: 1.0
OPERATING PROCEDURES
Stationary Electrified Date: 19.09.2017
Page 1 of 5
Crusher Plants

1. “Site” Related :

(A) Only Authorised Personnel With Proper PPE are Allowed to enter the Working
Area .
(B) No Person Should be allowed to Work in the Plant Unless he/she has Undergone
Vocational Training .
(C) Ensure that the Loading & Unloading (i.e. , Stockpile & Hopper) Areas are Free
from Slip , Trip & Fall Hazards .
(D) Keep Work Area Clean and Free of Rubbish Things ; Do not allow Material Build-
Up around the Equipment , Over Walkways , Platforms , Ladders and Under
Conveyors .
(E) Keep Safety Equipment (i.e. , Fire Extinguisher , First-Aid Kit etc.) in selected
Places and ensure that Work Area Personnel know about the Location and Proper
Use of the Safety Equipment .
(F) Make Sure that required Guards and Warning Signs are duly Provided .
(G) Sufficient Illumination as Compliant to DGMS Standards Should be there in &
around the Plant Area .
(H) Be Alert to Conditions which may Unclear Vision in and around Work Area ,e.g.,
Welding & alike .

2. “Equipment” Related :

(A) An Authorized Person Should be responsible for Control , Management &

Supervision of Safe Operation of the Plant .
(B) Ensure that the Lock Out and Tag Out System of Electrical Equipment and the
Plant are Used Only When in Working & reliable Conditions .
(C) Make an Inspection of all the Equipment & Panels as per the checklist Concerned .
(D) Ensure the Provision and Working Condition of Belt Sway Switch , Pull Cord
Switch , Emergency switch, Limit Switch & Zero Speed Switch in Conveyors .
(E) Keep Equipment , Panels & Switchgear Clean , Dry and Free of Dust Or Oil or
Grease .
(F) Store Spare Parts , Consumables and Tools etc. in the designated Places When not
actually in Use .

Prepared By Approved By
 Doc. No.
ELECTRICAL STANDARD TEMPL/ELEC./SOP-04
Version: 1.0
OPERATING PROCEDURES
Stationary Electrified Date: 19.09.2017
Page 2 of 5
Crusher Plants

3. “Starting” Related :

(A) Only Authorized Personnel equipped With Proper PPE are allowed to Enter the
Control Room .
(B) Ensure that You have been Properly Instructed for Control Room Operation and
Trained to do So by an Authorized Person .
(C) Read and Understand each of the Warning Cautions and Instructions in the
Various Instruction Manuals .
(D) Ensure that none of the Equipment Or Conveyors is Under Operations Locally .
(E) Ensure that the Crusher Area is Clear of Unauthorized People before Starting the
Plant .
(F) Ensure to have Checked the Starting Siren before Starting the Crusher Plant .
(G) Locate the Emergency Push Buttons & be Familiar With Operating those .
(H) Ensure the Availability of Feed Material to the Crusher Plant .
(I) Start the Plant in Sequence as Per the Flow Sheet Concerned .

4. “Running” Related :

(A) Keep all Parts of Your Body and Clothing Safely Clear of the Rotating , Moving &
Electrically Charged Parts all the time .
(B) No Person Should be allowed to adjust , repair , clean or lubricate the Equipment ,
Panels Or Switchgear in Operation .
(C) Operate the Plant Within the Design Capacity .
(D) Ensure to Start Dry Fog Or Water Sprinkler System So as to reduce the dust
according to the Feed Material Or Climatic Conditions While running the Crusher
Plant .
(E) While the Conveyor Belts and Other Equipment are Under Operation , the Field
Workers Should remain at an easily reachable distance of an Emergency Stop
Control .
(F) If any Fault Occurs in any Circuit , Isolate the affected Part Without any delay
from the Main Circuit and it Should remain Isolated Until the Fault is rectified .

Prepared By Approved By
 Doc. No.
ELECTRICAL STANDARD TEMPL/ELEC./SOP-04
Version: 1.0
OPERATING PROCEDURES
Stationary Electrified Date: 19.09.2017
Page 3 of 5
Crusher Plants
5. “Stopping” Related :

(A) Ensure the Unavailability of Material in the Feed Hopper .

(B) Stopping the Plant Should be in Sequence as Per the Flow Sheet Concerned .
(C) Stopping Should be initiated Only When the Plant becomes Idle ; Never Stop On
Load .
(D) Trip the MCC Incomer Breakers & Put Lock Out and Tag Out Over those So that
the Plant Can no way be Started again Until the Locking Mechanism is authorizedly
removed .

6. “Electrical” Related Only :

(A) Maintenance and Repairs Should Only be Carried Out by Qualified and Trained
Personnel along With Well Insulated Tools .
(B) Earthing Should always be as Per the Standard IS : 3043 .
(C) Every Person Working On an Electric Supply Line Or Apparatus Should Use
Proper PPE to remain Protected from any Kind of injury .
(D) Ensure the Lock Out and Tag Out System of Supply Isolating Point before Starting
of any Work .
(E) Always disconnect Battery Leads before Carrying Out any Maintenance as Battery
Contains Sulphuric Acid , an Electrolyte Which Can Cause Severe Burns and
Produce Explosive Gases : Avoid Contact With Skin , Eyes or Clothing .
(F) No Person Should Work On any Electric Supply Line Or Apparatus and No Person
Should assist Such a Person Unless he is duly Authorized in that respect .
(G) Prior to Operating Electricity Powered Tools , Ensure that You are On a Dry
Surface .
(H) No Electrical Panel , Switchboard Or Wiring Should be Left Uncovered for any
reason .
(I) Check the Provision , Incorporation and Condition of the Interlocking System .
(J) Use Only Original Fuses of Specified Current Rating .
(K) While Working inside the Crusher Plant , Always Ensure to Maintain Minimum
Safety Clearance from the Over Head Power Lines if any .
(L) Upon Completion of any Maintenance Activity , always Test the Concerned
Equipment before Starting the Plant .

Prepared By Approved By
 Doc. No.
ELECTRICAL STANDARD TEMPL/ELEC./SOP-04
Version: 1.0
OPERATING PROCEDURES
Stationary Electrified Date: 19.09.2017
Page 4 of 5
Crusher Plants
7. “Maintenance” Related :

(A) Ensure that all required PPE are in good Condition and Correctly Used .
(B) Never allow Unqualified Or Untrained Personnel to attempt Removal or
Replacement of any Part of the Plant , Panel , Switchgear Or Equipment and
anyone to remove large Or heavy Components Without Suitable Lifting Tool .
(C) Ensure the Lock Out and Tag Out System of the Equipment of interest both
Electrically and Mechanically before Carrying Out any Maintenance .
(D) Take Off Rings, Watches, Necklaces and Bracelets etc. if required before Carrying
Out any Maintenance Activity in the Plant .
(E) Do not Carry Out Maintenance Work of any Fuel System near Sources of Sparks
Such as Naked Lighting , Wiring Or Welding Equipment .
(F) Always do the Maintenance as Per the Check List at Specified Intervals .
(G) While Working at Heights , Always Use the Specified Ladder for Proper Rest &
Safe Working of the Person(s) On the Ladder .
(H) After Maintenance , Always Examine all the Fuel , Lubricant and Hydraulic Fluid
Lines Concerned for Leaks , Loose Connections and Damage etc. before Energizing
the System Electrically ; Any Defects Found must be rectified Without Delay .
(I) Do not Stand Or Allow Anyone to Stand Under Anything that is being Hoisted .
(J) Ensure to determine the Weight of the Object or Load Prior to a Lift So that the
Lifting Equipment Operates Within its Capabilities .
(K) Ensure that Your Lifting Device is Positioned On the determined Centre of Gravity
Or Point of Balance .
(L) Ensure that all Used Consumables and Replaced Parts are always disposed off Safely
and With Minimal Environmental Impact .

8. “Tools” Related :

(A) Ensure the Use of Correct Tools for the Jobs to be Carried Out .
(B) All the Tools Should be kept in Good Condition .
(C) Inspect the Tools to be Used Periodically & if any Defects Found , those Should be
tagged as “Out of Service” .
(D) Inspect each Sling Or Chain for Cuts , Marks , Bent Links , bent Hooks etc. before
each Use . If in doubt , never Use it .
(E) Use Slings of Proper Reach ; Never Shorten a Line by Twisting . Never Use Bolts &
Nuts With Chain Slings .

Prepared By Approved By
 Doc. No.
ELECTRICAL STANDARD TEMPL/ELEC./SOP-04
Version: 1.0
OPERATING PROCEDURES
Stationary Electrified Date: 19.09.2017
Page 5 of 5
Crusher Plants
9. “Arc Welding” Related :

(A) Ensure there Should not be any Physical damage Occurred to the Welding Cables ,
Welding Holders & the Machine itself .
(B) Ensure Use of a Welding Cable of Sufficient Length for Earthing Purpose Up to the
Welding Point .
(C) Keep Flammable Gases (Acetylene & LPG) far away from any Welding Point .

10. “Grinding” Related :

(A) Ensure that the Area Surrounding the Grinding Location is Clear of People Since a
Stream of Sparks from an Angle Grinder Can travel Up to Several Meters and thus
Cause Injury .
(B) Check the External Surface of the Grinder including the Power Cable and Plug also
So as to Ensure that there are no Breaks , Damages Or Defects . Any Defective Tool
Should be Tagged Out of Service and repaired before it is Used again .
(C) Ensure to have a firm Hold of the Grinder With both Your Hands as it Kicks While
Starting Up ; Angle Grinders Should never be Used With One Hand therefore .
(D) Switch On the Grinder and Always allow it to build up Full Speed before You Start
Grinding .

11. “Diesel Generator” Related :

(A) Basic Installation , Operation & Maintenance Knowledge is a Must .

(B) Mountings Bolts of Engine , Radiator , Alternator , Canopy & Fan Guard etc.
Should be Checked and to be Found Tightened Under All Circumstances .
(C) Engine Oil , Radiator Water , Coolant , Hoses and Clamps of those Should always be
Monitored against Any Leakages .
(D) Fan and Alternator Belts’ Condition to be Checked Prior to Starting .
(E) Battery Terminals and Positive-Negative Cables Should be Checked Properly .
(F) Alternator’s Output Cable and it’s Lugs & Gland Should be Checked .
(G) Internal Wiring of DG’s OEM System Should be Checked Properly Prior to
Starting .
(H) Check that the Display Indications are Working and in Good Condition .
(I) When Working Under Or around DG Sets, for Inspections or Repairs etc., the DG
must be Locked and Tagged Out and Immobilized & Secured against Inadvertent
Movement .

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