How to ensure safety under Refractory

Roofs
Refractory
PR RFR P10-25 V1.0 - MAY 2010 1/7
Note: this procedure replaces procedure PR RFR P07-27
“How to ensure safety for cyclone lining work”

Introduction
The purpose of this guideline is to recognize the specific hazards related to working under refractory roofs and
to outline the necessary requirements for this type of work.

The main risk is seen when working under roofs with a monolithic lining where we cannot judge, as per today,
if the metallic anchors or the ceramic anchor clips/claws are corroded and if the concrete panels are well in
place. Infiltrated salts are hydroscopic and any liquid phase is accelerating the corrosion process. Concrete may
appear fine but metallic anchors (clip/claw) could be severely corroded by various salts. Sagging concrete panels
are not always clearly identified but could slip later during the shutdown while lining works are in progress.
Dependent on panel size, the weight of a full panel is between 200kg to 300kg.

Brick roofs need to be checked for sagging phenomenon and the supporting steel construction should be
checked for integrity.

The cooler roof is supported by metallic beams which are commonly subject to overheating as they are covered
by clinker dust. Overheated metallic beams loose their strength and may not be able to support the load of the
refractory lining of the roof.

The following particular risks need to be addressed:

ƒ High temperature and dust during inspection due to hot lining, coating and material accumulation (meal
flushes)
ƒ Coating, refractory (corroded anchors) or pieces from the dip tube (thimble) may fall
ƒ Falling material / tools from above cyclone through meal pipe
ƒ Air blasters, compressed air nozzles, cardox
ƒ Radioactive level detection
ƒ Blocked escape routes (two ways of access and exit – confined space regulation)
ƒ Heavy loads on scaffold during demolition and refractory lining works
ƒ Such hazards can be eliminated or reduced to an acceptable level by appropriate prevention measures.

This guideline is applicable to all the employees and contractors of Lafarge.

All rights of reproduction, representation, adaptation and translation relating to this report belong to Lafarge SA. Lafarge SA reserves the right to exploit this
report or not and to freely distribute it to all of its current and future subsidiaries worldwide in any form, whether paper, electronic or digital, including via Procedure Template developed by
internet and/or intranet. This report along with its content is of a confidential nature. In particular, it may not be reproduced, copied, transmitted, published,
divulged and/or appropriated in whole or in part for personal use or for use by a third party without prior consent from Lafarge Cement Division / Direction des
Performances Cimentières, except for reproduction by or for affiliated Lafarge companies.
 How to ensure safety under Refractory
Roofs
Refractory
PR RFR P10-25 V1.0 - MAY 2010 2/7
Note: this procedure replaces procedure PR RFR P07-27
“How to ensure safety for cyclone lining work”

Prerequisites
ƒ Task specific risk assessments and job plans/safe work procedures should be generated before works
start.
ƒ External inspections for indication of potential internal failings such as dust, excessive corrosion,
sagging, bulging of shell, deformation, hot spots etc
ƒ Before kiln stops, extensive automatic and/or manual cleaning has to be performed (air blasting, Cardox
shot, Woma guns…) to remove or reduce build ups
ƒ Perform the full Energy Isolation (EI), apply the full HERA / HECP (Hazardous Energy Risk Assessment /
Hazardous Energy Control Procedure)
ƒ Full skin protection, particularly during demolition works
ƒ Follow Confined Space Regulations
ƒ Follow WAH and Scaffold Regulations
ƒ Gas temperature inside the cyclones and risers can cause heat stress and hypothermia, for workers.
ƒ Ensure negative pressure in the PHT system for draft and ventilation
ƒ Inspection openings at the cyclone roof shell are to be installed to check the refractory (monolithic)
lining.
ƒ Visual inspection for integrity of the lining
ƒ Mechanical check with a rod to get some understanding of the integrity of metallic anchors and the
fixing of the refractory lining
ƒ If necessary, provide inspection openings, one for each concrete panel to cast and/or to inspect
ƒ Hanging or loose debris are to be cleaned from outside using the access holes and manhole doors.
ƒ Demolition workers should be trained and competent and if necessary registered and certified by the
employer.
ƒ Guarantee easy access and exit
ƒ Handhold above cyclone doors
ƒ Available steps for access and exit

All rights of reproduction, representation, adaptation and translation relating to this report belong to Lafarge SA. Lafarge SA reserves the right to exploit this
report or not and to freely distribute it to all of its current and future subsidiaries worldwide in any form, whether paper, electronic or digital, including via Procedure Template developed by
internet and/or intranet. This report along with its content is of a confidential nature. In particular, it may not be reproduced, copied, transmitted, published,
divulged and/or appropriated in whole or in part for personal use or for use by a third party without prior consent from Lafarge Cement Division / Direction des
Performances Cimentières, except for reproduction by or for affiliated Lafarge companies.
 How to ensure safety under Refractory
Roofs
Refractory
PR RFR P10-25 V1.0 - MAY 2010 3/7
Note: this procedure replaces procedure PR RFR P07-27
“How to ensure safety for cyclone lining work”

Basic rules

1. General
ƒ Ensure that personal protective equipment are worn, including a dust, fumes mask (appropriate for the
condition) and safety harness, if required.

Implement full Energy Isolation (EI)

1.1 Lock-out procedure:
Before beginning of inspection, scaffolding, demolition and refractory installation work, ensure the lock out
procedure that involves:
ƒ 1. Electrical lock out
ƒ 2. Pneumatic lock out
ƒ 3. Mechanical lock out
ƒ 4. Release pressure from air blasters
ƒ 5. Stop Gamma radiation for level detection in cyclones!
ƒ 6. Please note that this is not an extensive list of all hazardous energies

1.2 Confined Space Regulation

ƒ Permit must be obtained prior to entry

1.3 Electrical Precaution

ƒ All equipments used within cyclones should be equipped with a constant pressure switch or control (also
called the dead man switch) that will shut-off the power when the pressure is released.
ƒ Be sure that the electrical equipment is double insulated to reduce the risk of fire and electric shock.
ƒ Electrical equipment should be limited to 110V or less (Prevent risk of electrical shock. This could be
achieved by measures such as applying “small safety voltage” (<50V) or apply a “separation
transformer, class II”, for electrical tools used in steel vessels. For details please refer to your electrical
department.)
ƒ Conform to any local electrical regulations (such as the use of safety isolating transformers)

1.4 Lighting
ƒ Sufficient lighting must be provided to ensure a safe work environment.
 How to ensure safety under Refractory
Roofs
Refractory
PR RFR P10-25 V1.0 - MAY 2010 4/7
Note: this procedure replaces procedure PR RFR P07-27
“How to ensure safety for cyclone lining work”

Basic rules

2. Specific

2.1 Lock out

Electrical lock out

ƒ As per site EI hazardous energy control procedure (HECP)

Mechanical lock out

ƒ Lock out meal pipe flaps with a blind plate and/or remove flaps to be able to effectively remove debris
ƒ During inspection mechanically lock the flap damper below each cyclone in closed position, ensure
safe removal of debris when unlocking

Potential Solution
 How to ensure safety under Refractory
Roofs
Refractory
PR RFR P10-25 V1.0 - MAY 2010 5/7
Note: this procedure replaces procedure PR RFR P07-27
“How to ensure safety for cyclone lining work”

Basic rules

Pneumatic lock
ƒ Lock out air blasters and empty tanks

Isolation of Gamma Rays

ƒ In case the plant uses Gamma Rays level detector at the cyclone cones and other places, the source must
be fully isolated.

Isolation of SNCR or SCR

ƒ In case the plant uses Ammonia, lock out the system and detect residues levels for further treatment

Hanging coating and loose refractory cleaning or loose pieces of the dip tube
(thimble)
ƒ The hanging coating and loose refractory at cyclone roofs must be cleared before entering the cyclones
for scaffolding work.
ƒ Use the manhole doors and poke holes provided in the cyclones for this purpose. Provide inspection
openings in the roof to check the steel structure and anchoring for corrosion.
ƒ Ensure that manholes and/or cleaning opening positions and sizes meet the need of cleaning most
frequent build ups. Any additional opening required for emergency access/cleaning must be properly
welded shut and returned (refractory) to the original situation.
 How to ensure safety under Refractory
Roofs
Refractory
PR RFR P10-25 V1.0 - MAY 2010 6/7
Note: this procedure replaces procedure PR RFR P07-27
“How to ensure safety for cyclone lining work”

2.2 Scaffolding work

ƒ Follow Lafarge WAH standards and scaffold regulations
ƒ Close the bottom level with a re-enforced platform of wooden planks
ƒ It is recommended to modify cyclones and risers to install self supporting platforms every 2.50m to
3.00m to have a safe working level and to reduce the impact of dropping concrete blocks. Each cyclone
shall be decked out as close to the dip tube (thimble) as possible. On the deck, closest to the dip tube
(thimble), an extra scaffold should be installed in a progressive manner to inspect the roof lining closely.
This scaffold should remain in place to reduce the potential impact of dropping concrete panels while
demolition or lining works are in progress.

2.3 Demolition work

ƒ Select the proper demolition equipment for the job.
ƒ Follow safety recommendation of equipment supplier and/or Lafarge standards
ƒ Do not allow anyone to stand in front or in line with the demolition equipment during this test.
ƒ Manage housekeeping to keep exits free from debris and do not overload platforms
ƒ Cordon off the manhole area while transporting the broken refractory to the pre-heater floor

2.4 Brick lining work

ƒ Keep the work area clean.
ƒ Do not over load the service platform with refractory.
ƒ Any cutting of brick is to be carried out outside the cyclone
ƒ Welding fumes require precautions in the vessels above as well
ƒ Check anchors for proper welding
ƒ Simultaneous brickwork one above the other in vertical directions is only allowed if working areas are
isolated
ƒ Leave the escape route through manhole door free from brick or tools
 How to ensure safety under Refractory
Roofs
Refractory
PR RFR P10-25 V1.0 - MAY 2010 7/7
Note: this procedure replaces procedure PR RFR P07-27
“How to ensure safety for cyclone lining work”

2.5 Concrete work

ƒ Ensure proper ventilation in the cyclones while welding anchors (minimal dust during welding)
ƒ Check if anchors are properly welded and if they are welded by competent welders! This will reduce the
risk of failures.
ƒ Ensure that the castable mixer machine is well protected from moving parts and dust emission
1 See procedures "How to ensure safety for castable mixing"
and "How to ensure safety for brick cutting"

2.6 Closing after work

ƒ Ensure all shuttering materials are removed
ƒ Inspect the cyclone for foreign material after the removal of scaffolding
ƒ Free the double flap from mechanical lock
ƒ Conduct ball or brick drop test to ensure that the material path is free
ƒ Close manholes and inspection doors. Seal them properly
ƒ Restore all lock outs back in place.
ƒ Clean the pre-heater floor before hand over the cyclone for operation