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Contact with Hot Meal

1 What is the name of the 2 What are its specific objectives related to the Priority Unwanted
critical control for Contact
Event (PUE)?
with Hot Meal?
Early Detection of build ups Provisions for 1) priority warning on high alarms to trigger process adjustments by CCR
and blockages operator (up to stopping the kiln) and 2) automatic kiln emergency stop on high-high
alarms

3 What are the critical 4 What are the activities 5 What can be sampled from
control performance
within the management
the set of activities for
requirements to meet the systems that support verification, providing a
objectives? having the critical control clear image of the critical
able to do what is required? control status?
Kiln feed trips on high-high level of Annual testing of interlocked kiln Completion rate of annual trip testing
cyclone blockage detection (or fan emergency stoppage is scheduled Number of times a high-high alarm
trip) and automatically triggers kiln in Computerized Maintenance failed to automatically trip (review of
emergency stoppage (automatic Management System (CMMS) signal history)
deferred response) Failures to trip documented and reported
as critical incident in iCare

Central Control Room (CCR) Operator Alarm setpoints are included in Standard Operators confirm they have ability and
receives high priority warning alarm of Operating Procedure (SOP) authority to stop kiln during emergency
cyclone blockage detection and build-up Operators understand the SOP and are
levels (e.g. pressure drop and temps) empowered to start emergency kiln
stoppage

Critical instrumentation provides reliable Scheduled preventative maintenance and Percentage of PM completion rate
signals calibration in CMMS as per manufacturer’s Number of deferred PMs
requirements/Corporate CEM guidance Number of defects found during
Classified as highest priority and critical calibration and PMs
equipment in CMMS

CCR Operator receives timely information Patroller routine inspection includes Operators confirm they have ability and
of Kiln back-end condition and amount condition of kiln back-end area and authority to stop kiln during emergency
of hot meal leakage assessment of hot meal leakage
Action triggers for kiln stoppage are
included in SOP for CCR Operator

6 What is the target performance for critical 7 What is the critical control performance
trigger for shutdown, critical control review or
control?
investigation?
All the inspection, maintenance and testings are carried out Kiln emergency stoppage not started upon automatic demand
100% without any deferments. The kiln emergency stoppage from the critical sensors. Kiln emergency stoppage not started
sequence is fully effective during tests by operator: failure to follow the SOP for emergency kiln
stoppage. Unauthorised maintenance deferment without Plant
Manager’s written authorisation

Creation date: 01/2021 • The latest and only controlled version of this document is available on the HSE intranet.
© 2021 Holcim - For internal use only