Crusher Blockage SOP: Safe Handling and Prevention

Keywords: Blockages in Crushers, Crusher Blockage, Jaw Crusher Jamming, Cone Crusher Block

Crusher blockages (common in Jaw, Cone, and Impact Crushers) are serious operational issues. The core principle for handling them is “Safety First, Prevention Always.”

Step 1:  Emergency Safety Shutdown (E-Stop & LOTO)

1. Stop Feeding Immediately: Shut down all upstream feeders and conveyors to prevent more material from entering and worsening the crusher blockage.

2. Complete Shutdown and Lockout/Tagout (LOTO):

   • Press the emergency stop button on the crusher host.

   • Crucial Step: Disconnect the main power supply and execute the Lockout/Tagout (LOTO) procedure. Ensure no one can accidentally restart the equipment during cleaning.

Step 2:  Diagnose the Blockage Cause

Quick diagnosis facilitates efficient removal:

• Material Issues: High moisture/clay content? Tramp iron or oversized feed?

• Equipment Issues: Downstream conveyor or screen failure? Improper Closed Side Setting (CSS)? Uneven wear of liners/jaws/hammers?

• Operational Issues: Surge feeding or non-uniform feed rate?

Step 3:  Safe Clearing of the Blockage

Critical Note: NEVER use hands to clear the blockage!

1. Jogging/Reversing (If Feasible):

   • For Jaw Crushers, in the LOTO state, use a professional pry bar or hydraulic device to reverse the flywheel motion, moving the swing jaw back to release the jammed material.

2. External Clearance:

   • Use long steel bars, pry tools, or hooks from the discharge opening or inspection ports, clearing material progressively from bottom to top, outside to inside.

3. Internal Clearance (If Necessary):

   • If the blockage is severe, the crushing chamber cover must be opened.

   • Strictly follow Confined Space Entry safety protocols: ventilation, gas testing, safety harness, and dedicated full-time observer.

   • Thoroughly remove all jammed stones and tramp material.

Step 4:  Restart and Test Run

1. Ensure no tools or debris remain inside the crushing chamber.

2. Remove LOTO devices and restore power.

3. Start the crusher under no-load conditions for 2-3 minutes, checking for abnormal noise or vibration.

4. Once stable, slowly and uniformly begin feeding, gradually increasing to normal capacity.

Systematic Prevention of Blockages in Crushers