Cirus is a 40 MW thermal research reactor with natural Uranium as a fuel. The reactor is cooled by demineralized light water and moderated by heavy water. During the refurbishing work, old failed fuel detection (FFD) system was replaced by new gamma based FFD system. Reactor operation resumed from Nov-2003 and since then six clad failed fuel (CFF) rod and one outer sheath rupture rod were identified and removed from the pile. This paper explains in detail about the procedure followed during CFF identification, removal and management of high volume of liquid and solid waste generated. It discusses the radiological problems faced and lessons learnt during split rod identification where the radiation field measured at the bottom of CFF rod varies between 0.5 - 1.0 Gy/h. It also discusses about the removal of CFF from the pile and the post split clean up operations on various components of primary coolant water system. All the activities during and after failed fuel rod removal are carried out in such a way that the radiation doses received by the personnel involved in above activity are As Low As Reasonably Achievable (ALARA).