By FLSmidth & Yanbu Cement TRAINING...

Cement Knowledge Center By FLSmidth & Yanbu Cement

TRAINING CATALOGUE


Cement Knowledge Center Training Catalogue 3

TRAINING CATALOGUE

4 Cement Knowledge Center Training Catalogue

The fastest, most effective way to

upskill cement plant staffFLSmidth and Yanbu Cement have teamed up to launch a cement production training center in the Kingdom of Saudi Arabia. The Centre's objective is to promote and develop the relevant technical and management competencies of local cement plant operators within all areas of cement production.

The FLSmidth Yanbu Cement Knowledge Center aims to develop the best-qualified professionals who can contribute to improving cement industry competencies and standards in the Middle East region.

Backed by industry heavyweightsThe Cement Knowledge Center will leverage the powerful syner-gies and proven best practices of FLSmidth and Yanbu Cement. FLSmidth is responsible for all educational content and will provide experienced, qualified instructors, while the training courses will be offered at Yanbu Cement’s production facilities, showcasing some of the latest cement production technologies.

Yanbu Cement One of Saudi Arabia’s largest cement manufacturers, Yanbu Cement has a total installed capacity above 7.0 million tonnes of clinker and cement dispatch capacity above 10 million tonnes per year.

Yanbu Cement is committed to furthering the broader agenda of the cement industry in Saudi Arabia, including effective Saudization and improving all aspects of the working environment.

FLSmidth As the leading full-service supplier of productivity enhancing solutions to the global cement industry, FLSmidth integrates pioneering products with extensive process know-how and end-to-end services. The company has a long history of providing training services in all aspects of cement production technology and management. Qualified instructors bring real-world experience of having worked directly in cement plant operations with a high level of academic competency.

Why a Cement Knowledge Center?Through government initiatives such as Saudization, Saudi Arabia and neighboring countries are increasingly requesting that facilities such as cement plants are operated and maintained by a local workforce. The Cement Knowledge Center has been created to meet this requirement. It provides the ideal forum for training plant operations staff with all the necessary skills and theoretical knowledge related to cement production.

The Cement Knowledge Center is located at Yanbu Cement's plant in Saudi Arabia. The unique training facility offers a combination of classroom and practical training on the plant.


From short, practical training courses through to comprehensive certification programs, the Centre caters for the day-to-day development needs of key positions in cement plant operations.

Full range of training programmes

The training center offers full certifica-tion programs Certification Programs for the most significant plant func-tions, including plant engineers, production technicians and lab technicians. All programs include practical and theoretical training at the academy.

Duration6-12 months

Programmes ■ Engineer Professional Development

Program (EPDP) ■ Central Control Room Operators ■ Patrollers/Production Technicians ■ Process Engineer ■ Quality Control ■ Mechanical Inspectors ■ Electrical Inspectors ■ Planners ■ Central Control Room

Operators Coach

CertificationParticipants are expected to put their learnings into practice on the job as part of the certification.

Participants who demonstrate sufficient competencies during their training will be awarded with an official qualifica-tion. This certifies that the participant has achieved the know ledge, skills and abilities to ensure safe, uninterrupted plant operations.

Participants will achieve essential knowledge and skills within specific discipline areas.

Programmes ■ Health, Safety & Environment ■ Quarry Operation & Raw

Material ■ Quarry Control & Laboratory

Practices ■ Proces & Operation ■ Electrical Maintenance ■ Instrumentation & Automation ■ Mechanical Maintenance

Duration2-3 months

These courses will enhance participants’ knowledge, skills and understanding within specific discipline areas. The training covers various site skills through group work, technical measure-ment and individual evaluation.

Courses ■ Health, Safety & Environment ■ Process & Operation ■ Quarry ■ Maintenance ■ Product & Quality

Duration5-10 days

The purpose of vocational training is to educate higher level technicians. The courses will provide participants with practical hands on experience with industry specifics.

Courses ■ Mechanical Technicians ■ Electrical Technicians ■ Instrumentation Technicians ■ Sheet Metal Work ■ Welder

DurationMinimum 40 weeks depending on the program

CERTIFICATION PROGRAMMES

MEDIUM TERM PROGRAMMES

SHORTER COURSES

VOCATIONAL TECHNICAL COURSES


Content

Process & Production 8Process Knowledge for Non-Process Engineers 9Cement Chemistry 10Fuel Safety, Handling & Combustion Technology 11Operational Safety 12Gas Handling 13Grinding Technology Level I 14Refractory I 15Kiln Operation I 16Process Optimization Level I 17Environmental Matters 18Grinding Technology Level II 19Kiln Operation II 20Process Optimization Level II 21Refractory II 23Performance Management Seminar 24AF & ARM Co-processing 25

Electrical Maintenance 26Electrical Maintenance Level I 27Energy Isolation 28Basic Maintenance Documentation (electrical) 29Electrical Inspection Level I 30Electrical Inspection Level II 31Instrumentation 32

Maintenance 33Mechanical PlanningLevel I 34Hydraulics 35Mechanical Inspection Level I 36Heavy Duty Gear and Reducer Technology 37Crushers, Stackers & Reclaimers 38Ball Mill Mechanics 39Vertical Roller Mill Mechanics 40Kiln Mechanics 41Cooler Maintenance 42Maintenance Manager Seminar 43Mechanical Maintenance Managers Seminar 44Root Cause Analysis & Down Time Analysis 45Material Handling 46


Quality & Product 47Cement Quality Level I 48Product Applications Fundamentals 49Effective Data AnalysisLevel I 50Laboratory Mastery 51Concrete Durability 52Cement Usage Properties 53Clinker Quality Mastery 54Raw Material & Raw Mix Design 55Alternative Fuels & Alternative Raw Materials 56Quality Mastery Program 57

Quarry 58Quarry Operations Safety 59Geomining & Raw Mix 60Quarry Operations & Process Risks 61Mining Operations 62Drilling & Blasting 63Mines Planning 64

Certification Programs 65What’s is Certification? 66Key Operators & Technicians Certification 67Engineer Professional Development Program 73Engineer Professional Development Program 75

Vocational Training 78Vocational Training 79Electrical Technician 80Mechanical Fitter Technician 81Mechanical Workshop Technician 82Welder Technician 83

Prices 84PricesFull catalogue 85Engineer Professional Development Program 88Process & Production Specialization 89Geo-mining Specialization 90Quality Control Specialization 91Mechanical Maintenance Specialization 92Electrical Maintenance Specialization 93Automation Specialization 94


Process & Production

Process & Production 8Process Knowledge for Non-Process Engineers 9Cement Chemistry 10Fuel Safety, Handling & Combustion Technology 11Operational Safety 12Gas Handling 13Grinding Technology Level I 14Refractory I 15Kiln Operation I 16Process Optimization Level I 17Environmental Matters 18Grinding Technology Level II 19Kiln Operation II 20Process Optimization Level II 21Refractory II 23Performance Management Seminar 24AF & ARM Co-processing 25


MethodsPresentations, discussions, exercises, calculations

PrerequisitesOn-the-job knowledge (1 – 4 years)

AudienceNon-process engineers of a plant

Duration 3 days

Price USD/trainee 2.000 SAR/trainee 7.500

Objectives After completing the training, the trainee will we able to:

■ Understand and describe fundamentals of the burning and grinding process

■ Understand and describe the main technologies of the burning and grinding process

■ Understand and describe the operational aspects of these progresses

■ Get familiar with kiln or mill audits as a means to assess a workshop

■ Get knowledge about operational KPIs and the relevance of benchmarking

■ Understand the specific needs of a process engineer ■ Describe the interfaces to the process department and

develop cross-functional thinking to improve communication and teamwork

Content ■ Cement making process from quarry to cement grinding ■ Clinker burning principles and technology ■ Grinding principles and technology ■ Raw mix fundamentals

Process Knowledge for Non-Process Engineers




AudienceNew Hired Engineers

Duration 5 days

Objectives ■ Understand and describe the raw material used in the industry ■ Understand and describe the transformation andmetallurgicalc

reactions happening during the burning process ■ Describe the main composition of raw mix & control parameters ■ Explain the impact of each modulus on clinkerization process ■ Understand and describe the effect of clinker formation phases

in the burning process ■ Understand and describe the main elements of clinker formation ■ Describe how the phases of the clinker is formed formation ■ Describe the Impact of the different ratios of the Kiln feed ■ Describe the impact of the major elements of clinker on

cement quality ■ Describe the mechanical performance of each clinker phase ■ Describe Cement hydration & the impact on cement hardening

properties Content

■ From Raw Mix to Clinker: main transformation steps ■ Clinker mineralogy ■ Clinker quality impact of major elements ■ Cement hydration & impact on cement properties ■ Cement properties during storage

Cement Chemistry





AudiencePlant Management Team, Engineers and Supervisors

Duration 5 days

Objectives To provide the knowledge and tools necessary to assess the safety and operational requirements for a solid/liquid fuel shop from storage/stockpile through to firing including high volatile matter solid fuel. After completing this training, the trainee will:

■ Understand and be able to assess the basic safety requirements for fuel operation and apply Industry best practices, tools and guidelines

■ Gain knowledge of the dangers involved during fuel operations ■ Gain general knowledge on other fuel safety and other solid fuels ■ Gain general knowledge on other fuel safety standards

Content ■ Core Process Risks during Fuel Handling & Operations ■ Hazard in coal grinding & mitigating action ■ High volatile matter coal/liquid usage and handling ■ Fuel safety standards ■ Fuel safety Management ■ Co grinding of different solid fuels ■ Combustion Technology

Fuel Safety, Handling & Combustion Technology



MethodsPresentation, discussions and interactive breakout exercises

PrerequisitesNone

AudiencePlant managers, safety responsible, process, production and maintenance engineers

Duration 2 days

Objectives Core Process Risks were identified as the most serious risksSpecifically related to the process of Cement Manufacturing.

By completing the virtual training, participants will be able to: ■ Recognize the risks of having spillages of hot material ■ Understand the main prevention and protection methods ■ Know the necessary requirements to avoid all safety

incidents occurred by incidental production stoppage ■ Know the internal and external reference documents

Content The session is based on the CPR core process risks about preventing risks related to hot meal and hot gas and covers:

■ Safety Standard: LOTOTO, WAH, Confined Space, Hot work ■ Risk Assessment related to Operational Safety ■ Main risks of hot material spillages ■ Preventive actions ■ Core Process Risk Guidelines ■ Examples of incidents ■ Sharing experience

Operational Safety



MethodsPresentations, On site Measurements, Exercises, Case studies, Group Work

PrerequisitesNone

AudienceProcess & Environmental Engineers

Duration 5 days

Objectives ■ Understand the importance of reliable Process Measurements

in order to develop the right action plans to improve plant’s performance

■ Perform basic measurements (temperature, moisture, pressure, etc.)

■ Perform correct sampling (Gases, materials, etc.) ■ Identify and select the right measurement points ■ Select the suitable measurement technique, equipment

and range according to process conditions ■ Understand ISO measurement standards ■ Measure gas composition & gas moisture ■ Ensure regular maintenance and calibration (Portable Gas ■ Analyzers, infrared pyrometer, thermocouple, stroboscope,

non-contact tachometer, isokinetic dust sampling probe, digital manometers, S and L pitot tubes and anemometers)

■ Check accuracy of “Process Control Instrumentation” (for temperature, pressure, rotation speed)

■ Perform air in-leakage measurements techniques ■ Fan “Performance Management” (fan characteristic,

curve determination) ■ Perform Gas flow calculations ■ Perform audits calculations and set recommendations

Content ■ Gas Fundamentals & Basics ■ Flow Measurement ■ Measurement at the Cooler & Preheater ■ Calculation of the Flows / results ■ Thermodynamics and Heat capacities ■ Fundamentals of Heat Balances Calculations ■ Fan Systems ■ Process Planning Activity ■ Process Measurement Techniques ■ Process Control Instrumentation

Gas Handling



Methods ■ Pre-course assignments, Classroom sessions,

Workshops, site-visits ■ PC’s/Laptops for the simulator training are required

AudienceGrinding process staff, process engineers/specialists, mill operators, production Engineers

Duration 5 days

PermissionsAccess to/from the mill installations. Relevant instrument readings

PurposeThe purpose of the training is meant to cover and give the partici-pants relevant knowledge, skills and understanding of ball mill grinding technology and its related topics.

Learning objectivesUpon completion of this training, the students should be able to:

■ Describe the material & gas flow in the raw/cement mill installation

■ Conduct the standard operation principles for the grinding processes

■ Understand the automatic control loop ■ Perform heat balance calculations ■ Knowing the interlocking's alarm limits and their consequences ■ Execute start & stop procedures and their standard sequences ■ Describe the raw materials, their composition and influence

on grinding performance ■ Describe and understand the CCR instrumentation outputs ■ Test the internal procedures for efficiency and consequences

Main contents ■ Ball Mill Safety: LOTOTO, WAH, Confined Space, Hot Work ■ Ball Mill operation – start/stop procedures ■ Separators, types and operation – Separator efficiency

and particle distribution ■ Ball Mill installations and grinding media charges ■ Grinding technology and operation through modern real

time simulation programs ■ Case stories group works solving specific simulations tasks ■ Mitigating actions during operation ■ Exercises and technical calculations

Grinding Technology Level I



Methods ■ Presentations, classroom exercises/workshops ■ Practical part with on-site exercises for brick lining

and concrete application (plant / supplier visit)

MethodsPresentation, Exercises on practical cases, Field Visit

PrerequisitesPlant personnel involved in refractory management

Audience ■ Process managers/ engineers ■ Production managers/ engineers ■ Optimization managers

Duration 5 days

Objectives After completing the training, the trainee will be able to:

■ Identifying the main types of bricks, their characteristics and properties and their place in the refractory lining of kiln, cooler and preheater

■ Understanding the state of the art refractory bricklaying ■ Describing the main types of refractory concrete and

its placing methods ■ Applying the rules governing refractory choice in specific

zones (nose rings, retention rings) ■ Using the bricking database

Content ■ Bricking Safety: LOTOTO, WAH, Confined Space, Hot Work ■ Types and characteristics of refractory ■ Techniques applied refractory installation ■ Usage of refractory for different zones ■ Rules for selecting bricks & castable for specific zones ■ Castables

Refractory I



Methods ■ Presentations, classroom exercises/workshops ■ Classroom presentations ■ Exercises ■ Site visit

Audience

■ Production Engineer ■ Shift Coordinators ■ Quality Engineers

Duration5 days

Objectives Bring a significant contribution to improve the plant reliability and performance factors by:

■ Improving kiln & mill stability ■ Implementing consistent control strategy from shift to shift ■ Developing higher ability to achieve and maintain production

& quality targets ■ Bringing equipment back into target range in optimal time ■ Reducing the number of production & process incidents (refracto-

ry incidents, process related incidents) ■ Control all major process lines within the cement manufacturing

operation ■ Monitor continuously all plant process lines (ensuring employee

safety, stable equipment operation, equipment integrity, operating targets & environmental regulations)

■ Control product quality at all stages of the cement manu facturing process

■ Coordinate plant resources to troubleshoot, inspect, and maintain plant equipment as required, to meet production demands and prevent failures

■ Maintain awareness of the automation system control strategy and makes recommendations for continuous improvement

To increase the knowledge of the trainees to a high standard through presentation and discussion. After completing this training, the trainee will be capable of:

■ Describe the basic principles of kiln operation ■ Understand the mechanism of combustion ■ Understand basic kiln strategy ■ Predict the kiln reactions at steady conditions when major

set-point changes are made ■ Define the important factors when increasing kiln production ■ Use the kiln operational guidelines for precalciner ■ Perform a kiln start-up procedures ■ Understand the effects due to volatile elements ■ Understand the operating principles of the cooler ■ Clean cyclone blockages according to Industry Best Practices

Kiln Operation I

Content ■ Principles of kiln operation ■ Kiln operational guidelines ■ Cooler systems



Methods ■ Laptop computer ■ Exercises on practical cases ■ Practical exercises using EXCEL ■ Replicating plant condition ■ Manufacturer's equipment and documentation ■ Study case and Exercises documentation

Audience ■ Production Manager ■ Production Engineer ■ Process Manager ■ Process Engineer ■ Control System Engineer ■ Electrical Engineer

Duration 5 days

Objectives ■ You will acquire a basic understanding of combustion and fuels,

beware of fuel Safety Basics, and understand the solid fuel grinding circuits and how to start optimizing a solid fuel Mill

■ Understanding the basic statistics and the sampling theory ■ Calculating fundamental sampling error and estimating the

parameters of the sampling constant ■ Designing protocols and calculating analytical and sample

preparation errors ■ Determining correctness of physical extraction and sampling

device ■ Analyzing of a sampling and preparation protocol ■ Understanding the basic theory of statistics ■ Calculating and interpreting basic statistics ■ Applying the theory for statistical process and quality control ■ To be able to solve plants problems by performing effective

data analysis applying level 1 statistical methods and tools: ӡ Quickly and effectively using key basic statistical functionalities and possibilities of EXCEL software

ӡ Benchmarking results with other plants Data related to Quarry & Geomining, Product & Quality, Process & Environment, and Production activities. For other type of data such as Finance data, the support needs to be adapted but logic remains the same

■ Know basic hardware and software characteristics of preferred PCS

■ Be able to develop an application software from call tender to site commissioning

■ Be able to update plant automation documentation for main tenance and further developments

Process Optimization Level I

Content ■ Fuels & combustion theory ■ Kiln heat & mass balance ■ Gas calculations ■ Combustion & kiln control ■ Waste fuels ■ Result interpretation/action plan ■ Clearly understand the role of the process function as related

to pyro processing ■ Identify the technical aspects of fuel combustion in the kiln ■ Statistics and sampling theory ■ Sampling preparation ■ Statistical process and quality control ■ Introduction to Quality control management software



MethodsPresentations, Exercises, Case studies

PrerequisitesNone

Audience ■ Plant Managers, Environment Managers ■ Process Managers, Optimization Managers ■ Production Managers, Environment Engineers ■ Process Engineers, Production Engineers

Duration 5 days


■ Understand & Implement Environment Management System as applicable to plant situation

■ Explain, calculate and analyze emission data & monitoring ■ Identify link between emissions & process levers ■ Understand, analyze and diagnose accuracy of environmental

emission reporting ■ Understand the main elements for Environment Audit

Content ■ Gas Fundamentals & Basics ■ Introduction to Environment & Pollution control ■ Environmental regional performance ■ Emissions ■ Dust collection & bag filter management ■ Environmental Audit ■ Environment Management System (EMS) ■ Environmental Reporting

Environmental Matters



Methods ■ Pre-course assignments, Classroom sessions, Workshops,

site-visits ■ PC´s/Laptops for the simulator training are required

AudienceGrinding process staff, process engineers/specialists, mill operators

Duration 10 days

PermissionsAccess to/from the mill installations

PurposeThe purpose of the training is meant to cover and give the participants relevant knowledge, skills and understanding of vertical mill grinding technology and its related topics.


■ Describe the material & gas flow in the raw/cement mill installation

■ Conduct the standard operation principles for the grinding processes

■ Understand the automatic control loop ■ Describe the raw materials, their composition and influence

on grinding performance ■ Execute start & stop procedures and their standard sequences ■ Perform heat balance calculations ■ Knowing the interlocking's alarm limits and their consequences ■ Describe and understand the CCR instrumentation outputs ■ Test the internal procedures for efficiency and consequences

Main contents ■ Vertical mill operation – vertical mill installations and wear

patterns ■ Separator efficiency, particle distribution and tromp curve ■ Mass air flow and heat balances ■ Drying and grinding of coal ■ Cement grinding and silo storage ■ Grinding technology and operation through modern

real time simulation programs ■ Case stories group works solving specific simulations tasks ■ Mitigating actions during operation ■ Exercises and technical calculations

Grinding Technology Level II



Methods ■ Slide presentations ■ Computers ■ Case studies and role plays ■ Action plan to be presented by participants at the end

of the session

Audience ■ Production Managers ■ Production Engineers ■ Process Managers ■ Process Engineers ■ Control System Engineers ■ Electrical Engineers ■ Kiln Coaches ■ Senior control operators, production supervisors

Duration 10 days

Objectives ■ Monitoring performance ■ Using training tools to train kiln operators Simulator Produce

& Maintain ■ Writing and getting the operators to write SOPs ■ Solving problems ■ Implementing coaching techniques to improve kiln

operators skills ■ The overall mission of the Kiln coach is to improve plant

performance by developing the Control Room Operators to a mastery level of competency. This is achieved through a continuous process of daily performance monitoring, evaluation and feedback, formalization and maintenance of procedures, practices, and strategies, structured training, assessment and development, creating motivation, autonomy, and responsibility for operational objectives

Content ■ Operation performance monitoring ■ Problem solving techniques workshop ■ Developing and using Standard Operating Procedures ■ Coaching techniques skills workshop ■ Communication skills ■ Conducting one-to-one training activity ■ Competencies-based training ■ Action plan ■ Describe the main activities and responsibilities of the Kiln ■ Coach Position ■ Describe the tools and methodology used to evaluate and

maintain daily performance of major process lines ■ Demonstrate effective strategies for developing Control Room

Operators ■ Describe the scientific approach to setting operational targets ■ Describe how to formalize operating incidents into effective

training opportunities ■ Describe the training tools available for operator development

and how they can be used effectively ■ Explain how an effective quarry plan can support a quality

finished product ■ Demonstrate increased technical leadership in raw mix & quality

Kiln Operation II

■ Demonstrate increased technical leadership in preprocessing techniques

■ Apply knowledge & skills in troubleshooting of equipment & process

■ Demonstrate increased technical leadership in mill grinding operations



Objectives ■ Describe and analyze kiln typical values ■ Evaluate the flame and compare it to optimal flame ■ Explain the role of volatiles ■ Apply physical and chemical laws to the gas flows, mass

and heat balance ■ Identify sampling points ■ Perform the measurements ■ Do the calculations ■ Analyze the results and write recommendations for process

optimization ■ Provide engineering support for manufacturing performance,

mastery of pyro processing knowledge and skills is required ■ The objectives of the Process Engineering -Pyroprocessing II/Kiln

Audit program will provide you with the ability to learn and practice these skills, all requisites for a Plant Process Engineer function

■ Identify the technical aspects of fuel combustion ■ Assess burner designs and be familiar with different burner types ■ Identify the different cooler designs and methods of optimization ■ Identify the different types of kiln and precalciner systems and

the sizing criteria used to size them ■ Perform a heat and mass balance of pyro-processing system ■ Interpret the results and make conclusions ■ Benchmark the performance and make appropriate recommen-

dations ■ Enable the plant to identify, manage & maintain plant critical

process sensors in order to achieve process performance reliability and consistency

■ Safety & Identification of Critical Process Sensors ■ Fundamentals of industrial process control, Flow measurement

& Maintenance ■ Process Control in practice with workshop ■ Understand the Fundamentals of Process Dynamics ■ Investigate the Impact of Integral Action on Controller ■ Performance ■ Understand Common Performance Criteria and their Application ■ Examine Derivative Mode and PID Control ■ Investigate the Application and Value of Cascade and Feed

Forward Control

Process Optimization Level II

■ Develop Intuition for Analyzing Process Dynamics and Improving Performance

■ Apply a Systematic Approach for Modeling and Tuning PID Controllers

Content Combustion:

■ Theory and fundamental laws ■ Different types of burner pipes ■ Parameters linked to flame impact

Burning equipment: ■ Preheater cyclones, precalciner cooler ■ Technologies: advantages and drawbacks ■ Volatile cycles ■ Burner pipe measurements and calculation exercise ■ Clinker temperature calorimetry exercise ■ Kiln heat and mass balance ■ Kiln Audit theory: Objectives, definitions, calculations

& measurements ■ Define the characteristics and the limits of the pyro-system

to be audited ■ On site measurements ■ Calculations ■ Data analysis ■ Report and recommendations

Program outline ■ Coolers equipment and optimization ■ Alternate raw materials and fuels ■ Kiln and cooler audits including mass, heat and volatile balances ■ Closing Kiln Audits ■ Volatilization cycles and impact on CKD ■ Kiln and cooler control strategies ■ Brick and Refractory management ■ Precalciners


Learning outcomes ■ Optimize the operation of a clinker cooler ■ Perform a volatile balance, analyze the results & offer a solution ■ Assess burner designs as applied to the kiln ■ Combustion basics ■ Types of kiln and precalciner systems ■ Coolers ■ Safety requirements / briefing ■ Preparation for the audit (measurement and sampling plan, tools) ■ Measurements, sampling and data collection/recording ■ Validation of data ■ Calculation and analysis tools ■ Interpretation/benchmarking of results ■ Report writing guidelines ■ Case studies to illustrate analysis & conclusion

Methods ■ Exercises on practical cases ■ Replicating plant condition ■ Manufacturer's equipment and documentation ■ Study case and Exercises documentation

Audience ■ Production Managers ■ Production Engineers ■ Process Managers ■ Process Engineers ■ Control System Engineers ■ Electrical Engineers

Duration 8 days



Methods ■ Presentations, classroom exercises/workshops ■ Practical part with on-site exercises for brick lining

and concrete application (plant/supplier visit)

Prerequisites ■ Refractory shall be part of the job description

Audience ■ Refractory champions ■ Production managers ■ Foremen ■ Practitioners

Duration 10 days

ObjectivesAfter completing the training, the trainee will be able to contribute actively to:

■ Defining needs for the next shutdown ■ Selecting the adequate refractory for different zones

in PHT/kiln/cooler ■ Deciding on refractory application (bricking, casting, gunning) ■ Developing lining concepts according to AF & ARM usage ■ Carrying out troubleshooting

Content ■ Safety requirements when working on refractory ■ Basic knowledge of refractory technology ■ Refractory selection according to specific stresses ■ Installation methods, pros and cons ■ Understand and supervise brick installation in the kiln ■ Understand and supervise lining of burners ■ Understand the impact of kiln mechanics on refractory ■ Understand kiln mechanics basics (optional) ■ Understand and supervise installation of monolithic ■ Case studies ■ Understand wear phenomena ■ Heating up and cooling under various conditions ■ Action planning

Refractory II



Methods ■ Presentation ■ Group work, discussion, case study ■ Coaching techniques, personal action plan

Prerequisites ■ Process Development Certificate or equivalent work

experience ■ Gas handling, pyro processing I & II ■ Grinding I & II or equivalent training/work experience

Audience ■ Optimization/performance managers ■ Development managers ■ Process managers ■ Production & quality managers

Duration 3 days

Objectives Make the process, optimization or performance managers awareof their roles and responsibilities for performance improvement in the field of process and how to define actions for improvement with the plant management team. The seminar should help to improve the following core activities of the plant process team:

■ Analyzing the short, mid and long term challenges concerning process and set up an appropriate work plan for improvement

■ Setting up and audit in accordance with plant priorities ■ Developing an inspection plan ■ Using adequately the group knowledge such as the Best ■ Practices, “Plant operation Management tools ■ Defining procedures for day-to-day performance analysis ■ Contributing to the development of the plant people in

the area of process ■ Discussing the outcome (based on written reports) with

the plant management team and understanding how the role fits into the requirements of Plant operation Management

■ Agreeing on action plans and following up their execution

Content ■ Functions & missions of the process/optimization manager,

organization models competencies ■ Process analysis ■ Audit performance and analysis ■ Process improvement ■ Management ■ Action plan

Performance Management Seminar



MethodsPowerPoint Presentation, Workshop

Prerequisites ■ More than 2 years of experience in process

or production department ■ Practicing industrial ecology professional

Audience ■ Technical engineer / manager ■ Industrial ecology

Duration 5 days


■ Understand & implement Resource Recovery Policy as applicable to plant situation

■ Identify impacts and mitigation measure of AF and ARM on process, emissions & product quality

■ Understand, analyze and diagnose accuracy of environmental emission reporting

■ Explain, calculate and analyze AF and ARM characteristics and potential savings

Content ■ Health and Safety Aspects of Co-Processing ■ AF and ARM Properties ■ Impacts and Mitigating Measures ■ Waste Pre-qualification Steps ■ Case Studies

ӡ RDF ӡ Biomass ӡ Hazardous Wastes

■ Stakeholder’s Relations ӡ Lobbying and Permitting ӡ Communication

AF & ARM Co-processing



Electrical Maintenance

Electrical Maintenance 26Electrical Maintenance Level I 27Energy Isolation 28Basic Maintenance Documentation (electrical) 29Electrical Inspection Level I 30Electrical Inspection Level II 31Instrumentation 32


MethodsPre-course assignments, Classroom sessions, Workshops, site-visits

PrerequisitesShould be authorized Electrical diploma Holder/Engineer to operate all substation Equipment

AudienceElectrical Substation Maintenance Electrician/engineers/ specialists Duration 5 days

Permissions Access to operate all Electrical substation equipment

Objectives ■ Understand the basics of the entire electrical system of the plant ■ Be able to add or remove consumers and make modifications

Content ■ Load distribution (LOC) ■ Transformer and cable dimensioning ■ Short circuit and selectivity ■ Power factor ■ Influence of harmonics (EMC) ■ Motor Control Centre (MCC) ■ Typical wiring systems ■ Intelligent solutions ■ Building forms ■ Electrical rooms

Electrical Maintenance Level I



MethodsClassroom presentations and worksite exercise

Prerequisites ■ Basics on Cement Manufacturing ■ CBT Energy Isolation

AudienceAll Duration 3 days


■ Understand advisories and best practices related to EI ■ Master risk assessment methodology for all energies ■ Apply LOTOTO procedure simple and complex ■ Implement and review HERA (Hazardous Energy Risk Assess-

ment) and HECP (Hazardous Energy Control Procedure)

Content ■ Energies hazards identification ■ Risk assessment and quantification ■ Elaboration of HERA and HECP document

Energy Isolation



MethodsPre-course assignments, Classroom sessions, Workshops, site-visits

PrerequisitesShould be authorized Electrical diploma Holder/Engineer to operate all substation Equipment

AudienceElectrical Substation Maintenance Electrician/engineers/ specialists Duration 3 days

PurposeThe purpose of the training is meant to cover and give the participants relevant knowledge, skills and understanding of Electrical Diagrams and Flows its related topics.


■ Safety, work and test procedures – log out/tag out ■ Describe the Single Line Diagram of Electrical Power System ■ Electrical Power System symbols ■ responsibilities ■ Safety tag description use and regulations ■ Nine (9) step lototo sequence ■ Protocols for specific situations

Main contents ■ Electrical Symbols ■ How to read Single Line Diagram in Substation ■ LOTOTO permit/Approver ■ Lock Box

Basic Maintenance Documentation (electrical)



MethodsClassroom presentations to learn about electrical distribution and electro technical basics

Prerequisites ■ Basic educational background in electrical technology ■ First experience in electrical maintenance in a cement

plant

Audience ■ Electrical inspector ■ Electrical method or method manager ■ Electrical planner

Duration 5 days

Objectives Inspection is a key function for mastering preventive maintenance and improving plant reliability.

■ Define clear roles & responsibilities associated with the inspection function

■ Review overall maintenance process & organization for Inspection process effectiveness

■ Raise the Inspectors competency level

ContentImprove Electrical Inspections at plant:

■ Identify the main electrical risks & apply preventive measures ■ Recognize different Maintenance Strategies and understand

the importance of Inspections to managing Preventive Maintenance

■ Apply electrical preventive maintenance: Build / Improve Inspection Plan for Electrical equipment

ӡ Perform adequate inspections on site ӡ Perform predictive measures & tests

Electrical Inspection Level I



MethodsAt the plant: classroom presentations, exercises, on-site inspections

Prerequisites ■ Basic electrical knowledge ■ Preparation phase of the Certification program completed

Audience ■ Electrical department heads ■ Electrical inspectors

Duration 5 days


■ Identify Safety hazards related to Electrical Inspections task and apply control measurements

■ Build / improve an inspection plan for an electrical equipment ■ Perform adequate inspections on site ■ Build an electrical inspection program for the plant ■ Perform predictive measures and tests

Content ■ Health & Safety module ■ Role and competencies of electrical inspectors ■ Inspection strategies ■ Method for building an inspection plan ■ Preventive maintenance ■ Predictive maintenance measures on tests

Electrical Inspection Level II



Methods ■ Presentations ■ Group activities

Audience ■ Instrumentation Technicians/Engineers. ■ Plant Controls Systems Engineers & Instrumentation

Technicians Duration 3 days

ObjectivesThis combination of practical information and hands-on experiences covers safety, proper installation, calibration, and maintenance of electronic instruments

■ Safety practices during installation, calibration, and maintenance procedures

■ Explain methods for reducing electrical hazards including intrinsically safe installation

■ Participants will able to examine characteristics of electronic control systems, techniques for installing electronic instruments, and procedures for configuring and calibrating transmitters, transducers, and controllers

■ Recognize the importance of maintenance in the proper operation of instruments and control systems

■ Use manufacturer's guidelines to configure instruments for specific process applications

■ Explain installation considerations and practices for instruments and control systems

■ Use P&ID, wiring, schematic, and installation detail drawings to install, calibrate, and verify proper operation of instruments

■ Explain methods for reducing electrical hazards including intrinsically safe installation

Content ■ Electrical Safety. ■ Connect wiring in an electronic control loop ■ Select and operate test equipment to measure electrical

properties and calibrate instruments ■ Calibrate electronic transmitters and controllers ■ Maintenance of operation instruments and control systems ■ Configuration of instruments for specific process applications ■ Installation and practices for instruments and control systems ■ P&ID, wiring, schematic, and installation detail drawings to install,

calibrate, and verify proper operation of instruments

Instrumentation



Maintenance

Maintenance 33Mechanical PlanningLevel I 34Hydraulics 35Mechanical Inspection Level I 36Heavy Duty Gear and Reducer Technology 37Crushers, Stackers & Reclaimers 38Ball Mill Mechanics 39Vertical Roller Mill Mechanics 40Kiln Mechanics 41Cooler Maintenance 42Maintenance Manager Seminar 43Mechanical Maintenance Managers Seminar 44Root Cause Analysis & Down Time Analysis 45Material Handling 46


Methods ■ Presentations ■ Group activities

Audience ■ Maintenance Engineers ■ Maintenance Planners

Duration 5 days

ObjectivesAfter completion of the course, participants will be able to:

■ Describe the impact of planning ■ Understand the planning process ■ Derive the work flow planning model ■ Understand Estimating practices ■ Understand Backlog Management ■ Become familiar with the roles and Planner Relationships

Content ■ Why Planning? ■ Features & Benefits ■ Planning Fundamentals ■ Roles & Resources ■ Planning Methodology ■ Backlog Management ■ Estimating ■ Planning Flow ■ Planning Simulation

Mechanical Planning Level I




PrerequisitesBasic Hydraulic knowledge

AudienceMaintenance Execution Manager, Execution Engineers & Snr Technicians, Maintenance Inspectors Duration 3 days

ObjectivesThe in-depth hydraulic training combines hydraulics and electro- hydraulics in order for maintenance staff to extend their technical and methodical knowledge. This enable specific issues relating to maintenance to be dealt with in more details.

■ A better understanding of the hydraulic equipment design and limitations.

■ Knowledge to address and find solutions to problems related to the hydraulic equipment in your plant.

■ Ability to review and optimise hydraulic system design and operating parameters.

Content ■ Standards and Safety regulations ■ Design and function of hydraulic power supply systems ■ Design and function of hydraulic valves and controlling direction,

speed, position & force ■ Hydraulic drives for linear & rotary movements ■ Electric signal control for hydraulic power section with switching

solenoid and proportional solenoid interfaces ■ Introduction to proportional technology ■ Maintenance, inspection, scheduled & fault-related repairs

on hydraulic systems ■ Systematic trouble shooting, damage analysis & weakness

elimination ■ Intensive practical training involving design & control systems ■ Basic industrial hydraulic systems ■ Stacker-reclaimer hydraulics ■ Vertical mill hydraulics ■ Kiln hydraulics ■ Clinker cooler hydraulics ■ HRP & ball mill hydraulics

Hydraulics



MethodsAt the plant: classroom presentations, exercises, on-site inspections & develop good examples of inspection job plans

Prerequisites2 years Mechanical Execution

AudienceMaintenance mechanical inspectors (and Reliability managers)

Duration 5 days

ObjectivesAfter the training the delegate will be able to understand & know:

■ Understanding inspection procedures for maintenance inspectors on various systems within a Plant

■ Knowledge & understanding Preventive Maintenance Goals and Activities

■ Understanding that Preventive Maintenance inspections and tasks prevent equipment from failing

■ Understand and assess existing inspection process

Content ■ Maintenance strategies ■ Importance of inspections for managing preventive maintenance ■ Define the inspector’s role (where it starts, where it stops,

how it fits in the overall maintenance process) ■ Define & follow-up inspection KPIs ■ Define 1st level and specific inspections (purpose & specificities) ■ Build / improve an inspection plan for an equipment

(using FMEA Methodology) ■ Perform 1st level inspections ■ Introduction to inspection tools (Thickness measurements,

rotational speed, Ultrasound pplication, Temperature) ■ Report & describe abnormalities

Mechanical Inspection Level I




Prerequisites ■ Good knowledge of drive unit in cement plant ■ Basic knowledge of gear technology ■ Minimum 2 years’ experience in a cement plant

AudienceReliability Engineers, Execution Maintenance Engineers, Inspectors

Duration 5 days

ObjectivesAfter completing the training, the trainee will be able to:

■ Understand the different designs of drive units ■ Explain the probable causes of failure of open gear & reducers ■ Challenge the first level and specific inspections done by

the plant ■ Understand supplier’s reports on gear calculations ■ Work on drive unit failure analysis and effective repair solutions

Content ■ Drive unit stoppage for incident ■ Failure modes of gears & reducers ■ Enclosed gear drives – design considerations ■ Open gear for kiln & mill – design criteria ■ Review of reducer types ■ Reducer breakdown risk analysis ■ Drive unit inspection including introduction to vibration ■ Open gear inspection – first level and specific ■ Reducer inspection – first level and specific ■ Auxiliary drive units for kiln & mill ■ Inspection of reducer or other types of large reducers ■ How to manage spare parts for main reducer?

Heavy Duty Gear and Reducer Technology




PrerequisitesMinimum 1 years’ experience in a cement plant

AudienceMechanical Maintenance staff

Duration 3 days

ObjectivesOn completion of this training, the participants will be able to:

■ Know and account for design, main components and their functions

■ List and explain main inspection points and routes ■ Describe relevant action plans for maintenance ■ List possible areas for preventive maintenance

Content ■ Design, function, components for the machinery ■ Standard maintenance procedures ■ Typical failure patterns and case studies ■ Elaborating inspections routes ■ Identification of important settings ■ Special maintenance procedures during stoppage/function ■ Plans for maintenance

Crushers, Stackers & Reclaimers






Duration 5 days

ObjectivesAfter completing the training, the trainee will:

■ Know the design, main components and their functions ■ Understand how a mill operates mechanically ■ Understand the critical points that need to be taken care of ■ Be able to define and carry out a complete first level mill

inspection ■ List and explain main inspection points and routes ■ Describe relevant action plans for maintenance ■ List possible areas for preventive maintenance ■ Describe ball mill lubrication system and installations

Upon completion of this training, the students should be able to:Know and account for design, main components and their functions

Content ■ Design, function, components for Ball Mill ■ Types of mills, mill internals and drives ■ Temperature, dimensional tolerance, thermal bending ■ Standard maintenance procedures ■ Typical failure patterns and case stories ■ Elaborating inspections routes ■ Identification of important settings ■ Special maintenance procedures during stoppage/function ■ Plans for maintenance

Ball Mill Mechanics






Duration 5 days

The vertical mil seminar is designed to train the personnel on the technology, operation and maintenance of vertical mil systems. The course focuses on best practices for the operation and maintenance of vertical mill systems to allow for energy savings, reduction in maintenance costs as well as the continuous improvement of the equipment operation.


■ Understand the design, main components and their functions ■ Describe the different elements of the vertical roller mill ■ Explain how a VRM operates ■ Create / improve and carry out first level and specific inspections

in VRM using the right tools ■ Describe relevant action plans for maintenance ■ List possible areas for preventive maintenance ■ Describe lubrication system function and installations ■ Define spare parts required ■ Troubleshoot and analyse failures on existing equipment

Content ■ General introduction ■ Working principles and forces ■ Roller and table liners wear control ■ Regeneration or replacement ■ Inspection points and main repair works ■ Grinding roller lubrication ■ Replacement of seals and bearings ■ Accumulator adjustment and replacement ■ Tensioning rod and possible damages ■ Torque support maintenance ■ Pressure frame alignment ■ Separator bearings lubrication and replacement ■ Tools for maintenance inspections ■ Gearbox ■ Basics about hydraulic systems / grinding forces ■ Special maintenance procedures during stoppage/function ■ Plans for maintenance ■ Spare parts

Vertical Roller Mill Mechanics




Prerequisites ■ General Cement Manufacturing knowledge ■ Minimum 5 years’ experience in a maintenance function

AudienceMechanical Engineers, Reliability Engineers, Execution Maintenance Engineers, Inspectors, Planners

Duration 5 days


■ Understand how a kiln operates mechanically ■ Know and account for kiln root causes, their symptoms and

their maintenance theory ■ Understand the relationships between process and mechanical

operations differentiating the factors that impact kiln operation ■ Be able to improve kiln inspections using troubleshooting tips

(using the available / required tools and applying the existing procedures and Best Practices ensuring the conditions for success of every classical maintenance job)

■ Execute important kiln diagnostic measurements ■ Evaluate, analyse and draw technical conclusions based on

the obtained results ■ Elaborate and describe relevant action plans for the kiln

maintenance

Content ■ Kiln design and conditions for successful operation ■ Kiln Force Analysis & load distribution ■ Troubleshooting (basics and advanced level) inspections ■ On-site kiln inspection & measurements ■ Basic mechanical operations of kiln maintenance:

bearings maintenance, roller skewing, girth-gear maintenance, tyre migration seals

■ Develop of relevant maintenance action plans (Individual & Plant Specific)

■ Kiln crank, actual balance, kiln axis & kiln ovality

Kiln Mechanics




Prerequisites ■ General Cement Manufacturing knowledge ■ Minimum 2 years’ experience in a maintenance function

Audience ■ Mechanical Engineers ■ Reliability Engineers ■ Execution Maintenance Engineers ■ Inspectors ■ Planners ■ Snr Mechanical Technicians

Duration 5 days


■ Know the design, main components and their functions ■ Describe the function and operation of the different type

of coolers ■ Create / update inspection check-list ■ Carry out first and specific inspections in grate coolers ■ Carry out execution activities in the coolers

Content ■ Safety Practices during Cooler Maintenance ■ Design, function, components for the machinery ■ Cooler technologies ■ Cooler inspections & routes ■ Identification of important settings ■ Cooler revamping ■ Standard maintenance procedures ■ Special maintenance procedures during stoppage/function ■ List possible areas for preventive maintenance ■ Plans for maintenance ■ Auxiliary equipment and its functions

Cooler Maintenance



MethodsThe seminar consists of theoretical classroom lectures, real life case studies and interactive work sessions

PrerequisitesCompleted Engineer Development Program

Audience ■ Maintenance managers ■ Maintenance engineers ■ Reliability engineers ■ Plant managers ■ Shift engineers ■ Maintenance Staff

Duration 3 days

ObjectivesFor maintenance managers to be able to perform the job of the Maintenance Manager, including:

■ Safety rules ■ Lead your Team ■ Communicate with their teams, with other departments,

and do networking ■ Implement, follow-up and improve the maintenance performance

indicators ■ Role of Maintenance Managers and roles of maintenance team

in the plant ■ Implementation of Maintenance processes ■ Optimization of Maintenance Processes and the way they are

linked

Content ■ Plant safety organization and manager’s role with regards

to safety ■ Manager’s role ■ Different maintenance types ■ Description of the maintenance process:

ӡ Maintenance functions: definition, role and indicators ӡ Link between all these functions ӡ Maintenance performance indicators

■ Budget elaboration and follow-up ■ Maintenance Cost

Maintenance Manager Seminar



MethodsThe seminar consists of theoretical classroom lectures, real life case studies and interactive work sessions. Working sessions are scheduled to allow for an interactive study of the design and function of the main equipment, focused routine preventive maintenance to minimize system downtime.

Prerequisites2 year minimum experience

AudienceMechanical Maintenance Staff

Duration 5 days

Objectives ■ Understanding of the VRM, Ball Mill, Pyroprocess equipment

design and their limitations ■ Optimise and standardise preventive maintenance techniques,

improving the overall equipment efficiency and reducing risk of bad practices

■ Review and implementation of the best maintenance practices to achieve sustainable and stable run time with the equipment

■ Learn about your cement plant maintenance programs

Content ■ Seminar covers maintenance aspects of the four main areas

of your cement plant: ӡ Vertical mills maintenance ӡ Types of gearboxes in vertical mills ӡ Ball mill maintenance ӡ Pyro processing systems maintenance (preheater, kiln and cooler)

■ Covers proper preventive maintenance programmes for all the different components of your cement plant – preheater tower, rotary kiln, clinker cooler, vertical mills, and ball mills

■ Maintenance plans for Plant specific equipment and learn how to perform the necessary maintenance and repair work to prevent breakdowns and ensure high availability, overall equipment efficiency, reliability and better profitability of the equipment

Day 1 – General Maintenance Practices ■ Policies and strategies ■ The Key Performance Indicators (KPI) – availability and cost ■ Root causes and symptoms ■ Effective site inspections ■ Safety ■ Computerised maintenance ■ Management systems ■ Ultrasonic analysis

Day 2 – Maintenance of Key Machinery ■ Kilns ■ Ball mills ■ Vertical mills ■ Coolers ■ Gears ■ Fans

Mechanical Maintenance Managers Seminar

Day 3 – Failure Mechanicms ■ Fatigue crack formation ■ Vibrations ■ Lubrication ■ Corrosion

Day 4 – Analysis & Repair Methods ■ Vibration analysis ■ Balancing ■ Oil analysis

Day 5 – Auxilliary Equipment ■ Cement plant transport equipment ■ Electrostatic precipitators ■ Bag filters (fabric filters) ■ Electrical equipment ■ Feeders ■ Crushers



Methods ■ At the plant: classroom presentations, exercises,

on-site inspections. ■ Case study to put method into practice

Prerequisites2 Year minimum experience

AudienceMaintenance, production or process engineers, with the responsibility for solving plant operation problems by leading teams of people

Duration 3 days


■ Perform root cause analysis methodology ■ Facilitate a root cause analysis by leading a team of participants ■ Identify effective solutions to event-based problems ■ Prepare the final root cause analysis report ■ Effectively communicate root cause analysis findings ■ Conduct down time analysis & application of pareto principle

Content ■ Cause of ineffective problem solving ■ How to define problem properly? ■ The cause and effect principle ■ Cause and effect analysis ■ Collecting data ■ Working on possible solutions ■ RCA process management, including communication tools ■ RCA Tracing Methodology ■ Down Time Analysis methodology

Root Cause Analysis & Down Time Analysis




on-site inspections ■ Case study to put method into practice

Prerequisites2 year minimum experience

AudienceMaintenance & Production Staff

Duration 10 days

ObjectivesThe purpose of the training is to give participants knowledge and understanding of material handling systems used withina cement manufacturing process.

After completion of this course, the delegates able to: ■ Know and account for main components and their functions ■ List and explain main inspection points and routes ■ Describe relevant action plans for maintenance ■ List relevant alarm sensors and possible areas for preventive

maintenance

Content ■ Design, function, components for the transport machinery:

Crusher, apron feeder, stacker, reclaimer, belt conveyor, weigh feeders, air slides, drag chain, Armond conveyor, bucket elevator, screw, clinker crusher, pneumatic conveyor systems, blowers,

■ fuller pump, air lift etc. ■ Maintenance procedures ■ Typical failure patterns and case studies ■ Inspections routes ■ Identification of important settings ■ Action plans for maintenance

Material Handling



Quality & Product

Quality & Product 47Cement Quality Level I 48Product Applications Fundamentals 49Effective Data AnalysisLevel I 50Laboratory Mastery 51Concrete Durability 52Cement Usage Properties 53Clinker Quality Mastery 54Raw Material & Raw Mix Design 55Alternative Fuels & Alternative Raw Materials 56Quality Mastery Program 57


MethodsPresentations, exercises, case studies (50% Theoretical & 50% Practical)

Prerequisites ■ Participants to get familiar about the cement

manufacturing process ■ CADIC

Audience ■ Quality Engineers ■ Lab Supervisor and Managers ■ Engineers from Process, Production & Quarry

Duration 5 days

ObjectivesAfter completion of the course delegates will be able to:

■ Properly use industrial levers to better satisfy customers’ requirements

■ Better understand customers’ need and the specificities of concrete applications

■ Make appropriate use of additives (cementitious and others) taking into account product characteristics and production/ process constraints

■ Be able to explain the variations and incidents linked to products (clinker or cement). Participants will be able to start contributing in achieving excellence in Quality basic management & consistency of products

■ Ability to explain usage qualities in application and how to satisfy customer requirement, how to mitigate risk and start contributing to innovation

Content ■ Concrete constituents, properties & applications ■ Raw Mix & Clinker Composition ■ Raw mix (raw material & its characteristics) ■ Clinker chemistry, mineralogy Bouge Formula ■ Clinker burning & Formation and clinker phases ■ Minor Elements ■ Hydration mechanisms,, Sulfates and alkalis influences,

Heat of hydration, Setting mechanism influencing parameters ■ Grinding & product performance, concept of grindability,

agglomeration/ weathering, main recommendations ■ Representative Sampling & Sampling Techniques

Cement Quality Level I



MethodsPresentations, hands-on training

PrerequisitesNone

Audience ■ Quality managers, Laboratory Managers & Senior chemist ■ Marketing Team

Duration 3 days

ObjectivesAfter completing the training, the participants will be able to:

■ Identify and describe the constituents used to manufacture mortar & concrete

■ Describe mortar & concrete mix design and placing ■ Understand and apply relevant standards ■ Identify the main applications ■ Understand the basic rules of product applications ■ Select the best product for the best application ■ Identify main concrete pathologies

Content ■ Definition of the constituents

ӡ Cement ӡ Additions ӡ Aggregates ӡ Water ӡ Admixtures ӡ Fibers

■ Basic rules of mortar & concrete mix design ■ Mortar & concrete placing ■ Main mortar & concrete applications ■ Concept of durability and pathology ■ Standards ■ Economical approach ■ Hands-on tests in mortar & concrete laboratory

Product Applications Fundamentals



MethodsPresentations, exercises, case studies (40% Theoretical & 60% Practical)

PrerequisitesFair knowledge of MS Excel program (English version)

AudienceEngineers and supervisors from quality, process, production and/or technical sales who need to use statistical analysis frequently

Duration 2 days

Impact ObjectivesAfter completion of this course delegates will be able to:

■ To be able to take a proper decision based on data analysis using statistical tools & methods

■ Be able to determine correlation between different parameters and to predict results by performing simple and multiple correlations

Content ■ Basic statistics (Mean, Median, Mode, Standard deviations,

Histogram, etc.) ■ Outliers Detections ■ Scatter Plots ■ Normal distribution curves ■ Statistical tests (t-Test & z-Test) ■ Quality Control Charts and Process Capability Control ■ Introduction to linear regression ■ Introduction to Multiple correlation analysis

Effective Data Analysis Level I

Price USD/trainee 2.000SAR/trainee 7.500


MethodsThe Lab Mastery Program is a blended learning opportunity

PrerequisitesCompletion of CDPD is recommended

Audience ■ Lab technician ■ Lab manager ■ Quality manager

Duration 8 days


■ Have a good understanding of the safety risks in a laboratory ■ Have a good understanding of the regulations applying in

a laboratory ■ Understand the laboratory referential and its related QTS on XRF,

free lime, blaine, chlorine, fuels and mechanical strengths ■ Be able to monitor the quality of the laboratory measurement

Content ■ XRF Basics ■ XRF Fused Bead & Pressed Pellet Preparation ■ XRF Spectrometer Stability ■ XRF Calibration ■ XRF Follow-up ■ Factors Impacting the Quality of XRF Results ■ QTS Free Lime ■ Normal Consistency & Set Time (ASTM) ■ Normal Consistency & Set Time (EN) ■ CEMCOM ■ QTS Fuel Analysis ■ QTS Chloride Analysis

Laboratory Mastery



MethodsPresentations, exercises, case studies (participants’ cases)

Prerequisites ■ Basic knowledge on concrete technology ■ Cement hydration knowledge ■ Example: “Product application fundamentals” training

Audience ■ Marketing and sales people, persons dealing with

customer complaints ■ Cement plant engineers ■ Cement laboratory managers

Duration 3 days


■ Have an overview about concrete durability and common forms of attack

■ Have an understanding of deterioration mechanisms ■ Be familiar with common test methods ■ Be able to identify characteristic cracking and destruction

patterns ■ Know about global / general standards and selected national/

regional regulations ■ Know about different options to improve concrete durability

ContentBasics on concrete durability and damage reactions:

■ Appearance of damages and cracking patterns ■ Concrete standard and exposition classes ■ National and other regulations ■ Cement characteristics vs. durability ■ Concrete characteristics vs. durability ■ How to improve durability ■ Quality control and test methods related to durability ■ Product risk management policy

Details on specific forms of attack: ■ Shrinkage / cracking ■ Carbonation ■ Freeze-thaw attack including de-icing salts ■ Chemical attack (including seawater, chloride and sulphate, ■ Mg, ammonia, acids, etc.) ■ Alkali-silica reaction ■ DEF (Delayed Ettringite Formation)

Concrete Durability



MethodsPresentation, Video

PrerequisitesNone

Audience ■ Technical Sales ■ Marketing & Technical Marketing ■ Product development ■ Plant Quality managers ■ Chief Chemists

Duration 2 days

ObjectivesAt the end of this training the participant will be able to understand:

■ The cement hydration mechanisms and the importance of sulphates and aluminates phases

■ The management and optimisation of sulphates in cement plant (milling temperature, measurement tools…)

■ The management of weathering (aging) in cement plant ■ The existing family of admixtures in the market (water reducers,

super plasticisers, grinding aids…) ■ The important parameters controlling the interactions between

cement and admixtures and their impact on concrete properties ■ The impact of temperature (hot weather) ■ This training is an interactive course; it is composed

of knowledge presentations ■ Each participant is invited to prepare and share a case study

representing an ongoing problem, which face his plant or customer

Content ■ Cement hydration ■ Parameters impacting on concrete performance ■ Concrete mix design optimization ■ Concrete durability ■ Cement usage properties

Cement Usage Properties



MethodsLaboratory practical application assignments

PrerequisitesSharing individual experience on quality application parameters

AudienceQuality managers

Duration 5 days


■ Contribute to plant variable cost reduction by optimizing the raw mix design which will contribute to maximizing the clinker reactivity and minimizing SHC and power cost

■ Solve the case study and apply the knowledge acquired to their specific plant

Content ■ Basic financial concepts ■ Raw mix design ■ My role in achieving kiln mastery ■ Composition optimization ■ Clinker reactivity ■ Optimize Clinker performance – Role of sulphates ■ Clinker performance ■ Case study

Clinker Quality Mastery



MethodsPresentation, Video

PrerequisitesNone

AudienceQuarry, Process and Quality Control Managers/Engineers

Duration 5 days

ObjectivesAfter completion of this training, participants will be able to:

■ Understand of interactions between quarry operations and raw mix preparation

■ Understand relationship between uniformity and process and product in terms of cost / Quality

■ Define factors along the process for kiln feed uniformity ■ Evaluate and improving raw mix logic and regularity ■ Improve possibility on raw mix control ■ Evaluate the cost effect for raw mix ■ Find possibility for new raw materials ■ Set-up C3S target for Kiln Feed Uniformity ■ Set-up and solving constraints for optimum quality of clinker ■ Understand volatile activity ■ Understand raw mix tools ■ Cascade and providing coaching and training at the plant ■ Understand interactions between quarry operations and raw

mix preparation ■ Improve kiln feed uniformity, homo silo efficiency & tools to

evaluate efficiency

Content ■ Raw mix preparation

ӡ Incomming Raw Materiala control ӡ Tools for raw mix design & parameters ӡ Volitile elements control

■ C3S and kiln feed uniformity ӡ Sampling Plan & uniformity statistical tool ӡ Homo silo & blending efficiency

■ Quality control management ӡ Quality control loop ӡ Action levers (FLS QCX)

Raw Material & Raw Mix Design



MethodsPresentations, plant experience sharing, workshop, case studies, plant and lab visit

Prerequisites ■ Completion of EPDP (Engineers Professional

Development Program) is recommended ■ Already attended

AudienceQuality, process, optimization and production engineers/managers

Duration 3 days

Impact On Clinker Reactivity


■ Understand the impact of different alternative fuels (AF) on quality, process

■ Become familiar using alternative raw materials (ARM) ■ Be aware of potential cost savings while using AF and ARM ■ Know how to sample and analyze AF ■ Be able to use XRD data to interpret the impact of AF on clinker

mineralogy ■ Be able to assess the quality risks and set-up preventive

measures to minimize them ■ Be able to develop a plant specific action plan to master ■ AF/ARM usage ■ Benefit from networking and knowledge sharing

Content ■ Lab safety precautions ■ Risk assessment of AF/ARM impact on quality ■ Parameters impacting clinker reactivity, levers for improvements ■ Different types of AF and their impact on clinker reactivity

and cement properties ■ AF/ARM management and incoming control ■ AF lab and potential lab equipment ■ Sampling, analytical measurement including sample preparation ■ XRD Rietveld and its capability for process/quality control

Alternative Fuels & Alternative Raw Materials



MethodsClass room, practical exercises, Case studies, Work Groups

Prerequisites“Cement Professional” or equivalent work experience. Basic statistics

AudienceQuality & Lab managers and their N-1

Duration 8 days

ObjectivesAfter completing the training, the trainees will be able to:

■ Foster the implementation of a risk management process and procedure

■ Explain the impact of risk materials on environment linked together with quality aspects

■ Explain elements of a system to assure reliable test results and apply steps to establish it

■ Explain the role of SCM and their impact on product quality and performance

■ Explain their role in the strategic cementitious process ■ Be a strong partner for sales /technical sales – understanding

the link between marketing and manufacturing (QDS & IQP) ■ Explain the basics of durability problems and way to handle

durability issues ■ Evaluate the impact of heavy metals in raw materials and

alternative fuels ■ Assist the plant management in the decision process and in

lobbying activities ■ Identify the critical steps to manage clinker and cement quality ■ Come up with a list of improvements for their plants

Content ■ Material Management Principles ■ From Raw Material to Cement ■ Material Management Principles ■ Cement Production & Environment ■ AF/ ARM-Control & Management ■ Plant objectives & Quality leadership

Quality Mastery Program



Quarry

Quarry 58Quarry Operations Safety 59Geomining & Raw Mix 60Quarry Operations & Process Risks 61Mining Operations 62Drilling & Blasting 63Mines Planning 64


MethodsQuarry visit, presentations, case study, exercises, etc.

PrerequisitesNone

AudiencePlant managers, quarry managers and quarry operations personnel

Duration 3 days

Objectives ■ Raise awareness on the potential core process risks related

to quarry operation, blasting and rock / ground instability

Content ■ Risks related to blasting activities in the quarry ■ Preventive measures to avoid blasting incidents ■ Basic concepts related to structural geology and rock stability ■ Risks related to rock / ground instability

Quarry Operations Safety



MethodsQuarry visit, presentations, case study, exercises, etc.

PrerequisitesNone

AudienceEngineers and technicians from quarry, process, production and quality

Duration 5 days

Objectives ■ Determine the most important parameters for safe

and efficient quarry operation ■ Understand interactions between quarry operations

and raw mix preparation ■ Understand how to reduce mining cost down to target

cost by effective mining operations ■ Use sampling statistics and geo-chemical modelling

to optimize cost ■ Develop good sampling procedures of materials to maintain

quality control of the process ■ Verify pertinence of quarry reserves & the link to raw

material handling ■ Evaluate and improving raw mix logic and regularity ■ Understand importance of standard deviation and

finding solution to improve it

Content ■ Safety in geomining ■ Principles of geology ■ Cement raw materials ■ Exploration and modelling ■ Surveying and sampling ■ Rock drilling and blasting ■ Mining operations ■ Crushers and screening ■ Raw mix: materials, chemistry, design, preparation, KFUI, tools ■ Quarry management ■ Quarry & raw mix line visit

Geomining & Raw Mix



MethodsQuarry visit, presentations, workshops, Q&A sessions, exercises, etc.

PrerequisitesEPDP

AudiencePlant quarry managers and engineers

Duration5 days

Objectives ■ Raise awareness on the potential core process risks related

to quarry operation, blasting and rock / ground instability ■ Make the quarry manager aware of the required quarry safety

practices in order to reduce accidents in quarries

Content ■ Risks related to blasting activities in the quarry ■ Preventive measures to avoid blasting incidents ■ Basic concepts related to structural geology and rock stability ■ Risks related to rock / ground instability

Impact of quarry on the environment ■ Safety legal background ■ PPE ■ Quarry safety policy ■ Contractors’ management ■ Incident / accident reporting ■ Ground control and rock stability ■ Mobile equipment safety ■ Slips, trips and falls ■ Electrical safety ■ Visual felt leadership

Quarry Operations & Process Risks



MethodsOverheads, case study, visit to a quarry & debriefing session, final action plan

PrerequisitesEPDP plus some practical experience gained in quarry operations (2 – 3 years)

Audience ■ Quarry managers ■ Mining engineers & geologists ■ Production managers and any manager responsible

for some subjects related with the content

Duration 5 days

Objectives ■ Identify the main mining methods and understand pit

design principles ■ Know the different options for loading & hauling

and their management ■ Choose fleet equipment and their management ■ Know the principles of overburden dump design and

its safe operation ■ Apply the good and best safety practices in quarries ■ Carry out performance audit / inspections in crushing

and sizing workshops ■ Identify key figures in mining costs

Content ■ Overburden stripping and placement ■ Loading methods ■ Haulage methods ■ Selection of criteria for fleet optimization and productivity ■ Mechanical mining techniques ■ Subcontracting quarrying operations ■ Crushing and screening

Mining Operations



MethodsPresentations, case studies, discussions, exercises and visit to a quarry/crushing workshop

PrerequisitesNone

Audience ■ Plant quarry engineers and geologists (who need to study

rock drilling and blasting in surface mines and quarries to be able to improve fragmentation and optimize drilling and blasting operations)

■ Quarry managers, shot firers or the explosive Supervisors

Duration 3 days

Objectives ■ Give the participants a theoretical background in the basic

principles of drilling and blasting and their application to surface mining

■ Develop the participants’ knowledge and experience to design the full system of blasting projects, with specific emphasis on fragmentation and environmental effect control

Content ■ Safety in drilling and blasting ■ Mine to mill concept ■ Surveying work ■ Drilling operation ■ Industrial explosive ■ Initiation, priming & firing systems ■ Rock breakage mechanisms ■ Designing surface blasting rounds ■ Blasting geology and rock mass properties ■ Rock fragmentation ■ Environmental effects of rock blasting ■ Quarry blast diagnosis ■ Blast optimization ■ Misfire handling ■ Planning of drilling and blasting work ■ Specialized blasting techniques

Drilling & Blasting



MethodsPresentations, case studies, discussions, exercises and visit to a quarry/crushing workshop

PrerequisitesOnce these sessions have been completed, you will be credited for the completion of the entire course

AudienceQuarry managers, and individuals with responsibility for managing quarry operations

Duration 3 days

Objectives ■ Understand raw material deposits through geological modelling,

permitting and pit design ■ Knowing how to obtain the optimum quality and quantity

of material for cement manufacturing ■ Be able to measure the impact of each raw material on

the raw mix design ■ Know how to adapt the operation of the quarry to any raw

material requirement change

Content ■ Part 1: Geological modelling ■ Part 2: Permitting, mine constraints & design ■ Part 3: Mining plan ■ Part 4: Quarry operations & tools ■ Part 5: Implementation

Mines Planning



Certification Programs

Certification Programs 65What’s is Certification? 66Key Operators & Technicians Certification 67Engineer Professional Development Program 73Engineer Professional Development Program 75


What’s is Certification?

Certification training is based on the principle of classroom training and On-the-job-practical exposure organized at Yanbu Academy.

On successful completion the session at the Academy the participant will return to his/her home plant and will complete the on-the-job-assignments under supervision of Home Plant Manager.

Each phase is validated by a formal examination that the participants need to pass before continuing the next phase. On completion of all formal sessions the participant will complete the qualification questionnaire. After successful completion of Qualification phase the participant will demonstrate that he/she has mastered the required competencies for the position & will then be certified by the Home Plant & Cement Knowledge Center, Certification committee.


Key Operators & Technicians Certification

CRO TRAINING & CERTIFICATION

Objective After completing training course, the participant will be able to:1. Develop CRO to the expected competency level2. Ensure that CRO know understand and use the plant operating procedure3. Improving kiln & mill stability4. Implementing a consistent control strategy.5. Bringing equipment’s back into target range in an optimal time6. Reducing the number of Production & Process incidents

Module Basic module Week 1 – Kiln Operations basics 1. Introduction & safety on the site, plant visit & environment regulations 2. What is Cement & Cement Chemistry3. Kiln operation basics – basic knowledge on cement manufacturing process and major plant equipment

Week 2 – Mill operation basics1. Grinding principles & major grinding equipment (Ball Mill & VRM2. Basic rules for stable mill operations3. Know, locate & follow-up the major process sensors

Week 3 – Auxiliary equipment1. Understand equipment function, components and principle of operation2. Define 1st level, running inspections lists for each equipment3. Perform production field inspections on equipment

FLSmidth "light" version = 5 days

Week 4 – Kiln operation basics 2) * Master combustion* Get the basic rules for stable kiln operations

Knowledge Assessment: Test Milling Operation, Test Auxiliary equipment. CRO Kiln Operation Basics Final Assessment.

Assessment developed by FLSmidth mainly Basic Cement Manufacturing for CRO's & Process Engineers

Implement In addition to implementing what they have learnt during the Basic Module – CRO to complete 5 on-the-job Assighnments

Assignment description document

Advanced Module Basic Review1. Run a kiln in stable conditions, reminders2. Control loops … including on the job activity in the plant3. CEMulex overview

Possibility to adapt and modify the scenario depending on plant specificities and problems

CEMulex Practical Exercises1. Kiln warms up, feed on, production ramp up2. Kiln cools down and shut down3. Kiln performance analysis4. Review & compiles applicable SOP''s for above 5. Review current Incident SOP's & identify additional incident SOP's 6. Kiln & Cooler incidents7. Quality control8. Mill operation basics reminders + quality control basics9. Mill Operataion & Control10. VRM Operation & Control

Qualification Final Knowledge Assessment CRO Qualification

Certification On-the-job, proven demonstration of ability to run the kiln within given performance criteria Kiln Coach monitoring, CRO daily Operation


PRODUCTION TECHNICIAN/PATROLLERS CERTIFICATIONObjectives After completing training course, the participant will be able to:

1. Develop Production Technician / Patroller to the expected competency level.2. Ensure understanding of cement manufacturing process3. Know & understand main equipment technology4. Know & understand auxiliary equipment5. Able to perform 1st level inspections according to pre-determined inspection routes 6. Reducing the number of Production & Process incidents

Build Basic Week 1 – Patroller role + Kiln & Mill Operations basics 11. Get the basic knowledge on cement manufacturing process and major plant equipment2. Know, locate & follow-up the critical process sensors for major equipment

Week 2 – Mill operation basics 1. Get the basics of Grinding principles & major grinding equipment (Ball Mill) 2. Get the basic rules for stable mill operations.3. Know, locate & follow-up the major process sensors 4. Patrollers' inspection

Week 3 – Auxiliary equipment (+/- 5 days)1. Understand equipment function, components and principle of operation2. Define the 1st level, running inspections lists for each equipment3. Perform production field inspections on equipment4. How to start & stop equipment locally, in the field, safely

Patroller Assessments Assessment Questionaire

Implement Participants must either create or to review patrollers inspection sheets minimum.These inspection sheets have to be checked and validated by the Patroller Coach

Patroller Implementation document

Advance Week 1 1. Ball Mill, Vertical Mill, Kiln & Grate Cooler Mechanics2. Practical on-the-jo Inspections 4-main equipment & use of inspection job plans

Patroller Advance version

Week 21. Review First Level Inspection 2. RCA Basic3. Common Patroller jobs4. How to measure silos safely and accurately5. Cyclone & tower cleaning, safely removing snowmen from the clinker cooler (Tools required to complete the task in a safe manner)

Assessments Test (one after each week of training) Assessment Questionaire

Certification General guidelines:Certification will be done by Yanbu Academy Plant. Certification guidelines will be provided by the FLSmidth

Patroller Certification


QUALITY CONTROL SHIFT OPERATOR (QCSO) Discover Plant Basic Advance Certify

Who to provide?

Plant coach, Quality manager and training responsibilities

Trainer: FLSmidth Quality Specialist Trainer: FLSmidth Quality Specialist Follow up by FLSmidth

Where? Home plant Classroom & On-the-job training Classroom & On-the-job training Plant

How? On the job: Safety training, lectures and self-study on Cecil computer

Theory and practical training On the job assignments

What? Safety Laboratory Safety Guideline and sampling safety checklist: Relevant parts by Quality Coach, quality manager and safety officer

1. Quality control2. Introduction Basic of quality control 3. Starting the shift 4. Data management5. Quality Information Management System6. Laboratory check & monitoring

Handing over and taking over the shift, including any safety issuesPreventive Maintenance of Lab Equipment and Sampler Sampling and Preparation – Assessment Validation of Results

Basic Cement manufacturing Raw meal / kiln feed analysis Review and improve Sampling skills and methods skills

Checking and coaching the person responsible for taking and preparing samples according to the control plan following relevant sampling SOP's and checklists

Basic mathematics and calculation Clinker analysis Discover Plant Action plan to be validated by QM and implemented in the next phase

Laboratory assessment methods Learning of all routine methods

Fuel analysis

Preparation of program Define three work issues during normal activities

Mill samples analysis

Evaluation Assessment based on basic theory 1. Cement manufacturing process

knowledge 2. Calculation and mathematics 3. Laboratory methods

Daily Assessment Daily Assessment to confirm the progress of the candidate

Validate KPI Checklist and evaluation of the result

Examination, theory and practice Plant coach and Quality Manager reviews performance

Tools Plant Checklist Daily Assessments of module completed Daily Assessments of module completed Certify Phase: Project Presentation

Assessments Laboratory Safety Guideline and sampling safety checklist

Laboratory Safety Guideline and sampling safety checklist

SOP’s for all routine task & analysis methods

Laboratory Safety Guideline and sampling safety checklist

Scenarios and presentations Scenarios and presentations KPIs checklist for Safety, Attitude, Sampling, Assessment & Industrial KPIs, Daily KPI monitoring file

Calculation and mathematics Assessment


MECHANICAL INSPECTORS TRAINING & CERTIFICATION

Discover Plant To raise Maintenance inspectors’ skills to the expected competency level. Ensure Inspectors, know understand and use the right inspection tools & procedures.After completing training course, the participant will be able to:1. Recognize different Maintenance Strategies and understand the importance of Inspections

to managing Preventive Maintenance2. Understand & define the role of the inspector (where it starts, where it stops, how it integrates

in overall Maintenance Process)3. Understand and assess existing inspection process4. Apply the methodology for building the Inspection plan for all main & auxiliary equipment.5. Develop Inspection Strategy sheet & Inspection Job Plans & Routes6. Perform 1st level & Spesific inspections using diagnostic tools7. Perform Vibration Analysis. 8. Report & describe abnormalities9. Compile detail specific inspection report.

Build Basic Week 1 – Inspection Methodology 1. Introduction Planner Role & Certification Program2. Methodology, Routine planning & Scheduling Planning3. Methodology and tools to write execution job plan (including Safety)4. Rules for spare parts management5. Rules for plant technical documentation management6. Methodology for writing specifications for maintenance operations contracts (Routine & Major operations) & Scheduling7. Risk Analysis

Weeks 2 & 3 – Equipment Technology1. Auxilliary Equipment Technology 2. Ball Mill, Vertical Mill, Belt & Screw Conveyors3. Inspection Tools:Dial gauge alignment, V-belt alighnment, Endoscopy, NDT, Ultra soundect….

Weeks 4 – MAXIMO (Optional) MAXIMO session not specific to Planners

Assessments to be passed (one after each week) Planner Assessment Test

Implement Delegates will be complete ten (10) Job Plans. Job plans to be validated by FLSmidth SME, feedback will be provided to delegate as well as Maintenance Coach.

Advance Week 1 – Methodology 1. Kiln Shutdown Planning & Scheduling (4 days) linked with specific rules & guidelines. 2. KSD management process3. Roles, responsibilities, timing, Planner’s role in KSD. 4. Subcontractors management5. Cost estimation & budgeting6. RCA

Weeks 2 & 3 1. Equipment Technology Rotary Kiln & Cooler, Pneumatic Conveyor mechanics, Gear Inspections.2. Spesific Inspection Tool, Lazer Alignment, thickness measurements, temperature measurements,

rotation speed

Week 4 – MAXIMO Use of MAXIMO to support KSD planning & scheduling

Final Assessments

Certification Planner Certification done at Plant Level with support of FLSmidth SME. Review Planner project assignment. Evaluation actual KSD preparation, planning & execution


PLANNERS TRAINING & CERTIFICATION

After completing training course, the participant will be able to:1. Assess the status of maintenance organization planning process.2. 'Understand why we need planning3. Define the planning process4. Understand & describe Planning methodology5. Define the role & the missions of the planner / Scheduler 6. Describe the work order cycle7. Assess own plant workflow and identify gaps8. Understand main exuipment & auxiliary equipment9. Kiln Shutdown & Scheduling10. Understanding of subcontractor safety management.11. Perform Planning on Maximo 12. Manage the technical documentation of the plant using the guidelines in order to: – Ensure the documents are up to date – Ensure the documents are complete & reliable – Ensure the availability & accessibility of the latest versions at any time

Plannner Basic Week 1 – Planning Methodology1. Introduction = planner role / certification program2. Methodology = Routine planning & scheduling 3. Planning – Safey – Methodology and tools – Spare parts management – Technical documentation management – Methodology for writing specifications for maintenance operations contracts

(Routine & Major operations) – Scheduling4. Risk Analysis

Weeks 2 & 3 – Equipment Technology1. Equipment Technology 2. Ball Mill, Vertical Mill, Belt & Screw Conveyors

Weeks 4 – MAXIMO (Optional) MAXIMO session not specific to planners

Assessments to be passed Planner Assessment Test

Implement Complete expected number of Job Write One specification / call for tender

Advance Week 1 – Methodology 1. Kiln Shutdown Planning & Scheduling. 2. KSD overall management processs 3. Roles, responsibilities, timing4. Mastering Kiln Shut Down5. KSD scheduleing 6. Subcontractors management 7. RCA 8. Lack of cost estimation 9. Maintenance budget to be more detailed

Weeks 2 & 3 – Equipment Technology1. Rotary Kiln & Cooler2. Auxilliary Equipment

Week 4 – MAXIMO (Optional) 1. Use of MAXIMO to support KSD planning & scheduling

Assessments to be passed (one after each week)

Certification Planner project assignemt & KSD scheduling


KILN COACH TRAINING & CERTIFICATION PATH

Objective After completing training course, the participant will be able to:1. Develop CRO Coach to the expected competency level2. Able to compile, revise & coach CRO’s on plant operating procedures3. Implement Improvements on kiln & mill stability4. Implement & coach CRO’s on control strategies to achieve consistent contro5. Monitor & follow-up on CRO’s actions to bringing equipment’s back into target range in an optimal time6. Reducing the number of Production & Process incidents7. Implement CRO Performance Tracking

Basic & Advance 1. Safety2. Safety Risk Assessment 3. Introduction & Role of a Kiln coach4. Safety & Safety Risk Assessment5. Kiln / Production roles considering Coaching guidelines & Performance Tracking Tool6. Continuous improvement: Through Systematic Problem-Solving Methodology 1st step: Performance monitoring -> key indicators for Raw Mill, Kiln, Cement Mill 2nd step: Analysis of Operation deviations, RCA 3rd step: Brainstorm & evaluate solutions, Knowledge sharing & Best Practices 4th step: Implementing solutions 7. Setting operating standards - Developing & using standard operating procedures, importance

of CRO’s to follow SOP’s, review & update SOP8. Leadership & Communication skills 9. Effective Coaching Skills 10. CRO performance monitoring and follow up 11. Implement Performance Tracking Tool12. Action plan: Coaching Implementation 13. PXP

Implement The kiln coach must implement what has been covered above through completion of on-the-job assighnments

Kiln Coach development kit

Certify 1. CRO Qualification Assessment Test2. Assessment using the Kiln Simulator3. Assessment Matrix


Engineer Professional Development Program

Methods ■ The Engineer Professional Development Program (EPDP) for

Young Engineers, is a fast track structured development process training program, which require high availability & capacity of the participant to absorb the new knowledge within six (6) months. The Participant acquire knowledge through formal classroom session at Cement Knowledge Center by FLSmidth & Yanbu Cement Company, plant assignments under the supervision of Plant Experts, as well as, group and individual projects.

■ The (EPDP) is structured to develop participants with a global mindset on how to work in an autonomous manner but also to work effectively in team. Candidate will acquire the technical knowledge and management skills to be one of the main

actors in his plant based on their technical discipline knowledge and contribute effectively, in improving plant efficiencies & variable cost reduction programs. It is expected that candidates completing the program successfully will become the future leaders in the plant.

PrerequisitesEnglish: Participants should have appropriate skills to be able to understand and actively contribute to group discussions

AudienceYoung engineers less than 3 years’ experience. Bachelor in engineering (chemical, process, industrial, Geomining, Electrical Maintenance, Mechanical Maintenance)

Process & Production Specialization Duration (Days)

Fuel Safety, Handling & Combustion 3

Refractory I 5

Process Optimization (level I) 5

Grinding Technology (level II) 10

Kiln Operation II 10

Process Optimization (level II) 8

Refractory II 10

LOTOTO 3

RCA & Downtime Analysis 3

Effective Data Analysis (Level I) 2

Clinker Quality Mastery 5

Raw Mix Design 5

Mining Operations 5

Mines Planning 3

Expert Control Principles 3

Critical Sensors 3

Industrial Knowledge Management 2

Geomining Specialization Duration (Days)

Quarry Operations & Process Risks 5

Mining Operations 5

Drilling & Blasting 3

Mines Planning 3

Modeling Software 3


Quality Control Specialization Duration (Days)

Product Applications Fundamentals 3

Effective Data Analysis (Level I) 2

Laboratory Mastery 5

Concrete Durability 3

Cement Usage Properties 2

Clinker Quality Mastery 5

Raw Mix Design 5

Quality Mastery Program 8

Mines Planning 3

Modeling Software 3

Electrical Maintenance Specialisation Duration (Days)

Electrical Maintenance (Level I) 5

LOTOTO 3

Electrical Inspection (level I) 5

Electrical Inspection (level II) 5

Maintenance KPI Workshop 2


Instrumentation Fundementals 3

Automation Specialization Duration (Days)

LOTOTO 3



Expert Control Principles 3

Critical Sensors 3

Gas Analyzer Maintenance 3

Instrumentation Fundamentals 3

Industrial Knowledge Management 2

Automation (level II) 3

Mechanical Maintenance Specialization Duration (Days)

LOTOTO 3



Mechanical Maintenance (level I) 5

Hydraulics 3

Mechanical Inspection (level I) 5

Heavy Duty Gear Maintenance 3

Cooler Maintenance 5

Kiln Special Maintenance 5

Vertical Mill Maintenance 5

Crusher Maintenance 2

Ball Mill Maintenance 5



01

04

04

05 06

07

02

03

Selection and HiringThe Anchor point in the whole program as it determines the quality of the outcome.

SpecializationThe Cement professional now is ready to perform in his new specialization.

Induction“Know your plant”Induction program.

AssessmentA structured psychometric and knowledge assessment that defines the quality of the trainee and set expectations after EPDP.

3 WayCommitment Certification

PerformanceTracking

EPDP Concentrated transformation boot camp competency based to develop Cement Professionals.


ENGINEER PROFESSIONAL DEVELOPMENT PROGRAMHiring Assessment Geo-mining

& raw mix preparation

Pyro and mill

operations

Quality & Product

Material & Gas

Handling

Qualifica-tion

Perfor-mance

Tracking

Technical Specialisa-

tions

Managerial Specialisa-

tions

Induction of program

AssessmentMath's

ChemistryPhysics

Welcome & safety induction

(1-day)

Assignments revision (1-day)

Assignments revision 2

(1-day)

Assignments revision 3

(1-day)

Project delivery(2-days)

KPIs for each

participant


Leadership

Setting stage of learning (1-day)

Operational safety

(2-days)

Cement chemistry(5-days)

Maintenance safety

(2-days)

Project discussion

(1-day)

Geo-mining Budgetting

Cement manu-

facturing (5-day)

Grinding technology

(level 1) (5-day)

Cement quality 1(5-days)

Material handling(5-days)

Sumative assessment

(1-day)

Quality control

Resource planning

Quarry operation

safety(2-days)

Kiln operation 1

(5-days)

Automation level 13-days)

Gas handling(5-days)

Certification cermony

(1-day)

Mechanical & electrical

maintenance

Advanced project

management

Geo-mining and raw mix

(5-days)

Kiln & Mill Simulator

(1-day)

Basic maintenance documents

(3-days)

Qualification project (1-days)

Automation

Assesment/Assignment

(1)(1-day)

Assessment/Assignment

(2) (1-day)


(3)(1-day)


(4)(1-day)

Home-plant FLSmidth Yanbu

Cement Academy

FLSmidth Yanbu

Cement Academy

Home-plant On the job assignment

FLSmidth Yanbu

Cement Academy


FLSmidth Yanbu

Cement Academy


FLSmidth Yanbu

Cement Academy


FLSmidth Yanbu

Cement Academy


FLSmidth Yanbu

Cement Academy

FLSmidth Yanbu

Cement Academy

15 15 15 15 18 12 15 15 5

125 working days – 6 months


Methods ■ Part of overall Engineer Development Path, that defines

the development of plant engineers ■ Based on an experimental learning model, it is a 12 to 18

month track with formal training and on-the-job training & coaching to build the required competencies

■ Structured plant observations ■ Structured induction into the plant and function ■ Line manager taking the lead to guide the development

process ■ Classroom instructions

Objectives ■ Integrate the Participant safely, through the acquisition of

knowledge about the plant: organization, people, processes & systems

■ Provide structure and accelerate the development of new Engineers in acquire foundation knowledge in the various domains of Cement Manufacturing within 6 months from joining the EPDP Program

■ Develop main competencies required by Engineers in the different Engineering functions

■ Enable the Participant to be confident, develop transversal competencies to contribute to the plant performance effectively

■ Guide Plant Managers & HR Business Partners to develop IDP’s for their Trainee / Participants to master Foundation Cement Manufacturing Competencies

■ Guide Young Engineers to have a clear role definition, understand what competencies are required & assist them to participate actively in Individual Development Planning interviews

■ Create a platform for line Managers to be directly responsible for the development of their people

■ Help Participants to build a network of professional contacts among peers & experts

ContentEPDP

■ Process Knowledge for Non Process Engineers ■ Cement Chemistry ■ Operational Safety ■ Gas Handling ■ Grinding Technology (level I) ■ Kiln Operation I ■ Maintenance Safety ■ Basic Maintenance Documentation ■ Material Handling ■ Cement Quality (Level I) ■ Quarry Operations Safety ■ Geomining & Raw Mix ■ Automation (level I)



Vocational Training

Vocational Training 78Vocational Training 79Electrical Technician 80Mechanical Fitter Technician 81Mechanical Workshop Technician 82Welder Technician 83


Vocational training Phases:The vocational training program consist of different 4 phases of 30 days each, depending on the vocational program followed by the learner. Learners will be assessed on a weekly basis as well as final vocational test at end of each phase & final certification assessment to demonstrate competence.

Sixty presents (60%) of the program consist of theoretical class room training & forty percent (40%) practical application at Yanbu Training Academy. After completion of each phase the learner will be provided with on-the-job assignment log sheet. The learner will return to his home plant and complete the assignment (3 – 6 months) with the assistance of an experience Technician. Each task must be completed 3 times and once competent signed off by the relevant Engineer.

On completion of (Home Plant phase) the learner will return for the next phase of training at Yanbu Training Academy. After completion of all theoretical & practical on-the-job assignment the Learner will be allowed to enroll for final vocational assessment & certification.

Vocational Training

For final certification the learner will submit a Portfolio of evidence (POE) that will include:

■ Modules completed & self-tests & formal assessment documents ■ Practical Assignment logbook indicating all the tasks completed &

signed off as being competent by the relevant Manager/Engineer ■ Validation of POE by Yanbu Training Academy Training Manager

On submission of the POE the learner will be enrolled for final certification preparation and assessment

The following vocational training will be available ■ Electrical Technician ■ Mechanical Fitter Technician ■ Mechanical Workshop Technician ■ Welder Technicians




PrerequisitesTechnical School Qualification Grade 12

AudienceElectrical Learners

Duration 120 days excluding time to complete practical on job mandatory assignments

ObjectivesElectrical vocational training is a combination of on-the-job training (OJT) and related classroom instruction under the supervision of a Technical Professional in which workers learn the practical and theoretical aspects of a highly skilled occupation. The delegates progress will be continuously assessed during the training on knowledge as well as practical completion of on the job assign-ments.

After successful completion of all Training phases & on-the-the assignments the Learner will be able to:

■ Perform Electrical maintenance electrical technician tasks safely according to International Best Maintenance Practices

Content ■ Phase 1 Basic Electrical ■ Phase 1 On-the-job practical assignment (home plant) ■ Phase 2 Intermediate Electrical ■ Phase 2 On-the-job practical assignment (home plant) ■ Phase 3 Advance Electrical ■ Phase 3 On-the-job practical assignment (home plant) ■ Phase 4 Final Electrical ■ Phase 4 On-the-job-practical assignment ■ Final Certification Test

Electrical Technician

Price USD/trainee 40.750SAR/trainee 153.000





AudienceMechanical Fitting Learners


ObjectivesMechanical Fitter vocational training is a combination of on-the-job training (OJT) and related classroom instruction under the super-vision of a Trade Professional in which workers learn the practical and theoretical aspects of a highly skilled occupation. The dele-gates progress will be continuously assessed during the training on knowledge as well as practical completion of on the job assignments.


■ Perform Fitter Maintenance Technician tasks safely according to International Best Maintenance Practices

Content ■ Phase 1 Basic Mechanical Fitting (30 days) ■ Phase 1 On-the-job practical assignment (home plant 3-4 Months) ■ Phase 2 Basic Mechanical Fitting (20 days) ■ Phase 2 On-the-job practical assignment (home plant 3-4 months) ■ Phase 3 Advance Mechanical Fitting (30 days) ■ Phase 3 On-the-job practical assignment (home plant 3-4 months) ■ Phase 4 Advance Mechanical Fitting 27 days ■ Phase 4 On-the-job-practical assignment (home plant 3-4 months ■ Final Certification Test (5 days)

Mechanical Fitter Technician




on-site inspections. ■ Case study to put method into practice


AudienceMechanical Learners


ObjectivesMechanical Workshop Technician vocational training is a combina-tion of on-the-job training (OJT) and related classroom instruction under the supervision of a Trade Professional in which workers learn the practical and theoretical aspects of a highly skilled occupation. The delegates progress will be continuously assessed during the training on knowledge as well as practical completion of on the job assignments.


■ Perform Workshop Technician tasks safely according to International Best Maintenance Practices

Content ■ Phase 1 Basic Mechanical (Workshop) (30 days) ■ Phase 1 On-the-job practical assignment (home plant 3-4 Months) ■ Phase 2 Advance Mechanical Workshop (30 days) ■ Phase 2 On-the-job practical assignment (home plant 3-4 months) ■ Final Certification Test (5 days)

Mechanical Workshop Technician






AudienceMechanical Learners


ObjectivesWelder vocational training is a combination of on-the-job training (OJT) and related classroom instruction under the supervision of a Trade Professional in which workers learn the practical and theoretical aspects of a highly skilled occupation. The delegates progress will be continuously assessed during the training on knowledge as well as practical completion of on the job assignments.


■ Perform Welding tasks safely according to International Best Maintenance Practices

Content ■ Phase 1 Basic Welding (15 days) ■ Phase 1 On-the-job practical assignment (home plant 3-4 Months) ■ Phase 2 Advance Welding (15 days) ■ Phase 2 On-the-job practical assignment (home plant 3-4 months) ■ Final Certification Test (2 days)

Welder Technician



Prices

Prices 84PricesFull catalogue 85Engineer Professional Development Program 88Process & Production Specialization 89Geo-mining Specialization 90Quality Control Specialization 91Mechanical Maintenance Specialization 92Electrical Maintenance Specialization 93Automation Specialization 94


Prices Full catalogue


Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Process Knowledge for Non Process Engineers 3 2.000 7.500

Cement Chemistry 5 3.000 11.250

Fuel Safety 3 2.000 7.500

Operational Safety 2 1.500 5.625

Gas Handling 5 3.000 11.250

Grinding Technology (level I) 5 3.000 11.250

Refractory I 5 3.000 11.250

Kiln Operation I 5 3.000 11.250

Process Optimization (level I) 5 3.000 11.250

Fuels Safety, Handling & Combustion 5 3.000 11.250

Environmental Matters 5 3.000 11.250

Quality Control

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Cement Quality (Level I) 5 3.000 11.250

Product Applications Fundementals 3 2.000 7.500

Effective Data Analysis (Level I) 2 2.000 7.500

Laboratory Mastery 5 3.000 11.250

Concrete Durability 3 2.000 7.500

Cement Usage Properties 2 2.000 7.500

Clinker Quality Mastery 5 3.000 11.250

Raw Mix Design 5 3.000 11.250

ARM Impact on Clinker Reactivity 2 2.000 7.500

AF & Solid Fuels impact on Clinker Mastery 3 2.000 7.500

Quality Mastery Program 8 8.000 30.000 All prices include food and accommodation costs


Mechanical Maintenance

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Mechanical Maintenance (level I) 5 3.000 11.250

Material Handling 10 5.000 18.750

Hydraulics 3 3.000 11.250

Mechanical Inspection (level I) 5 3.000 11.250

Heavy Duty Gear Maintenance 3 2.000 7.500

Cooler Maintenance 5 3.000 11.250

Kiln Special Maintenance 5 8.000 30.000

Vertical Mill Maintenance 5 3.000 11.250

Crusher Maintenance 2 2.000 7.500

Ball Mill Maintenance 5 3.000 11.250

Realibility Driven Maintenance Seminar 3 3.000 11.250

Maintenance KPI Workshop 2 2.000 7.500

RCA & Downtime Analysis 3 5.000 18.750

Mechanical Maintenance Manager Seminar 3 5.000 18.750

Electrical Maintenance

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Electrical Maintenance (Level I) 5 3.000 11.250

Maintenance Safety 3 2.000 7.500

LOTOTO 3 5.000 18.750

Basic Maintenance Documentation 3 2.000 7.500

Electrical Inspection (level I) 5 3.000 11.250

Electrical Inspection (level II) 5 3.000 11.250

Electrical Maintenance Manager Seminar 3 3.000 11.250 All prices include food and accommodation costs


Automation Specialisation

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

LOTOTO 3 5.000 18.750



Expert Control Principles 3 3.000 11.250

Critical Sensors 3 3.000 11.250

Gas Analyser Maintenance 3 3.000 11.250

Instrumentation Fundementals 3 3.000 11.250

Industrial Knowelege Management 2 2.000 7.500

Automation (level II) 3 5.000 18.750

Geomining

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Quarry Operations Safety 3 2.000 7.500

Geomining & Raw Mix 5 3.000 11.250

Quarry Operations & Process Risks 5 3.000 11.250

Mining Operations 5 3.000 11.250

Drilling & Blasting 3 2.000 7.500

Mines Planning 3 2.000 7.500


All prices include food and accommodation costs



EPDP

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Process Knowledge for Non Process Engineers 3 2.000 7.500

Cement Chemistry 5 3.000 11.250

Operational Safety 2 1.500 5.625

Gas Handling 5 3.000 11.250

Grinding Technology (level I) 5 3.000 11.250

Kiln Operation I 5 3.000 11.250

Maintenance Safety 3 2.000 7.500

Basic Maintenance Documentation 3 2.000 7.500

Material Handling 10 5.000 18.750

Cement Quality (Level I) 5 3.000 11.250

Quarry Operations Safety 3 2.000 7.500

Geomining & Raw Mix 5 3.000 11.250

Automation (level I) 3 3.000 11.250

Total 57 35.500 133.125


623 $/day

EPDP


Process & Production Specialization

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Fuel Safety 3 2.000 7.500

Refractory I 5 3.000 11.250

Process Optimization (level I) 5 3.000 11.250

Grinding Technology (level II) 10 5.000 18.750

Kiln Operation II 10 5.000 18.750

Process Optimization (level II) 8 5.000 18.750

Refractory II 10 5.000 18.750

LOTOTO 3 5.000 18.750










Total 85 59.000 221.250


665 $/day


EPDP

Total is 354,375 SAR/trainee

and that is 2,495 SAR/day

of effective training.

+

=



Geo-mining Specialization

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Quarry Operations & Process Risks 5 3.000 11.250


Drilling & Blasting 3 2.000 7.500


Modeling Software 3 5.000 18.750

Total 19 15.000 56.250


664 $/day


EPDP




+

=



Quality Control Specialization

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee








Supplementary Cementitous Materials 3 2.000 7.500

Basic Understanding of XRD 2 3.000 11.250

Quality Mastery Program 8 8.000 30.000



Total 44 32.000 120.000


665 $/day


EPDP




+

=



Mechanical Maintenance Specialization

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee








Quality Mastery Program 8 8.000 30.000



Total 44 32.000 120. 000


752 $/day


EPDP




+

=



Electrical Maintenance Specialization

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

Electrical Maintenance (Level I) 5 3.000 11.250

LOTOTO 3 5.000 18.750

Electrical Inspection (level I) 5 3.000 11.250

Electrical Inspection (level II) 5 3.000 11.250




Total 37 24.000 90.000


717 $/day


EPDP




+

=



Automation Specialization

Course NameDuration

(Days) Price

USD/trainee Price

SAR/trainee

LOTOTO 3 5.000 18.750





Gas Analyser Maintenance 3 3.000 11.250




Total 25 31.000 116.250


810 $/day


EPDP




+

=



More informationFor more information about Cement Knowledge Center, please contact us on [email protected]

Copyright © 2019 FLSmidth. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. C

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