THE FASTEST, MOST EFFECTIVE WAY - Cement Knowledgecement-knowledge.com/img/CKC-Training catalogure -...

THE FASTEST, MOST EFFECTIVE WAYTO UPSKILL CEMENT PLANT STAFF

FLSmidth and Yanbu Cement have teamed up to launch a cement production training center in the Kingdom of Saudi Arabia. The Center’s objectives are 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 synergies 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 CEMENTOne 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.

FLSMIDTHAs 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 its 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.

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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.

CERTIFICATION PROGRAMMES

MEDIUM TERM PROGRAMMES

SHORTER COURSES

VOCATIONAL TECHNICAL COURSES

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

Participants will achieve essential knowledge and skills within specific discipline area

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

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

Duration6-12 months

Duration2-3 months

Duration5-10 days

Minimum 40 weeks depending on the

programme

Programmes

• Engineer Professional Development Program (EPDP)• Central Control Room Operators• Patrollers/Production Technicians• Process Engineers• Quality Control• Mechanical Inspectors• Electrical Inspectors• Planners• Central Control Room Operators Coach

Programmes

• Health, Safety & Environment• Quarry Operation & Raw Materials• Quarry Control & Laboratory Practices• Proces & Operation

Courses

• Health, Safety & Environment• Process & Operation• Quarry

Courses

• Mechanical Technicians• Electrical Technicians• Instrumentation Technicians

Certification

Participants 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 qualification. This certifies that the participant has achieved the knowledge, skills and abilities to ensure safe, uninterrupted plant operations.

• Electrical Maintenance• Instrumentation & Automation• Mechanical Maintenance

• Maintenance• Product & Quality

• Sheet Metal Work• Welder

FULL RANGE OF TRAINING PROGRAMMES

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

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PROCESS & PRODUCTION

ELECTRICAL MAINTENANCE

Maintenance

Mechanical Planning Level I 34

Hydraulics 35

Mechanical Inspection Level I 36

Heavy Duty Gear and Reducer Technology 37

Crushers, Stackers & Reclaimers 38

Ball Mill Mechanics 39

Vertical Roller Mill Mechanics 40

Kiln Mechanics 41

Cooler Maintenance 42

Maintenance Manager Seminar 43

Mechanical Maintenance Managers Seminar 44

Root Cause Analysis & Down Time Analysis 45

Material Handling 46

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CONTENT

Process Knowledge for Non-Process Engineers 9

Cement Chemistry 10

Fuel Safety, Handling & Combustion Technology 11

Operational Safety 12

Gas Handling 13

Grinding Technology Level I 14

Refractory I 15

Kiln Operation I 16

Process Optimization Level I 17

Environmental Matters 18

Grinding Technology Level II 19

Kiln Operation II 20

Process Optimization Level II 21

Refractory II 23

Performance Management Seminar 24

AF & ARM Co-processing 25

Electrical Maintenance Level I 27

Energy Isolation 28

Basic Maintenance Documentation (electrical) 29

Electrical Inspection Level I 30

Electrical Inspection Level II 31

Instrumentation 32

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Process & Production 8

Process Knowledge for Non-Process Engineers 9

Cement Chemistry 10

Fuel Safety, Handling & Combustion Technology 11

Operational Safety 12

Gas Handling 13

Grinding Technology Level I 14

Refractory I 15

Kiln Operation I 16

Process Optimization Level I 17

Environmental Matters 18

Grinding Technology Level II 19

Kiln Operation II 20

Process Optimization Level II 21

Refractory II 23

Performance Management Seminar 24

AF & ARM Co-processing 25

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PROCESS KNOWLEDGEFOR NON-PROCESS ENGINEERS

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

Methods Presentations, discussions, exercises, calculation

PriceUSD/trainee 2.000SAR/trainee 7.500

On-the-job knowledge (1 – 4 years)

Non-process engineers of a plant

3 days

Prerequisites

Audience

Duration

Methods8

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Electrical Maintenance 26

Electrical Maintenance Level I 27

Energy Isolation 28

Basic Maintenance Documentation (electrical) 29

Electrical Inspection Level I 30

Electrical Inspection Level II 31

Instrumentation 32

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ELECTRICAL MAINTENANCELEVEL I

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

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

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

Electrical Substation Maintenance Electrician/engineers/specialists


5 days

Prerequisites

Audience

Duration

10

MA

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MAINTENANCE

Maintenance 33

Mechanical Planning Level I 34

Hydraulics 35

Mechanical Inspection Level I 36

Heavy Duty Gear and Reducer Technology 37

Crushers, Stackers & Reclaimers 38

Ball Mill Mechanics 39

Vertical Roller Mill Mechanics 40

Kiln Mechanics 41

Cooler Maintenance 42

Maintenance Manager Seminar 43

Mechanical Maintenance Managers Seminar 44

Root Cause Analysis & Down Time Analysis 45

Material Handling 46

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MECHANICAL PLANNINGLEVEL I

Objectives

After completing the training, the trainee will we 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

Methods• Presentations• Group activities

• Maintenance Engineers• Maintenance Planners

5 days


Audience

Duration

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QUALITY & PRODUCT

Quality & Product 47

Cement Quality Level I 48

Product Applications Fundamentals 49

Effective Data Analysis Level I 50

Laboratory Mastery 51

Concrete Durability 52

Cement Usage Properties 53

Clinker Quality Mastery 54

Raw Material & Raw Mix Design 55

Alternative Fuels & Alternative Raw Materials 56

Quality Mastery Program 57

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CEMENT QUALITYLEVEL I

Objectives

After 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

Methods Presentations, exercises, case studies (50% Theoretical & 50% Practical)

• Participants to get familiar about the cement manufacturing process• CADIC

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

5 days


Prerequisites

Audience

Audience

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QUARRY

Quarry 58

Quarry Operations Safety 59

Geomining & Raw Mix 60

Quarry Operations & Process Risks 61

Mining Operations 62

Drilling & Blasting 63

Mines Planning 64

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QUARRY OPERATIONS SAFETY

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

Methods Quarry visit, presentations, case study, exercises, etc.


None

Plant managers, quarry managers and quarry operations personnel

3 days

Prerequisites

Audience

Duration

16

CE

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CERTIFICATION PROGRAMS

Certification Programs 65

What is Certification? 66

Key Operators & Technicians Certification 67

Engineer Professional Development Program 73


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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

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

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VOCATIONAL TRAININGSAR/TRAINEE 133.125

Vocational Training 78

Vocational Training 79

Electrical Technician 80

Mechanical Fitter Technician 81

Mechanical Workshop Technician 82

Welder Technician 83

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VOCATIONAL TRAINING

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 percent (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.

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

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Prices 84

Prices Full catalogue 85


Process & Production Specialization 89

Geo-mining Specialization 90

Quality Control Specialization 91

Mechanical Maintenance Specialization 92

Electrical Maintenance Specialization 93

Automation Specialization 94

PR

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PRICES

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PRICES FULL CATALOGUE



Course NameDuration (Days)

Price USD/trainee

PriceSAR/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

Course NameDuration (Days)

Price USD/trainee

PriceSAR/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

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For 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 11-19 000-91ENG V3

THE FASTEST, MOST EFFECTIVE WAY - Cement Knowledgecement-knowledge.com/img/CKC-Training catalogure -...

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