CRO complete path training Programme

STATUS - CONTROL ROOM OPERATOR CERTIFICATION - TRAINING PROGRAM - LAFARGE CIMENT HOGHIZ
Summary Induction 1 - Health & Safety - Environment 1- Cement manufacturing basics 2- LUCIE 3 - Introduction to plant Equipment 4- Laboratory functions & Quality 8.44 STATUS_CRO_TRAINING_PROGRAM_CRO_before_ final_ theoretical_test 9.72 8.64 9.62 8.98 8.42 Deadtime Barta Elena 100% Huntai Alexandrin Crutu Sofia a 100% 100% Ionescu Maria 100% Jondre Viorica 100% Grama
Lacramioara

100%

Foundations

Februarie noiembrie 2009

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

THEORETICAL TEST - CRO - 03.03.2010

Apr-10 Apr-10 Oct-10

93.1%

100.0%

97.5%

98.9%

99.4%

94.3%

1.0 KHD SIMULATOR TRAINNING

Control Room Operator Specific Training

2.0 SOPs review 3.0 Certification operator final report 4.0 Certification operator

CRO_Complete_path_training_programme21 09 06.xls

Division Training Dept. / DR /

CRO complete path training Programme

INDUCTION

TOTAL:

1 - HEALTH & SAFETY - ENVIRONMENT

Plant Health and Safety Mgt system Plant Heath and Safety policy PPE used Plant secutity / safety / emergency procedures Identification of safety first aiders and fire brigades STOP or local safety observation & monitoring system Plant Safety equipment location Risk Analysis Contractors management system Work at height Work in confined space/ silos cleaning LoTo procedure and Work permit systems Accident record and analysis Use of fire fighting equipment

Environment LAFARGE and Plant environment policy and procedures Main environmental risks: Dust, gases, Noise, vibrations, Fuel caracteristic, ARM and ARF, soils and waters contamination local regulations compliance and plant commitments

CRO_Complete_path_training_programme21 09 06.xls

Division Training Dept. / DR /

CRO complete path training Programme

1 Programat de efectuat

Barta Elena
Efectuat instruire / data Inter Evaluare

Huntai Alexandrina

Crutu Sofia

Ionescu Maria
Inter Evaluare

Jondre Viorica
Efectuat instruire / data Inter Evaluare

Grama Lacramioara Inter Evaluare

FOUNDATIONS

Resp. instruire

Efectuat instruire / data Inter Evaluare Efectuat instruire / data Inter Evaluare Efectuat instruire / data

Efectuat instruire / data

Class Training

OJT

25.5

8.44

25.5

9.72

25.5

8.64

25.5

9.62

25.5

8.98

25.5

8.42

1- cement manufacturing basics

1.1 Basics of Physico Chemistry: C2S, C3S, Free lime, Calcination etc CECIL lesson 1 - Cement CECIL lesson 2: Raw mix/clincher composition 1.2 Clinker caracteristics CECIL lesson 3: Clincher quality CECIL lesson 4: Minor clinker elements 1.3 Important parameters (cement ratios) CECIL lesson 5:Raw mix ratio (without calculations) 1.4 Raw materials: CECIL lesson 7: What raw mix, what clinker? 1.5 Quarry: Drilling and blasting; Crushing / stacking / reclaiming / CECIL lesson 8: Influence of raw mix on burning 1.6 Mill grinding (mill and separator) CECIL lesson Grinding basics: Introduction to grinding CECIL lesson Mill technology: Ball mills CECIL lesson Separators: 1.Air separators 1.7 Possible mill adjustments / influence on production and fineness CECIL lessons mill operations: 1. Operate a ball mill 1.8 Preheating feed CECIL lesson 11: L-T Diagram 1.9 Burning process & clinkerisation CECIL lesson 22: Kiln structure 1.1O Cooling CECIL lesson 28: Discharge heat exchanges CECIL lesson 29: Grate cooler technology 1.11 Kiln - preheater connection CECIL lesson 30: Grate cooler operation 1.12 Kiln - cooler connection CECIL lesson 31: Kiln Hood 1.13 The burner(s)

26
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

100.0%
1 1 1 1 1 1 1 1 1 6.32 8.89 8.26 10.00 7.78

100.0%
1 1 1 1 1 1 1 1 1 9.47 10.00 10.00 10.00 10.00

100.0%
1 1 1 1 1 1 1 1 1 6.32 10.00 7.83 9.47 10.00

100.0%
1 1 1 1 1 1 1 1 1 9.47 10.00 10.00 10.00 10.00

100.0%
1 1 1 1 1 1 1 1 1 8.42 10.00 10.00 10.00 7.78

100.0%
1 1 1 1 1 1 1 1 1 8.42

Georgescu P.

1 1 1 1 1 1 1 1 1 1 1 1 9.41

1 1 1 1 1 1 1 1 1 1 1 1 8.82

1 1 1 1 1 1 1 1 1 1 1 1 8.24

1 1 1 1 1 1 1 1 1 1 1 1 8.24

1 1 1 1 1 1 1 1 1 1 1 1 7.65

1 1 1 1 1 1 1 1 1 1 1 1

CECIL lesson 33
1.14 Refractories

CECIL lesson 24: Refractories 2 - LUCIE Raw mill Solid fuel mill Cement mills Kilns 3 - Introduction to plant Equipment 2.1 Plant equipment Big Blasterer Rigole, transportoare cu banda, snec, transportoare cu racleti, Filtre cu saci Dozatoare cu banda, cantare, cantare cu rotor, debitmetre de Suflante, ventilatoare Elevatoare cu cupe Sistemul de distributie a aerului comprimat si compresoare 4 - Laboratory functions & Quality control 4.1 Introduction to Quality Develop Exploraid assignment for Quality Dpt. 4.2 Sampling Safety rules in the lab. 4.3 Laboratory functions Raw mix design concepts Quality Management Necesary analysis 4.4 Chemical Analysis Laboratory Equipment (Mills, Chemical analysis, X ray, Microscopy ) A, C, S, F, analysis, Free lime, Minor elements, volatiles 4.5 Physical tests Making test cubes compression - extension tests, 1, 2, 7, 28 days blaine, sieve, % passing, % retained Vicat

Demeter I.

1 1 1

0.25 0.25

0.25 0.25 0.25 0.5 0.25 0.25 0.25

0.5 0.5 0.5 0.5 0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5 0.5 0.5

0.5 0.5 0.5 0.5 0.5 0.5 0.5

Georgescu P.

0.25 0.5 0.25 0.25 0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

Stefania M.
0.25 0.25 0.25 0.25 0.25 0.25 0.25

0.25

0.25

0.25

0.25

0.25

0.25

0.25

CRO_Complete_path_training_programme21 09 06.xls

Division Training Dept. / DR /

CRO complete path training Programme

Control Room Operator - Final Certification Stage (On the Job)

Responsible

Dead line

1.0 KHD SIMULATOR TRAINNING

Simulator presentation

1.1 Operating the Pyro line

Normal kiln operatios Kiln warming up Kiln feed on Cooler ajustments Cyclone blockage Combustion control Kiln Shutdown Incidental problems (ring formation, hot spot, equipments stop)

1.2 Operating the Raw line

Normal raw mill operations Raw mix control

P. Georgescu

Apr-10

1.3 Operating the solid fuel mill

High temperature in vertical coal mill

1.4 Operating the finish mill

Normal mill operations Mill overloading High temperature in a cement mill Cement change

SIMULATOR TEST 2.0 SOPs

2.1 Kiln SOPs 2.2 Petcoke SOPs 2.3 Raw mill SOPs 2.4 Cement mill operation P.Georgescu
Apr-10

3.0 Certification operator final report

3.1 Operating targets report 3.1.1 Establised a list with operator targets ( parameter, deviation cryteria - time, value, deadband ); 3.2 Create a folow -up template of operator targets 3.3 Evaluate the "Operator targets and SOPs compliance" of each operator 3.5 Production Manager and TC validates the operator reports W. Weislehner P.Georgescu P.Georgescu W. Weislehner P.Georgescu W. Weislehner V. Zoicas May-10

May-10 Sep-10 Oct-10

4.0 Certification operator

CRO_Complete_path_training_programme21 09 06.xls Division Training Dept. / DR /

Cuptor
Pornire cuptor dupa o oprire de lunga durata; Operare cuptor in conditii stabile Rupere inel din cuptor; Procedura oprire cuptor scurta durata; Oprire incidentala alimentare faina; Oprire incidentala ID Fan; Oprire pfister faina Deblocare de ciclon Oprire incidentala suflanta aer axial arzator; Oprire incidentala suflanta pfister cocs si suflanta pfister pompa moler; Functionare cuptor cu Lucie

Mori (Faina, Cocs & Ciment)

Pornire/oprire instalatie de macinare (Faina, Cocs & Ciment) Operare moara in conditii stabile Schimbarea tipului de ciment Supraincarcare moara Temperatura prea mare in ciment

Responsabil

Termen

Status
100% 60% 85% 85% 85% 85% 85% 85% In lucru In lucru

Observatii
Cerut feedback Discutat cu operatorii Discutat cu operatorii Discutat cu operatorii Discutat cu operatorii Discutat cu operatorii Discutat cu operatorii Discutat cu operatorii

Responsabil

Termen

Status
0% 0% 0% 0% 0%

Observatii

Process parameter Kiln feed rate [t/h] NOx of kiln backend gas

Target Value Deadband

Time of Disturbance START

Disturbance cause

Operator reactions

Notices