CRO Training & Certification Project 08 12 22 version

* 080925 TD-TS Certif v6.doc Certifcation standard = Generic whatever

Reference documents: to be * 060914 - CRO - plant readiness analysis.xls the job (not only CRO)
studied and implemented * CRO job profile extract from CementPlantJobProfiles_August07.doc Assessment: Extensive = CTS version,
before starting the project * CRO_CompetencyProfile_eng.xls extract from Standard competency profiles for key jobs simplified = TCEA version
* Control Room Operator Assessment V4.doc and its guide from CTS & CRO assessment_ini.doc from TCEA Division = Competency & Job profiles

* Safety = plant induction 080520 Key jobs Exploraid.doc =

* Introduction to cement Manufacturing reference document created by TC Training
* CECIL Basics Lessons: 1 to 5 + 7 to 13 + 15+18+19+20+22+29+33+Intro to grinding + Ball mills + Air Separators managers (Vienna April 08). Good starting
Prepare and more if possible ! point but could be improved. CTS
* Produce & Maintain Customers Use Characteristics module if available in the plant assignments (Trainee PE B-01.doc etc.)
* Exploraid assignments defined among CPDP assignments. also to be taken into account.

Week 1 = Kiln Operations basics 1

Intro & safety on site + plant visit + environment regulations ( 1 day)
What is cement + Physico chemistry (3/4 day)
Kiln operation basics 1 (3,5 days)
- Get the basic knowledge on cement manufacturing process and major plant equipment
- Know, locate & follow-up the critical process sensors for major equipment
- Minor Element influence

Week 2 = Mill operation basics

- Get the basics of Grinding principles & major grinding equipment (Ball Mill)
- Get the basic rules for stable mill operations
- Know, locate & follow-up the major process sensors
Foundation module
Week 3 = Auxiliary equipments TCEA "light" version = 5 days.
- Understand equipment function, components and principle of operation CTS extensive version also available.
- Define 1st level, running inspections lists for each equipment
- Perform production field inspections on equipment

Week 4 = Kiln operation basics 2)

* Master combustion
* Get the basic rules for stable kiln operations
Tests to be passed (one after each week): Created by TCEA. Also exisring ATC tests,
* Quiz_Milling Operation.doc essentially about CECIL content.
* Quiz_Auxiliary equipment.doc
* CRO_KilnOpBasics_Final Assessment.doc
In addition of implementing what they've learnt during the Foundation Module, participants have specific Version developed and piloted by Africa
assignments: school plant + TCEA, sept.oct. 2008
Implement * Burning: Control loops activity, Impact of coal & alternative fuels, KFUI, Production ramp up
* Grinding: Ball mill management, Fineness management, Optimum circulating load
Specific evaluation grids exist with key messages to be found in the reports written by CROs.

Run a kiln in stable conditions, reminders Day 1

Control loops … including on the job activity in the plant Day 2
SIMULEX, KHD simulator overview Day 3
Kiln warming up, feed on, production ramp up
Kiln cool down and shutdown 2 days
Kiln performance analysis TCEA / Africa school plant Pilot session
Kiln incidents: rings, cyclone blockage, hot spot (inc. Reminders about refractory), feed cut, fuel stoppage, cold / starting 2008 Oct. 13th
Professionalization module
hot kiln … about 6 days. Existing training package to be
improved
Cooler operations and incidents 1 day
Mill operation basics reminders + quality control basics 1 day
Cement mill start up, operation, stoppage + change of cement type
Cement mill incidents 1,5 day
Raw Mill start up, stoppage, incidents 0,5 day
Pass CECIL lessons test 3 (up to 56) ATC tests … still draft
Simulation test (1,5 day / trainee)
Warm up & start up 4 times (20%)
Emergency & normal stoppage (20%)
Professionnalization tests 2 incidents fixing out of 8 (2x 10%)
80 hrs of Simulex practice (30%)
Written test (10%)

On shift at home plant: CR operation under supervision of a senior operator and kiln coach We need to work on !
Conditions to be met for certification:
- Operate and maintain the kiln on stable condition (10 basic rules)
Certification - Operate Kiln warm up & start up after major repair
- Operate a planned and an emergency shut downs