1. 1
EASTERN MEDITERRANEAN UNIVERSITY
FACULTY OF ENGINEERING
DEPARTMENT OF MECHANICAL
ENGINEERING
MENG400
SUMMER PRACTICE REPORT
Academic Year: FALL 2015
Training Advisor: Assoc. Prof. Dr. Hasan Hacışevki
Submitted By:
Abdullah Awad
138942
Submitted to the Summer Practice Committee in partial fulfillment of the requirements for
the Summer Practice Course MENG400
Eastern Mediterranean University
Gazimagusa, TRNC
November/2015
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Note: Passing Score is 65% for Satisfactory “S” Grade
Jury Member 1:. ………………………………. Sign: ……………………
Jury Member 2:………………………….……. Sign: ……………………
Date of Presentation:……../……../ 2013
CATEGORIES % OF TOTAL SCORE JURY MEMBERS
SCORE
Place and Type of Job Conducted 10
Record and Logbook Keeping 20
Company’s Supervisor Evaluation 20
Report Writing 50
TOTAL SCORE 100%
EVALUATION FORM
MENG400
SUMMER PRACTICE
3. 3
Contents
Chapter 1 .........................................................................................................................................8
Introduction......................................................................................................................................8
Chapter 2 .........................................................................................................................................9
Company information ........................................................................................................................9
Chapter 3 .......................................................................................................................................11
Product information.........................................................................................................................11
3.1 company works and production lines........................................................................................11
3.1.1 Constructions of building and high ways .................................................................................11
3.1.2 Water and power station ......................................................................................................13
3.1.3 Oil and gas..........................................................................................................................13
3.1.4 Cement and asphalt plants....................................................................................................14
3.1.5 INDUSTRIAL SERVICES..........................................................................................................15
3.1.6 EQUIPMENT & MACHINERIES................................................................................................17
3.1.6 CGCS STANDARD PRODUCTS .................................................................................................18
3.2 Working mechanism in the company ........................................................................................18
3.3 Management departments and their functions ..........................................................................19
3.3.1 PLANNING ..........................................................................................................................19
3.3.2 Organizing ..........................................................................................................................19
3.3.3 Staffing...............................................................................................................................19
3.3.4 Directing.............................................................................................................................19
3.3.5 Quality Controlling ...............................................................................................................19
3.3.6 Contract Administration .......................................................................................................20
3.4 Organization of the company ...................................................................................................21
3.5 Departments description.........................................................................................................22
3.5.1 Engineering department.......................................................................................................22
3.5.2 Human resources department...............................................................................................22
3.5.3 Public relations department ..................................................................................................23
3.5.4 Accounting department........................................................................................................23
3.5.5 CONTRACTS DEPARTMENT....................................................................................................23
3.5.6 Project managers department...............................................................................................23
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3.5.7 IT Department.....................................................................................................................24
3.5.8 CORPORATE COMMUNICATION DEPARTMENT.........................................................................24
Chapter 4 .......................................................................................................................................25
Work performed..............................................................................................................................25
4.1 Brief history of cement............................................................................................................25
4.2 Safety ...................................................................................................................................25
4.3 Cement manufacturing process................................................................................................26
4.3.1 Uprooting rocks...................................................................................................................27
4.3.2 Raw materials used in the cement industry .............................................................................28
4.3.3 Methods of cement industry .................................................................................................31
4.3.4 Laboratory and quality control in cement industry ...................................................................31
4.3.5 Sections of cement factory....................................................................................................37
4.4Some problems encountered in cement manufacturing processes ................................................53
4.4.1 Maintenance of mixer: .........................................................................................................53
4.4.2Aggregate batching plant switch failure ...................................................................................54
4.4.3 Water pump........................................................................................................................55
4.4.4 Screw conveyor failure .........................................................................................................55
4.5 Some calibration methods and standards ..................................................................................56
4.5.1 Conveyor Scale Calibration (figure 4.38):.................................................................................56
4.5.2 Test Weights Calibration .......................................................................................................57
4.5.3 Calibration of aggregate scales ..............................................................................................58
4.5.4Calibration of additives system...............................................................................................58
Chapter 5 .......................................................................................................................................60
PERSONAL DEVELOPMENT ........................................................................................................60
Chapter 6 .......................................................................................................................................61
DISCUSSION/CONCLUSION .........................................................................................................61
Appendix I ......................................................................................................................................63
Main equipment and machines ..........................................................................................................63
Appendix II.....................................................................................................................................73
Tables and charts.............................................................................................................................73
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Table of figures
FIGURE 1 (FIGURE 1.1) COMBINED GROUP COMPANY LOGO 8
FIGURE 2 (FIGURE 2.1) COMPANY SHAREHOLDER 10
FIGURE 3 (FIGURE 3.1) IT IS CONSTRUCTION, COMPLETION AND MAINTENANCE OF ROADS,
STORM-WATER DRAINAGE, SEWER AND OTHER SERVICES FOR SUBIYA HIGHWAY WHICH COST
ABOUT 112,000,000 DOLLAR 11
FIGURE 4 (FIGURE 3.2) HEAD QUARTER OF MANPOWER & GOVERNMENT RESTRUCTURING
PROGRAM 11
FIGURE 5 (FIGURE 3.3)DESIGNS, CONSTRUCTION, COMPLETION AND MAINTENANCE OF MAIN
SERVICES WORKS FOR 1,220 PLOTS AND CONSTRUCTION AND MAINTENANCE OF BUILDINGS
BLOCK (B) AT JABER AL AHMAD CITY 12
FIGURE 6 (FIGURE 3.4)DESIGNS, CONSTRUCTION AND COMPLETION WORK OF SHEIKH JABERAL
SABAH BRIDGE 12
FIGURE 7 (FIGURE 3.5) SUPPLY, ERECTION, OPERATION AND MAINTENANCE OF GAS TURBINE
POWER GENERATING UNITS AT SUBIYA POWER STATION WATER DISTILLATION PLANT SITE 13
FIGURE 8 (FIGURE 3.6)SUPPLY AND CONSTRUCTION AND MAINTENANCE OF 4 X 1600 MM
DISTILLED WATER PIPELINES FROM AZZOUR NORTH DISTILLATION PLANT TO AZZOUR WDC II
MEW/MC/4491-2012/2013 (DUCTILE PIPES) 13
FIGURE 9 (FIGURE 3.7)CONSTRUCTION OF CRUDE EXPORT LINE, INCOMING GROUP PRODUCTION
FEEDERS AND PIPELINES TO NEW GC16 AND NEW EFFLUENT WATER LINE TO MWIP WEST
KUWAIT 13
FIGURE 10 ( FIGURE 3.8)CONSTRUCTION OF FLOW LINES AND ASSOCIATED WORKS NORTH
KUWAIT FIELDS 14
FIGURE 11 (FIGURE 3.9)CEMENT PLANT 14
FIGURE 12 (FIGURE 3.10)ASPHALT PLANT 14
FIGURE 13 (FIGURE 3.11)COMPANY ORGANIZATION CHART 21
FIGURE 14 (FIGURE 4.1) CEMENT MANUFACTURING PROCESSES 26
FIGURE 15 (FIGURE 4.2)RAW MATERIALS INCLUDED IN CEMENT INDUSTRY 28
FIGURE 16 (FIGURE 4.3)LIMESTONE 28
FIGURE 17 (FIGURE 4.4)GYPSUM 29
FIGURE 18 (FIGURE 4.5) SAND 29
FIGURE 19 (FIGURE 4.6) PURE LIMESTONE 30
FIGURE 20 (FIGURE 4.7) BUZOLANA 30
FIGURE 21 (FIGURE 4.8) IRON SLAG 30
FIGURE22 (FIGURE 4.9) CHEMICAL LABORATORIES IN CEMENT PLANT 32
FIGURE 23 (FIGURE 4.10) BLAINE DEVICE USED TO MEASURE SMOOTHNESS OF CEMENT 33
FIGURE 24 (FIGURE 4.11) VECAT DEVICE USED TO MEASURE THE STRUCTURE OF CEMENT 34
FIGURE 25 (FIGURE 4.12) AUTOCLAVE OR USHATHELET DEVICES USED FOR STABILITY TEST 35
FIGURE 26 (FIGURE 4.13) AAZORIM DEVICE USED FOR COMPRESSIVE TEST 36
FIGURE 27 (FIGURE 4.14) LIMESTONE QUARRY 37
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FIGURE 28 (FIGURE 4.15) HAMMER CRUSHER 38
FIGURE 29 (FIGURE 4.16) RAW MEAL DRYER 39
FIGURE 30 (FIGURE 4.17) RAW MATERIALS STORAGE ANDADDITIVES PAR 40
FIGURE 31 (FIGURE 4.18) CONVEYOR BELT AND PILES OF CRUSHED MATERIAL USED IF THE
CRUSHER STOPS WORKING 40
FIGURE 32 (FIGURE 4.19) PILES OF CRUSHED RAW MEALS 41
FIGURE 33 (FIGURE 4.20) RAW MATERIAL MILLING MACHINE 41
FIGURE 34 (FIGURE 4.21) MIXINGAND STORAGE TANKS BEFORE HEAT TREATMENT 43
FIGURE 35 (FIGURE 4.22) PREHEATER TOWER 44
FIGURE 36 (FIGURE 4.23) PREHEATER TOWER EXPLANATIONS 45
FIGURE 37 (FIGURE 4.24) ROTARY KILN 46
FIGURE 38 (FIGURE 4.25) ROTARY KILN COMPONENTS 46
FIGURE 39 (FIGURE 4.26) CLINKERS BEFORE ENTERING THE COOLER 47
FIGURE 40 (FIGURE 4.27) GRATE COOLER 48
FIGURE 41 (FIGURE 4.28) GRATE COOLER SKETCHES 48
FIGURE 42 (FIGURE 4.29) CLINKER STORAGE SILOS 49
FIGURE 43 (FIGURE 4.30) CLINKER WITH GYPSUM MILLING 50
FIGURE 44 (FIGURE 4.31) CLINKER MILLING MACHINE 50
FIGURE 45 (FIGURE 4.32) CEMENT SILOS 51
FIGURE 46 (FIGURE 4.33) PACKAGING OF CEMENT IN BAGS 52
FIGURE 47 (FIGURE 4.34) CEMENT MIXER 53
FIGURE 48 (FIGURE 4.35) CONTROL SYSTEM FOR INSPECTION OF MIXING PARTS AND ERROR
INVESTIGATING 54
FIGURE 49 (FIGURE 4.36) WATER PUMP FOR THE MIXING TANK 55
FIGURE 50 (FIGURE 4.37) SCREW CONVEYOR BROKEN SHAFT 55
FIGURE 51 (FIGURE 4.38) CONVEYOR BELT CALIBRATIONS 56
FIGURE 52 (FIGURE 4.39) CONTROLS AND MONITORING OF ADDITIVESAND MIXING SYSTEM 58
FIGURE 53 (FIGURE I.1) GENERAL VIEW 63
FIGURE 54 (FIGURE I.2) LIMESTONES (SECOND CRUSHING) 63
FIGURE 55 (FIGURE I.3) CRUSHED LIMESTONES CONVEYOR BELT 64
FIGURE 56 (FIGURE I.4) LIMESTONES SILOS ANDADDITIVES BEFORE MILLING 64
FIGURE 57 (FIGURE I.5) RAW MEAL DRYER MACHINES 65
FIGURE 58 (FIGURE I.6) RAW MEAL GRINDING 65
FIGURE 59 (FIGURE I.7) PREHEATER TOWERS 66
FIGURE 60 (FIGURE I.8) ROTARY KILN 66
FIGURE 61 (FIGURE I.9) GRATE COOLER 67
FIGURE 62 (FIGURE I.10) IN THE LEFT SIDE COOLING SECTION, THE RIGHT SIDE CLINKER
STORAGE SILOS 67
FIGURE 63 (FIGURE I.11) CLINKERS MILLINGAFTERADDING GYPSUM 68
FIGURE 64 (FIGURE I.12) CEMENT STORAGE AND FILLING 68
FIGURE 65 (FIGURE I.13) CEMENT BAGS 69
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FIGURE 66 (FIGURE I.14) PLANT CONTROL CABIN 69
FIGURE 67 (FIGURE I.15) AGGREGATE WITH GRINDING BALL FOR TESTING IN THE LOS ANGELES
TESTING MACHINE, 70
FIGURE 68 (FIGURE I.16) THIS MACHINE ROTATES ABOUT 30-33 ROTATIONS PER MINUTE, IN THIS
TEST WE WILL SET THE LOSANGELES MACHINE TO 500 REVOLUTIONS 70
FIGURE 69 (FIGURE I.17) AGGREGATE SCALINGAFTER MILLING 71
FIGURE 70 (FIGURE I.18) SIEVE ANALYSIS 71
FIGURE 71 (FIGURE I.19) AWARDS AND CERTIFICATES 72
FIGURE 72 (FIGURE II.1) AGGREGATE TESTS 73
FIGURE 73 (FIGURE II.2) SIEVE ANALYSIS CALCULATION FOR COARSE AGGREGATES (ASTM
C136) 74
FIGURE 74 (FIGURE II.3) COARSE AGGREGATE SPECIFICATIONS (ASTM C33) 74
FIGURE 75 (FIGURE II.4) COARSE AGGREGATES PERCENTAGE PASSING GRA PH. 75
FIGURE 76 (FIGURE II.5) MIN, MAX AND SAMPLE GRAPH FOR FINE AGGREGATES 75
FIGURE 77 (FIGURE II.6) SILO CAPACITIES 76
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Chapter 1
Introduction
Figure 1 (figure 1.1) combined group company logo
Summer training is the way you can learn about the real world jobs and how you can link
whatever you done with your knowledge from your academic education.
I applied for one of biggest companies in the Arabian Gulf which is for contracting and
development in many fields.
Combined Group Contracting Company (CCGCC) is perseverance, diligent work, non-stop
development and improvement; a focus on quality and customer satisfaction, the company
became a publicly traded shareholding company.
It constantly moved from strength to strength over the past five decades. Company staff is
among who are some of the finest names in the contracting industry in the Arab world.
In those 40 days training I met a very Collaborator people who helped me to accomplish
my training and I liked their helping, accuracy, experiences, speed and team work which
provide sweetness in the department.
In this practice days the most important knowledge I have it in this plant it comes from
manufacturing course which provide a very important basics for different production
procedure and machines that is nearly the same in the company plant.
I enjoyed this experiment and I will introduce in next chapters some detailed information
about the company and the work which I done their and how we can improve this
experiment in real fields next years.
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Chapter 2
Company information
Belief, vision, common sense, hard work, professionalism, collaboration, cooperation, the
desire to make things possible, and common mutual interest among company people,
alliances, suppliers, customers (Private and government sectors) are behind their humble,
and continued growth.
Combined Group Contracting Company (CCGCC) was established on 15th November,
1965 in Kuwait as a limited liability company with a paid up capital of KD 7,500. With
perseverance, diligent work, non-stop development and improvement, a focus on quality
and customer satisfaction, the company became a publicly traded shareholding company
with a paid up capital of KD 11,160,834/ approximately US$ 40,000,000.
The total revenues reached almost KD 155,000,000 /- in 2013, and CGCC has constantly
moved from strength to strength over the past five decades. Staffs are currently over
10,000 employees and more than 50 mechanical engineers in different fields, among who
are some of the finest names in the contracting industry in the Arab world.
Activities now span the oil sector where they have become main contractors for pipelines
for companies like Kuwait Oil Company and the Joint Operations. In the roads and
infrastructure sector, they are currently executing several large projects including the
Subbiya Highway in Kuwait, and the Northern Industrial Area in North Doha, Qatar.
CGCC has the highest degree of specialization in the Roads and Infrastructure sector from
bridges to tunneling; CGCC is a dominant force in the industry in the region. The
company is also executing several large road and infrastructure maintenance projects in
Kuwait.
They also possess the expertise to deliver the large and complex projects with the ability
to efficiently employ resources, manpower and equipment in Kuwait and international
markets
CGCC has been steadily growing, and year on year have won a number of significant
projects which include building construction, infrastructure and oil related development
projects. The total value of projects executed between 2004 and 2009 was in excess of KD
555 million (US$ 2,054,000,000)
CGCC was awarded ISO certification 9001:2000. This was updated in November 2009 to
ISO 9001:2008. Also in 2009 CGCC was awarded ISO 14001:2004 for Environmental
Management Systems, and OHSAS18001:2007 for Occupational Health and Safety
Management.
Combined Group Contracting Company expanded into the international market since
1999. CGC has executed projects in various areas totaling approximately 167 Million
Dollars. The projects span to such countries as Indonesia, Tajikistan, Mongolia,
Uzbekistan, Georgia, and Lebanon. Currently CGCC is active in Lebanon and Albania
executing Roads and bridges projects.
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Clients of the company in Kuwait, Qatar and emirates:
Ministry of Public Works, Kuwait Oil Company, Kuwait Oil Gulf Company, Ministry of
Electricity and Water, Public Authority for Housing Welfare, National Guard, Ministry of
Health, Ministry of Oil, Kuwait Petroleum Company, Central Tenders Committee,
Ministry of Energy & Industry, Qatar Petroleum and others.
The Group Shareholders:
Figure 2 (figure 2.1) company shareholder
Combined Group Contracting Company
Address: Block No. 2, Plot No. 284
Al Ardiya Industrial, State of Kuwait
Mailing Address: P.O. Box: 4819, Safat 13049, Kuwait
Telephone: (965) 22254545
Fax: (965) 24344610 – (965) 24344686
Email: info@cgc-kw.com.
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Chapter 3
Product information
3.1 company works and productionlines
Combined Group Contracting Company has proudly achieved a high degree of customer
satisfaction in over 250 completed projects during the past 25 years. The company has
completed and ongoing projects with both private and government sectors in many
countries in the Gulf region, the Middle East, and Asia.
3.1.1 Constructions ofbuilding and high ways
In the Construction sector, CGCC has completed major buildings in Kuwait, some of
which have become homes to prestigious educational institutions. CGCC has also
accomplished the construction of an outstanding governmental housing projects and
different projects in different areas as shown in the (figures 3.1 - 3.10).
Figure 3 (figure 3.1)it is Construction, completion and maintenance of roads, storm-water
drainage, sewer and other services for Subiya Highway which cost about 112,000,000 dollar
Figure 4 (figure 3.2) Head Quarter of Manpower & Government Restructuring Program
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Figure 5 (figure 3.3)Designs, Construction, Completion and Maintenance of Main Services
Works for 1,220 Plots and Construction and Maintenance of Buildings Block (B) at Jaber Al
Ahmad City
Figure 6 (figure 3.4)Designs, Construction and Completion Work of Sheikh JaberAl Sabah
Bridge
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3.1.2 Water and power station
Figure 7 (figure 3.5) supply, erection, operation and maintenance of gas turbine power
generating units at subiya power station water distillation plant site
Figure 8 (figure 3.6)Supply and construction and maintenance of 4 x 1600 mm distilled water
pipelines from azzour north distillation plant to azzour wdc ii mew/mc/4491-2012/2013
(Ductile Pipes)
3.1.3 Oil and gas
Figure 9 (figure 3.7)Construction of crude export line, incoming group production feeders and
pipelines to new GC16 and new effluent water line to MWIP west Kuwait
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Figure 10 ( figure 3.8)Construction of flow lines and associated works north Kuwait fields
3.1.4 Cement and asphalt plants
Figure 11 (figure 3.9)Cement plant
Figure 12 (figure 3.10)Asphalt plant
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3.1.5 INDUSTRIALSERVICES
The CGCS Facilities Management − Industrial Services business line delivers multi-
disciplinary services to a wide range of industries in mechanical, electrical,
instrumentation and controls, communication, water and wastewater applications. This
business unit is a leading one-stop-shop for industrial services including plant operation,
maintenance and solutions. It undertakes plant operation and maintenance (O&M), key
performance indicator (KPI) based maintenance, annual and long-term maintenance,
proactive, preventive and shutdown maintenance on a full responsibility basis,
modernization, modification and extension works, retrofits, refurbishment and repair
works, emergency repair works, and scaffolding services, and delivers systems and
solutions. These services are offered to all industrial facilities and clients.
Industrial services have a presence in the following industrial sectors:
1- Oil and gas (up-stream and down-stream).
2- Petrochemicals.
3- Power (power plants and desalination plants).
4- Power transmission and distribution.
5- Water (pumping and lifting stations, booster stations and water networks).
6- Wastewater (sewage treatment, reclamation plants, pumping and lifting stations, and
wastewater networks).
7- Civil Infrastructure, such as road and storm-water drainage networks.
8- O&M and multi-disciplinary service contracts for BOT, BOOT, BOO and PPP
infrastructure projects.
9- Infrastructure and other industries.
The delivery of Industrial Services operations has been organized into several service
disciplines:
1- Industrial maintenance:
- Industrial maintenance services for all industries.
- Complete shutdowns – on a full responsibility basis, including general refinery turn-
arounds (GRTAs).
- Unit shutdowns – on a full responsibility basis.
- Scaffolding services.
2- Mechanical:
- Boilers, heat exchangers and cooling systems.
- Air pre-heaters.
- Maintenance, servicing and overhaul of stationary equipment.
- Maintenance, trouble-shooting and overhaul of rotary equipment.
- Catalyst and life support management.
- Hydro jetting and hydro testing.
- Valves, valve reconditioning and installation.
- Surface preparation and protection.
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- Filters.
- Insulation services.
- Specialized services.
- Piping fabrication, modification and welding services.
3- Electrical:
- EHV sub-stations, GIS switch gears.
- MV & LV sub-stations, distribution systems, RMUs.
- Transformers (power and distribution).
- Overhead transmission lines.
- Power cables (EHV, HV, XLPE).
- Switchgear services.
- Motors and drives (soft-starter and VFD) services.
- Street lighting services.
- Sub-station protection.
- Energy/smart metering, AMR solutions.
- Event logger, fault recording, earthling systems.
4- Instrumentation and controls (I&C):
- DCS, PLC, SCADA, management information systems (MIS).
- Analyzer technology and emissions monitoring.
- Water analytic systems.
- Flame scanner and combustion detection.
- Performance and condition monitoring.
- DC systems, i.e. PS, batteries and chargers, and LV systems.
- Substation controls, automation/SCADA.
- Firefighting maintenance.
5- Communication:
*Wireless networks:
- Satellite communication services.
- Microwave and digital radio networks.
- GSM and CDMA cellular networks.
- VHF, UHF – conventional and trunking radio networks.
- Broadband solutions – LAN/WANS and VPN networks.
- Fleet management technology and special solutions.
*Wire line networks:
- Fiber-optic metro and long-haul networks.
- Broadband solutions.
- PABX, VOIP and billing platforms.
- Security and SCADA networks.
- Inside and outside plant systems.
- Camera surveillance, CCTV and recording services.
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6- Sewage works & water networks:
- Sewage treatment and reclamation plants.
- Pumping stations, lifting stations and booster stations.
- Water and wastewater network maintenance services, modification and repair works.
- Desalination and water treatment services.
- Water purification and filtering.
- Civil repair of box culverts, sea outfalls and pipe-line repairs.
Other activities:
Electro-Mechanical and Civil works for Oil Gas field projects, EPC project handlers (Oil
Gas sector), Fabrication of Piping Spools and Manifolds, Engineering Services for Fired
Heaters and Boilers, Reciprocating Compressor overhaul and refurbishment, Pipelines and
Piping Installation, Plant; Equipment installation, Storage Tanks, Shut Down activities,
Structural Steel installations, Road; Infrastructure work, Civil construction; maintenance
jobs, RO Water Treatment plants, Drinking water plants, Waste Water Treatment plants,
Power Generation units, Pumps, Water Supply; Drainage system, HVAC units.
3.1.6 EQUIPMENT& MACHINERIES
CGCS Duct Fabrication Workshop is equipped with various ranges of latest automation
machines especially for HVAC duct works fabrication. Our improved machinery and
construction makes for outstanding performance for our products with quick and accurate
production. Our latest machineries helps us to facilitate our customers with high standard
HVAC ducting products with exceptionally low leakage and extremely efficient.
MajorEquipment’s:
- Fully automated coil line.
- Computerized plasma cutting machine, with two cutting beds.
- Spiral welding machine.
- Stich welding machine.
- TDF roll forming machine.
- Pittsburg & pocket joint roll forming machine.
- Cleat former machine.
- Shearing machines.
- Electrical folding machine (Adjustable degree).
- Press break bending machine.
- Spot welding machine.
- Flanging machine.
- Round rolling machine.
- Elbow making machine.
- Swaging machine.
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3.1.6 CGCS STANDARDPRODUCTS
- Square and rectangular ducts and fittings.
- Round spiral duct and fittings.
- Fire rated ducts.
- Volume control dampers.
- Motorized dampers.
- Sound attenuators.
- Sand trap louvers.
- Pressure relief dampers.
- Plenum boxes.
- Access doors and etc.
3.2 Working mechanism in the company
Each project that the company signed has it is own procedure, but the general
procedure as follow:
1- When the company signed a contract the first step is done by the engineering
departments to study if it is possible to accomplish it, the cost, difficulties, design, and
the duration they need to complete it. After that those studies are sending to
accounting department to figure out the overall final cost and the benefit to the
company.
2- Contracting department show the final price to the client and discuss about it.
3- If the client accepts that, the company head and their members provide the project
manager with the regulations and he starts the preparation for the project.
4- Engineers, technician and foremen preparing the work site and the material, cars,
machines…etc.
5- The first engineering department (civil engineer) starts the basic things such as
preparing the basis, safeties and the structure need to be done.
6- Some parts of the project can be made in the company workshop, if it is not possible
they can order it from markets.
7- They put all of those parts of the structure in the site and starts to fit it, assembly and
examinations.
8- If everything is according to the project regulations and standards they submit it to the
client.
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3.3 Management departments and their functions
3.3.1 PLANNING
The basic functions of the department’s planning engineers are:
1- establishing the work breakdown structure of the project
2- preparing the project plan and schedule
3- establishing the reporting system for the project in line with company procedures
4- collecting data and preparing daily, weekly and monthly reports
5- Analyzing productivity.
3.3.2 Organizing
The department operates on a matrix organizational structure. Project control staff
members are imbedded in the project organization but are linked functionally to the
department, enabling Project Control Services to achieve a high consistent quality in the
services it provides to projects.
3.3.3 Staffing
The company has different staff ranging according to the project needs such as civil
engineer, mechanical, electrical, industrial, accountants, foremen and workers.
3.3.4 Directing
The orders come from general manager who supervise project manager, the last in turns
supervise the engineers and this operation continue until the final workers in the company.
3.3.5 Quality Controlling
Before construction activities begin, quality control staff members gain an understanding
of the requirements in the project specifications and applicable design codes and then
create an effective quality control system for the project. Inspection and test plans (ITPs)
are designed in such a way that at each stage verification and measuring activities can be
carried out to ensure that results are within specified limits or tolerances to prevent costly
re-working. During project execution, quality control staff routinely monitor activities
20. 20
rather than waiting for a problem to appear.
3.3.6 Contract Administration
The basic function of contract administrators is to monitor payments and correspondence
concerning contracts and to advise project managers on contractual matters.
Subcontract agreements are prepared by contract administrators in coordination with the
on-site project teams. The draft forms of subcontracts, as well as associated review forms
and checklists, are reviewed by the contracts administration manager or the project
controls services director.
Where the projects are re-measurable, the contracts administrator also maintains accurate
work-in-progress records and a record of the final account as agreed with the client. These
records are updated daily and are used to prepare applications for payment and to prepare
payments to subcontractors.
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3.5 Departments description
3.5.1 Engineering department
The Engineering Services Department provides the company’s projects in the commercial
and industrial, petroleum, chemical and power sectors with a full range of engineering
services from conceptual design to procurement and construction. However to service
CGCS overseas projects, the Engineering Services Department has satellite offices in
Qatar, Abu Dhabi and Dubai in the UAE.
In these offices, the department prepares drawings of existing facilities. It designs and
produces shop drawings for all mechanical, electrical and plumbing works to be
undertaken by CGCS. It details pump rooms, substations and HT rooms and produces
composite drawings and builders’ layouts. The Engineering Services Department also
produces piping layouts and isometrics, the detailing of pipe supports and test packages. It
creates fabrication drawings for piping, industrial steel and pressure vessels. The
department produces material take-offs to assist the tendering and procurement
departments. It coordinates with sites and consultants to resolve design inconsistencies
and prepares as-built drawings.
3.5.2 Human resources department
The goal of CGCS Human Resource Department is to advance the overall mission of the
company through the acquisition, retention, and support of qualified, skilled and
competent staff. HR achieves its objectives by recruiting, employing, retaining, and
developing staff and by maximizing excellent employee relations and excellent personal
and group performance through internal consulting, problem resolution, and the provision
of efficient, cost-effective, customer-responsive human resource services.
Strategic Directions:
1- To promote and support recruiting strategies and collaborate with departments, projects
and customers to create a high performing, diverse workforce.
2- To respond to the needs of the company and its customers in a helpful, supportive, and
pro-active manner and provide "quality" services on which can be relied upon.
3- To respond appropriately, creatively, effectively and timely with policy and procedure
changes.
4- To develop staff excellence through training and consultation for employees that
encourages growth and opportunity and fosters good, open communication and an overall
positive work environment for all employees.
5- To equitably and fairly administer company policies, procedures, and benefits.
The most common Human Resource jobs that are grouped in the Human Resource
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Department are the Human Resources Director, Human Resources Manager, Human
Resources Generalist, and Human Resources Assistant.
3.5.3 Public relations department
It is the practice of managing the flow of information between the organization and its
public. It is the planned and sustained effort to establish and maintain goodwill and
mutual understanding between organization and its public. The company has good
relationships with different public ministries and private clients in Kuwait and around the
world.
3.5.4 Accounting department
The functions of this department are as follow:
-Money out: making payments and keeping the bills paid.
-Money in: processing incoming payments.
-Payroll: make sure everyone gets paid (including the government).
-Reporting: preparing financial reports, e.g. P&L, Balance sheets and budgets.
-Financial Controls: to avoid errors, fraud and theft.
3.5.5 CONTRACTS DEPARTMENT
The Contracts Department is responsible for negotiating and agreeing a variety of other
agreements, prior to review by the Legal Department, such as agency, distributorship,
value added re-seller, consultancy, and joint venture, consortium, and shareholder
agreements. For each of these types of agreements, Contracts has established standard
terms to which it always tries to adhere.
3.5.6 Project managers department
The primary functions of a Project Manager vary from company to company but they all
revolve around managing the four basic components of a project, namely resources, time,
budget, and scope.
Some general functions are:
-To act as a liaison with the client and/or with top management.
-To coordinate the process from start to end.
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3.5.7 IT Department
The IT Department was established to implement, monitor and maintain CGCS data
network, computer systems, servers, and business applications. As the company has
expanded and prospered, the use of IT has evolved significantly and the department now
offers services and supports in the field of information technology to all other departments
and to CGCS numerous projects.
IT Department is divided into two units:
- Management Information System Unit
- Technical Support Unit
3.5.8 CORPORATE COMMUNICATIONDEPARTMENT
The department supports the various businesses of the company in building and
communicating the right corporate messages that reflect the vision, mission and values of
CGCS and sustain its culture and reputation.
It is divided in two units:
1- Branding Unit:
The Branding Unit is responsible for the entire process involved in creating and designing
all the company’s advertising materials schemes offline and online to accord with and
facilitates the attainment of the business objectives. The Unit also maintains and controls
the persona of the company to ensure the continuity in the quality of the company’s image
and that it is coherent at all levels of business.
2- Events Management Unit:
The Events Management Unit is responsible for coordinating and organizing events,
conferences and sponsorships in all the business industries CGCS operates in. The Unit is
involved from the concept phase through to the completion stage assuring the alignment
of the events with the company’s vision and mission.
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Chapter 4
Work performed
CGCS has different works in many fields such as buildings, streets and highways, oil and
gas services, asphalt and cement plant. I choose cement plant and attend all the procedure
of cement manufacturing from raw materials to packaging. Next I will explain all the
details in this plant and what technologies are used.
4.1 Briefhistory of cement
Concrete is an extremely versatile material, being used in the production of anything from
nuclear radiation shields to playground structures and from bridges to yachts. It is able to
be used in such a wide variety of applications because it can be poured into any shape,
reinforced with steel or glass fibers, precast, colored, has a variety of finishes and can
even set under water. Modern concrete is made by mixing aggregate (sand, stones and
shingle) with cement and water and allowing it to set of these ingredients. Cement is a
fine grey powder which when reacted with water hardens to form a rigid chemical mineral
structure which gives concrete its high strengths. Cement is in effect the glue that holds
concrete together. The credit for its discovery is given to the Romans, who mixed lime
(CaCO3) with volcanic ash, producing a cement mortar which was used during
construction of such impressive structures as the Colosseum. When the Roman Empire
fell, the information on how to make cement was lost and was not rediscovered until the
16th century.
4.2 Safety
Occupationalsafetystrategyis in three elements:
1- Worker is come first place to keep his effective, creative and able to perform the practical
duty on what should be done.
2- Established the basic unit of industrial (economic) which is directly linked to the
production processes in addition to securing better standard of living for a worker
Production.
3- Product quality and quantity
OccupationalSafetydefinition:
Is the branch of a total of the basic knowledge of systems and measures under which the
worker protection and the establishment of the potential dangers and injuries on the job.
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Occupationalsafetygoals:
- Study of factors affecting the health and production rights.
- Studying the reality of working machinery and materials used in production and its impact
on human health.
- Develop procedures to remove the harmful elements in human beings and in line with the
importance of increasing the yield of the production facility.
4.3 Cement manufacturing process
Figure 14 (figure 4.1) cement manufacturing processes
The cement industry is usually divided into three groups:
1- Production
2- Production Service
3- General Service
Production
Section that is includes raw materials in various stages of production from side and exit
from another side contrary to what they used to be physically or chemically, or both.
Parts of the production department:
- Quarry
- Crusher
- Stacker/Reclaimed
- Dryer
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- Raw mill
- Final Mixing
- Kiln
- Cement mill
- Packing House
Directproduction aid sections:
The sections that provide direct production diverse sections in order to aid the completion
of its work to the fullest.
Parts of direct production aid section:
- Work shop
- Electrical
- Instruments
- Desalination
- Power Plant
- Laboratory
- Civil service
Cement manufacturing stages:
- Referto (figure 4.1); the stages are as following:
1. Uprooting rocks.
2. Jackhammers.
3. First mixing broken rock.
4. Drying crushed material (if needed).
5. Grinding crushed materials required proportions.
6. Blending and homogenization of milled material.
7. Creating materials for burning.
8. The burning of heterogeneous materials and put up for the production of clinker.
9. Clinker cooling.
10. Clinker storage.
11. Clinker grinding with the addition of gypsum.
12. Storage of cement.
13. Packing and storage of cement.
4.3.1 Uprooting rocks
- Uprooting rocks without bombing, by using multiple machines.
- Cliff and packing the rocks.
- Transfer of rock by truck (dampers).
- Placed rocks in the quarries.
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4.3.2 Raw materials usedin the cement industry
Figure 15 (figure 4.2)raw materials included in cement industry
The first group (basic):
Is the group that cannot form a mixture without one of its elements, It is divided into:
1. Limestone (CaCO3) as shown in (figure 4.3)
Figure 16 (figure 4.3)limestone
Is responsible for providing a compound (CaO) necessary to interact inside the oven, and
enters the lime stone by almost 75% in the mix materials.
2. Clay
Intervention by 25%, which is responsible for providing three compounds, namely:
- Silica SiO2
- Alumina Al2O3
- Iron Oxide Fe2O3
Place added: mill raw materials
Second Group (modified or corrected):
Are substances that are added to the basic groups in the case of a lack of mud to a oxides
29. 29
((SiO2 - Al2O3 - Fe2O3((
- Addition in order to remove deviation in mud compounds
- Add a few percentages, because the concentration of the modified material is very large.
- Place of Addition: in the raw material mill
Third group (additives):
It is divided into:
1. Mandatory:
Figure 17 (figure 4.4)gypsum
Material: gypsum as shown in (figure 4.4).
Place added: cement mill.
Addition amount: 5-3% of the proportion of clinker.
The goal of the addition: adding gypsum with clinker in cement mills to regulate the
Cement sclerosis time (any delay sclerosis time), which is known as the "time of
uncertainty."
The index to add gypsum: SO3 ← shall be increased by 1.5-2.5%.
2. Optional:
- Sand as shown in (figure 4.5).
Figure 18 (figure 4.5) sand
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- Pure lime as shown in (figure 4.6).
Figure 19 (figure 4.6) pure limestone
- Buzolana. as shown in (figure 4.7)
Figure 20 (figure 4.7) buzolana
- Iron slag as shown in (figure 4.8).
Figure 21 (figure 4.8) iron slag
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Objectives of additives:
- For manufacturing of other types of cement.
- Reduce the cost in order to compete.
4.3.3 Methods of cement industry
As is well known, there are three ways the cement industry:
1. Wet method.
2. Dry method.
3. Half Dry method
In CGC the method use is the dry method.
Dry method:
It is the way it had been widely used after the Second World War to replace the wet
method and half dry method due to a variety of reasons, especially the high percentage of
water in the meal feeding the furnace and the large energy consumption resulting from the
evaporation of the water, that helped in technological advances in the cement industry in
this area.
Mixed materials that feed the furnace in the dry way are crushed, soft and dry so that the
moisture content is not more than the 1% which makes this method is economically the
most capable and the most widespread.
The most important characteristics of the dry method are summarized in the
following:
- Energy saving where modern furnaces consume less than 800K.kalori /1 kg of clinker.
- High productivity, especially furnaces with large diameter.
- Ability to control the best attributes of the product, whatever the nature of the materials.
- The possibility of applying the prior calcination of materials system, helping to increase
production capacity and reduce the length of the oven.
- Ensure the safety better for the environment.
4.3.4 Laboratory and quality control in cement industry
If the oven is heart of the factory, the lab is the mind that flows into sections production
quality standards has to be reported for cement within the specifications and standards. It
was an integral part laboratory to conduct all of the tests required to assess the product
and correct deviations in the various stages of production and analysis, in addition to the
tests and analyzes which specializes in quality control and quality assurance.
Sections and functions of the laboratory
1. The chemical laboratory:
- Analysis of various samples of raw materials (limestone, mud, sand, iron ore, Bozzolana,
32. 32
gypsum, bauxite etc. ........ of different chemical analyzes as shown in ( figure 4.9 ).
- Analyzes of material fed into the furnace (total oxides).
- Analyzes of cement (total oxides).
- Analyzes of clinker (calcium oxide - Iron Oxide - aluminum oxide - silica – magnesium
oxide- Lime oxide free - burning waste - non-soluble substances - chlorides and alkali if
necessary.
- Calculated values and factors for mixing materials fed to the kiln, clinker and cement.
- Record the results in their own records.
- Prepare the necessary solutions and reagents.
- Identify own constants intravenously manufacturer.
- Record all information intravenously in their records.
- Open a special register preparation and consumption.
- Supervision of the insurance and analysis of distilled water.
Figure22 (figure 4.9) chemical laboratories in cement plant
2. Department of Physical and mechanical tests:
This section is for the necessary tests according to standard adopted for various physical
and mechanical tests of Portland cement, and I will mention the most important supported
analyses:
Smoothness test:
This test is conducted to estimate the smoothness of cement expressed in specific surface
area, which is defined as the total surface areas measured in centimeters squared to
cement particles in one gram. The device is called ( Blaine ) as shown in (figure 4.10) for
purpose of air permeability.
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Figure 23 (figure 4.10) Blaine device used to measure smoothness of cement
- Principle method:
Determine the specific surface area of cement by measuring the passage of time it takes
for a given volume of air within a specific layer of cement with certain permeability.
- Devices used:
Device / Blaine / is used for air permeability, the device consists of the following main
parts:
1. Manometer glass.
2. Cell permeability / cylinder of glass or metal from non-corrosive /
3. Disk regularly perforated metal from non-corrosive.
4. Piston of glass or metal from non-corrosive.
5. Circular nomination average porosity paper.
6. Stopwatch.
Identify the standard textures to cement paste:
This method is competent to set the amount of water required for the formation of
standard-strength cement paste used in each of the test time of uncertainty, and test the
stability of size.
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Figure 24 (figure 4.11) Vecat device used to measure the structure of cement
Definitions:
- The time required to start sclerosis:
It is the period of time between the moment of adding water to dry cement and the
moment of entry by force of Vicat needle Device as shown in (figure 4.11) in paste of
cement to a distance of not more than 5 mm from almost Vicat mold base.
- The time needed to end sclerosis:
Is the period of time between the moment of adding water to dry cement and the moment
in which Vicat needle Device left impact in the cement paste without appears the impact
of on the base ring installed around the needle.
35. 35
Stability test ( expansion)
Figure 25 (figure 4.12) Autoclave or Ushathelet devices used for stability test
Used device called ( Ushathelet ) as shown in (figure 4.12) for this purpose, cement
stability test is measured by the expansion of the size of a standard cement paste under
certain circumstances. Ushathelet a device used to measure the expansion of the cement
paste. The device basically consists of a cylinder made of copper alloy with flexible or
any suitable metal, a wall thickness of 0.5 mm, and 30 mm internal diameter. A height of
30 mm, and longitudinally notch installed on both ends, on each notch two indicators
tapered tip. Also there is a device for this purpose called ( autoclave ), measure the
stability of cement by change in length of the samples of cement after treatment with
steam in this device under test pressure (20 kg / cm) and temperature (215 meters) for
three hours.
- Devices used:
- Templates:
Consists of a metal is susceptible to cement, and its parts solid and coherent to prevent
leakage and non-curvature when linking.
- Autoclave
consists of a high pressure steam drum, where there is a place to put thermometer
provided with automatic controller valve, pressure gauge, and safety valve, and valve
ventilation allows air exit when heated start, also allows the release of the vapor pressure
remaining at the end of the cooling period in addition to the availability of other
conditions.
36. 36
- Height Measure Device:
The machine is valid to measure the length exceeds + 0.05 mm and be equipped with a
steel rod for calibration.
Pressure resistance test:
Figure 26 (figure 4.13) Aazorim device used for compressive test
Is used for this purpose device called ( Aazorim ) as shown in (figure 4.13) and
pressurized samples (cubes) taken from test bending resistance until the fracture and
compressive strength are calculated from the following equation: D = the crush load /
actual area under to pressure.
3. shifts Laboratory:
Laboratory functions are distributed as follows:
A. Analyzes and tests:
- Analysis of total carbonate.
- Test the smoothness of cement / Blaine /.
- To measure the weights of clinker / specific weight /.
- Grinding and drying and preparation materials to be analyzed.
37. 37
- Measurement of moisture in the various stages of production.
- Record the results of tests in the designated records.
- Delivery test results directly to the competent departments.
B. Bring samples from:
- Blending and storage silo.
- Raw materials half and final manufactured.
- Product of milled materials.
- Material fed to the furnace.
- Products of clinker cooler.
- The entrance to the cement mills.
- Products of the cement mills.
- Cement sold.
4.3.5 Sections ofcement factory
Crushing section
Figure 27 (figure 4.14) limestone quarry
Crushers functions are reduction of large volumes of rock and turn it into a small size (2.5
- 3 cm) as shown in (figure 4.14) to match the technology with the subsequent sections in
addition to facilitate the transfer of materials and trading with them as well as to facilitate
the work of the mill.
38. 38
- Hammer crusherparts:
Figure 28 (figure 4.15) hammer crusher
A. Crusher hopper.
It is a wide at the top and narrows at the bottom, its structure consist of steel or reinforced
concrete, interior section is covered with steel plates for protection against cracking and
breaking.
B. Crusher structure.
Consists of two cylinders and all axes carrying several hammers and varies weight
depending on the crusher, so those cylinders spin down cut, where materials crushed by
hammer and by collision materials to each other, in terms of materials come out of the
bottom of the breaker with small sizes required.
C. Filter screen.
Is a filter that works to grab stuck in the air dust, resulting from crushing so that a filter
reserves dust within and empties automatically via the spiral metal conveyor to the main
carrier of the crusher so that this dust (fine dusts) are associated with the crushed material
to the initial mixing fields and filtering process resulted well, so that air comes out clean
to the outside air through the chimney slightly from very fine dust.
D. Various conveyors
Conveyors are metal or rubber and designed to transfer material from one stage to another.
These are designed to accommodate a previous phase. For example, the metal conveyor in
bottom of the hopper has been designed to withstand the pressures of large volumes of
rock. All parts are shown in (figure 4.15).
39. 39
Drying section
Used to drying high humid materials, partly or all, according to absorbed moisture, are
commonly used in clay drying. Enter moisture about 8-9% and 2-3% moisture that exit.
- Dryer parts:
Figure 29 (figure 4.16) Raw meal dryer
A. Hot air chamber
Its function to raise the average air temperature to approximately 500 Celsius, so that
guarantees hot air for drying by conduction.
This room consists of primary and secondary fan air pump in addition to the pump for oil
fuel.
Inside this room is built from fiery brick to withstand the heat of hot air.
B. Dried cylinder.
It is a cylinder of steel, internal coated with bricks and thermal drag installed on the inner
perimeter contributes to raising the wet material in order to have the greatest petition with
hot air. The cylinder is tilted slightly toward the exit to facilitate the movement of
materials inside.
C. Distributor and organizer of the material
It is a metal tank, its function to regulate conduct of dried material when they fall on a
rubber conveyor.
D. Electric filter
Its function to cleaning air from dust and stuck it back through the spiral conveyor to
unload the rubber conveyor compound and from it to the dry material warehouse, and is
due to ionization.
40. 40
E. Different conveyors.
The transfer of materials and the air from stage to other, and where there is a rubber and
spiral conveyor with the duct of air. All previous parts are shown in (figure 4.16).
The initial mixing section fields
Large repositories are either rectangular or in a circular shape, they gets materials from
crusher conveyor as shown in (figure 4.17).It is dedicated to provide a great strategic asset
for the operation of raw materials mills if crusher stop, where can accommodate of
thousands tens of basic materials, corrected and additional materials which are stored
separately.
Figure 30 (figure 4.17) Raw materials storage and additives par
- STACKER:
It collects material in the form of layers as shown in (figure 4.18), where mixing and
homogeneity take place until fill the entire field.
Figure 31 (figure 4.18) conveyor belt and piles of crushed material used if the crusher stops
working
41. 41
- RECLIMER
Scraping piled material as inclined sections (thin layers) and drags them across to a rubber
conveyor to mill raw materials as shown in (figure 4.19).
Figure 32 (figure 4.19) piles of crushed raw meals
Milling of raw material section
Figure 33 (figure 4.20) Raw material milling machine
The mill is grinding crushed material after determining their proportions and converts
those materials to a fine powder in way that fit to the technological work of subsequent
sections as shown in (figure 4.20).
- Raw materials mill Parts:
1. Primary weighted repositories of the material to be milled.
2. Mill raw materials (body windmill rotor).
3. Secretions and Cyclone.
42. 42
4. Electric filter.
5. Different conveyors.
6. Air heating chambers.
- Some of technical data in raw materials mill:
1. Types of milled material: Limestone, clay, sand, iron and ore.
2. Number of rooms: one room in addition to one meter for drying.
3. The form and type of linkage with Gearbox: peripheral (side).
4. Production capacity: 325 tons per hour.
5. Inside Air: hot gases from top of the first heater + gas from the drying part.
6. Product control: 16-18% in the entrance.
7. Length and Diameter: 11.75_ 5.4 m.
8. Balls shipment weight: 240 tons.
9. The electric motor capacity: 4.2 MW
10. Separator: extension by four Cyclones.
11. The method of transfer materials to the separator shall withdraw by fans.
12. Crossing the air speed: 70 to 80 m per second
13. speed of the mill: 13.8 P-minute cycle
14. moisture materials used: 6.5 _5.5%
15. Exit moisture materials: 0.5%
- Raw materials mill mechanism:
1. Materials enter through mill after weighing scales to determine the percentage of each
material, when material entering mill is dried by hot gases coming from the top of the first
heater, so material get rid of the moisture.
2. Material pass the first part of the mill, where the large diameter balls, and platelets that
help to carry them, where the material grinding in a collision way.
3. Material pass to the second part where the balls with smaller volumes, and classified
platelets, where grinding and soften the material has been done.
4. Material drag by air fans to the detachment, where soft material is separated from the
coarse material in a centrifugation manner.
5. The soft fall down to the bottom of separator, to conveyor where they transfer to the final
mixing tanks, while the coarse material goes back again to the mill where it is softening.
43. 43
Feeding the furnace section
Figure 34 (figure 4.21) mixing and storage tanks before heat treatment
It is the section that regulates the conduct of mixed heterogeneous materials as shown in
(figure 4.21), ranging from storage to the final homogeneity across the furnace section
dedicated to adjust the weights of materials when they enter the oven.
- Parts of feeding the furnace section:
1. Mixing tank and is considered one of the most important parts of the cement plants.
Mixing mechanism by inflatable airbags and it can move and disturb materials, which
helps in the homogeneity of these materials. It must be consider in mind that the humidity
should be less than 1%. The purpose of mixing and homogenization is:
A. To ensure the work of the oven (quality and production).
B. Reduction in the cost.
C. Increase in productivity.
2. Intermediate tanks it is as diverse as feeding, discharge and regulates the yleviled of
materials and insurance balance of the furnace tank.
3. Scales their function to automatically weight materials within 24 hours before entering the
furnace.
4. Different conveyors like vertical, horizontal and tracked.
Kiln section
Is the section where the disintegration of the calcium carbonate (CaCO3) with raising the
temperatures of melted materials and their interaction within the rotary kiln for the
44. 44
production of clinker and then cooled in special coolers, which is the main section in the
cement industry.
- Parts of the kiln:
1. Preheater
Figure 35 (figure 4.22) preheater tower
45. 45
Figure 36 (figure 4.23) preheater tower explanations
Preparation materials to enter the rotary kiln as shown in (figure 4.22) to raise temperature
of raw materials and the dissolution of calcium carbonate (CaCO3) by almost 90%,
according to the following equation:
CaCO3 "CaO + CO2 , through heat exchange between the material coming from the
blending and homogenization silos (from the top) with the coming of the coolant gas
passes through rotary kiln (from the bottom) the opposite direction.
2. By pass.
Its function get rid of the gases coming from the cooler and enter the kiln, contained part
of alkalis and chlorides, which caused a blockage at the entrance of the oven and the first
floor of preheater, disposal proportion ranging between (10-20%)
3. Filter.
Layering dust in gases exiting from the top of the first heater and returned to the material.
Types: fabric and electric filter.
46. 46
1. Rotary kiln.
Figure 37 (figure 4.24) rotary kiln
Metal rotary cylinder materials enter it, where they disintegrate fused and then merge with
each other due to the high heat, produce new compounds known as clinker phase (product
centrist).
- Its components as shown in (figure 4.25):
Figure 38 (figure 4.25) rotary kiln components
A. Iron Cylinder, which expands a certain length and a certain diameter in addition to a
certain inclination, has a dedicated rotation speed.
B. Three double rollers in order the cylinder stand upon them.
C. Cupboards determine the path, in order to allow the oven to move up and down steadily.
D. Kiln engine.
E. The fire tube (torch)
F. The fiery brick which is inside the oven
47. 47
- Inside of the oven it divides to several fake areas as temperatures and stages of
transformation of materials, namely:
A. Materials entry zone, length of 14 meters and the temperature (1100-1150).
B. Calcination zone, 10 meters in length.
C. The protection zone, 11 meters in length
D. The transition zone, 11 meters in length.
E. Combustion zone, a length of 34 meters and the temperature (1400-1450).
F. Cooling area, length of 2 meters and the temperature (1100-1200).
- Reactions that take place inside the oven:
A. Thermal decomposition ( 990 C ):
All oxides of alumina (Al2O3) interact with a portion of the oxides of calcium generating
mono calcium aluminum (CaO.Al2O3) and denoted by (CA), but the average product, on
the other hand start oxides, silica (SiO2) to merge with calcium oxide (CaO) the problem
of bilateral Silicate calcium (SiO2.2CaO) and denoted by (C2S) in this phase, but at low
concentrations.
B. crystal Deformation ( 1285 C ):
Intermediate output of the first phase (CA) unite turns into a complex three-aluminum
calcium (3CaO.Al2O3) and denoted by (C3A) and at the same moment merge iron oxides
(Fe2O3) with calcium oxide (CaO) component (C2F) and the most complex, to become
its interaction with aluminum fluorides Alumina quad calcium (4CaO.Al2O3. Fe2O3) and
denoted by (C4AF), which begins the formation of (C2S) to complete.
C. Fusion ( T >1285 ):
In this temperature and excessive heating of materials, saturated (C2S) remaining calcium
oxides and produces calcium silicate trilogy (SiO2.3CaO) and the code name of (C3S).
D. Mergers and form clinker:
Materials and oxides combine with each other and interact in order to be certain reactions
new material differs from the previous stages chemically and physically and mechanically.
E. Crystallization of the fluid phase:
Clinker is cooled at the end of the kiln (cooling zone) so that takes the form of rigid
(relatively) and increasing strength by cooling in special coolers.
Figure 39 (figure 4.26) clinkers before entering the cooler
48. 48
2. Grate Cooler
Figure 40 (figure 4.27) grate cooler
Clinker cooling which come out of rotary kiln, from temperature 1200 Celsius to about
110 Celsius, almost in ten to fifteen minutes. It follows the detonator cooling system as
shown in (figure 4.27).
- Its components as shown in (figure 4.28) :
Figure 41 (figure 4.28) grate cooler sketches
A. row of tiles fixed followed by another one moving.
B. Tiles in first parts tilted and steadier than others made of a certain metal alloy of steel and
chrome because of the high temperature of clinker.
C. Moving part of the tiles lead to push clinker forward, length of at least 12 cm.
D. Air enters from spaces between the mobile and fixed tiles to cool the clinker.
E. The end of the cooler there is crusher to reduce the size of the clinker.
F. Wheels and axles to support the track.
49. 49
- The principle of cooling:
It depends on the air coming from fans, which is usually at the bottom of the cooler which
comes into contact with the clinker surface, cools and turns into a hot air.
The amount of air used for cooling varies according falling clinker temperature from the
kiln and gradient particleboard falling, the amount of air required for cooling is estimated
in general (3/2 to 3/3) kg of air per kg of clinker.
- Cooling mechanism:
Air enters through the air pumps and directly come into contact with the clinker,
then heading to the top of the cooler, is divided into:
A. The first section enter the kiln what is called secondary air (almost 1200 Celsius).
B. Section II pull to the calcined area in the primary heated location, and called tertiary air
(almost 900 Celsius).
C. Section III (almost 260 Celsius) withdrawn from the heat exchanger for cooling and sent
to the filtration process and into the clinker stores.
- The clinker come down from the oven at a temperature of about 1150 Celsius and
almost come into contact with the air, it breaks down to:
A. The first part of clinker (60-70%) moves to the crusher by the alternating movement
cooler tiles and from the conveyor belt up to the clinker stores as shown in (figure 4.28).
B. The second part (30-40%) can come down through the holes in the tiles, heading to the
conveyor and then to the clinker stores.
C. The last part of the clinker (3-4%) holds mostly air and moving with it.
Figure 42 (figure 4.29) clinker storage silos
50. 50
Cement grinding section
Figure 43 (figure 4.30) clinker with gypsum milling
Figure 44 (figure 4.31) clinker milling machine
Not much different from the raw materials mill as shown in (figure 4.20), there are simple
differences between the two:
A. Use the water spray to cool the mill temperature in certain percentage in order not to lose
gypsum physical and chemical properties.
Using the hot air coming from the heater with initial humidity is less than 1% in order to
be grinding well.
Material entering the mill is clinker with mandatory addition of the ordinary gypsum is
mandatory with the addition of other materials such as Buzolana.
B. Materials used are the main materials with the modified material.
C. Productive capacity higher than the raw material mill.
D. Smoothness is measured in in the laboratory of cement mill by using Blaine device.
E. Most of mills are two separated rooms.
51. 51
Packing Department:
There are two types to fill cement:
A. Cement stored silos to trucks directly.
Figure 45 (figure 4.32) cement silos
- Securing strategic asset for the company in the case of cement mills stopped.
- Natural cooling of cement in silos in order to maintain the specifications.
- Fill trucks by cement in fluid way as shown in (figure 4.32).
52. 52
B. Packaging in bags weighing 50 kg.
Figure 46 (figure 4.33) packaging of cement in bags
It is encapsulated in cement with certain specifications bags weighing 50 kg and through
the corridors and filling machines prepared for that on normal and automatic way as
shown in (figure 4.33)
- Parts of Packing department:
A. Silo it is a silo which pouring of concrete is from the top and extracted from the bottom to
fill the trucks.
B. Intermediate warehouses organize the material to the packing machine, and secure the
continuous balance to work.
C. Different types, including the antenna and the vertical and rubber conveyors and is
working to move the materials through boilers.
D. Scales and machinery for packaging is prepared and programmed to operate on the filling
of bags 50 kg, and is done through a certain balance for the machine slots.
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4.4Some problems encounteredin cement manufacturing
processes
4.4.1 Maintenance ofmixer:
Figure 47 (figure 4.34) cement mixer
In the process of normal feeding and mixing, concrete mixer as shown in (figure 4.34)
may have an occasional trip. The reason and troubleshooting methods as follows:
- Reason 1: Feeding too much, because concrete mixer overload, this situation needs to
check whether the whole weighing system is ok, whether there is residual material or
second feeding phenomenon.
- Reason 2: The distance between mixing blade and lining board is too big, increases the
resistance. In this case, first check the distance between mixing blade and lining board,
then check the lining board thickness, if the thickness is little than 2-3mm, change it in
time.
- Reason 3: Concrete mixer's drive belt is too loose, low efficiency of transmission system.
In this case, check the tightness of drive belt, adjustment or replacement the drive belt.
- Reason 4: The safety maintenance switch on mixing cover is vibrated loose, cause
downtime. In this case, repair the safety maintenance switch.
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4.4.2Aggregate batching plant switchfailure
Concrete batching plant work for a long time, coupled with the daily maintenance is not
good, there will be some faults and problems, timely discovery and solve the problems is
very important as shown in (figure 4.35). Aggregate batching plant switch failure, usually
due to the low pressure gas supply system, running pin stuck, discharging mouth
deformation or stuck by foreign body, etc. we can handing it by adjusting the air pressure,
filling lubricating butter, and repair the discharging mouth.
Figure 48 (figure 4.35) control system for inspection of mixing parts and error investigating
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4.4.3 Water pump
Figure 49 (figure 4.36) water pump for the mixing tank
Water pump as shown in (figure 4.36) provide the sufficient amount which used for
cooling of cement and mixing, if there is wrong with this pump it will cause several
problems such as less production rate, too much equipment maintenance, less quality...etc.
So we must check it in short period to avoid those problems.
The most common problems with water pump is blades where is corrodes and fail because
of high speed and several materials which are in contact with.
So we should replace it with new one after clean it from inside and lubricate bearings and
checking.
4.4.4 Screwconveyor failure
Figure 50 (figure 4.37) screw conveyor broken shaft
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The most common failure with screw conveyor is broken shaft as shown in (figure 4.37) due to
high transit load of materials and less care of workers and the controller.
In our case we unload the screw and disassemble it and order new shaft to continue our work.This
is cost a lot by stop working and the shaft is slightly expensive, so we should take care of that.
4.5 Some calibrationmethods andstandards
4.5.1 Conveyor Scale Calibration (figure 4.38):
Figure 51 (figure 4.38) conveyor belt calibrations
1. Before the calibration, the belt scale conveyor must run for about one hour to warm up the
system.
2. The bypass chute must be in the bypass position. Ensure that material does not enter the
mixing drum.
3. Run approximately 10 tons of aggregate over the belt scale conveyor to ensure proper
seating of the conveyor belt on the rollers and better weighting accuracy.
4. While the aggregate is running, have the master feed control adjusted until the aggregate
meter reads the expected production rate. With split stockpiles, more than one bin of the
same size of aggregate may have to be used.
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5. Use the bypass chute to discard the aggregate.
6. With the belt scale conveyor running empty, place the Moisture Content Dial Setting on
zero.
7. Place the AC test switch in the x10 position, this multiplies the count rate on the totalizer
tonnes counter by 10 so that an accurate zero can be obtained.
8. Adjust the totalizer fine zero control until the tonnes counter does not count forward or
backward. Record the reading as Zero
9. Place the AC test switch back to the normal position.
10. Record the Span Setting to the nearest two hundredths of a tonne.
11. Position a tared truck capable of handling at least 10 tonnes of aggregate, under the
bypass chute. Be sure that the bypass chute and the truck box are clear of all excess
material and the chute is still in the bypass position
12. Run all conveyor belts, except the bin feeder belt.
13. Simultaneously start the bin feeder belt and the stop watch.
14. When at least 10 tonnes of aggregate have run over the belt scale and before the truck box
over-flows, simultaneously stop the bin feeder belt and the stop watch.
15. When the totalizer tonnes counter stops counting, record on the data sheet the Final
Totalizer Reading
16. Convert the loading time in minutes and seconds to seconds and record as Elapsed Time
17. Weigh the loaded truck on the platform scale and record the net weight in kg as Truck
Scale Wt. of Aggregate.
18. Calculate the wet aggregate Production Rate in tonnes/hour using the formula:
(Truck Scale Wt. of Aggregate in kg Elapsed Time in seconds) *3.6
19. Calculate the Totalizer Count in tonnes.
20. Determine the Truck Scale Weight of Aggregate in tonnes
21. Compare the Totalizer Count to the Truck Scale Wt. of Aggregate ± 0.5%.
22. If the belt scale cannot meet this accuracy it must:
- find the problem with the belt scale and/or truck weigh scale
- correct the problem,
- Recalibrate the belt scale.
4.5.2 Test Weights Calibration
1. Have the operator hang on the belt scale or lower the test weight handle, if applicable,
weights that approximately simulate the expected production rate.
2. Ensure the Moisture Content Dial Setting is on zero.
3. When the totalizer tonnes counter is at an even tonne, simultaneously take a totalizer
reading and start the stop watch.
4. Note and record the Aggregate Meter Reading in t/h the Process Meter Reading in t/h if
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applicable, and the Rate Meter Reading in %.
5. When at least six minutes have elapsed and the totalizer counter is at an even tonne,
simultaneously take a totalizer reading and stop the stop watch.
6. Record the number of tonnes counted by the totalizer as Totalizer Count.
7. Convert the Elapsed Time in minutes and seconds to seconds and record it in.
8. Determine the Totalizer Count in kilograms
9. Calculate the Totalizer Production Rate in t/h.
10. Compare Aggregate Meter Reading, and Process Meter Reading, if equipped, to the
Totalizer production Rate. The meters must be within 1% of the production rate.
11. If the meters are not within 1% of the production rate, the operator must adjust the meters
until they equal the production rate.
12. Have the operator remove the test weights from the belt scale or raise and lock the test
weight handle, if applicable.
4.5.3 Calibrationofaggregate scales
A minimum of five substantially equally-spaced loads, covering the weighing range, are
applied in ascending order and then removed, with the output at zero loads at the
completion of the run also being recorded. Where hysteresis, non-linearity (decreasing), or
combined error are to be determined, the calibration loads are to be removed in the same
steps as they were applied. This procedure is then repeated twice to give a total of at least
eighteen data points (the initial zero load output is recorded for reference).
4.5.4Calibrationof additives system
Figure 52 (figure 4.39) controls and monitoring of additives and mixing system
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This is done by taking some simple from the mixer machine, and then sends it to the
laboratory and check the proportion of each material in the simple.
If these proportions are not according to the standard and required percentages, we check
valves and slots of each material part such as water, clay, cement….etc. and fix it to
desired amount as shown in (figure 4.39).
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Chapter 5
PERSONAL DEVELOPMENT
This training has greatly improved my knowledge in the mechanical, electrical and instruments
part of engineering. It exposed me to real life practical manufacturing of different type of cement
and how this process is done from zero to final product.
It shows me the standards, consideration, failure and how to search for the reasons and fix it in
professional manner.
I got familiar with different types of valves, pumps, compressors and how they work.
Going to university gave me the theoretical knowledge of this real life practice, so therefore I
would say that having gone through this training has given me much confidence to defend myself
when it comes to dealing with cement plant manufacturing or maintenance of mechanical parts.
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Chapter 6
DISCUSSION/CONCLUSION
Looking through this report we can understand that every step in cement industry required
large preparation to increase productivity and efficiency as well as decreasing the
problems and faults which will cost the company a lot and affect the work progress.
CGC provide all the requirement that need to be competitive throughout industrial and
contracting fields, as a result of that it became the main sector for almost all constructions
and production applications in Kuwait.
If we discuss the result of that success it referred to the high technological machines
which I encountered through my training period and controlling by a number of powerful
engineers.
The final cement is satisfy all the standards which are listed by ASTM after gone in
sequential laboratories and testing.
It is really fantastic training that I ever did it in my life, because you can realize how
difficult to accomplish all of process in a successful manner and finally feeling happy to
what you did there.
All the staff there were very helpful and give me information as possible as they can to
improve my knowledge and practice in real works.
The period for the practical training divided into three stages:
Production period: included production engineers where the focus was on the work of
the engineers in the factory and the tasks entrusted to them and how to control the factory
production quality and quantity, and explore the problems with solutions.
Laboratory period: included one production engineer and laboratory technician where
the focus was on experiments carried out by the Technical and method of work and the
number of repeating them and reasons for this and giving me chances to do it myself.
Quarries and Quality period: has included geological engineer, where the focus was on
how to invest the quarries in the right way and explore the area of raw materials and how
to uproot them.
Having gone through this industrial training as a mechanical engineer, I personal believe
that industrial training is the best way to practically improve the knowledge and technical
any engineer and recognize the difference between theoretical and practical applications.
Those forty days is very important to any student to feel the stresses and try to improve
himself to retain the difficulties which may encountered in the near future. Those
difficulties will improve the innovations and scientific thinking to solve problems. This
period also teach me how we can take responsibilities and don’t depend on other people to
achieve my job. Also those days teach me how to respect other workers and try to help
anyone who need it and communicate with new and experience people from different
knowledge and culture background.
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My training in CGCS involved inspection of various steps in cement manufacturing,
laboratories, maintenance and calibrations of different instruments to insure the quality of
the products.
My personal suggestion is that the maximum period of this training should be increase
because the period given for this training is quite short for a student to gain as much
knowledge as he/she can gain. Theories given to engineers are most times written and
heard, but practice of these theories will make it perfect, therefore more practical work
should be included in our academic work. Indeed this training was 90-95% beneficial to
me as a mechanical engineer.
Also I suggest the department to make contracts with several companies to facilitate our
training in a powerful companies and eliminate the difficulties to find the acceptance letter
from them.
Finally, I would like to thank CGCS for giving me this chance to improve and prepare
myself for my future career throughout their perfect staff.
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Appendix I
Main equipment and machines
Figure 53 (figure I.1) general view
Figure 54 (figure I.2) limestones (second crushing)
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Figure 55 (figure I.3) crushed limestones conveyor belt
Figure 56 (figure I.4) limestones silos and additives before milling
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Figure 57 (figure I.5) raw meal dryer machines
Figure 58 (figure I.6) raw meal grinding
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Figure 67 (figure I.15) aggregate with grinding ball for testing in the Los Angeles Testing
Machine,
According to the ASTM C131
Figure 68 (figure I.16) this machine rotates about 30-33 rotations per minute, in this test we will
set the Los Angeles machine to 500 revolutions
