making the impossible possible 2017 - aluminium bahrain · 2018-04-03 · recovery story as a case...

2017Training Review

Making the Impossible Possible

Training Booklet 2017

His Royal HighnessPrince Khalifa

bin Salman Al KhalifaThe Prime Minister of the

Kingdom of Bahrain

His Majesty KingHamad bin Isa

Al KhalifaThe King of the

Kingdom of Bahrain

His Royal HighnessPrince Salman

bin Hamad Al KhalifaThe Crown Prince, Deputy

Supreme Commanderand First Deputy Prime Minister

Content08 CEO message

10 Management Courses Executive Training Series Soft Skills Tim’s Academy

32 Tim’s Book Club

34 MBA & TDP Alba MBA Program Vocational Training Program

36 Technical Courses

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““ Our training programs and development initiatives are rooted in Alba’s goals

Message from the CEO“The power of knowledge and education”

At Alba, we believe that knowledge is power and education is the key to achieve it.

Our people are and will always be our most valuable resources. In today’s competitive world, by training and developing our human assets we can ensure success for the Company. We believe that by partnering with our employees and providing them with the right tools for success, we will be able to have a better future for Alba. It is only through dedication and diligent commitment to education that Alba and its people will continue to grow and prosper for future generations.

In the past, Alba’s investment in its employees’ growth has yielded positive results and lead us to our reputation of one of the world’s leading aluminium smelters. Our training programmes and development initiatives are rooted in Alba’s goals of operational excellence and our social commitment towards developing the community. Through employee development programmes, we strive to improve employee capabilities and organisational competences, which in turn lead to a more productive and satisfied workforce. Alba also works closely with both, local and international universities as well as educational institutes to deliver programmes for the professional development of Bahraini nationals, which give them the right exposure to best international standards and practices.

Alba recognises that a strong learning culture helps build a productive workforce. Training and developing our people is a long-term strategic objective and our focus will always be to enhance the leadership proficiency of our employees and create leaders who will be able to turn challenges into opportunities.


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““ The Executive Training Series is the ideal platform to further enhance our leadership abilities

01- Management CoursesExecutive and Management Series

An important aspect of the developmental framework of Alba’s strategic succession planning is the incorporation of high-quality Executive education and training modules in the core capacity building of individuals. The Executive Training Series was introduced by Alba CEO Tim Murray as the ideal platform to further enhance the leadership and management capabilities of the executive team and empower them to manage the future challenges and turn them into fruitful opportunities. This year, the training department organized a number of qualitative training programs and modules that focused on the importance of strategic communication, personal traits and leadership capabilities as the team prepares for the next chapter of Alba’s journey of success. These modules were prepared and designed by renowned international speakers from prestigious educational and professional establishments to ensure maximum impact and return on investment.

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Alba Next Generation Leadership Program – Phase 1

Duration: 2 DaysSpeaker: Professor Scott Snell Overview: The “Next Generation Leadership Program” is the outcome of the effective partnership between Alba and the prestigious Darden Graduate School of Business at the University of Virginia, USA to incorporate the best academic and practical knowledge into the development of the next line of Alba leaders. Designed and presented by Professor Scott Snell, the two-module curriculum was focused on leadership through Managing change, Growth, Strategy Execution, Agility and Talent management. The course combines academic body of work with real life examples and proven methods to achieve a better level of effectiveness across the various levels of the organization.

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Leadership Tomorrowland

Duration: 1 DaySpeaker: Mr. John Skladan Overview: “Leadership Tomorrowland” is a specialized Executive Leadership workshop based on practical experience and knowledge. It was designed and presented by industry leader and management expert John Skladan in continuation of Alba CEO’s 2017 expectations to cover topics such as Safety, Training, Change Management, Succession Planning, Leadership, Communication and the SAS Methodology.

Real life examples, success stories and proven management concepts were incorporated as part of this workshop to provide the attendees with the necessary tools and methods of managing the daily job responsibilities and plan effectively for the upcoming challenges and milestones. The workshop was also extended to attendees from Alba’s 1st and 2nd line management staff to ensure uniformity of message, clarify of objectives and operational alignment across all departments.

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Every Leader is an Artist

Duration: 1 DaySpeaker: Dr. Michael O’MalleyOverview: Based on the best selling book by the same name, Dr. Michael O’ Malley uses prominent examples from the world of fine arts to highlight the similarities between the creative process of producing artistic masterpieces and leadership. A total of 12 different traits that join artists to business leaders are discussed with particular emphasis on the principles that can help leaders become more creative and effective in their approach to leading others in the workplace. Dr. O’Malley is a well-regarded expert in the field of Human Resources Development with over 25 years of experience including leadership roles in Hay Group and Mercer Consulting. He has also taught at the University of Colorado and Columbia Business School and holds a PhD from Vanderbilt University (USA).

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Alba Next Generation Leadership Program – Phase 2

Duration: 2 DaysSpeaker: Professor Lynn IsabellaOverview: Phase 2 of Alba’s “Next Generation Leadership” program follows up on the foundations that were established in phase 1 by focusing on areas of personal effectiveness, team work excellence and objective settings. The various modules of this program are based on the concepts of building a better understanding of personal leadership strengths and challenges, coaching as means to effective leadership and identifying the characteristics of building high performing teams. Professor Isabella have been working with Darden Graduate School of Business at the University of Virginia on a number of turnkey Executive training modules on coaching, leadership, effective management and goal setting.

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The Power of Strategic Conversations

Duration: 2 DaysSpeaker: Mark MagnaccaOverview: “The Power of Strategic Conversations” is the next level of communication effectiveness that was introduced in the first session presented by Mr Mark Magnacca in 2016. Participants were given a proven, powerful set of ideas and attitudes that can transform the way they interact with each other, their clients, their suppliers, and their employees. The course is also designed to reach a better understanding of the power of the right words delivered in the right way and the impact of linking the lessons learned from past experiences and situations to face the upcoming challenges. Mark is a well-known trainer, speaker and sales coach and the author of the best selling book “So what?” And he Mark been helping business leaders and individuals reach a better level of effectiveness and mastery in the skills of communication and interpersonal skills.

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Crisis Management “Line 5 Recovery Story”

Duration: 1 DaySpeaker: Alba CEO – Tim Murray Overview: Alba CEO Tim Murray’s 1-day workshop on crisis management is designed to elaborate on the basic skills and knowledge needed to deal with any sudden emergency situation, using Alba’s Line 5 Recovery Story as a case study. The Workshop features many activities including SWOT analysis and video display of the “Line 5 Recovery Story” session, which was conducted by CEO Tim Murray during the 32nd International Aluminium Conference, to discuss the key success factors, namely resilience, direct communication, willingness to embrace challenges and turning them into opportunities, setting big goals, momentum and optimism, which allowed Alba not only to overcome the Line 5 crisis, but to set a new industry benchmark.

Soft Skills Training

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Supervisory Management Development Program

Duration: 5 DaysSpeaker: EMIC Training by Simon DoyleOverview: The course is designed to empower Alba supervisors to perform improved activities in required areas of the organization. It also looks at ways to improve performance through planning, resource allocation and managing time effectively, as well as building skills needed to develop efficient work relationships in order to meet agreed business objectives.

Course outline: • Building self-esteem and assertive skills• Effective communication techniques• The art of delegating effectively• Solving simple workplace problems and making routine decisions• Building better teams• Conflict resolution techniques• Business Coaching techniques

Industrial and Employee Relations Program

Duration: 4 daysSpeaker: Robert Coates, UK based management consultantOverview: Maintaining effective industrial and employee relations is relevant to all operational and support departments and not only the Human Resources department. A positive workplace that encourages healthy working relationships between team members has a significant impact on productivity and job satisfaction. The course is designed to provide the participants with the necessary skills and tools to manage everyday issues and challenges related to industrial and employee relations.

Course outline:• Introduction to industrial and employee relations • identifying main causes of employee motivation and drive• Classification of conflict resolution tools and methods • Managing employee relations cases and situations • Coaching tools to create collaborative solutions ““ Putting T

in tomorrowland

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The Six Sigma Green Belt Training Program

Duration: 5 daysSpeaker: In-house Master Black Belt Specialists Overview: The Six Sigma green belt training program is an important component in Alba’s continuous improvement setup. Candidates get familiar with the basic DMAIC stages of any continuous improvement project with real life examples and success stories from various departments within Alba. Ideas generated during the course or shortly after completing it are developed further in collaboration with the assigned Master Black Belt to formulate practical green belt projects that contribute in the company’s cost saving and process improvement initiatives and programs.

Course outline:• Introduction to process improvement and lean management • Applying root cause analysis techniques • Classification of measuring tools and methods • Carrying out process and data analysis

High Performance Leadership Training Program

Duration: 4 days Speaker: EMIC Training by Andrew Card and Simon Doyle Overview: The High Performance Leadership Training Program is a vital part of Alba’s succession planning efforts to increase the capacity of the company’s middle management staff and prepare them to assume extended leadership opportunities and challenges. The course covers vital aspects of leadership such as effective time management, planning and delegation, advanced management and leadership principles and techniques.

Course outline: • Self-assessment of existing leadership skills• Effective time management techniques • Identification of the role played by Emotional Intelligence in the workplace • Managing conflicts within team members effectively• Advanced coaching and mentoring skills • Performance appraisal methods and systems

Green belt projects are the key to creative solutions

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Tim’s Academy

As part of its commitment towards developing people and investing in education Alba officially launched Tim’s Academy in the presence of the Executive Management, Directors and Managers with the aim to continue the people development initiatives launched by Alba’s Chief Executive Officer, Tim Murray.

Tim’s Academy is based on the following foundations:- The MBA Alumni Sessions: To impart the knowledge of Alba’s MBA graduates to Alba employees at different levels through short training workshops.- The Executive Education Series: Workshops and short courses delivered by the CEO, Executive Team, Expert Consultants and Academic Professors; - Tim’s book club: which includes all books recommended by Alba CEO to all employees on topics such as personal development, leadership, business growth and success.

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The SAS Mini MBA Program:

A very important aspect of Alba’s MBA program is to secure a systematic framework to transfer the gained knowledge back to the rest of the employees and increase the return on investment in terms of effectiveness and knowledge sharing. The year, Alba MBA graduates, who completed their program requirements from renowned universities in the US, UK and Bahrain, took part in the 2nd edition of SAS Mini MBA Program, following the popularity of the 1st batch of this innovative program in 2016.The participants in the SAS mini MBA program received intensive workshops on topics covered by major MBA programs around the world such as: • Financial Management• Strategic Planning• Human Resources Management• Managing change• Marketing strategies and planning • Leadership styles and toolsThis initiative comes under the umbrella of Alba CEO Tim Murray’s drive and focus on the importance of knowledge and education as a pivotal part of the company’s leadership development and the preparation of the next generation of leaders


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“

“ Building a Strong Reading Culture in Alba

02- Tim’s Book Club

An initiative by the Executive Management of Alba, Tim’s Book Club has been established with the sole aim of developing a reading culture in Alba. This facility has been introduced to all Alba employees to encourage them in developing the fundamental skills requires for enlightenment and success in life. Through this Club, employees have access to well-known Business and Management Books as well as other publications related to self-help, personal development and success in life. Books are added to the reading list after careful assessment and recommendation from Alba CEO based on the following set of selection criteria:

• Strong leadership concepts and lessons from well-known authors • Inspirational stories or personal example of triumph over difficulty • Effective methods of building and maintaining high performing teams• Principles used by successful companies or leaders to achieve growth• Conceptual approaches to self-development and helping others

Selected books get converted into 1-day workshops, thus giving the attendees the unique opportunity to meet the author of the book in person and attain lessons learnt from it. Tim’s Book Club was also integrated into the Training & Development Program (TDP) for all 1st and 2nd management staff.

In 2017, reference to the book “Team of Teams” was made during the Line 5 Recovery project to highlight the importance of agility and adaptability in emergency situations. A new book under the title “Every Leader is an Artist” was added to the book club and the author of the book: Dr. Michael O’Malley was invited to give a series of workshops on the power of the creative mind and the similarities between famous artists and great leaders with examples from the history of fine arts.

The author of the book “So what?” Mark Magnacca shared his experience on the power of strategic conversation as Alba gets prepared for the next challenge in Line 6 Expansion Project. The combination of the power of reading and meeting the author of the book is a critical success factor in Alba’s journey as one of the leading industrial organizations in the region in terms of training and development.


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03- MBA & TDP

Number of MBA

Students by Year

When it comes to qualitative educational programs, Alba is proud to have one of the most unique academic educational programs in the region through its Masters in Business Administration (MBA) program. This program has provided the opportunity for more than 50 Alba employees to attain higher degrees in business administration from renowned universities and apply their newly acquired skills to overcome various leadership and organizational challenges.The MBA program is supported by the Training and Development Program (TDP), which is an intensive developmental framework designed to help talented Alba staff in getting managerial positions in various departments based on the manpower and production needs and requirements. A total of 79 potential employees are currently undergoing various Training and Development Programs in various departments and it is expected that the majority of these candidates will complete their programs successfully and become ready to assume higher supervisory positions in the future.

Development Programs – Vocational Training

Alba’s Vocational Training scheme has been a unique and vital part of the company developmental programs for over 25 years with regular intake of vocational trainees from different technical and engineering disciplines. The VT program is also an effective source of increasing the rate of Bahrainis in non-supervisory maintenance positions within ALBA. A typical VT program has a duration of 2 years with a minimum academic requirement of National Diploma in a technical field. Upon completion of the program, trainees join different maintenance crews to receive their on-the-job training modules and increase their level of competency and know-how.

MBA Graduates up to 2016

MBA graduates in 2017

MBA graduates in 2018

Total MBA graduates

35

13

7

55


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04- Technical Courses

Alba is built on the strong foundations of technical knowledge and experience. Everything we do here is directly linked to our level of competency and technical skills and we are proud to have one of the best technical training frameworks in the region if not the world. Our proven record of in-house vocational training, assessment and mentoring programs have been instrumental in providing our operational and maintenance teams with a continuous influx of talented Bahrainis that have both the potential and passion to take Alba to the next level. Our extensive portfolio of external and internal technical courses is one of decisive factors that makes Alba an employer of choice and a destination for many young technicians, skilled operators and aspiring engineers and year 2017 was another memorable stage of our trainees in term of quantity as well as quality of technical training courses received.

““ Technical knowledge is the backbone of our future

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TECHNICAL COURSES EXTERNAL

Course Title: Zero Equipment BreakdownDuration: 3 daysSpeaker: Mike SondaliniCourse outline:

• Introduction to equipment reliability concepts• Limitations of machines and materials• Determining the reliability of parts• Instilling reliability principles into maintenance• Introduction to profit centered maintenance• The business of maintenance

Course Title: Effective Administration of EPC & EPCM ContractsDuration: 3 daysSpeaker: Coen Snyman Course outline:

• Introduction to contract management on major construction contracts• Familiarization with contract laws and legal principles• Project definition: getting the contracts ready for a project• Project implementation:• Project close-out: contract completion and claim settlement• Dealing with occasional but high impact events

Course Title: Low ACD Operation TrainingDuration: 5 daysSpeaker: Jean Pierre FigueCourse outline:

• Theoretical aspects of the acd and how to calculate acd.• Discovering the best practices for low acd operation• Alba’s best practice monitoring tool• The proposed action plan

Course Title: Training on Vehicle Fleet ManagementDuration: 3 daysSpeaker: Robert WilsonCourse outline:

• Fleet management principles and techniques• Fundamentals of fleet management• Fleet management information systems, analytical tools and methods• Performance measurement and benchmarking• Outsourcing and supplier management

Course Title: Training On Job Evaluation & Job AnalysisDuration: 3 daysSpeaker: Ms. Sedef Demircan Course outline:

• Job analysis training• Job analysis process

• Elements of job descriptions• Writing job descriptions• Job evaluation training• Overview of job evaluation• The hay guide chart and profile method of job evaluation know how• The hay guide chart and profile method of job evaluation problem solving• The hay guide chart and profile method of job evaluation accountability

Course Title: Advanced Procurement Negotiations & StrategiesDuration: 3 daysSpeaker: Mr. Tony EvansCourse outline:

• Negotiations and the request process• Group exercise - difference - reactive versus proactive• Group exercise - tender specifications• Communications, request for proposal (rfp)/tender, and interactive negotiations• Enhancing negotiations through the rfp / tender processes• Negotiations equals increased cost reduction• Leveraging pricing agreements and long term suppliers• Procurement negotiation & strategy plan

Course Title: Back to School Training - Carbon Plant’s Processes & EquipmentDuration: 3 daysSpeaker: Solios‘s ExpertCourse outline:

• Paste plant process review• Weighing and dosing• Liquid pitch & heat transfer medium• Pre-heating screw• Conveying systems• Dynamic classifiers• Ball mill, autogenous mill & rotary breaker• Paste mixing

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TECHNICAL COURSES 2017 MAINTENANCE - ELECTRICAL

Course Title: Induction Furnace Control And Maintenance Duration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Working principle of induction furnace• Study of power & control schematic diagram• Converter, inverter &melt manager controls• Furnace earth leakage monitoring• Rebuilding of coil insulation & furnace assembly• High voltage & furnace operational safety

Course Title: Eot Crane Electrical Controls & BrakeDuration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Different types / makes of EOT cranes in ALBA• Crane Terminology & Specification. • Crane current collecting system• Understand the various modes of operation• Crane duty motors and speed control• Different types of electrical braking system

Course Title: Crane Pendant To Wire Less Remote ConversionDuration: 2 days Speaker: Sr. Instructor Electrical, RavichandranCourse Outline:

• Working principle of EOT crane wireless Remote control system• Study of power & control schematic diagram• Interpretation of Pendant PB station & remote control station drawing• Understand the configuration of wireless Transmitter & Receiver unit• Plant visit & Testing of Operation

Course Title: Motor Control Center (MCC)Duration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Role of MCC in a distribution system• Various design of MCC• Familiarize with the different types of MCC in Alba• Identify various components of a MCC• Understanding protection, isolation and switching.• LV circuit breakers & maintenance• Study and Interpretation of Plant drawings.

Course Title: Motor Manager – MM IIDuration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Operating principles

• Principle of operation• Hardware connection and documentation• Introduction to mm ii software• Testing simulations- over-current, over-load, earth faults • Special discussion of SI/GE motor manager

Course Title: Altivar 66/71 (VSD)Duration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Operating principles• Technical characteristics• Constant & variable torque applications• Programming- use of graphic key pad, terminals & laptop• General configuration – partial & total unlock access• Application functions, diagnostic mode & fault management

Course Title: Architecture And Control Of The PTA CranesDuration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Introduction to the PTA and its various important tools.• Comprehensive study on the function and controls of various tools viz.• Shovel- working principle and controls• Bath pipe –working principle and controls.• Understanding and troubleshooting electrical controls of new PTA cranes, which includes: -• Reading and interpreting Electrical diagrams.

Course Title: Industrial SensorsDuration: 2 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline

• Learn about different types of industrial sensors used in the plant• Understand the working principle of different types of sensors like inductive, capacitive, magnetic and

photo electric sensors:• The training aid can be outfitted with a variety of photoelectric sensors and proximity sensors. Up on

which the sensors can be mounted.• Control is performed though an on-board, “smart relay” controller• Hands on practice of connecting and testing different types of sensors.

Course Title: Electrical Control Circuit TroubleshootingDuration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• All learning activities reflect realistic industrial applications.• Familiarize with different types of interlocks used in electrical control circuit.• Applications are simulated through a broad range of industrial-quality, panel mounted components.• Performance-based testing is provided through the use of 80 fault creation switches and a built in

testing timer.

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Course Title: Motor Control Starter WiringDuration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Wiring the three phase direct online starter• Wiring the three phase Forward Reverse starter• Wiring the three phase Two speed Motor Starter• Troubleshooting the wye/star configured squirrel cage AC motor

Course Title: Soft Starter Duration: 2 days Speaker: Sr. Instructor Electrical, RavichandranCourse Outline:

• Operating principles of soft starter• Technical characteristics• Understanding electrical schematics related to soft starter• Smooth start up and smooth stopping of motor• Parameter configurations

Course Title: Transformer Construction And MaintenanceDuration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Explain the basic operation of a transformer. • Discuss turns ratios and calculate terminal voltage and current. • Discuss terminal markings and various single phase and three phase wiring schemes. • Discuss the electrical testing performed on transformers such as insulation resistance testing,

excitation and power factor testing.

Course Title: 380 V Incomer ProtectionDuration: 2 daysSpeaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Introduction on different types of incomers (3 pole/ 4 pole) • Need of Incomer protection• The migration of protection schemes from electro mechanical to Numerical versions.• Advantages and disadvantages of Numerical protection schemes• A brief description on installed Incomer protection schemes in ALBA.

Course Title: H.V. Isolation And Deisolation Duration: 2 daysSpeaker: Sr. Instructor Electrical, RavichandranCourse Outline:

• Brief Introduction to HT Breakers• H.V. Safety precautions• Pre-checks to be carried out before Isolation• Steps for Isolation

Course Title: Rockwell: Maintaining And Troubleshooting Control Logix (Logix 5000)Duration: 5 days Speaker: Sr. Instructor Electrical, Ravichandran

Course outline: • Communicating with a Logix 5000 controller• Creating and organising a new RSLogix 5000 Project. • Creating a periodic task in an RSLogix 5000 Project• Organising data in an RSLogix 5000 Project• Entering, Editing and Verifying Ladder Logic in an RSLogix 5000 Project• Communicating with a Local I/O module• Configuring a Logix 5000 Controller to Produce, Consume and Share data over a network

Course Title: Rockwell: Developing RSLogix 5000 And Control NetDuration: 5 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Communicating with a Logix 5000 controller• Creating and Organising a new RSLogix 5000 Project. • Creating a periodic task in an RSLogix 5000 Project• Organising data in an RSLogix 5000 Project• Entering, Editing and Verifying Ladder Logic in an RSLogix 5000 Project• Configuring a Logix 5000 controller to produce, consume and share data over a network

Course Title: Rockwell: Developing RSview Machine Edition Applications For Panel View Plus Duration: 5 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Introducing RSView Machine Edition• Creating a new application• Tags and Tag database• Creating Graphic displays• Trending and data Logging

Course Title: Maintaining And Troubleshooting A Devicenet NetworkDuration: 5 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Identifying device net network components• Maintaining and troubleshooting a device net cable system• Maintaining and troubleshooting a device net power supply• Troubleshooting a device net network

Course Title: Rockwell: Power Flex 700 Vfd Drives CourseDuration: 5 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Configuring Drive Parameters Using the LCD HIM • Configuring Drive Parameters Using Drive Explorer Software• Configuring Drive Parameters Using Drive Executive Software• Installing and Configuring a Remote I/O Communications Adapter• Installing and Configuring a ControlNet Communications Adapter

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Course Title: RS View ME Conversion For Panel View Plus TerminalDuration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Preparing Panel view plus terminal for operation• Converting Panel view applications using RS View ME software • Configuring communications in an RS View applications• Confirming and viewing diagnosis for an RS View applications• Down loading an RS View ME applications to PV+ terminal.

Course Title: Panel View 1000 - PB32Duration: 3 days Speaker: Sr. Instructor Electrical, RavichandranCourse outline:

• Getting Started with PV1000 Terminal• Creating an Application using Panel Builder 32• Planning a Remote I/O Application• Creating a Tag Database• Creating Screen Selectors & Titles

TECHNICAL COURSES 2017 MAINTENANCE - INSTRUMENT Course Title: Rockwell: Control Logix Fundamentals And Basic ProgrammingDuration: 5 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Identifying logix5000 system components• Identifying RSLogix 5000 software components• Creating and modifying an RSLogix 5000 project

Course Title: Rockwell: Maintenance And Troubleshooting Control LogixDuration: 5 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Connecting a Computer to a Communications Network in a control Logix system• Interpreting RSLogix 5000 Project Organisation and Execution• Monitoring and Editing Tag values in an RSLogix 5000 Project• Identifying Local I/O tags in a Logix 5000 system

Course Title: Plc (Allen Bradley Plc-5) – Special CourseDuration: 5 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• PLC-5 addressing methods• Processor details, configuration and maintenance of the processor• Programming files and data files, building ladder logic, using all important instruction, running

programs on-line on• Simulation, monitoring and solving problems• On-line programming and advanced instructions• Analogy programming and pid applications

Course Title: MicroLogix / SLC 500 & RSLogix 500Duration: 5 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Introduction to SLC family• SLC 500 fixed controller• SLC 500 modular controller• Hardware components• Introduction to RSLogix 500 programming software• Controller properties / channel configuration / I/O configuration• Entering rungs, instructions and addresses / mapping quick keys

Course Title: Supervisory Control And Data Acquisition (SCADA) RS View 32 + RSlinxDuration: 5 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Getting started• Setting up communication for device tags• Creating a database for device tags• Configuring the activity log• Creating and editing elementary graphic displays• Attaching controls to graphic objects

Course Title: Cast House Burner Control SystemDuration: 2 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Introduction to CH furnaces. • Introduction to burner system interlocks. • Start-up & shut down sequence• Adjustment of gas/air ratio

Course Title: Gas AnalysersDuration: 2 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Introduction to gas analysers• Introduction to principle of analysis • Different types of sensors used• Hardware & system components• Calibration of the analyser

Course Title: Belt Weighing Feeders Systems Calibration & SettingsDuration: 2 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Introduction to weighing. • Introduction to belt weighing. • Different types of belt weighing systems• Connection of load cells & other sensors

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Course Title: PTA – Crane Weighing SystemDuration: 2 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Principles of load cells• Overview of weighing systems• Procedure for calibration• Communication / connection to PLC

Course Title: PTA – Crane Control Logix ProgramDuration: 3 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Overview of PTA - PLC system• Structure of PTA program• Explanation of difficult instructions & their functions• Troubleshooting exercise

Course Title: PTA Crane – Compressor ControlsDuration: 2 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Principles of compressor operation• Features of micromat• Procedure for calibration of pr. Switches for loading & unloading of compressor• Function of air dryers• Menu structure & parameters of micromat

Course Title: Usage of BEAMEX CalibratorsDuration: 1 daySpeaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Function of MC5 & MC6 calibrators• Usage demonstration of various functions of the calibrator• Hands on Practise

Course Title: Calciner Kilns Burner ControlDuration: 2 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Principles of burner systems• Overview of calciner kiln burners• Burner start-up & shutdown interlocks• Burner flame supervision• Interlocks & logics associated with burner control in PLC

Course Title: Calciner Gas HeatersDuration: 1 daySpeaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Principles of burner systems

• Safety while working in grs• Overview of gas heaters• Gas heater start-up & shutdown interlocks• Gas heater flame supervision• Interlocks & logics associated with burner control in PLC

Course Title: Power Plant Gas HeatersDuration: 2 daysSpeaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Principles of burner systems• Safety while working in GRS• Overview of gas heaters• Gas heater start-up & shutdown interlocks• Gas heater flame supervision

Course Title: Water AnalysersDuration: 2 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Principle of measurement of PH• Principle of measurement of conductivity• Principle of measurement of residual chlorine• Calibration of various analysers

Course Title: Carbon Coriolis Mass Flow MeterDuration: 2 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Principles of mass flow• Coriolis principle• Features of micro motion F series• Procedure for characterization• Parameters of micro –motion• Communication with hart HH

Course Title: Industrial Communication Networks Duration: 3 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• RS 232, RS 485 communications• Simplex, Half Duplex and Full-Duplex transmission• Bit and Baud Rate• OSI model of communication layers• Types of industrial networks• Protocols & topologies

Course Title: Process Control & PID Tuning Duration: 3 days Speaker: Sr. Instructor Instrument, Y V R Murty

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Course outline:• Principles of control• Control modes and proportional control• Integral control and derivative control• Application of three-term controller• Factors and methods of tuning • Open loop method / closed loop method

Course Title: Process Control & PID Tuning Duration: 3 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Control modes and proportional control• Integral control and derivative control• Application of three-term controller• Tuning loops• Fast response • Factors and methods of tuning • Open loop method / closed loop method

Course Title: Siemens PLC – S7 Duration: 3 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• S7 – Family • S7 – Software • Create new project • PLC - hardware • Connecting to PLC • Uploading / Downloading

Course Title: Control Valves & Actuators Duration: 3 days Speaker: Sr. Instructor Instrument, Y V R MurtyCourse outline:

• Introduction to Control Valves• Flow Characteristics• Flashing & Cavitation• Step wise valve CV calculation• Valve seat leakage classification• Comparisons of different types of valve applications

TECHNICAL COURSES 2017 MAINTENANCE - MECHANICAL Course Title: Basic Welding Technology Duration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Process fundamentals• Safety practices in welding• Types of fusion welding• Types of joints and welding position

Course Title: Advance Welding TechnologyDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Condition that affect weld beads• Pre and post heating• Basic engineering materials

Course Title: Condition Monitoring BasicsDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Fundamental of vibration• Waveform/spectrum• Units of measurements• Source of contamination• How contaminants compound problems• Water contamination

Course Title: Basic Coupling And Shaft AlignmentDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Methods of shaft alignment• Basics of measurement technology• Alignment tolerances

Course Title: Care And Maintenance Of BearingsDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Bearing Selection and Application• Bearing Fits and Internal Clearances• Sealing Arrangement• Bearing Designation• Mounting and dismounting• Bearing lubrication

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Course Title: Maintenance of Belt ConveyorDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Belt engineering and reference data • Tension calculation • Belt tracking guide• Belt grade

Course Title: Maintenance of BUSS MixerDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Principles of Operation• Maintenance of the barrel and screw• Clearance adjustment of the kneading teeth• Maintenance of the gear unit• Bearings and stuffing box

Course Title: Overhauling of Liquid Pitch PumpDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Various Types of Pumps • Basic Principles of operation • Replacement of parts • Mechanical Sealing System

Course Title: Contamination ControlDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Source of contamination• How contaminants compound problems• Water contamination• Fluid cleanliness standard (ISO)• Clearances of hydraulic components

Course Title: Vibration Analysis BasicsDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Maintenance Practices• Condition monitoring and its benefits• Vibration fundamentals• Equipment fault and diagnosis of common fault condition

Course Title: Mechanical Maintenance of PumpsDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio Pavia

Course outline:• Types of pumps• Fluid Issue• Over Pressurization• Replacement of parts• Mechanical sealing system

Course Title: Engineering MaterialsDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Properties of engineering materials• Classification of material• Standard specification of alloy steel

Course Title: Oxygen Acetylene Cutting ProcessDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Process fundamentals• Oxy acetylene flame• Flame adjustment• Equipment for oxy acetylene process• Set-up and operation of the equipment

Course Title: Locating & Non Locating BearingsDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Bearing selection and application• Bearing fits and internal clearances• Sealing arrangement• Mounting and dismounting• Bearing lubrication• Bearing failure

Course Title: TribologyDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:

• Principles of tribology• Friction and wear• Contamination control• Source of contamination• Filters/filtration• Solid contamination code• Condition monitoring

Course Title: Maintenance of Compressor For PTADuration: 3 days Speaker: Sr. Instructor Mechanical, Asterio Pavia

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Course outline:• Compressor basics• Overview of the main features of various types of compressors• Main elements of compressor construction• Guidelines for trouble-free centrifugal compressor operation• Positive displacement compressors: reciprocating and rotary• Compressor inspection, maintenance, control, performance testing and troubleshooting• Guidelines for trouble-free centrifugal compressor operation

Course Title: Non Destructive TestDuration: 2 days Speaker: Sr. Instructor Mechanical, Asterio PaviaCourse outline:Purpose of NDTMethods of NDTPrinciples of different methods

TECHNICAL COURSES 2017 MAINTENANCE - HYDRAULICS & PNEUMATICS Course Title: Basic Pneumatics & Hydraulics Duration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Fundamental physical principles of pneumatics & hydraulics• Tasks of pneumatics & hydraulic installations• Components of pneumatics & hydraulic system• Graphic and circuit symbols• Design of pneumatics & hydraulic system and its circuit diagram• Procedures for solving control problems• Hands on practical exercises on pneumatics & hydraulic trainer

Course Title: Advanced HydraulicsDuration: 2 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Pilot controlled pressure valves.• Pilot controlled directional valves.• 3-way flow control valve.• Closed loop hydro-static drive.• Shut off valve (unloader valve).• Pneumatic Position Controller.• Hands on practical exercise on hydraulic & pneumatic trainer.

Course Title: Proportional Valve Amplifier Card Working & AdjustmentDuration: 1 daySpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Basic principles of operation • Adjustment of the amplifier card and purposes• Response threshold, inversion range, hysteresis• Troubleshooting and checks done

Course Title: Troubleshooting of HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• The HIT and MISS approach• Safety procedure for shutting down the machine• Machine faults & machine malfunction procedure• Machine fault block diagram• System faults & system malfunction procedure

Course Title: Anode Press & Vibro Compactor HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of anode press & vibro compactor hydraulics system • Individual hydraulics components of anode press & vibro compactor and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: MTS & Start-up Tilter & Aux Beam HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of MTS & start up tilters & pneumatics & hydraulics system • Individual hydraulics components of MTS & start up tilters hydraulics and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: Crucible Cleaning Machine HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of crucible cleaning system hydraulics system • Individual hydraulics components of crucible cleaning system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: Bath Treatment Plant HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of bath treatment plant system hydraulics system • Individual hydraulics components of bath treatment plant system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: Bath Treatment Plant HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of bath treatment plant system hydraulics system

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• Individual hydraulics components of bath treatment plant system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: Butt Precleaning & Finishing HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of butt pre-cleaning & finishing system hydraulics system • Individual hydraulics components of butt pre-cleaning & finishing system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: Butt & Thimble Stripper HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of butt & thimble stripper system hydraulics system • Individual hydraulics components of butt & thimble stripper system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: CH Furnace & VDC HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of CH furnace & VDC system hydraulics system • Individual hydraulics components of CH furnace & VDC system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: CH Homogenizing Plant HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of CH homogenizing plant system hydraulics system • Individual hydraulics components of CH homogenizing plant system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: CH Screw Compressor & Air Dryer SystemDuration: 1 daySpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of CH screw compressor & Air Drier system • Individual hydraulics components of CH screw compressor & Air Drier system • Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: CH Swarf Presss Plant HydraulicsDuration: 2 days

Speaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of CH swarf press system hydraulics system • Individual hydraulics components of CH swarf press system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: CH TAC Plant HydraulicsDuration: 1 daySpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of CH TAC plant system hydraulics system • Individual hydraulics components of CH TAC plant system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: CH SERMAS Saw HydraulicsDuration: 2 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of CH SERMAS slab saw system hydraulics system • Individual hydraulics components of CH SERMAS slab saw system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: CH Slab Tong HydraulicsDuration: 1 daySpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of CH Slab Tong System hydraulics system • Individual hydraulics components of CH Slab Tong System and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

Course Title: Kilns Crane HydraulicsDuration: 3 daysSpeaker: Sr. Instructor Hydraulics & Pneumatics, Kamal K JanCourse outline:

• Study of components and circuits of kilns crane system hydraulics system • Individual hydraulics components of kilns crane system and their functions• Usual problems in the system, their causes and solutions• Normal parameters of the system and their operational check

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TECHNICAL COURSES 2017 MAINTENANCE - AUOMOTIVE Course Title: Cummins Engine QSB 4.6 /6.7 Familiarization And Maintenance Duration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review diesel engine’s theory of operation • Construction and application of cummin’s diesel engines • Major operating systems of cummin’s diesel engines• Common rail fuel injection system

Course Title: Cummins Electronic Control System (Cm 850) FamiliarizationDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on cummins QSB 4.5/6.7 familiarization and maintenance • ECM (CM 850) design concepts • Input devices: sensors and switches • Output devices: Fuel Injector Solenoid

Course Title: Cummins Engine QSB 4.6 /6.7 Troubleshooting Using In-site Service ToolsDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on cummins electronic control system (CM 850) familiarization• In-site service tools: components and setup• In-site program application• Troubleshooting codes• Practical troubleshooting

Course Title: Cummins Engine QSB 4.6 /6.7 Troubleshooting Using Fuel Leak TestDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on cummins engine familiarization and maintenance• Fuel leak test tools: components and setup• Principles of the leak test• Analysing failures• Practical leak test procedure

Course Title: Hydraulic Components Test BenchDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on principles of hydraulics• Hydraulic components test bench design and operations• Safety in using hydraulic components test bench• Design modifications implemented

Course Title: Hydraulic Components Test – Pumps / MotorsDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on hydraulic components test bench design and operations• Review on principles of pumps and motors – design and operations• Hydraulic component pumps and motors - set up and testing procedures• Test results and its analysis

Course Title: Hydraulic Components Test – CylindersDuration: 1 day Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on hydraulic components test bench design and operations• Review on principles of cylinders – design and operations• Hydraulic component cylinders - set up and testing procedures• Test results and its analysis

Course Title: Hydraulic Troubleshooting – Cooling SystemDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on science of hydraulic maintenance• Review on the hydraulic system design and operations of the cooling system• Common causes of hydraulic failures on the cooling system• Conducting a systematic approach in hydraulic troubleshooting

Course Title: Hydraulic Troubleshooting – Drive SystemDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on science of hydraulic maintenance• Review on the hydraulic system design and operations of the drive• Common causes of hydraulic failures on the drive system• Conducting a systematic approach in hydraulic troubleshooting

Course Title: Hydraulic Troubleshooting - Brake SystemDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on science of hydraulic maintenance• Review on the hydraulic system design and operations of the brake system • Common causes of hydraulic failures on the brake system• Conducting a systematic approach in hydraulic troubleshooting

Course Title: Hydraulic Troubleshooting - Service SystemDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on science of hydraulic maintenance• Review on the hydraulic system design and operations of the service operations

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• Common causes of hydraulic failures on the service system• Conducting a systematic approach in hydraulic troubleshooting

Course Title: Hydraulic Troubleshooting - Steering SystemDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on science of hydraulic maintenance• Review on the hydraulic system design and operations of the steering system• Common causes of hydraulic failures on the steering system• Conducting a systematic approach in hydraulic troubleshooting

Course Title: Auto Hydraulic Refresher Course Duration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review on the hydraulic principles• Hydraulic components and reading circuit diagram• Hydraulic system design and operations review• Science of hydraulic maintenance• Practical exercises

Course Title: Auto Hydraulic ComponentsDuration: 3 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Fundamental physical principles of hydraulics• Refresher on basic principles of hydraulics• Design and construction of a pump• Design and construction of an actuator• Design and construction of control valves• Design and construction of other hydraulic components

Course Title: Automotive Engineering PrinciplesDuration: 3 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Areas and volume• Forces in structures• Stresses strain and material properties• Fluid mechanics• Thermal and energy system• Engineering processes

Course Title: Auto Hydraulic Designing PrinciplesDuration: 3 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Basic laws governing fluid power • Hydraulic pumps and motors calculations• Hydraulic cylinder calculations

• Piping calculations ad sizing hydraulic lines• Hydraulic fluid selection• Schematic drawing of a hydraulic circuit• Discussion of previous design modifications made

Course Title: Conducting Failure AnalysisDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Failure analysis concepts• Discussing historical data• Concept of failure analysis• Conducting failure analysis• Report and recommendation.

Course Title: Solving And Preventing Hydraulic Problems Part 1 – System, Oil And HosesDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Preventing hydraulic failures• Hydraulic system troubleshooting – check the easy things first• How to avoid hydraulic troubleshooting mistakes• Hydraulic system oil types and manufacturer’s recommendations• The true cost of hydraulic oil leaks• High hydraulic fluid temperature – how it causes premature failures• Solving hydraulic system overheating problems• Dealing with water in the hydraulic fluid• Dealing with air contamination of hydraulic fluid• Hydraulic filters that do more harm than good• Hydraulic filter conditioning monitoring• Flushing the hydraulic system• Hydraulic hose failure, cause and prevention

Course Title: Solving And Preventing Hydraulic Problems Part 2 – Hydraulic Pumps And ActuatorsDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Review of part 1 session• Preventing hydraulic failures• Determining condition and performance of hydraulic components• Common causes of hydraulic component failures• Hydraulic failure, cause and prevention• Proactive maintenance

Course Title: Engineering Drawing (Mechanical And Welding)Duration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Engineering drawing• Basic drawing elements (formats, title block, parts list, revision block, etc.)• Part views (Multiview, auxiliary, and isometric)

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• Section views• General dimensions• Tolerances• Finish and welding symbols.

Course Title: Vehicle Micro / Compact Logix FundamentalsDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Program logic controls• Types of modules • Understanding control system • Identifying hardware system components • Identifying software components • Checking the system

Course Title: Oil Analysis And Particle CounterDuration: 2 days Speaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Importance of oil condition• Qualitative and quantitative analysis• Spectrolnf system description• Fluid scan system description

Course Title: Engine Emission Analysis Duration: 1 daySpeaker: Sr. Instructor Automotive, Danilo A PerezCourse outline

• Importance of engine emission analysis• Concept of emission analysis• BEA general information• Conducting emission analysis• Maintenance of equipment

TECHNICAL COURSES 2017 OPERATIONS - POWER Course Title: Electrical OperationsDuration: 4 days Speaker: Sr. Instructor Power, Purnayya Course outline

• Transformers• Rectiformers • Switchgear• Battery chargers

Course Title: RO & STP OperationsDuration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• RO3 – Major components, systems and operations• RO3 DM – Major components, systems and operations• STP1 – Major components, systems and operations• STP2 – major components, systems and operations

Course Title: GT Operations: PS – 3 (Level 1)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Gas turbine – Major components and systems• Gas Turbine – Starting sequence • Gas Turbine – Shutdown sequence • Basics control systems and operating limits• Factors influencing performance

Course Title: Boiler Operations: PS – 3 (Level 1)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• HRSG – Major components and systems• HRSG – Starting sequence • HRSG – Shutdown sequence • Basics control systems and operating limits• Factors influencing performance

Course Title: Steam Turbine Operations: PS – 3 (Level 1)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Steam Turbine – Operating procedures• Water Steam Cycle - Operating procedures• Generators – Operating procedures• Basics control systems and operating limits• Factors influencing performance

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Course Title: Auxiliaries Operations PS – 3Duration: 5 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Fuel gas Supply system – PS 3• Air compressor station – 2 • Rectiformers – Line 4

Course Title: Gt Operations: PS – 4 (Level 1)Duration: 5 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Gas turbine – Major components and systems • Gas Turbine – Starting sequence • Gas Turbine – Shutdown sequence • Basics control systems and operating limits • Factors influencing performance

Course Title: Boiler Operations: PS – 4 (Level 1)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• HRSG – Major components and systems • HRSG – Starting sequence • HRSG – Shutdown sequence • Basics control systems and operating limits

Course Title: Steam Turbine Operations: PS – 4 (Level 1)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Steam Turbine – operating procedures• Water Steam Cycle - operating procedures• Generators – operating procedures• Basics control systems and operating limits• Factors influencing performance

Course Title: Auxiliaries Operations PS – 4Duration: 5 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Fuel gas supply system – PS 4• Air compressor station – 3• Rectiformers – Line 5

Course Title: Gt Operations PS – 3 (Level 2)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Aluminium electrolysis process• Gas treatment process

• Phenomenon of adsorption• GTC process parameters• Air slides & airlifts

Course Title: Gt Operations PS – 4 (Level 2)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Aluminium electrolysis process• Gas treatment process• Phenomenon of Adsorption• GTC process parameters• Air Slides & Airlifts• HDPS - Hyper Dense Phase System

Course Title: Steam Operations PS – 2 (Level 2)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Heat recovery steam generator operation• Water steam cycle operation• Steam turbine operation• Control systems and operating limits

Course Title: Steam Operations PS – 3 (Level 2)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline


Course Title: Steam Operations: PS – 4 (Level 2)Duration: 4 days Speaker: Sr. Instructor Power, PurnayyaCourse outline


Course Title: Chemical ControlDuration: 3 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Water chemistry & treatment• Reverse osmosis plants• Sewage water treatment plants• Lab tests & analysis

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Course Title: Power Station PerformanceDuration: 5 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Parameters affecting output & efficiency• Gas turbine efficiency and heat rate calculations• Steam cycle efficiency and heat rate calculations• Combined cycle efficiency and heat rate calculations

Course Title: Calciner Operator Skills Duration: 2 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• General plant layout• Calcining process fundamentals• Green coke handling & blending –process flow sheet• Rotary kiln – process operation• Incinerator-process operation• Hot flue gas handling• Indirect coke cooler• Calcined Coke Handling

Course Title: Desalination Operations (Level 2)Duration: 2 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Desalination and different methods in practice• MSF Vs MED• MED process important aspects• Chemicals used in desalination• Factors affecting GOR• Chemical cleaning

Course Title: Marine Operator SkillsDuration: 2 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Alumina unloading, storage and transport• Green coke unloading, storage and transport• Liquid pitch unloading, storage and transport• Safety aspects• Environment aspects

Course Title: Shell Repair Operator Skills Duration: 2 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Aluminium electrolysis process• Shell change procedure• Cathode sealing• Lining materials & properties

Course Title: POT Repair Operator Skills Duration: 2 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Aluminium Electrolysis Process• Shell Change Procedure• Cathode Sealing• Lining Materials & Properties• Ramming Procedure & Quality

Course Title: TAC Plant Operator Skills Duration: 2 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• General plant layout • Pot operation basics• TAC basics• TAC operation• Cast House basics

Course Title: FTP & GTC Operator Skills Duration: 2 days Speaker: Sr. Instructor Power, PurnayyaCourse outline

• Aluminium electrolysis process• Gas treatment process• Phenomenon of adsorption• GTC process parameters• Air slides & airlifts• HDPS - Hyper Dense Phase System

TECHNICAL COURSES 2017 OPERATIONS –RED & CH PROCESS Course Title: Reduction Process Course Duration: 5 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• General plant layout & process functions of Alba • Carbon anode manufacturing process• Basic electricity & chemistry related to smelter operation• Raw material used for aluminium production• Aluminium electrolysis process• Bath properties & effect of additives• Current efficiency & efficiency figures• Pot design and bus bar electrical circuit

Course Title: Low ACD Operation Training Duration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium electrolysis process

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• Why operate at a low ACD• Theoretical aspects of ACD• Importance of operating at low ACD• Impacts of low ACD operation on pot performance

Course Title: Cell Preheating & Dry Start Up OperationDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium electrolysis process• Resistor preheating method & procedure• Theoretical aspects of dry start up method• Normal start up vs. dry start up• Impact of start-up practice on cathode life • Pot normalization procedure

Course Title: Heat Balance In Aluminium Electrolysis Duration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium Electrolysis Process• Heat Balance• Heat loss distribution• Side wall and side ledge• Cryolite – alumina phase diagram• Addition of aluminium fluoride & super heat• Addition of soda ash & super heat• Hot cell & troubleshooting

Course Title: Reduction Line1-5 ALPSYS Dual Micro Pot SystemDuration: 2 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• General Pot Level 1 & 2 Layout & Process Functions • ALPSYS Pot Controller Operating Principle & Pot Electricity • Test Bench Exercises – Level1 on Specific Operating Modes • Pot Control System - Level2 Graphs

Course Title: ALPSYS - Pot Alumina Feeding System And ControlDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium electrolysis process• Alumina characteristics • Alumina dissolution• Aims and principles of alumina feeding control• Control by slope calculation• Alumina feeding control• Alumina feeding disturbances• Overfeeding procedures

Course Title: ALPSYS - Pot Thermal ControlDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium electrolysis process• Thermal equilibrium- influence of aluminium fluoride• Fluoride balance• Principles and functions of thermal control• Calculating alf3 corrections• Calculating alf3 feeding periods• Thermal additional resistance

Course Title: Reduction Process Control & MeasurementsDuration: 5 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium background• Basic electricity, chemistry & raw material related to pot room• Aluminium electrolysis process • Pot operational activities• Sampling and analysis• Line 1-3 pot measurements and targets• Line 4-5 pot measurements and targets• Line 4-5 pot preparation, preheating & start-up measurements

Course Title: Cathode Lining Course And Pot AutopsyDuration: 4 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium electrolysis process• Shell design• Cathode block properties• Lining design• Lining materials & properties• Cathode failure - pot autopsy• Side wall failure

Course Title: Cathode Sealing And Induction Furnace OperationDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium electrolysis process• Cathode sealing process flow chart• SERMAS & GNA System• Induction furnace – working principle• Induction furnace – charging procedure• Target cast iron composition• Cooling water system• Emergency & furnace tripping

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Course Title: Gtc Operation And Process ParametersDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Aluminium electrolysis process• Gas treatment process• Phenomenon of adsorption• GTC process parameters• PTA filling station- acm samples

Course Title: Anode Raw Materials And Properties Duration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• General plant layout & process functions of Alba • Green coke quality & properties• Impact of green coke quality on CPC quality• CPC - physical properties & its impact on anode quality• CPC – chemical properties & its impact on anode quality• Liquid pitch - physical properties & its impact on anode quality• Liquid pitch- chemical properties & its impact on anode quality

Course Title: Paste Plant Operation And Green Anode Quality Duration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• General plant layout & process functions of Alba • Basics about calcined coke manufacturing process• Raw material & its properties used for green anode production• Paste plant process flow sheet• Dry aggregate preparation

Course Title: Anode Baking Process And Baked Anode Quality Duration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Baking process & operation• Fire group description• Temperature and fire cycle description• Anode transformation during baking process• Baking parameters vs anode quality• Anode consumption mechanisms

Course Title: Baked Anode Core Sample Properties & AnalysisDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Objectives of anode baking• Baking process & operation• Anode core sample properties• Core sample analysis & targets

• Aluminium electrolysis process• Impact of anode quality on pot operation

Course Title: FTP/GTC Operation And Process ParametersDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Anode baking kilns process• Fume treatment process• Phenomenon of adsorption• FTP process parameters• Primary alumina handling system• Secondary alumina handling system

Course Title: Anode Rodding Operation And Rodded Anode QualityDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Anode rod assembly design parameters• Butt cleaning and impact of anode quality• Anode sealing & stub-carbon connection• Stub/rod/casting defects and its impact on pot room process performance• Operation of induction furnace, sintering program• Composition of cast iron and its metallurgy• Factors that influences the anode performance in pot room process

Course Title: Induction Furnace Operation & Cooling Water SystemDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Anode rodding process overview• Cast iron properties• Cast iron – types: grey vs. White• Induction furnace – working principle• Target cast iron composition• Additives & its effect on cast iron quality• Theory of stub-carbon connection

Course Title: Carbon Anode Quality & Anode Performance Duration: 5 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• Carbon raw material quality and its impact on anode production & quality.• Paste plant process parameter & impact on anode quality• Green anode – defects, their causes & rejection criteria• Kiln process parameters & impact on anode quality• Critical stages of baking process• Baked anode – defects, their causes & rejection criteria • Rodding process parameters & impact on anode quality• Impact of anode quality & anode performance in smelter operation

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Course Title: Carbon Lab Analysis And Quality ParametersDuration: 4 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outlineCarbon Plant Process Overview

• Raw material quality control- lab analysis & quality parameters• Green anode quality control - lab analysis & quality parameters• Baked anode quality control - lab analysis & quality parameters• Rodded anode quality control - lab analysis & quality parameters• Impact of anode quality on pot room operation

Course Title: Calciner Quality Control & Process ParametersDuration: 3 days Speaker: Sr. Instructor Process, Muthu SaravananCourse outline

• General plant layout & process functions of Alba• Green coke sources, handling & storage system• Green coke blending & process parameters• Calcining process fundamentals• Green & calcined coke sampling & analysis• Calcined coke – physical properties & its impact on anode quality

Course Title: Cast House Process Course Level 1Duration: 5 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Bauxite to aluminium production. • Alba Process Layout & Cast house Plant Process Layout • Basics about cast house operation & products • Hot metal handling and preparation methods. • Aluminium alloy series and applications • Molten metal treatment (TAC plant, degassing, filtration methods) • Basic Principle of Airslip Billet Casting. • Properzi Ingot, Standard Ingot and Alloy Ingot casting.

Course Title: Cast House Process Course Level 2Duration: 5 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• To provide detailed technical know-how & understanding about CH equipment’s technology & process.

• To provide an overview of “alba processes & equipment”.• To make them more aware about upstream & downstream plants process & equipment.• To improve upon their “safety observations & practices”.

Course Title: CH Metallurgy & Quality ControlDuration: 5 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Concept of cast aluminium product quality• Alba specification & customer quality requirement

• Impact of furnace preparation (alloying, stirring, skimming and sampling) on product quality• Billet & slab casting metallurgy process parameters• Metallurgy process audit activities• Casting defects & defects detection, measurement & control system (Slice Etching Test, AlScan,

PODFA & Porosity Test)

Course Title: Alloy, Scrap Melting & Recovery CalculationDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Objective and requirements• Safety hazards related with alloy calculator and associated furnace area activities• Alloy series & designation• Various alloying elements and its purpose• Alba alloy specification• Alloy calculation methods according to the furnace situation• Scrap melting & alloying elements recovery calculation• Abnormal condition & control in furnace area• MES alloy calculation system & reports discussion

Course Title: CH Furnace Technology & Alloy PreparationDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• CH furnace process • Objective and technical background • Molten metal & other safety hazards related with furnace operation • Working principle of equipment’s & technical parameters associated with furnaces. • Activities in furnace (scrap charging, metal handling, alloying elements addition, stirring, skimming,

hot cleaning...etc.) Procedure • Off analysis correction and dross management • Abnormal condition & control in furnace area

Course Title: Wagstaff Billet Casting Technology & OperationDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Safety hazards and characteristics of molten aluminium• Aluminium alloy solidifications• Wagstaff air slip casting technology• Wagstaff billet casting equipment function• Casting equipment pre checks & parameters• Billet casting defects & troubleshooting

Course Title: Slab Casting Technology & OperationDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Characteristics and hazards of molten aluminium• Aluminium alloy solidifications• Pechiney & wagstaff tools slab dc casting technology

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• Slab casting equipment pre checks• Slab casting parameters and abnormal condition• Casting defects and troubleshooting• Slab customer end process & product quality aspects

Course Title: Properzi Ingot Casting Technology & OperationDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Properzi ingot casting process & alloy solidification mechanism• Molten metal & other safety hazards related to properzi ingot • Working principle of equipment’s & process parameters associated with properzi ingot.• Activities in properzi ingot (furnace tilting control, launder preparation, ACD, CFF, rod feeder, casting

wheel preparation, shearing, cooling, stacking … etc.) • Properzi ingot MES and other reports / records – discussion

Course Title: Standard Ingot & Alloy Ingot Casting SystemDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Standard & alloy ingot casting process & alloy solidification• Objective and technical background• Molten metal & other safety hazards related to alloy ingot• Working principle of equipment’s & process parameters associated with standard & alloy ingot casting.• Activities in standard & alloy ingot casting (furnace tilting control, launder preparation, ACD, CFF,

casting wheel preparation, demoulding, stacking etc.)

Course Title: Billet Homogenising Technology & OperationDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Billet homogenizing heat treatment process• Safety hazards related with homogenising• Working principle of equipment’s & process parameters associated with homogenizing.• Activities in homogenising (log tracking, monitoring HEC, HOC, air cooling and water cooling,

inspection … etc.)• Homogenizing system, alarms and its control• Homogenizing defects & troubleshooting• Homogenizing & sawing MES and other reports / records

Course Title: CH Mouldshop & Water Treatment SystemDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Layout of cast house water treatment system • Water chemistry • Chemicals used & their purpose • Water treatment process CH2 & CH3 • Impact of water quality on casting process • Water quality and moulds • Individual mould preparation testing• Casting station inspection & troubleshooting

Course Title: Ultrasonic Inspection System Duration: 2 daysSpeaker: Sr. Instructor Process, Gobi DassCourse outline

• Billet ultrasonic inspection method & technology• Safety hazards related with ultrasonic inspection system• Working principle of equipment’s & process parameters associated with ultrasonic inspection.• Activities in ultrasonic inspection (laydown station, ultrasonic system preparation, probe checking,

counter, log washing unit, identification stamping unit … etc.) • Ultrasonic inspection system pre check, starting casting, monitoring & control process parameters.

Course Title: Khuff Gas Plant & Process ParametersDuration: 1 daySpeaker: Sr. Instructor Process, Gobi DassCourse outline

• Billet khuff gas process• Objective and technical background• Safety hazards related with khuff gas plant unit• Khuff gas plant system operation, monitoring & control process parameters.• Khuff gas plant, alarms and its control• Khuff gas plant log sheet, reports / records – discussion

Course Title: Cast House Process Course For MarketingDuration: 2 days Speaker: Sr. Instructor Process, Gobi DassCourse outline

• Objective and technical background• Molten metal & other safety hazards related with furnace operation• Working principle of equipment’s & technical parameters associated with furnaces.• Activities in furnace (scrap charging, metal handling, alloying elements addition, stirring, skimming,

hot cleaning...etc.) Procedure• Off analysis correction and dross management • Abnormal condition & control in furnace area

Course Title: T - Ingot & Alloy T - Ingot Casting SystemDuration: 1 daySpeaker: Sr. Instructor Process, Gobi DassCourse outline

• Characteristics and hazards of molten aluminium • Aluminium alloy solidifications• CH2 t- ingot casting system• CH3 t- ingot casting system• T ingot casting equipment pre checks• T ingot casting parameters and abnormal condition• Casting defects and troubleshooting• T ingot customer end process & product quality aspects

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““ A+ performance is a target that we all aspire to achieve

Course Title: Quantometer TestingDuration: 1 daySpeaker: Sr. Instructor Process, Gobi DassCourse outline

• Characteristics and hazards of associated quantometer testing • Working principle of quantometer equipment• Sample requirements for quantometer & preparation• Calibration requirements for quantometer testing• Quantometer testing equipment pre checks

Course Title: ALSCAN TestingDuration: 1 daySpeaker: Sr. Instructor Process, Gobi DassCourse outline

• Characteristics and hazards of associated with ALSCAN testing • Working principle of ALSCAN equipment• Testing requirements for ALSCAN• ALSCAN testing equipment pre checks • Operating ALSCAN equipment• ALSCAN testing results and reports discussion

Aluminuim Bahrain B.S.C.

making the impossible possible 2017 - aluminium bahrain · 2018-04-03 · recovery story as a case...

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