PERSONNEL TRAINING

GENERAL

a) The Contractor shall designate his skilled and qualified personnel (four persons) who is
competent in his area of specialty on the modern cement plants and who has a minimum
of 4 years’ experience. If the Owner's personnel are not satisfied with the training inputs
of the Contractor's personnel, the Owner may ask for a change of such personnel. The
Contractor shall give the technical instructions and training to the Owner's technical
personnel and explain all the technical problems within the scope of the Contract.

b) The Contractor shall submit the preliminary training program to the Owner for his
comments 3 (three) months before the training starts. 1 (one) month before the start of the
training, the final training program shall be fixed by both parties.

c) Before the training starts, the Contractor shall explain in detail to the Owner's personnel
the operating regulations and other precautions for work.

d) The Contractor shall take necessary measures to ensure the security of the Owner's
personnel during their stay in China.

e) The training fee is included in the total value of the Contract. It includes the training
charges, local travel charges (in China), boarding and lodging (Contractor’s guesthouse)
cost in China for offsite training.

f) If the training is carried out in China, the Owner's technical personnel shall obey the
country’s laws and regulations and the rules of the training institution.

OBJECTIVE OF TRAINING

This training is for the purpose that the technical department’s personnel coming from the
Owner have a basic realization to structure and maintenance for the equipment in this
cement clinker production, it includes the cement process, the equipment operation, the
structure and maintenance, the request for the function and the maintenance to the
electrical, control and automation equipment.

TRAINING METHODOLOGY

Proposed training methodology is based on two phases approach as follows:

• “Off Site” Training:

In this Contract, the “Offsite training” means the training of the Owner’s personnel to be
conducted by the Contractor in China or UAE (based on Owner decision). The training is
to be achieved by imparting theoretical training (in class room mode) followed by
participative visits to “under erection/commissioning/trouble shooting” of the similar

Annex 10 Training Program 1/11 Contract

installations to a friendly cement factory.

• “On Site” Training: Enhancing the theoretical knowledge by actual hand-on experience
on installation, commissioning and trouble shooting of the machinery and systems for the
project. This is proposed to be achieved by imparting “On Site” training during erection
and commissioning of the Contract Plant.

After the theoretical training, trainees should acquire some knowledge and skills such as:

• The characteristic and the usage for the main equipment;

• Operation parameter and implementation;

• The step to the start and closure;

• Automatic equipment and sequential system;

• Safety guide.

THE PLACE OF TRAINING

Training place shall be based on type of training i.e for “Off Site” place of training will be
in China or UAE and for “On Site” mainly in the Site.

“OFF SITE” TRAINING ORGANIZATION

The training person will be divided into five groups as follows:

• First group : The person for Mechanical device attendant

• Second group : The person for Production and operator

• Third group : The person for Electricity attendant

• Fourth group : The person for Automation attendant

• Fifth group : The person for quality control personnel

No. of persons
Function Persons including
(Off-site)

Process & 8 Process engineer, the process operator, the

Mechanical daily management for producing and technical
personnel and the newly recruited personnel

Electrical 4 Electrical engineer, the daily management for

electrical and maintenance technical personnel
and the newly recruited personnel

Control & 2 Automation engineer, the technical person for

management and maintenance to the

Annex 10 Training Program 2/11 Contract

 No. of persons
Function Persons including
(Off-site)
Automation instrument.

Computer application software engineer,

computer hardware engineer and the newly
recruited personnel

Maintenance 4 Mechanical engineer, the technical person for

equipment maintenance and the newly
recruited personnel

Quality 2 Quality control engineer, laboratory lab

Control technician and the newly recruited personnel

Total 20

TRAINING ARRANGEMENT FOR OWNER’S ENGINEERS

No Item Location Total man-months

1 Training China 40

CLASS ROOM TRAINING

Training Need Coverage

The theoretical training 1) The project technical process, process unit

for the main equipment specification model and disposition characteristic
operation, structure
maintenance 2) The production operation control process parameter,
the order for the process line start and stop, the
(8 hour class) interconnection relations

3) The safety guide for main equipment operational and

production management

4) The main engine structure, maintenance keys etc

5) Raw material control , mixture and homogenization.

The theoretical training 1) The power distribution structural drawing for

for electrical systems and distribution network of the project. The load
installations calculations and system studies of the distribution
network

2) Power distribution station, electricity room, division

Annex 10 Training Program 3/11 Contract

 Training Need Coverage
for the transformer substation;

3) Electrical machinery drives, the electrical

transmission, the electrical control of the project

4) Electrical equipment disposition and characteristic;

5) Earth network and earthing systems

Control and Automation 1) Plant distributed control system network structure

training drawing, hardware, disposition characteristic;

2) Plant measuring appliances, control flow, model

control loop;

3) Plant instrument arrangement including special-

purpose detector set

4) Computer software’s and the general introduction to

various software applications used in the plant

These class hour arrangements are flexible, the main basis is the reception of the trainee
personnel's understanding and degree of adjustment to perform .

FIELD INSTALLATION VISITS

“Off site” training shall be carried out at a similar installation in a cement plant in China.
This part of the “off site” training will be carried out as an participative “hands-on” real
life field situations and shall be imparted by the process of organising visits to the
installations of the similar main equipment . These visits shall be arranged alongwith
equipment service engineers. During the training, the service engineer shall explain the
installation process and debugging solutions. Main focus of this training shall be to enable
trainee achieve and grasp the familiarity with equipment and common problems
associated with installation and commissioning of the machinery. Trainee will obtain the
knowledge enhancement vis-à-vis equipment & installation covering the following:

• The main point of equipment installation;

• The design feature of the equipment;

• The knowledge of equipment routine maintenance, service, maintenance.

Focus of this training is to know well the equipment proposed to be installed for the
project, the process and the preparation for the test run work

TRAINING PLAN

Annex 10 Training Program 4/11 Contract

 System Content Class Room Field Visit

Quality 1) Principle of Theoretical training by the Contractor’s engineer

control instrument. technical personnel will take to the field
followed by case studies and teaches or
2) Usage and from service engineers. demonstrate.
maintains of the
instrument

3) Debugging of the
instrument

4) Trouble elimination
of the instrument

Cooler 1)Daily Inspection, Theoretical training by the Contractor’s engineer

system maintenance technical personnel will take to the field
followed by case studies and teaches or
2)System disposition from service engineers. demonstrate.

3)Installment and
debugging

4)Trouble elimination

Raw mill and 1) Correct usage of Theoretical training by the Contractor’s engineer
Coal mill the equipment technical personnel will take to the field
system followed by case studies and teaches or
2) Equipment from service engineers. demonstrate.
maintenance

3) General trouble
elimination

Packing 1) Correct usage of Theoretical training by the Contractor’s engineer

Machine (Not the equipment technical personnel will take to the field
applied) followed by case studies and teaches or
2) Equipment from service engineers. demonstrate.
maintenance

3) General trouble
elimination.

X-ray 1) Correct usage of Theoretical training by the Contractor’s engineer

Analyser the equipment technical personnel will take to the field
followed by case studies and teaches or
2) Equipment from service engineers . demonstrate .
maintenance

3) General trouble

Annex 10 Training Program 5/11 Contract

 System Content Class Room Field Visit
elimination

Industrial TV 1) Correct usage of Theoretical training by the Contractor’s engineer

system the equipment technical personnel will take to the field
followed by case studies and teaches or
2) Equipment from service engineers. demonstrate.
maintenance

3) General trouble
elimination

Main 1) Principle and Theoretical training Contractor’s engineer

transformer structure followed by case studies will take to the field
from service engineers. and teaches or
2) Technological demonstrate.
process and testing
method

3) Routine
maintenance

11 KV 1) Principle and Theoretical training by the Contractor’s engineer

Switch structure technical personnel will take to the field
cabinet followed by case studies and teaches or
2) Technological from service engineers . demonstrate .
process and testing
method

3) Routine
maintenance and
maintain.

4) Trouble shooting

Relay 1) Principle and Theoretical training by the Contractor’s engineer

protection structure technical personnel will take to the field
followed by case studies and teaches or
2)Testing method from service engineers . demonstrate .

3)Routine
maintenance and
maintain.

4)Trouble elimination

Annex 10 Training Program 6/11 Contract

 System Content Class Room Field Visit

MV 1) Principle and Theoretical training by the Contractor’s engineer

frequency structure technical personnel will take to the field
converter followed by case studies and teaches or
2) Debugging from service engineers . demonstrate .

3) Routine
maintenance and
maintain.

4) Trouble elimination

LV frequency 1) Principle and Theoretical training by the Contractor’s engineer

converter structure technical personnel will take to the field
followed by case studies and teaches or
2) Debugging from service engineers . demonstrate .
3) Routine
maintenance and
maintain.

4) Trouble elimination

AC Drive 1) Principle Theoretical training by the Contractor’s engineer

panel for kiln technical personnel will take to the field
2) Debugging followed by case studies and teaches or
from service engineers . demonstrate .
3)Routine
maintenance and
maintain

4)Trouble elimination

Starter 1) Principle Theoretical training by the Contractor’s engineer

technical personnel will take to the field
2) Debugging followed by case studies and teaches or
from service engineers . demonstrate
3) Routine
maintenance trouble
shooting

Weighing 1) Principle Theoretical training by the Contractor’s engineer

equipment technical personnel will take to the field
2) Debugs and followed by case studies and teaches or
demarcates from service engineers . demonstrate .

3)Routine
maintenance and
maintain

Annex 10 Training Program 7/11 Contract

 System Content Class Room Field Visit

4) Trouble elimination

Gas analyzer 1) Principle Theoretical training by the Contractor’s engineer

technical personnel will take to the field
2) Debugs and followed by case studies and teaches or
demarcates from service engineers . demonstrate .

3) Routine
maintenance and
maintain

4) Trouble elimination

Kiln shell 1) Principle Theoretical training by the Contractor’s engineer

scanning technical personnel will take to the field
2) Debugs and followed by case studies and teaches or
demarcates from service engineers . demonstrate.

3) Routine
maintenance and
maintain

4) Trouble
elimination.

Dust 1) Principle Theoretical training by the Contractor’s engineer

monitoring technical personnel will take to the field
2) Debugs and followed by case studies and teaches or
demarcates from service engineers . demonstrate .

3) Routine
maintenance and
maintain.

4) Trouble
elimination.

Temperature 1) Principle Theoretical training by the Contractor’s engineer

instrument technical personnel will take to the field
pressure and 2) Debugs and followed by case studies and teaches or
current demarcates from service engineers . demonstrate .
instrument
3) Routine
maintenance and
maintain.

Annex 10 Training Program 8/11 Contract

 System Content Class Room Field Visit

4) Trouble
elimination.

Instrument to 1) Principle Theoretical training by the Contractor’s engineer

level of technical personnel will take to the field
material 2) Debugs and followed by case studies and teaches or
demarcates from service engineers . demonstrate .

3) Routine
maintenance and
maintain.

4) Trouble
elimination.

Vibrating 1) Principle Theoretical training by the Contractor’s engineer

instrument technical personnel will take to the field
2) Debugs and followed by case studies and teaches or
demarcates from service engineers . demonstrate .

3) Maintenance.

4) Trouble
elimination.

Actuator 1) Principle Theoretical training by the Contractor’s engineer

technical personnel will take to the field
2) Debugs and followed by case studies and teaches or
demarcates from service engineers . demonstrate .

3) Routine
maintenance and
maintain.

4) Trouble
elimination.

Operating 1) Daily inspection, Theoretical training by the Contractor’s engineer

system maintenance technical personnel will take to the field
followed by case studies and teaches or
2) Trouble elimination from service engineers . demonstrate .

“ON SITE” TRAINING

Annex 10 Training Program 9/11 Contract

TRAINING PLAN

Description Duration Remarks

Production Processes 3 man x 4 days Instructor. To
1) Raw grinding
be covered in 3 sessions.
2) Pyroprocessing
3) Balance sections

Mechanical General man x 5 days Instructor

Maintenance 1
Electrical General 2 days Instructor
Maintenance 1 man
Automation General man x 3 days Instructor
Maintenance 1
Software 1 man x 12 days Instructor
Programming
Refractory 1 man x 2 days Instructor
management
Process filters 1 man x 1 day Instructor
(EP)
Clinker cooler 1 man x 2 days Instructor
(1) raw mill/kiln bag filter
Process filters 2 man x 1 day Instructor. Two (2) other process bag filters
(Bag Filter) (2) sessions
Fans and Blowers 1 man x 0.5 day Instructor

Kiln Burner and man x 1 day Instructor

precalciner burner 1
Weigh feeders, flow man x 2 days Instructor Including calibration
meter, load cell, belt (manual, automatic)
scale & Weigh-bridge
Bucket elevators, 1 man x 0.5 day Instructor
chain & pan
conveyors
Compressors 1 man x 1 day Instructor
Man elevator 1 man x 0.5 day Instructor
Rotary packer 1 man x 1 day Instructor
Fluid coupling 1 man x 1 day Instructor
Variable Speed 1 man x 1 day Instructor
Drives

Annex 10 Training Program 10/11 Contract

 Description Duration Remarks
MV Switch-gear 1 man x 3 days Instructor Including MV cells
Scanner 1 man x 2 days Instructor
Fire fighting 1 man x 1 day Instructor
detection
Level Meter 1 man x 1 day Instructor
Gas analyzer 1 man x 2 days Instructor
Pyrometer 1 man x 1 days Instructor

Note: Period for all of the above shall be defined in the training Master Plan.

TRAINING EVALUATION
After training, the Contractor shall check and evaluate the trained people, the result of
examination and critique shall be handed over to the Owner directly, and the Contractor
shall offer the suggested name list of the working people to the Owner based on the
examination and critique result.

Annex 10 Training Program 11/11 Contract