EASTERN  MEDITERRANEAN  UNIVERSITYFACULTY OF ENGINEERING

DEPARTMENT OF MECHANICALENGINEERING

MENG400

SUMMER PRACTICE REPORT

Academic Year: FALL 2015

Training Advisor: Assoc. Prof. Dr. Hasan Hacışevki

Submitted By:

Abdullah Awad

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138942

Submitted to the Summer Practice Committee in partial fulfillment of the requirements forthe Summer Practice  Course MENG400

Eastern Mediterranean University

Gazimagusa, TRNC

November/2015

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EVALUATION FORMMENG400

SUMMER PRACTICE

CATEGORIES % OF TOTAL SCORE JURY MEMBERSSCORE

Place and Type of Job Conducted 10

Record and Logbook Keeping 20

Company’s Supervisor Evaluation 20

Report Writing 50

TOTAL SCORE 100%

Note: Passing Score is 65% for Satisfactory “S” Grade

Jury Member 1:. ………………………………. Sign: ……………………

Jury Member 2:………………………….……. Sign: ……………………

Date of Presentation:……../……../ 2013

ContentsChapter 1...........................................................................................................................................................8

Introduction.......................................................................................................................................................8

Chapter 2...........................................................................................................................................................9

Company information........................................................................................................................................9

Chapter 3.........................................................................................................................................................11

Product information.........................................................................................................................................11

3.1 company works and production lines....................................................................................................11

3.1.1 Constructions of building and high ways............................................................................................11

3.1.2 Water and power station....................................................................................................................13

3.1.3 Oil and gas..........................................................................................................................................13

3.1.4 Cement and asphalt plants.................................................................................................................14

3.1.5 INDUSTRIAL SERVICES.........................................................................................................................15

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3.1.6 EQUIPMENT & MACHINERIES.............................................................................................................17

3.1.6 CGCS STANDARD PRODUCTS..............................................................................................................18

3.2 Working mechanism in the company....................................................................................................18

3.3 Management departments and their functions....................................................................................19

3.3.1 PLANNING...........................................................................................................................................19

3.3.2 Organizing...........................................................................................................................................19

3.3.3 Staffing................................................................................................................................................19

3.3.4 Directing.............................................................................................................................................19

3.3.5 Quality Controlling..............................................................................................................................19

3.3.6 Contract Administration.....................................................................................................................20

3.4 Organization of the company................................................................................................................21

3.5 Departments description.......................................................................................................................22

3.5.1 Engineering department.....................................................................................................................22

3.5.2 Human resources department............................................................................................................22

3.5.3 Public relations department...............................................................................................................23

3.5.4 Accounting department......................................................................................................................23

3.5.5 CONTRACTS DEPARTMENT.................................................................................................................23

3.5.6 Project managers department............................................................................................................23

3.5.7 IT Department....................................................................................................................................24

3.5.8 CORPORATE COMMUNICATION DEPARTMENT..................................................................................24

Chapter 4.........................................................................................................................................................25

Work performed...............................................................................................................................................25

4.1 Brief history of cement..........................................................................................................................25

4.2 Safety.....................................................................................................................................................25

4.3 Cement manufacturing process.............................................................................................................26

4.3.1 Uprooting rocks..................................................................................................................................27

4.3.2 Raw materials used in the cement industry.......................................................................................28

4.3.3 Methods of cement industry..............................................................................................................31

4.3.4 Laboratory and quality control in cement industry............................................................................31

4.3.5 Sections of cement factory.................................................................................................................37

4.4Some problems encountered in cement manufacturing processes.......................................................53

4.4.1 Maintenance of mixer:.......................................................................................................................53

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4.4.2Aggregate batching plant switch failure..............................................................................................54

4.4.3 Water pump........................................................................................................................................55

4.4.4 Screw conveyor failure........................................................................................................................55

4.5 Some calibration methods and standards.............................................................................................56

4.5.1 Conveyor Scale Calibration (figure 4.38):............................................................................................56

4.5.2 Test Weights Calibration.....................................................................................................................57

4.5.3 Calibration of aggregate scales...........................................................................................................58

4.5.4Calibration of additives system............................................................................................................58

Chapter 5.........................................................................................................................................................60

PERSONAL DEVELOPMENT......................................................................................................................60

Chapter 6.........................................................................................................................................................61

DISCUSSION/CONCLUSION.......................................................................................................................61

Appendix I........................................................................................................................................................63

Main equipment and machines........................................................................................................................63

Appendix II......................................................................................................................................................73

Tables and charts..............................................................................................................................................73

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Table of figures FIGURE 1  (FIGURE 1.1) COMBINED GROUP COMPANY LOGO 8 FIGURE 2 (FIGURE 2.1) COMPANY SHAREHOLDER 10 FIGURE 3 (FIGURE 3.1) IT IS CONSTRUCTION, COMPLETION AND MAINTENANCE OF ROADS, STORM-

WATER DRAINAGE, SEWER AND OTHER SERVICES FOR SUBIYA HIGHWAY WHICH COST ABOUT 112,000,000 DOLLAR 11

FIGURE 4  (FIGURE 3.2) HEAD QUARTER OF MANPOWER & GOVERNMENT RESTRUCTURING PROGRAM11

FIGURE 5 (FIGURE 3.3)DESIGNS, CONSTRUCTION, COMPLETION AND MAINTENANCE OF MAIN SERVICES WORKS FOR 1,220 PLOTS AND CONSTRUCTION AND MAINTENANCE OF BUILDINGS BLOCK (B) AT JABER AL AHMAD CITY 12

FIGURE 6  (FIGURE 3.4)DESIGNS, CONSTRUCTION AND COMPLETION WORK OF SHEIKH JABERAL SABAH BRIDGE 12

FIGURE 7  (FIGURE 3.5) SUPPLY, ERECTION, OPERATION AND MAINTENANCE OF GAS TURBINE POWER GENERATING UNITS AT SUBIYA POWER STATION WATER DISTILLATION PLANT SITE 13

FIGURE 8 (FIGURE 3.6)SUPPLY AND CONSTRUCTION AND MAINTENANCE OF 4 X 1600 MM DISTILLED WATER PIPELINES FROM AZZOUR NORTH DISTILLATION PLANT TO AZZOUR WDC II MEW/MC/4491-2012/2013 (DUCTILE PIPES) 13

FIGURE 9  (FIGURE 3.7)CONSTRUCTION OF CRUDE EXPORT LINE, INCOMING GROUP PRODUCTION FEEDERS AND PIPELINES TO NEW GC16 AND NEW EFFLUENT WATER LINE TO MWIP WEST KUWAIT

13 FIGURE 10 ( FIGURE 3.8)CONSTRUCTION OF FLOW LINES AND ASSOCIATED WORKS NORTH KUWAIT

FIELDS 14 FIGURE 11 (FIGURE 3.9)CEMENT PLANT 14 FIGURE 12 (FIGURE 3.10)ASPHALT PLANT 14 FIGURE 13 (FIGURE 3.11)COMPANY ORGANIZATION CHART 21 FIGURE 14  (FIGURE 4.1) CEMENT MANUFACTURING PROCESSES 26 FIGURE 15   (FIGURE 4.2)RAW MATERIALS INCLUDED IN CEMENT INDUSTRY 28 FIGURE 16 (FIGURE 4.3)LIMESTONE 28 FIGURE 17 (FIGURE 4.4)GYPSUM 29 FIGURE 18   (FIGURE 4.5) SAND 29 FIGURE 19  (FIGURE 4.6) PURE LIMESTONE 30 FIGURE 20 (FIGURE 4.7)  BUZOLANA 30 FIGURE 21 (FIGURE 4.8) IRON SLAG 30 FIGURE22 (FIGURE 4.9) CHEMICAL LABORATORIES IN CEMENT PLANT 32 FIGURE 23 (FIGURE 4.10) BLAINE DEVICE USED TO MEASURE SMOOTHNESS OF CEMENT 33 FIGURE 24 (FIGURE 4.11) VECAT DEVICE USED TO MEASURE THE STRUCTURE OF CEMENT 34 FIGURE 25 (FIGURE 4.12) AUTOCLAVE OR USHATHELET DEVICES USED FOR STABILITY TEST 35 FIGURE 26 (FIGURE 4.13) AAZORIM DEVICE USED FOR COMPRESSIVE TEST 36 FIGURE 27  (FIGURE 4.14) LIMESTONE QUARRY 37

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FIGURE 28 (FIGURE 4.15) HAMMER CRUSHER 38 FIGURE 29 (FIGURE 4.16) RAW MEAL DRYER 39 FIGURE 30 (FIGURE 4.17) RAW MATERIALS STORAGE AND ADDITIVES PAR 40 FIGURE 31 (FIGURE 4.18) CONVEYOR BELT AND PILES OF CRUSHED MATERIAL USED IF THE CRUSHER

STOPS WORKING 40 FIGURE 32 (FIGURE 4.19) PILES OF CRUSHED RAW MEALS 41 FIGURE 33  (FIGURE 4.20)  RAW MATERIAL MILLING MACHINE 41 FIGURE 34  (FIGURE 4.21) MIXING AND STORAGE TANKS BEFORE HEAT TREATMENT 43 FIGURE 35 (FIGURE 4.22)  PREHEATER TOWER 44 FIGURE 36 (FIGURE 4.23) PREHEATER TOWER EXPLANATIONS 45 FIGURE 37 (FIGURE 4.24)  ROTARY KILN 46 FIGURE 38 (FIGURE 4.25)  ROTARY KILN COMPONENTS 46 FIGURE 39 (FIGURE 4.26) CLINKERS BEFORE ENTERING THE COOLER 47 FIGURE 40  (FIGURE 4.27) GRATE COOLER 48 FIGURE 41 (FIGURE 4.28) GRATE COOLER SKETCHES 48 FIGURE 42 (FIGURE 4.29)  CLINKER STORAGE SILOS 49 FIGURE 43 (FIGURE 4.30) CLINKER WITH GYPSUM MILLING 50 FIGURE 44 (FIGURE 4.31) CLINKER MILLING MACHINE 50 FIGURE 45 (FIGURE 4.32) CEMENT SILOS 51 FIGURE 46 (FIGURE 4.33) PACKAGING OF CEMENT IN BAGS 52 FIGURE 47 (FIGURE 4.34) CEMENT MIXER 53FIGURE 48  (FIGURE 4.35) CONTROL SYSTEM FOR INSPECTION OF MIXING PARTS AND ERROR

INVESTIGATING 54 FIGURE 49  (FIGURE 4.36) WATER PUMP FOR THE MIXING TANK 55 FIGURE 50  (FIGURE 4.37) SCREW CONVEYOR BROKEN SHAFT 55 FIGURE 51  (FIGURE 4.38) CONVEYOR BELT CALIBRATIONS 56 FIGURE 52 (FIGURE 4.39) CONTROLS AND MONITORING OF ADDITIVES AND MIXING SYSTEM 58 FIGURE 53 (FIGURE I.1) GENERAL VIEW 63 FIGURE 54 (FIGURE I.2) LIMESTONES (SECOND CRUSHING) 63 FIGURE 55 (FIGURE I.3) CRUSHED LIMESTONES CONVEYOR BELT 64 FIGURE 56 (FIGURE I.4) LIMESTONES SILOS AND ADDITIVES BEFORE MILLING 64 FIGURE 57 (FIGURE I.5) RAW MEAL DRYER MACHINES 65 FIGURE 58 (FIGURE I.6) RAW MEAL GRINDING 65 FIGURE 59  (FIGURE I.7) PREHEATER TOWERS 66 FIGURE 60  (FIGURE I.8) ROTARY KILN 66 FIGURE 61  (FIGURE I.9) GRATE COOLER 67 FIGURE 62  (FIGURE I.10) IN THE LEFT SIDE COOLING SECTION, THE RIGHT SIDE CLINKER STORAGE

SILOS 67 FIGURE 63 (FIGURE I.11) CLINKERS MILLING AFTER ADDING GYPSUM 68 FIGURE 64 (FIGURE I.12) CEMENT STORAGE AND FILLING 68 FIGURE 65 (FIGURE I.13) CEMENT BAGS 69 FIGURE 66 (FIGURE I.14)  PLANT CONTROL CABIN 69

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FIGURE 67  (FIGURE I.15) AGGREGATE WITH GRINDING BALL FOR TESTING IN THE LOS ANGELES TESTING MACHINE, 70

FIGURE 68 (FIGURE I.16)  THIS MACHINE ROTATES ABOUT 30-33 ROTATIONS PER MINUTE, IN THIS TEST WE WILL SET THE LOS ANGELES MACHINE TO 500 REVOLUTIONS 70

FIGURE 69 (FIGURE I.17)  AGGREGATE SCALING AFTER MILLING 71 FIGURE 70  (FIGURE I.18) SIEVE ANALYSIS 71 FIGURE 71  (FIGURE I.19) AWARDS AND CERTIFICATES 72 FIGURE 72  (FIGURE II.1) AGGREGATE TESTS 73 FIGURE 73   (FIGURE II.2) SIEVE ANALYSIS CALCULATION FOR COARSE AGGREGATES (ASTM C136)

74 FIGURE 74   (FIGURE II.3) COARSE AGGREGATE SPECIFICATIONS (ASTM C33) 74 FIGURE 75  (FIGURE II.4) COARSE AGGREGATES PERCENTAGE PASSING GRAPH. 75 FIGURE 76  (FIGURE II.5) MIN, MAX AND SAMPLE GRAPH FOR FINE AGGREGATES 75 FIGURE 77  (FIGURE II.6)  SILO CAPACITIES 76

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Chapter 1

Introduction

Figure 1 (figure 1.1) combined group company logo

Summer training is the way you can learn about the real world jobs and how you can link whatever you done with your knowledge from your academic education.I applied for one of biggest companies in the Arabian Gulf which is for contracting and development in many fields.Combined Group Contracting Company (CCGCC) is perseverance, diligent work, non-stop development and improvement; a focus on quality and customer satisfaction, the company became a publicly traded shareholding company.It constantly moved from strength to strength over the past five decades. Company staff is

among who are some of the finest names in the contracting industry in the Arab world.

In those 40 days training I met a very Collaborator people who helped me to accomplish my training and I liked their helping, accuracy, experiences, speed and team work which provide sweetness in the department.In this practice days the most important knowledge I have it in this plant it comes from manufacturing course which provide a very important basics for different production procedure and machines that is nearly the same in the company plant.I enjoyed this experiment and I will introduce in next chapters some detailed information about the company and the work which I done their and how we can improve this experiment in real fields next years.

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Chapter 2

Company information

Belief, vision, common sense, hard work, professionalism, collaboration, cooperation, the desire to make things possible, and common mutual interest among company people, alliances, suppliers, customers (Private and government sectors) are behind their humble, and continued growth.Combined Group Contracting Company (CCGCC) was established on 15th November, 1965 in Kuwait as a limited liability company with a paid up capital of KD 7,500. With perseverance, diligent work, non-stop development and improvement, a focus on quality and customer satisfaction, the company became a publicly traded shareholding company with a paid up capital of KD 11,160,834/ approximately US$ 40,000,000. The total revenues reached almost KD 155,000,000 /- in 2013, and CGCC has constantly moved from strength to strength over the past five decades. Staffs are currently over 10,000 employees and more than 50 mechanical engineers in different fields, among who are some of the finest names in the contracting industry in the Arab world.Activities now span the oil sector where they have become main contractors for pipelines for companies like Kuwait Oil Company and the Joint Operations. In the roads and infrastructure sector, they are currently executing several large projects including the Subbiya Highway in Kuwait, and the Northern Industrial Area in North Doha, Qatar. CGCC has the highest degree of specialization in the Roads and Infrastructure sector from bridges to tunneling; CGCC is a dominant force in the industry in the region. The company is also executing several large road

and infrastructure maintenance projects in Kuwait.

They also possess the expertise to deliver the large and complex projects with the ability to

efficiently employ resources, manpower and equipment in Kuwait and international markets

CGCC has been steadily growing, and year on year have won a number of significant projects which include building construction, infrastructure and oil related development projects. The total value of projects executed between 2004 and 2009 was in excess of KD 555 million (US$ 2,054,000,000)CGCC was awarded ISO certification 9001:2000. This was updated in November 2009 to ISO 9001:2008. Also in 2009 CGCC was awarded ISO 14001:2004 for Environmental Management Systems, and OHSAS18001:2007 for Occupational Health and Safety Management.Combined Group Contracting Company expanded into the international market since 1999. CGC has executed projects in various areas totaling approximately 167 Million Dollars. The projects span to such countries as Indonesia, Tajikistan, Mongolia, Uzbekistan, Georgia, and Lebanon. Currently CGCC is active in Lebanon and Albania executing Roads and bridges

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projects.

Clients of the company in Kuwait, Qatar and emirates:Ministry of Public Works, Kuwait Oil Company, Kuwait Oil Gulf Company, Ministry of Electricity and Water, Public Authority for Housing Welfare, National Guard, Ministry of Health, Ministry of Oil, Kuwait Petroleum Company, Central Tenders Committee, Ministry of Energy & Industry, Qatar Petroleum and others.The Group Shareholders:

Figure 2 (figure 2.1) company shareholder

Combined Group Contracting CompanyAddress: Block No. 2, Plot No. 284Al Ardiya Industrial, State of KuwaitMailing Address: P.O. Box: 4819, Safat 13049, KuwaitTelephone: (965) 22254545Fax: (965) 24344610 – (965) 24344686Email: info@cgc-kw.com.

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Chapter 3

Product information

3.1 company works and production lines

Combined Group Contracting Company has proudly achieved a high degree of customer satisfaction in over 250 completed projects during the past 25 years. The company has completed and ongoing projects with both private and government sectors in many countries in the Gulf region, the Middle East, and Asia.

3.1.1 Constructions of building and high ways

In the Construction sector, CGCC has completed major buildings in Kuwait, some of which have become homes to prestigious educational institutions. CGCC has also accomplished the construction of an outstanding governmental housing projects and different projects in different areas as shown in the (figures 3.1 - 3.10).

Figure 3 (figure 3.1) it is Construction, completion and maintenance of roads, storm-water drainage, sewer and other services for Subiya Highway which cost about 112,000,000 dollar

Figure 4 (figure 3.2) Head Quarter of Manpower & Government Restructuring Program

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Figure 5 (figure 3.3)Designs, Construction, Completion and Maintenance of Main Services Works for 1,220 Plots and Construction and Maintenance of Buildings Block (B) at Jaber Al Ahmad City

Figure 6 (figure 3.4)Designs, Construction and Completion Work of Sheikh JaberAl Sabah Bridge

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3.1.2 Water and power station

Figure 7 (figure 3.5) supply, erection, operation and maintenance of gas turbine power generating units at subiya power station water distillation plant site

Figure 8 (figure 3.6)Supply and construction and maintenance of 4 x 1600 mm distilled water pipelines from azzour north distillation plant to azzour wdc ii mew/mc/4491-2012/2013 (Ductile Pipes)

3.1.3 Oil and gas

Figure 9 (figure 3.7)Construction of crude export line, incoming group production feeders and pipelines to new GC16 and new effluent water line to MWIP west Kuwait

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Figure 10 ( figure 3.8)Construction of flow lines and associated works north Kuwait fields

3.1.4 Cement and asphalt plants

Figure 11 (figure 3.9)Cement plant

Figure 12 (figure 3.10)Asphalt plant

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3.1.5 INDUSTRIAL SERVICES

The CGCS Facilities Management − Industrial Services business line delivers multi-disciplinary services to a wide range of industries in mechanical, electrical, instrumentation and controls, communication, water and wastewater applications. This business unit is a leading one-stop-shop for industrial services including plant operation, maintenance and solutions. It undertakes plant operation and maintenance (O&M), key performance indicator (KPI) based maintenance, annual and long-term maintenance, proactive, preventive and shutdown maintenance on a full responsibility basis, modernization, modification and extension works, retrofits, refurbishment and repair works, emergency repair works, and scaffolding services, and delivers systems and solutions. These services are offered to all industrial facilities and clients.Industrial services have a presence in the following industrial sectors:1- Oil and gas (up-stream and down-stream).2- Petrochemicals.3- Power (power plants and desalination plants).4- Power transmission and distribution.5- Water (pumping and lifting stations, booster stations and water networks).6- Wastewater (sewage treatment, reclamation plants, pumping and lifting stations, and

wastewater networks).7- Civil Infrastructure, such as road and storm-water drainage networks.8- O&M and multi-disciplinary service contracts for BOT, BOOT, BOO and PPP

infrastructure projects.9- Infrastructure and other industries.The delivery of Industrial Services operations has been organized into several service disciplines:1- Industrial maintenance:- Industrial maintenance services for all industries.- Complete shutdowns – on a full responsibility basis, including general refinery turn-

arounds (GRTAs).- Unit shutdowns – on a full responsibility basis.- Scaffolding services.2- Mechanical:- Boilers, heat exchangers and cooling systems.- Air pre-heaters.- Maintenance, servicing and overhaul of stationary equipment.- Maintenance, trouble-shooting and overhaul of rotary equipment.- Catalyst and life support management.- Hydro jetting and hydro testing.- Valves, valve reconditioning and installation.- Surface preparation and protection.- Filters.

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- Insulation services.- Specialized services.- Piping fabrication, modification and welding services.3- Electrical:- EHV sub-stations, GIS switch gears.- MV & LV sub-stations, distribution systems, RMUs.- Transformers (power and distribution).- Overhead transmission lines.- Power cables (EHV, HV, XLPE).- Switchgear services.- Motors and drives (soft-starter and VFD) services.- Street lighting services.- Sub-station protection.- Energy/smart metering, AMR solutions.- Event logger, fault recording, earthling systems.4- Instrumentation and controls (I&C):- DCS, PLC, SCADA, management information systems (MIS).- Analyzer technology and emissions monitoring.- Water analytic systems.- Flame scanner and combustion detection.- Performance and condition monitoring.- DC systems, i.e. PS, batteries and chargers, and LV systems.- Substation controls, automation/SCADA.- Firefighting maintenance.5- Communication:

*Wireless networks:- Satellite communication services.- Microwave and digital radio networks.- GSM and CDMA cellular networks.- VHF, UHF – conventional and trunking radio networks.- Broadband solutions – LAN/WANS and VPN networks.- Fleet management technology and special solutions.

*Wire line networks:- Fiber-optic metro and long-haul networks.- Broadband solutions.- PABX, VOIP and billing platforms.- Security and SCADA networks.- Inside and outside plant systems.- Camera surveillance, CCTV and recording services.

6- Sewage works & water networks:- Sewage treatment and reclamation plants.

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- Pumping stations, lifting stations and booster stations.- Water and wastewater network maintenance services, modification and repair works.- Desalination and water treatment services.- Water purification and filtering.- Civil repair of box culverts, sea outfalls and pipe-line repairs.Other activities:Electro-Mechanical and Civil works for Oil Gas field projects, EPC project handlers (Oil Gas sector), Fabrication of Piping Spools and Manifolds, Engineering Services for Fired Heaters and Boilers, Reciprocating Compressor overhaul and refurbishment, Pipelines and Piping

Installation, Plant; Equipment installation, Storage Tanks, Shut Down activities, Structural

Steel installations, Road; Infrastructure work, Civil construction; maintenance jobs, RO Water Treatment plants, Drinking water plants, Waste Water Treatment plants, Power Generation units, Pumps, Water Supply; Drainage system, HVAC units.

3.1.6 EQUIPMENT & MACHINERIES

CGCS Duct Fabrication Workshop is equipped with various ranges of latest automation machines especially for HVAC duct works fabrication. Our improved machinery and construction makes for outstanding performance for our products with quick and accurate production. Our latest machineries helps us to facilitate our customers with high standard HVAC ducting products with exceptionally low leakage and extremely efficient.

Major Equipment’s:- Fully automated coil line.- Computerized plasma cutting machine, with two cutting beds.- Spiral welding machine.- Stich welding machine.- TDF roll forming machine.- Pittsburg & pocket joint roll forming machine.- Cleat former machine.- Shearing machines.- Electrical folding machine (Adjustable degree).- Press break bending machine.- Spot welding machine.- Flanging machine.- Round rolling machine.- Elbow making machine.- Swaging machine.

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3.1.6 CGCS STANDARD PRODUCTS

- Square and rectangular ducts and fittings.- Round spiral duct and fittings.- Fire rated ducts.- Volume control dampers.- Motorized dampers.- Sound attenuators.- Sand trap louvers.- Pressure relief dampers.- Plenum boxes.- Access doors and etc.

3.2 Working mechanism in the company

Each project that the company signed has it is own procedure, but the general procedure as follow:

1- When the company signed a contract the first step is done by the engineering departments to study if it is possible to accomplish it, the cost, difficulties, design, and the duration they need to complete it. After that those studies are sending to accounting department to figure out the overall final cost and the benefit to the company.

2- Contracting department show the final price to the client and discuss about it.3- If the client accepts that, the company head and their members provide the project

manager with the regulations and he starts the preparation for the project.4- Engineers, technician and foremen preparing the work site and the material, cars,

machines…etc.5- The first engineering department (civil engineer) starts the basic things such as preparing

the basis, safeties and the structure need to be done.

6- Some parts of the project can be made in the company workshop, if it is not possible

they can order it from markets.7- They put all of those parts of the structure in the site and starts to fit it, assembly and

examinations.8- If everything is according to the project regulations and standards they submit it to the

client.

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3.3 Management departments and their functions

3.3.1 PLANNING

The basic functions of the department’s planning engineers are:1- establishing the work breakdown structure of the project2- preparing the project plan and schedule3- establishing the reporting system for the project in line with company procedures4- collecting data and preparing daily, weekly and monthly reports

5- Analyzing productivity.

3.3.2 Organizing

The department operates on a matrix organizational structure. Project control staff members are imbedded in the project organization but are linked functionally to the department, enabling Project Control Services to achieve a high consistent quality in the services it provides to projects.

3.3.3 Staffing

The company has different staff ranging according to the project needs such as civil engineer, mechanical, electrical, industrial, accountants, foremen and workers.

3.3.4 Directing

The orders come from general manager who supervise project manager, the last in turns supervise the engineers and this operation continue until the final workers in the company.

3.3.5 Quality Controlling

Before construction activities begin, quality control staff members gain an understanding of the requirements in the project specifications and applicable design codes and then create an effective quality control system for the project. Inspection and test plans (ITPs) are designed in such a way that at each stage verification and measuring activities can be carried out to ensure that results are within specified limits or tolerances to prevent costly re-working. During project execution, quality control staff routinely monitor activities rather than waiting for a problem to appear.

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3.3.6 Contract Administration

The basic function of contract administrators is to monitor payments and correspondence concerning contracts and to advise project managers on contractual matters.Subcontract agreements are prepared by contract administrators in coordination with the on-site project teams. The draft forms of subcontracts, as well as associated review forms and checklists, are reviewed by the contracts administration manager or the project controls services director.Where the projects are re-measurable, the contracts administrator also maintains accurate work-in-progress records and a record of the final account as agreed with the client. These records are updated daily and are used to prepare applications for payment and to prepare payments to subcontractors.

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3.4 Organization of the company

Figure 13 (figure 3.11)company organization chart

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3.5 Departments description

3.5.1 Engineering department

The Engineering Services Department provides the company’s projects in the commercial and industrial, petroleum, chemical and power sectors with a full range of engineering services from conceptual design to procurement and construction. However to service CGCS overseas projects, the Engineering Services Department has satellite offices in Qatar, Abu Dhabi and Dubai in the UAE.In these offices, the department prepares drawings of existing facilities. It designs and produces shop drawings for all mechanical, electrical and plumbing works to be undertaken by CGCS. It details pump rooms, substations and HT rooms and produces composite drawings and builders’ layouts. The Engineering Services Department also produces piping layouts and isometrics, the detailing of pipe supports and test packages. It creates fabrication drawings for piping, industrial steel and pressure vessels. The department produces material take-offs to assist the tendering and procurement departments. It coordinates with sites and consultants to resolve design inconsistencies and prepares as-built drawings.

3.5.2 Human resources department

The goal of CGCS Human Resource Department is to advance the overall mission of the company through the acquisition, retention, and support of qualified, skilled and competent staff. HR achieves its objectives by recruiting, employing, retaining, and developing staff and by maximizing excellent employee relations and excellent personal and group performance through internal consulting, problem resolution, and the provision of efficient, cost-effective, customer-responsive human resource services.Strategic Directions:

1- To promote and support recruiting strategies and collaborate with departments, projects and customers to create a high performing, diverse workforce.

2- To respond to the needs of the company and its customers in a helpful, supportive, and pro-active manner and provide "quality" services on which can be relied upon.

3- To respond appropriately, creatively, effectively and timely with policy and procedure changes.

4- To develop staff excellence through training and consultation for employees that encourages growth and opportunity and fosters good, open communication and an overall positive work environment for all employees.

5- To equitably and fairly administer company policies, procedures, and benefits.The most common Human Resource jobs that are grouped in the Human Resource Department are the Human Resources Director, Human Resources Manager, Human Resources Generalist,

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and Human Resources Assistant.

3.5.3 Public relations department

It is the practice of managing the flow of information between the organization and its public. It is the planned and sustained effort to establish and maintain goodwill and mutual understanding between organization and its public. The company has good relationships with different public ministries and private clients in Kuwait and around the world.

3.5.4 Accounting department

The functions of this department are as follow:-Money out: making payments and keeping the bills paid.-Money in: processing incoming payments.-Payroll: make sure everyone gets paid (including the government).-Reporting: preparing financial reports, e.g. P&L, Balance sheets and budgets.-Financial Controls: to avoid errors, fraud and theft.

3.5.5 CONTRACTS DEPARTMENT

The Contracts Department is responsible for negotiating and agreeing a variety of other agreements, prior to review by the Legal Department, such as agency, distributorship, value added re-seller, consultancy, and joint venture, consortium, and shareholder agreements. For each of these types of agreements, Contracts has established standard terms to which it always tries to adhere.

3.5.6 Project managers department

The primary functions of a Project Manager vary from company to company but they all revolve around managing the four basic components of a project, namely resources, time, budget, and scope.Some general functions are:-To act as a liaison with the client and/or with top management.-To coordinate the process from start to end.

3.5.7 IT Department

The IT Department was established to implement, monitor and maintain CGCS data network,

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computer systems, servers, and business applications. As the company has expanded and prospered, the use of IT has evolved significantly and the department now offers services and supports in the field of information technology to all other departments and to CGCS numerous projects.IT Department is divided into two units:

- Management Information System Unit- Technical Support Unit

3.5.8 CORPORATE COMMUNICATION DEPARTMENT

The department supports the various businesses of the company in building and communicating the right corporate messages that reflect the vision, mission and values of CGCS and sustain its culture and reputation.It is divided in two units:

1- Branding Unit:The Branding Unit is responsible for the entire process involved in creating and designing all the company’s advertising materials schemes offline and online to accord with and facilitates the attainment of the business objectives. The Unit also maintains and controls the persona of the company to ensure the continuity in the quality of the company’s image and that it is coherent at all levels of business.

2- Events Management Unit:The Events Management Unit is responsible for coordinating and organizing events, conferences and sponsorships in all the business industries CGCS operates in. The Unit is involved from the concept phase through to the completion stage assuring the alignment of the events with the company’s vision and mission.

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Chapter 4

Work performed

CGCS has different works in many fields such as buildings, streets and highways, oil and gas services, asphalt and cement plant. I choose cement plant and attend all the procedure of cement manufacturing from raw materials to packaging. Next I will explain all the details in this plant and what technologies are used.

4.1 Brief history of cement

Concrete is an extremely versatile material, being used in the production of anything from nuclear radiation shields to playground structures and from bridges to yachts. It is able to be used in such a wide variety of applications because it can be poured into any shape, reinforced with steel or glass fibers, precast, colored, has a variety of finishes and can even set under water. Modern concrete is made by mixing aggregate (sand, stones and shingle) with cement and water and allowing it to set of these ingredients. Cement is a fine grey powder which when reacted with water hardens to form a rigid chemical mineral structure which gives concrete its high strengths. Cement is in effect the glue that holds concrete together. The credit for its discovery is given to the Romans, who mixed lime (CaCO3) with volcanic ash, producing a cement mortar which was used during construction of such impressive structures as the Colosseum. When the Roman Empire fell, the information on how to make cement was lost and was not rediscovered until the 16th century.

4.2 Safety

Occupational safety strategy is in three elements:1- Worker is come first place to keep his effective, creative and able to perform the practical duty

on what should be done.2- Established the basic unit of industrial (economic) which is directly linked to the production

processes in addition to securing better standard of living for a worker Production.3- Product quality and quantity

Occupational Safety definition:Is the branch of a total of the basic knowledge of systems and measures under which the worker protection and the establishment of the potential dangers and injuries on the job.

Occupational safety goals:

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- Study of factors affecting the health and production rights.- Studying the reality of working machinery and materials used in production and its impact on

human health.- Develop procedures to remove the harmful elements in human beings and in line with the

importance of increasing the yield of the production facility.

4.3 Cement manufacturing process

Figure 14 (figure 4.1) cement manufacturing processes

The cement industry is usually divided into three groups:1- Production2- Production Service3- General Service

ProductionSection that is includes raw materials in various stages of production from side and exit from another side contrary to what they used to be physically or chemically, or both.

Parts of the production department:- Quarry- Crusher- Stacker/Reclaimed- Dryer- Raw mill- Final Mixing

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- Kiln- Cement mill- Packing House

Direct production aid sections:The sections that provide direct production diverse sections in order to aid the completion of its work to the fullest.

Parts of direct production aid section:- Work shop- Electrical- Instruments- Desalination- Power Plant- Laboratory- Civil service

Cement manufacturing stages:- Refer to (figure 4.1); the stages are as following:1. Uprooting rocks.2. Jackhammers.3. First mixing broken rock.4. Drying crushed material (if needed).5. Grinding crushed materials required proportions.6. Blending and homogenization of milled material.7. Creating materials for burning.8. The burning of heterogeneous materials and put up for the production of clinker.9. Clinker cooling.10. Clinker storage.11. Clinker grinding with the addition of gypsum.12. Storage of cement.13. Packing and storage of cement.

4.3.1 Uprooting rocks

- Uprooting rocks without bombing, by using multiple machines.- Cliff and packing the rocks.- Transfer of rock by truck (dampers).- Placed rocks in the quarries.

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4.3.2 Raw materials used in the cement industry

Figure 15 (figure 4.2)raw materials included in cement industry

The first group (basic):Is the group that cannot form a mixture without one of its elements, It is divided into:

1. Limestone (CaCO3) as shown in (figure 4.3)

Figure 16 (figure 4.3)limestone

Is responsible for providing a compound (CaO) necessary to interact inside the oven, and enters the lime stone by almost 75% in the mix materials.

2. ClayIntervention by 25%, which is responsible for providing three compounds, namely:

- Silica SiO2- Alumina Al2O3 - Iron Oxide Fe2O3

Place added: mill raw materials Second Group (modified or corrected):

Are substances that are added to the basic groups in the case of a lack of mud to a oxides

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((SiO2 - Al2O3 - Fe2O3 ((- Addition in order to remove deviation in mud compounds- Add a few percentages, because the concentration of the modified material is very large.- Place of Addition: in the raw material mill Third group (additives):

It is divided into:1. Mandatory:

Figure 17 (figure 4.4)gypsum

Material: gypsum as shown in (figure 4.4).Place added: cement mill.Addition amount: 5-3% of the proportion of clinker.The goal of the addition: adding gypsum with clinker in cement mills to regulate the Cement sclerosis time (any delay sclerosis time), which is known as the "time of uncertainty."The index to add gypsum: SO3 ← shall be increased by 1.5-2.5%.

2. Optional:- Sand as shown in (figure 4.5).

Figure 18 (figure 4.5) sand

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- Pure lime as shown in (figure 4.6).

Figure 19 (figure 4.6) pure limestone

- Buzolana. as shown in (figure 4.7)

Figure 20 (figure 4.7) buzolana

- Iron slag as shown in (figure 4.8).

Figure 21 (figure 4.8) iron slag

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Objectives of additives:- For manufacturing of other types of cement.

- Reduce the cost in order to compete.

4.3.3 Methods of cement industry

As is well known, there are three ways the cement industry:1. Wet method.2. Dry method.3. Half Dry method

In CGC the method use is the dry method. Dry method:

It is the way it had been widely used after the Second World War to replace the wet method and half dry method due to a variety of reasons, especially the high percentage of water in the meal feeding the furnace and the large energy consumption resulting from the evaporation of the water, that helped in technological advances in the cement industry in this area.Mixed materials that feed the furnace in the dry way are crushed, soft and dry so that the moisture content is not more than the 1% which makes this method is economically the most capable and the most widespread.

The most important characteristics of the dry method are summarized in the following:- Energy saving where modern furnaces consume less than 800K.kalori /1 kg of clinker.- High productivity, especially furnaces with large diameter.- Ability to control the best attributes of the product, whatever the nature of the materials.- The possibility of applying the prior calcination of materials system, helping to increase

production capacity and reduce the length of the oven.- Ensure the safety better for the environment.

4.3.4 Laboratory and quality control in cement industry

If the oven is heart of the factory, the lab is the mind that flows into sections production quality standards has to be reported for cement within the specifications and standards. It was an integral part laboratory to conduct all of the tests required to assess the product and correct deviations in the various stages of production and analysis, in addition to the tests and analyzes which specializes in quality control and quality assurance.

Sections and functions of the laboratory1. The chemical laboratory:- Analysis of various samples of raw materials (limestone, mud, sand, iron ore, Bozzolana,

gypsum, bauxite etc. ........ of different chemical analyzes as shown in ( figure 4.9 ).- Analyzes of material fed into the furnace (total oxides).

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- Analyzes of cement (total oxides).- Analyzes of clinker (calcium oxide - Iron Oxide - aluminum oxide - silica – magnesium oxide-

Lime oxide free - burning waste - non-soluble substances - chlorides and alkali if necessary.- Calculated values and factors for mixing materials fed to the kiln, clinker and cement.- Record the results in their own records.- Prepare the necessary solutions and reagents.- Identify own constants intravenously manufacturer.- Record all information intravenously in their records.- Open a special register preparation and consumption.- Supervision of the insurance and analysis of distilled water.

Figure22 (figure 4.9) chemical laboratories in cement plant

2. Department of Physical and mechanical tests:This section is for the necessary tests according to standard adopted for various physical and mechanical tests of Portland cement, and I will mention the most important supported analyses:

Smoothness test:This test is conducted to estimate the smoothness of cement expressed in specific surface area, which is defined as the total surface areas measured in centimeters squared to cement particles in one gram. The device is called ( Blaine ) as shown in (figure 4.10) for purpose of air permeability.

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Figure 23 (figure 4.10) Blaine device used to measure smoothness of cement

- Principle method:Determine the specific surface area of cement by measuring the passage of time it takes for a given volume of air within a specific layer of cement with certain permeability.

- Devices used:Device / Blaine / is used for air permeability, the device consists of the following main parts:

1. Manometer glass.2. Cell permeability / cylinder of glass or metal from non-corrosive /3. Disk regularly perforated metal from non-corrosive.4. Piston of glass or metal from non-corrosive.5. Circular nomination average porosity paper.6. Stopwatch. Identify the standard textures to cement paste:

This method is competent to set the amount of water required for the formation of standard-strength cement paste used in each of the test time of uncertainty, and test the stability of size.

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Figure 24 (figure 4.11) Vecat device used to measure the structure of cement

Definitions:- The time required to start sclerosis:

It is the period of time between the moment of adding water to dry cement and the moment of entry by force of Vicat needle Device as shown in (figure 4.11) in paste of cement to a distance of not more than 5 mm from almost Vicat mold base.

- The time needed to end sclerosis:Is the period of time between the moment of adding water to dry cement and the moment in which Vicat needle Device left impact in the cement paste without appears the impact of on the base ring installed around the needle.

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Stability test ( expansion )

Figure 25 (figure 4.12) Autoclave or Ushathelet devices used for stability test

Used device called ( Ushathelet ) as shown in (figure 4.12) for this purpose, cement stability test is measured by the expansion of the size of a standard cement paste under certain circumstances. Ushathelet a device used to measure the expansion of the cement paste. The device basically consists of a cylinder made of copper alloy with flexible or any suitable metal, a wall thickness of 0.5 mm, and 30 mm internal diameter. A height of 30 mm, and longitudinally notch installed on both ends, on each notch two indicators tapered tip. Also there is a device for this purpose called ( autoclave ), measure the stability of cement by change in length of the samples of cement after treatment with steam in this device under test pressure (20 kg / cm) and temperature (215 meters) for three hours.

- Devices used:- Templates:

Consists of a metal is susceptible to cement, and its parts solid and coherent to prevent leakage and non-curvature when linking.

- Autoclaveconsists of a high pressure steam drum, where there is a place to put thermometer provided with automatic controller valve, pressure gauge, and safety valve, and valve ventilation allows air exit when heated start, also allows the release of the vapor pressure remaining at the end of the cooling period in addition to the availability of other conditions.

- Height Measure Device:The machine is valid to measure the length exceeds + 0.05 mm and be equipped with a steel rod for calibration.

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Pressure resistance test:

Figure 26 (figure 4.13) Aazorim device used for compressive test

Is used for this purpose device called ( Aazorim ) as shown in (figure 4.13) and pressurized samples (cubes) taken from test bending resistance until the fracture and compressive strength are calculated from the following equation: D = the crush load / actual area under to pressure.

3. shifts Laboratory:Laboratory functions are distributed as follows:

A. Analyzes and tests:- Analysis of total carbonate.- Test the smoothness of cement / Blaine /.- To measure the weights of clinker / specific weight /.- Grinding and drying and preparation materials to be analyzed.- Measurement of moisture in the various stages of production.- Record the results of tests in the designated records.- Delivery test results directly to the competent departments.

B. Bring samples from:

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- Blending and storage silo.- Raw materials half and final manufactured.- Product of milled materials.- Material fed to the furnace.- Products of clinker cooler.- The entrance to the cement mills.- Products of the cement mills.- Cement sold.

4.3.5 Sections of cement factory

Crushing section

Figure 27 (figure 4.14) limestone quarry

Crushers functions are reduction of large volumes of rock and turn it into a small size (2.5 - 3 cm) as shown in (figure 4.14) to match the technology with the subsequent sections in addition to facilitate the transfer of materials and trading with them as well as to facilitate the work of the mill.

- Hammer crusher parts:

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Figure 28 (figure 4.15) hammer crusher

A. Crusher hopper.It is a wide at the top and narrows at the bottom, its structure consist of steel or reinforced concrete, interior section is covered with steel plates for protection against cracking and breaking.

B. Crusher structure.Consists of two cylinders and all axes carrying several hammers and varies weight depending on the crusher, so those cylinders spin down cut, where materials crushed by hammer and by collision materials to each other, in terms of materials come out of the bottom of the breaker with small sizes required.

C. Filter screen.Is a filter that works to grab stuck in the air dust, resulting from crushing so that a filter reserves dust within and empties automatically via the spiral metal conveyor to the main carrier of the crusher so that this dust (fine dusts) are associated with the crushed material to the initial mixing fields and filtering process resulted well, so that air comes out clean to the outside air through the chimney slightly from very fine dust.

D. Various conveyorsConveyors are metal or rubber and designed to transfer material from one stage to another. These are designed to accommodate a previous phase. For example, the metal conveyor in bottom of the hopper has been designed to withstand the pressures of large volumes of rock. All parts are shown in (figure 4.15).

Drying sectionUsed to drying high humid materials, partly or all, according to absorbed moisture, are commonly used in clay drying. Enter moisture about 8-9% and 2-3% moisture that exit.

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- Dryer parts:

Figure 29 (figure 4.16) Raw meal dryer

A. Hot air chamberIts function to raise the average air temperature to approximately 500 Celsius, so that guarantees hot air for drying by conduction.This room consists of primary and secondary fan air pump in addition to the pump for oil fuel.Inside this room is built from fiery brick to withstand the heat of hot air.

B. Dried cylinder.It is a cylinder of steel, internal coated with bricks and thermal drag installed on the inner perimeter contributes to raising the wet material in order to have the greatest petition with hot air. The cylinder is tilted slightly toward the exit to facilitate the movement of materials inside.

C. Distributor and organizer of the materialIt is a metal tank, its function to regulate conduct of dried material when they fall on a rubber conveyor.

D. Electric filterIts function to cleaning air from dust and stuck it back through the spiral conveyor to unload the rubber conveyor compound and from it to the dry material warehouse, and is due to ionization.

E. Different conveyors. The transfer of materials and the air from stage to other, and where there is a rubber and spiral conveyor with the duct of air. All previous parts are shown in (figure 4.16).

The initial mixing section fieldsLarge repositories are either rectangular or in a circular shape, they gets materials from crusher

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conveyor as shown in (figure 4.17).It is dedicated to provide a great strategic asset for the operation of raw materials mills if crusher stop, where can accommodate of thousands tens of basic materials, corrected and additional materials which are stored separately.

Figure 30 (figure 4.17) Raw materials storage and additives par

- STACKER:It collects material in the form of layers as shown in (figure 4.18), where mixing and homogeneity take place until fill the entire field.

Figure 31 (figure 4.18) conveyor belt and piles of crushed material used if the crusher stops working

- RECLIMERScraping piled material as inclined sections (thin layers) and drags them across to a rubber conveyor to mill raw materials as shown in (figure 4.19).

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Figure 32 (figure 4.19) piles of crushed raw meals

Milling of raw material section

Figure 33 (figure 4.20) Raw material milling machine

The mill is grinding crushed material after determining their proportions and converts those materials to a fine powder in way that fit to the technological work of subsequent sections as shown in (figure 4.20).

- Raw materials mill Parts:1. Primary weighted repositories of the material to be milled. 2. Mill raw materials (body windmill rotor).3. Secretions and Cyclone.4. Electric filter.5. Different conveyors.6. Air heating chambers.

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- Some of technical data in raw materials mill:1. Types of milled material: Limestone, clay, sand, iron and ore.2. Number of rooms: one room in addition to one meter for drying.3. The form and type of linkage with Gearbox: peripheral (side).4. Production capacity: 325 tons per hour.5. Inside Air: hot gases from top of the first heater + gas from the drying part.6. Product control: 16-18% in the entrance.7. Length and Diameter: 11.75_ 5.4 m.8. Balls shipment weight: 240 tons.9. The electric motor capacity: 4.2 MW10. Separator: extension by four Cyclones.11. The method of transfer materials to the separator shall withdraw by fans.12. Crossing the air speed: 70 to 80 m per second13. speed of the mill: 13.8 P-minute cycle14. moisture materials used: 6.5 _5.5%15. Exit moisture materials: 0.5%- Raw materials mill mechanism:1. Materials enter through mill after weighing scales to determine the percentage of each

material, when material entering mill is dried by hot gases coming from the top of the first heater, so material get rid of the moisture.

2. Material pass the first part of the mill, where the large diameter balls, and platelets that help to carry them, where the material grinding in a collision way.

3. Material pass to the second part where the balls with smaller volumes, and classified platelets, where grinding and soften the material has been done.

4. Material drag by air fans to the detachment, where soft material is separated from the coarse material in a centrifugation manner.

5. The soft fall down to the bottom of separator, to conveyor where they transfer to the final mixing tanks, while the coarse material goes back again to the mill where it is softening.

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Feeding the furnace section

Figure 34 (figure 4.21) mixing and storage tanks before heat treatment

It is the section that regulates the conduct of mixed heterogeneous materials as shown in (figure 4.21), ranging from storage to the final homogeneity across the furnace section dedicated to adjust the weights of materials when they enter the oven.

- Parts of feeding the furnace section:1. Mixing tank and is considered one of the most important parts of the cement plants.

Mixing mechanism by inflatable airbags and it can move and disturb materials, which helps in the homogeneity of these materials. It must be consider in mind that the humidity should be less than 1%. The purpose of mixing and homogenization is:

A. To ensure the work of the oven (quality and production).B. Reduction in the cost.C. Increase in productivity.2. Intermediate tanks it is as diverse as feeding, discharge and regulates the delivery of materials

and insurance balance of the furnace tank.3. Scales their function to automatically weight materials within 24 hours before entering the

furnace.4. Different conveyors like vertical, horizontal and tracked. Kiln section

Is the section where the disintegration of the calcium carbonate (CaCO3) with raising the temperatures of melted materials and their interaction within the rotary kiln for the production of clinker and then cooled in special coolers, which is the main section in the cement industry.

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- Parts of the kiln:

1. Preheater

Figure 35 (figure 4.22) preheater tower

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Figure 36 (figure 4.23) preheater tower explanations

Preparation materials to enter the rotary kiln as shown in (figure 4.22) to raise temperature of raw materials and the dissolution of calcium carbonate (CaCO3) by almost 90%, according to the following equation:CaCO3 "CaO + CO2 , through heat exchange between the material coming from the blending and homogenization silos (from the top) with the coming of the coolant gas passes through rotary kiln (from the bottom) the opposite direction.

2. By pass.Its function get rid of the gases coming from the cooler and enter the kiln, contained part of alkalis and chlorides, which caused a blockage at the entrance of the oven and the first floor of preheater, disposal proportion ranging between (10-20%)

3. Filter.Layering dust in gases exiting from the top of the first heater and returned to the material.Types: fabric and electric filter.

1. Rotary kiln.

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Figure 37 (figure 4.24) rotary kiln

Metal rotary cylinder materials enter it, where they disintegrate fused and then merge with each other due to the high heat, produce new compounds known as clinker phase (product centrist).

- Its components as shown in (figure 4.25):

Figure 38 (figure 4.25) rotary kiln components

A. Iron Cylinder, which expands a certain length and a certain diameter in addition to a certain inclination, has a dedicated rotation speed.

B. Three double rollers in order the cylinder stand upon them.C. Cupboards determine the path, in order to allow the oven to move up and down steadily.D. Kiln engine.E. The fire tube (torch)F. The fiery brick which is inside the oven

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- Inside of the oven it divides to several fake areas as temperatures and stages of transformation of materials, namely:

A. Materials entry zone, length of 14 meters and the temperature (1100-1150).B. Calcination zone, 10 meters in length.C. The protection zone, 11 meters in lengthD. The transition zone, 11 meters in length.E. Combustion zone, a length of 34 meters and the temperature (1400-1450).F. Cooling area, length of 2 meters and the temperature (1100-1200).- Reactions that take place inside the oven:A. Thermal decomposition ( 990 C ):

All oxides of alumina (Al2O3) interact with a portion of the oxides of calcium generating mono calcium aluminum (CaO.Al2O3) and denoted by (CA), but the average product, on the other hand start oxides, silica (SiO2) to merge with calcium oxide (CaO) the problem of bilateral Silicate calcium (SiO2.2CaO) and denoted by (C2S) in this phase, but at low concentrations.

B. crystal Deformation ( 1285 C ): Intermediate output of the first phase (CA) unite turns into a complex three-aluminum calcium (3CaO.Al2O3) and denoted by (C3A) and at the same moment merge iron oxides (Fe2O3) with calcium oxide (CaO) component (C2F) and the most complex, to become its interaction with aluminum fluorides Alumina quad calcium (4CaO.Al2O3. Fe2O3) and denoted by (C4AF), which begins the formation of (C2S) to complete.

C. Fusion ( T >1285 ):In this temperature and excessive heating of materials, saturated (C2S) remaining calcium oxides and produces calcium silicate trilogy (SiO2.3CaO) and the code name of (C3S).

D. Mergers and form clinker:Materials and oxides combine with each other and interact in order to be certain reactions new material differs from the previous stages chemically and physically and mechanically.

E. Crystallization of the fluid phase:Clinker is cooled at the end of the kiln (cooling zone) so that takes the form of rigid (relatively) and increasing strength by cooling in special coolers.

Figure 39 (figure 4.26) clinkers before entering the cooler

2. Grate Cooler

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Figure 40 (figure 4.27) grate cooler

Clinker cooling which come out of rotary kiln, from temperature 1200 Celsius to about 110 Celsius, almost in ten to fifteen minutes. It follows the detonator cooling system as shown in (figure 4.27).

- Its components as shown in (figure 4.28) :

Figure 41 (figure 4.28) grate cooler sketches

A. row of tiles fixed followed by another one moving.B. Tiles in first parts tilted and steadier than others made of a certain metal alloy of steel and

chrome because of the high temperature of clinker.C. Moving part of the tiles lead to push clinker forward, length of at least 12 cm.D. Air enters from spaces between the mobile and fixed tiles to cool the clinker.E. The end of the cooler there is crusher to reduce the size of the clinker.F. Wheels and axles to support the track.

- The principle of cooling:

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It depends on the air coming from fans, which is usually at the bottom of the cooler which comes into contact with the clinker surface, cools and turns into a hot air.The amount of air used for cooling varies according falling clinker temperature from the kiln and gradient particleboard falling, the amount of air required for cooling is estimated in general (3/2 to 3/3) kg of air per kg of clinker.

- Cooling mechanism:Air enters through the air pumps and directly come into contact with the clinker, then heading to the top of the cooler, is divided into:

A. The first section enter the kiln what is called secondary air (almost 1200 Celsius).B. Section II pull to the calcined area in the primary heated location, and called tertiary air

(almost 900 Celsius).C. Section III (almost 260 Celsius) withdrawn from the heat exchanger for cooling and sent to the

filtration process and into the clinker stores.- The clinker come down from the oven at a temperature of about 1150 Celsius and almost

come into contact with the air, it breaks down to:A. The first part of clinker (60-70%) moves to the crusher by the alternating movement cooler

tiles and from the conveyor belt up to the clinker stores as shown in (figure 4.28).B. The second part (30-40%) can come down through the holes in the tiles, heading to the

conveyor and then to the clinker stores.C. The last part of the clinker (3-4%) holds mostly air and moving with it.

Figure 42 (figure 4.29) clinker storage silos

Cement grinding section

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Figure 43 (figure 4.30) clinker with gypsum milling

Figure 44 (figure 4.31) clinker milling machine

Not much different from the raw materials mill as shown in (figure 4.20), there are simple differences between the two:

A. Use the water spray to cool the mill temperature in certain percentage in order not to lose gypsum physical and chemical properties.Using the hot air coming from the heater with initial humidity is less than 1% in order to be grinding well.Material entering the mill is clinker with mandatory addition of the ordinary gypsum is mandatory with the addition of other materials such as Buzolana.

B. Materials used are the main materials with the modified material.C. Productive capacity higher than the raw material mill.D. Smoothness is measured in in the laboratory of cement mill by using Blaine device.E. Most of mills are two separated rooms.

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Packing Department:There are two types to fill cement:

A. Cement stored silos to trucks directly.

Figure 45 (figure 4.32) cement silos

- Securing strategic asset for the company in the case of cement mills stopped.- Natural cooling of cement in silos in order to maintain the specifications.- Fill trucks by cement in fluid way as shown in (figure 4.32).

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B. Packaging in bags weighing 50 kg.

Figure 46 (figure 4.33) packaging of cement in bags

It is encapsulated in cement with certain specifications bags weighing 50 kg and through the corridors and filling machines prepared for that on normal and automatic way as shown in (figure 4.33)

- Parts of Packing department:A. Silo it is a silo which pouring of concrete is from the top and extracted from the bottom to fill

the trucks.B. Intermediate warehouses organize the material to the packing machine, and secure the

continuous balance to work.C. Different types, including the antenna and the vertical and rubber conveyors and is working to

move the materials through boilers.D. Scales and machinery for packaging is prepared and programmed to operate on the filling of

bags 50 kg, and is done through a certain balance for the machine slots.

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4.4Some problems encountered in cement manufacturing processes

4.4.1 Maintenance of mixer:

Figure 47 (figure 4.34) cement mixer

In the process of normal feeding and mixing, concrete mixer as shown in (figure 4.34) may have an occasional trip. The reason and troubleshooting methods as follows:

- Reason 1: Feeding too much, because concrete mixer overload, this situation needs to check whether the whole weighing system is ok, whether there is residual material or second feeding phenomenon.

- Reason 2: The distance between mixing blade and lining board is too big, increases the resistance. In this case, first check the distance between mixing blade and lining board, then check the lining board thickness, if the thickness is little than 2-3mm, change it in time.

- Reason 3: Concrete mixer's drive belt is too loose, low efficiency of transmission system.  In this case, check the tightness of drive belt, adjustment or replacement the drive belt.

- Reason 4: The safety maintenance switch on mixing cover is vibrated loose, cause downtime. In this case, repair the safety maintenance switch.

4.4.2Aggregate batching plant switch failure

Concrete batching plant work for a long time, coupled with the daily maintenance is not good, there will be some faults and problems, timely discovery and solve the problems is very important as shown in (figure 4.35). Aggregate batching plant switch failure, usually due to

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the low pressure gas supply system, running pin stuck, discharging mouth deformation or stuck by foreign body, etc. we can handing it by adjusting the air pressure, filling lubricating butter, and repair the discharging mouth.

Figure 48 (figure 4.35) control system for inspection of mixing parts and error investigating

4.4.3 Water pump

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Figure 49 (figure 4.36) water pump for the mixing tank

Water pump as shown in (figure 4.36) provide the sufficient amount which used for cooling of cement and mixing, if there is wrong with this pump it will cause several problems such as less production rate, too much equipment maintenance, less quality...etc. So we must check it in short period to avoid those problems.The most common problems with water pump is blades where is corrodes and fail because of high speed and several materials which are in contact with.So we should replace it with new one after clean it from inside and lubricate bearings and checking.

4.4.4 Screw conveyor failure

Figure 50 (figure 4.37) screw conveyor broken shaft

The most common failure with screw conveyor is broken shaft as shown in (figure 4.37) due to high transit load of materials and less care of workers and the controller.In our case we unload the screw and disassemble it and order new shaft to continue our work.This is

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cost a lot by stop working and the shaft is slightly expensive, so we should take care of that.

4.5 Some calibration methods and standards

4.5.1 Conveyor Scale Calibration (figure 4.38):

Figure 51 (figure 4.38) conveyor belt calibrations

1. Before the calibration, the belt scale conveyor must run for about one hour to warm up the system.

2. The bypass chute must be in the bypass position. Ensure that material does not enter the mixing drum.

3. Run approximately 10 tons of aggregate over the belt scale conveyor to ensure proper seating of the conveyor belt on the rollers and better weighting accuracy.

4. While the aggregate is running, have the master feed control adjusted until the aggregate meter reads the expected production rate. With split stockpiles, more than one bin of the same size of aggregate may have to be used.

5. Use the bypass chute to discard the aggregate.6. With the belt scale conveyor running empty, place the Moisture Content Dial Setting on zero.7. Place the AC test switch in the x10 position, this multiplies the count rate on the totalizer

tonnes counter by 10 so that an accurate zero can be obtained.

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8. Adjust the totalizer fine zero control until the tonnes counter does not count forward or backward. Record the reading as Zero

9. Place the AC test switch back to the normal position.10. Record the Span Setting to the nearest two hundredths of a tonne.11. Position a tared truck capable of handling at least 10 tonnes of aggregate, under the bypass

chute. Be sure that the bypass chute and the truck box are clear of all excess material and the chute is still in the bypass position

12. Run all conveyor belts, except the bin feeder belt.13. Simultaneously start the bin feeder belt and the stop watch.14. When at least 10 tonnes of aggregate have run over the belt scale and before the truck box

over-flows, simultaneously stop the bin feeder belt and the stop watch.15. When the totalizer tonnes counter stops counting, record on the data sheet the Final Totalizer

Reading16. Convert the loading time in minutes and seconds to seconds and record as Elapsed Time 17. Weigh the loaded truck on the platform scale and record the net weight in kg as Truck Scale

Wt. of Aggregate.18. Calculate the wet aggregate Production Rate in tonnes/hour using the formula:

(Truck Scale Wt. of Aggregate in kg\ Elapsed Time in seconds) *3.6

19. Calculate the Totalizer Count in tonnes.20. Determine the Truck Scale Weight of Aggregate in tonnes21. Compare the Totalizer Count to the Truck Scale Wt. of Aggregate ± 0.5%.22. If the belt scale cannot meet this accuracy it must:

- find the problem with the belt scale and/or truck weigh scale- correct the problem,- Recalibrate the belt scale.

4.5.2 Test Weights Calibration

1. Have the operator hang on the belt scale or lower the test weight handle, if applicable, weights that approximately simulate the expected production rate.

2. Ensure the Moisture Content Dial Setting is on zero.3. When the totalizer tonnes counter is at an even tonne, simultaneously take a totalizer reading

and start the stop watch.4. Note and record the Aggregate Meter Reading in t/h the Process Meter Reading in t/h if

applicable, and the Rate Meter Reading in %.5. When at least six minutes have elapsed and the totalizer counter is at an even tonne,

simultaneously take a totalizer reading and stop the stop watch.6. Record the number of tonnes counted by the totalizer as Totalizer Count.7. Convert the Elapsed Time in minutes and seconds to seconds and record it in.

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8. Determine the Totalizer Count in kilograms9. Calculate the Totalizer Production Rate in t/h.10. Compare Aggregate Meter Reading, and Process Meter Reading, if equipped, to the Totalizer

production Rate. The meters must be within 1% of the production rate.11. If the meters are not within 1% of the production rate, the operator must adjust the meters until

they equal the production rate.12. Have the operator remove the test weights from the belt scale or raise and lock the test weight

handle, if applicable.

4.5.3 Calibration of aggregate scales

A minimum of five substantially equally-spaced loads, covering the weighing range, are applied in ascending order and then removed, with the output at zero loads at the completion of the run also being recorded. Where hysteresis, non-linearity (decreasing), or combined error are to be determined, the calibration loads are to be removed in the same steps as they were applied. This procedure is then repeated twice to give a total of at least eighteen data points (the initial zero load output is recorded for reference).

4.5.4Calibration of additives system

Figure 52 (figure 4.39) controls and monitoring of additives and mixing system

This is done by taking some simple from the mixer machine, and then sends it to the laboratory and check the proportion of each material in the simple.If these proportions are not according to the standard and required percentages, we check

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valves and slots of each material part such as water, clay, cement….etc. and fix it to desired amount as shown in (figure 4.39).

Chapter 5

PERSONAL DEVELOPMENT

This training has greatly improved my knowledge in the mechanical, electrical and instruments part of engineering. It exposed me to real life practical manufacturing of different type of cement and how this process is done from zero to final product.It shows me the standards, consideration, failure and how to search for the reasons and fix it in professional manner.

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I got familiar with different types of valves, pumps, compressors and how they work.Going to university gave me the theoretical knowledge of this real life practice, so therefore I would say that having gone through this training has given me much confidence to defend myself when it comes to dealing with cement plant manufacturing or maintenance of mechanical parts.

Chapter 6

DISCUSSION/CONCLUSION

Looking through this report we can understand that every step in cement industry required large preparation to increase productivity and efficiency as well as decreasing the problems and faults which will cost the company a lot and affect the work progress.CGC provide all the requirement that need to be competitive throughout industrial and contracting fields, as a result of that it became the main sector for almost all constructions and production applications in Kuwait.If we discuss the result of that success it referred to the high technological machines which I

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encountered through my training period and controlling by a number of powerful engineers.The final cement is satisfy all the standards which are listed by ASTM after gone in sequential laboratories and testing.It is really fantastic training that I ever did it in my life, because you can realize how difficult to accomplish all of process in a successful manner and finally feeling happy to what you did there.All the staff there were very helpful and give me information as possible as they can to improve my knowledge and practice in real works.The period for the practical training divided into three stages:Production period: included production engineers where the focus was on the work of the engineers in the factory and the tasks entrusted to them and how to control the factory production quality and quantity, and explore the problems with solutions.Laboratory period: included one production engineer and laboratory technician where the focus was on experiments carried out by the Technical and method of work and the number of repeating them and reasons for this and giving me chances to do it myself.Quarries and Quality period: has included geological engineer, where the focus was on how to invest the quarries in the right way and explore the area of raw materials and how to uproot them.Having gone through this industrial training as a mechanical engineer, I personal believe that industrial training is the best way to practically improve the knowledge and technical any engineer and recognize the difference between theoretical and practical applications. Those forty days is very important to any student to feel the stresses and try to improve himself to retain the difficulties which may encountered in the near future. Those difficulties will improve the innovations and scientific thinking to solve problems. This period also teach me how we can take responsibilities and don’t depend on other people to achieve my job. Also those days teach me how to respect other workers and try to help anyone who need it and communicate with new and experience people from different knowledge and culture background.My training in CGCS involved inspection of various steps in cement manufacturing, laboratories, maintenance and calibrations of different instruments to insure the quality of the products.My personal suggestion is that the maximum period of this training should be increase because the period given for this training is quite short for a student to gain as much knowledge as he/she can gain. Theories given to engineers are most times written and heard, but practice of these theories will make it perfect, therefore more practical work should be included in our academic work. Indeed this training was 90-95% beneficial to me as a mechanical engineer. Also I suggest the department to make contracts with several companies to facilitate our training in a powerful companies and eliminate the difficulties to find the acceptance letter from them.Finally, I would like to thank CGCS for giving me this chance to improve and prepare myself for my future career throughout their perfect staff.

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Appendix I

Main equipment and machines

Figure 53 (figure I.1) general view

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Figure 54 (figure I.2) limestones (second crushing)

Figure 55 (figure I.3) crushed limestones conveyor belt

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Figure 56 (figure I.4) limestones silos and additives before milling

Figure 57 (figure I.5) raw meal dryer machines

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Figure 58 (figure I.6) raw meal grinding

Figure 59 (figure I.7) preheater towers

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Figure 60 (figure I.8) rotary kiln

Figure 61 (figure I.9) grate cooler

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Figure 62 (figure I.10) in the left side cooling section, the right side clinker storage silos

Figure 63 (figure I.11) clinkers milling after adding gypsum

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Figure 64 (figure I.12) cement storage and filling

Figure 65 (figure I.13) cement bags

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Figure 66 (figure I.14) plant control cabin

Figure 67 (figure I.15) aggregate with grinding ball for testing in the Los Angeles Testing Machine,

According to the ASTM C131

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Figure 68 (figure I.16) this machine rotates about 30-33 rotations per minute, in this test we will set the Los Angeles machine to 500 revolutions

Figure 69 (figure I.17) aggregate scaling after milling

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Figure 70 (figure I.18) sieve analysis

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Figure 71 (figure I.19) awards and certificates

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Appendix II

Tables and charts

Figure 72 (figure II.1) aggregate tests

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sieve size A (g) B(g) B-A (g)(B-A)/∑*100 CP% PP%

25 mm 1339.2 1339.2 0 0 0 100

19 mm 1312.5 1926.1 613.6 12.2 12.2 87.8

12.5 mm 1312.5 4846.2 3533.7 70.6 82.8 17.2

9.5 mm 1312.3 2062.3 750 14.9 97.7 2.3

4.75 mm 1233.9 1334.1 100.2 2.0 99.7 0.3

2.36 mm 1087.1 1087.7 6 0.012 99.71 0.29

pan 0800.8 0804.8 15 0.29 100 0

Total 8398.3 13400.4 5002.1 100 493 207 Figure 73 (figure II.2) Sieve Analysis Calculation for coarse Aggregates (ASTM C136)

Sieve No % Passing

Min Max

1” (25 mm) 100 100¾ “ (19 mm) 100 100

½ “ (12.5 mm) 100 1003/8 “ (9.5 mm) 85 100No.4 (4.75 mm) 10 30No.8 (2.36 mm) 0 10No.16(1.18 mm) 0 5

Figure 74 (figure II.3) Coarse Aggregate Specifications (ASTM C33)

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0 2 4 6 8 10 120

2

4

6

8

10

12

Coarse aggregates percentage passing graph

Sieve size

Pass

ing 

perc

ent

Figure 75 (figure II.4) Coarse aggregates percentage passing graph.

1 10 1000

20

40

60

80

100

120Percentage passing for coarse aggregates

sample MIN MAX

seive size

%passing

Figure 76 (figure II.5) Min, Max and Sample graph for fine aggregates

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Figure 77 (figure II.6) silo capacities

***

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