Final Lafarge Presentation

Internship Presentation Siti Mardiah binti Johani 1st April – 1st July 2015Asst. Engineer – Process Dept

Content 1. Objective of Industrial Training

2. What I’ve been exposed to

3. What I’ve learned

Conclusion

Date | 2

1. Objective

Get exposure on professional working environment Gain beneficial industrial experience Applying theoretical knowledge on practical job Get a taste on how working life would be Discover self potential and weakness

Date | 3

2. What I’ve been exposed to

Date | 4

In Lafarge Pasir Gudang Plant

Technical Knowledge

Non-Technical Knowledge

2.1 Technical Knowledge 2.1.1 Assisting on inspection job

Date | 5

Mill inspection 1. Calculation on volume loading done according to Vade Mecum’s guide book 2. Observation on liners, ball coating, intermediate diaphragm and protocols on

entering a confined space ( LOTOTO )

Weigh Out 1. Objective to verify % error between reading on site and DCS reading 2. Had the chance to lead on weigh out according to Production’s request

a. Sequencing equipment during start up and shut down Objective

1. To change the current way of shutting down the plant via centralized system and turn it into a sequenced stoppage

2. Save power as a more efficient shut down can help reduce power wastage 3. Planning a sequence that can prevent mill from trip

Method Used 1. Observation on methods used by CRO during PM 2. Listing out problems that rise during shutdown and try to provide ample time and

sequence for the equipments. 3. Do calculation on time and cost saved based on estimation timing given by CRO

Date | 6

2.1 Technical Knowledge 2.1.2 From projects assigned

2.1 Technical Knowledge

Proposed solution

Date | 7

Group Current situation Change4_5Clinker and GypsumFeeding

Needed to Off and re ON then reoff due to interlock that trips mill if there is no feeding for more than 10 minutes

For PM, prevent mill from trip when there is no feeding for more than 10 minutes. Set time for 20 minutes at least, to empty out mill

4_4Mill Main Drive

NCNC

4_3Cement Auxilliary

NCNC

4_2Separator and circulation

- Normally CRO adjust the fan opening 2.27 to, decrease the opening gradually from the moment they off group 4_5

- After stoppage of purging 2.26 bag filter, there is a rise of power in BE 2.20 up to 30 KW. CRO have to stop feeding into the bucket to prevent trip

- Set in program to have cascade decrease in opening of fan 2.27 from current to 0% within 20 minutes

- Set all 2.26 screw conveyer and rotary valve in 4_2 to stop when the purging stops. Also it has to be re ON after an estimated time of 1 minutes to clear out the materials inside the SC&RV

4_1Transport to Cement silo

- CRO switch ON and OFF the screw conveyer and rotary valve in an unsystematic way . Large amount of materials lies inside screw conveyer.

- Switch ON screw conveyer and its couple one by one for 2 minutes then OFF

2.1.2 From projects assigned

Date | 8


Conclusion With an estimated number of 2 PM/mnth, savings up to RM 433.50/yr

Work left to be done Test out proposed timing sequence for shutdown and start up

Study on programming interlocks


b. Idling equipment on silo B Objective

1. Eliminate idling equipment 2. To save power from idling equipment during tanker loading

Method 1. Study automated system in silos, where improvement can be made. Potential for

improvement was identified in silo B. 2. Identify equipment used during tanker loading in silo B.3. Learn how the system works when there is tanker loading cement. 4. Plan how to eliminate the idling equipment

Proposed solution When lorry driver pushes the pendant switch to lower down the bellow, itautomatically activates the equipments in silo B. When he pushes the pendant switchto bring up the bellow, it deactivates the whole system.

Date | 9

2.1.2 From projects assigned

Date | 10

Calculation done with consideration of these parameters :

Parameters Remark

1Frequency of tanker coming in on each loading point Data collected from supply chain

2Tanker waiting behind the current loading tanker

Taken into consideration through the

percentage of manual action taken

3Rise in motor consumption during each start up Only for a few seconds thus negligible

4The percentage of motor capacity used when running Only 80% motor capacity used

5Operator shutting the system when not in used Assume 50% from total time saved

6 Simultaneous pumping 30% number of lorries



Conclusion Saving up to RM 12 308.25/yr and with an estimated cost of RM5 000, expected

payback will be in 0.41 yr.

Work left to be done Co-operation from E&I department to plan the programming and provide electrical wiring

on silo B

2.1.2 From Misson assigned

Date | 11

c. PID on weigh feeder Objective

1. Stabilize and optimize weigh feeder output ( TPH)

Method handling PID 1. PID tuning involves access to the equipment during manual and automatic mode.

We had to identify what are the parameter that we want to tune and what disturbances could give major impact on that particular parameter

2. Tuning on : Clinker feed (TPH)Disturbance: Speed of belt conveyer

3. Tuning during manual mode could give us data on the dynamic of the process. We can have information on how fast does the process react to disturbances.

4. The most common method to tune in manual mode is through echelon method. About 10% rise in speed of belt conveyer is applied on the weigh feeder.

Date | 12


6. After calculation, we have to enter it inside the weigh feeder system and let it run in auto mode. Observation on how the process reacts is needed for tuning. Tuning involves user adapting to the process and change the value accordingly

Conclusion I was unable to complete the project due to limitation on this plant. When the weighfeeder is in manual mode, we are unable to get access to its feed reading.Thus, if disturbances are made, we won’t get the data on how the process hadreacted. Proposed solution : Try and Error tuning in auto

Date | 13


d. Analyse on Grinding Aid Trial Objective

1. To find a grinding aid that gives the best results in terms of quality, process and cost.

Method 1. Analyse the data2. Several discussions had been made to verify the analysis done on the results. In

order to choose the best GA, rating is given to GA with best performance to low performance

3. Before making a final decision, a meeting with production, quality and process team along with the plant manager had been held to further discuss on the findings

Conclusion Based on analysis done, GA (Grinding Aid) Mapei had shown the best performance and

is recommended to be used in PGP

Date | 14


e. Analyse on Gypsum and Anhydride Addition Objective

1. Find the right ratio for gypsum and anhydride addition that can give best result in IST (initial setting time )

2. Other monitored parameters :

Date | 15

2.1 Technical Knowledge 2.1.2 From project assigned

So3 percentage

Within 2.8 to 3% ( set by quality team)

SA 3500 to 3700 cm2/g Gypsum If possible , low % because running out of natural

supply Strength2d strength 28d strength

High strength Average strength 2 days : 28.50 Average strength 28 days : 53.00

Pattern Consistency in results gained through experience

Method 1. Work on raw data2. Analyse data according to parameters set earlier

Results

Date | 16


Discussion

Date | 17


% of Gypsum 0255075100

Initial setting time (min)

1131 minute later than 75% of

gypsum

12513 minutes

late than 75% gypsum

12513 minutes

late than 75% gypsum

112Lowest IST

1131 minute later than 75% of

gypsum

SA (350-370 m2/kg )

379.62.5% higher

than target

355.6In range

365.8In range

374.21% higher

than targeted 370

364.4In range

SO3(2.8-3%)

3.289% higher than target

2.732.5% lower than target

3.258% higher than target

3.23 7% higher

than target 3

2.2121% lower than

target

2 days strength 31.6423.5930.5732.7626.83

28 days strength 55.065053.3154.3252.01

Consistency in results

3/4 results between

range 110<IST<1

30

1/4 results between

range 110<IST<130

1/4 results between range 110<IST<130

4/4 results between

range 110<IST<130

2/4 results between range 110<IST<130

Cost

Saving up to RM 22 899.28 /yr when using 75% gypsum

ConclusionMore pros can be seen on the results gained from 75% of gypsum + 25% onanhydride than the other compositions in terms of IST, 2d strength, resultsconsistency and costs.

Date | 18


H&S Blitz Program I was able to participate in many trainings :

1. WAH Training : Definition of WAH, at-risk behaviour, fall protection system and ways to calculate our fall was explained

2. Tools and Equipment : Explanation on hand powered tools, non-powered tools, how inspection must be done regularly, and measures needed to be taken to prevent unwanted incidents

3. Hot Work: Explanation on type of welding (welding arch, welding iron rod, welding torch), combination of oxygen and acetylene could give out big and sharp fire, Pre Job before welding and permit needed to do welding.

4. Energy isolation : Explanation on types of energy, importance of energy isolation, basic requirement to do energy isolation, existence of working procedure such as HECP and HERA, LOTOTO

5. Hazardous substances: Chemical substances that are present this plant that gives threat to our health. Example such as cement, raw materials and chemicals used for lab testing

Fire Fighting training in Bomba Pasir Gudang

DOM meetings

RCA ( Root Cause Analysis)

Date | 19

2.1 Technical Knowledge 2.1.3 From Training and Activities Joined

Date | 20

2.2 Non-Technical Knowledge

1. Human relation As the plant has a small number of employees. I had the chance to know and work with

almost all of them. People here are very nice, welcoming and helpful. There is a positive working environment here which makes people feel good about coming to work. I can see that most people have a balance between work and personal life.

2. Quality of work and Managing time Based on comments on my work, I still need to improve the quality of mywork. As I am not really a meticulous person, I will try to improve myself on lookingmore closely into tiny details.

3. Autonomous Assignments given to me are closely linked with electrical and instruments which isnot my strongest field of study. I had to be guided closely by Mr. Badrul as he had toexplain to me how the system in PGP works. I need to improve myself on thisparticular field as being a process engineer also requires me to be at ease with E&I.

4. Leadership On issues raised, a leader must quickly identify the problem, see how it can be solvedor set a discussion about it and must be able to make a quick and smart decision. To be a good leader is not easy as they have to be aware of every single thing, bothtechnical and management side. They have to be encouraging and appreciative ofpeople’s work.

Date | 21

2.2 Non-Technical Knowledge

1. Assignments given to me helps me to understand better operations in the plant and on cement industry

2. I am able to identify my weakness and will work on improving myself. But, far yet to discover my potential

Date | 22

3. What I’ve learned

Get exposure on professional working environment Gain beneficial industrial experience Applying theoretical knowledge on practical job Get a taste on how working life would be Discover self potential Discover weakness

Date | 23

Conclusion

Date | 24

Thank You

Documents

Final Lafarge Presentation