Cement Factory Maintenance Course
A 6 week modular course exploring the maintenance of cement factories, including
the different maintenance challenges faced by different cement factories around
the world, the assessment of cement manufacturing equipment condition, common
maintenance and reliability problems, their solution and the organisation of the
maintenance function on a cement factory.
Course Content
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In module 1 the course explores the different maintenance challenges presented by
cement factories, dependent on their scale, location, number of lines operated
and vintage. Also the ways in which maintenance will be judged, not only from
the availability of the equipment and the costs of maintenance, but also from
the overall equipment effectiveness. Availability of spare parts will make a
vital contribution to the effectiveness of maintenance, but what level of spare
parts can or should be provided? Many factors which will impact on the
effectiveness of maintenance throughout the life of the cement factory are
determined when the factory is laid out and the equipment is designed. These
factors need to be taken into consideration when cement factories are first
established as they will never be able to be changed in the future.
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In module 2 of the course the inter-related issues of cement factory condition
assessment, common problems and their resolution are explored. Cement kilns must
operate for long, continuous campaigns to minimise their thermal energy
consumption. In order to do this, their mechanical condition must be regularly
assessed and adjusted, if necessary, to prevent long-term damage and the
requirement for major repair involving massive loss of time and clinker
production. A cement kiln is in fact an assemblage of inter-connected
sub-systems which must all operate reliably. The kiln is only as reliable as the
weakest of these sub-systems, so the raw meal preparation, kiln feed system,
fuel preparation and delivery, clinker cooling and transport and the exhaust gas
venting and dedusting systems are all expected to operate for these long
campaigns. There will be some overtaking capacity in some of these sub-systems
allowing limited time for maintenance, but all will be expected to give reliable
performance.
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In the final module of the course the theories of maintenance organisation, as
they relate to cement factories, are explored. What is the role of breakdown,
preventive and condition based maintenance in cement factories? How do
approaches such as Total Productive Maintenance and Reliability Centred
Maintenance apply to cement factories? What changes on the organisation of
maintenance and the skills of the maintenance personnel are required to
implement these changes in cement factory maintenance philosophy? Computerised
maintenance management systems make a vital contribution to these approaches to
maintenance and are a prerequisite for the effective maintenance of a modern
cement factory.
Course Material
Throughout the course the lectures are supplemented with exercises allowing participants to relate the course material to their cement factories, or
the cement factories of their clients in the case of equipment or service
suppliers to the cement industry. Certification is achieved by completing a
satisfactory level of exercises, and by end of module exams.
The course is complete with downloadable handouts of the lectures,
exercises, and reading material for the training record.
Next Course Starts:
21 July 2008
Or select a course start date:
Cost
The cost of the Cement Factory Maintenance online training
course is:
UK£500
EUR€700
US$1000
Reductions for group bookings at the following rate:
3 Students - 10% discount
4-5 Students - 15% discount
6 + Students - 20% discount
All discounts are applied automatically during checkout.
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Certification
Students who successfully complete the course are awarded a certificate and a
copy of the Cement Plant Operations Handbook.
Sample Lecture
View a sample lecture