16.30 ferdinand pecson, nlsupervision
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World Class Plant Performance with NLS O&M
Ferdinand A. Pecson Ph. D, MBA, BS ME
Cemtech Dubai, 5-8 March 2011
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Company Profile
NLSupervision A/S specializes in offering everything needed for the successful commissioning of a cement plant and its subsequent management, operation and maintenance.
NLSupervision Egypt currently has O&M contracts with Arabian Cement Company located in Suez Governorate and Wadi El-Nile Cement Company located in Bene Suef Governorate.
Outside Egypt, NL Supervision A/Shas contracts in four other countries: Iran, Libya, Angola and Tunisia
NLSupervision Company A/SHffdingsvej 34DK-2500 ValbyDenmarkTel.: +45 3618 3780Fax: +45 3645 6415
Cemtech Dubai, 5-8 March 2011
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Our Value Proposition to Our Customers
Maximize your return on your investment by achieving rapid ramp-up from commissioning and guaranteeing high plant availability and high levels of production throughout the life of the project.
Support your goal of being a dependable provider of excellent quality cement to your customers
Help you be an attractive business partner for users of cement by operating your cement plant according to international standards for Quality (ISO 9001), Environment (ISO 14001) and Safety (OSHAS 18001)
Enable you to focus your resources on revenue generation
Help you sustain high levels of productivity and performance even after the O&M contract, by providing your plant with state-of-the art systems and a highly competent organization.
Cemtech Dubai, 5-8 March 2011
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Our Mission: Sustained Excellent Performance
Cemtech Dubai, 5-8 March 2011
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The Five Key Drivers of Our Success
Customer Focus
Excellence in Operation & Maintenance
Passion for Safety
Engaged Employees
Care for the Environment
Cemtech Dubai, 5-8 March 2011
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Delivering Results by Being Close to our Customer
Philosophy of Our customers
success is our success
Daily Coordination Meetings at
Plant Level
Quarterly Planning of
Production
Planning shutdowns according
to customer needs
Joint Iftar Parties
Cemtech Dubai, 5-8 March 2011
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Reputation
Senior Management
Immediate Superior
Co-operation
Daily Work
Remuneration
Development
Action areas Result areas
Perception Behaviour
Satisfaction
Motivation
Satisfaction & Motivation Loyalty
Retention
Commitment
Delivering Results by Engaging our People
Employees continued to run Ramliya Plant all throughout the Egypt Crisis!
Cemtech Dubai, 5-8 March 2011
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Delivering Results through State-of-the Art O&M Systems
O&M Organization
Training/Coaching
Preventive Maintenance
Production & Maintenance
Planning
Quality of Execution
Measures of Performance
Failure Reporting & Root-cause
analysis
Communi-cation
Continuous Improve-
ment
Thermoteknix VisIR 3:32:01 PM 2/16/2007 e : 1.00 Bg : 25.0C-20.0
160.0
38.9
94.7Celsius
45.0
50.0
55.0
60.0
65.0
70.0
75.0
80.0
85.0
90.0
WINDING JUNCTION100.3
WINDING JUNCTION95.1
Cemtech Dubai, 5-8 March 2011
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Delivering Results through Continuous Improvement
Raw Mill Situation
Quartz content of materials on grinding table is up to 23% compared with just 7% in raw materials High load of large particles on the separator due to high gas velocity in the nozzle ring and in the transition zone between mill and separator High wear at outlet duct & cyclones
Improvements
Switched to sintercast roller segments Increased nozzle ring area Raised lower housing of separator by 2 m Installed densit lining at outlet duct & cyclones
Cemtech Dubai, 5-8 March 2011
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Delivering Results through Continuous Improvement
Kiln Situation
High wear of refractory of tertiary air damper Alkali attack on kiln nose ring area Process control by Operator
Improvements
Switched to silicon carbide castable for the tertiary air damper, nose ring and area between nose ring and retainer ring Installed Process Control Expert (PXP)
Cemtech Dubai, 5-8 March 2011
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Delivering Results through Continuous Improvement
Cooler Situation
Cross-bar cooler designed for 6000 tpd
Recurring red rivers
Improvements
Upgraded cross-bar cooler to seagull design, which increased kiln output to 6700 tpd
Cemtech Dubai, 5-8 March 2011
Before upgrade
After upgrade
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Delivering Results through NLS Copenhagen Technical Support
Performance Diagnostic
Center
Spare Parts Support
Bottleneck assessment
Efficiency improvements
Mechanical Inspections
Technical Training
Research &Development
Cemtech Dubai, 5-8 March 2011
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Delivering Results by Preparing Future Cement Engineers
Partnership with Helwan
University
Total of 40 Engineering
Students in the First Year
Theoretical and Practical
Cement Technology
Training
Cemtech Dubai, 5-8 March 2011
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Delivering Results, SAFELY
Building a Culture of Safety
Focus on hazards control
Work Safety Guidelines
OHSAS 18001 Certification
5S Implementation together
with Arabian Cement
Cemtech Dubai, 5-8 March 2011
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Delivering Results, by having FUN!
Cemtech Dubai, 5-8 March 2011
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Actual Results
2,009 2,010 Kiln Average Production Rate, % of design capacity
103% 106%
Kiln Net Availability, % 92% 92%Kiln MTBF, hrs 301 256Safety LTIFR 6.9 2.81
Cemtech Dubai, 5-8 March 2011
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We signed a second contract with NL Supervision because they deliver their commitments and can be depended on to support us even in difficult times. They are strongly focused on solving bottleneck issues, improving plant productivity and ensuring long-term plant reliability.
Arabian Cement aspires to be the clinker and cement producer of reference; we see NL Supervision as the partner who can support us with that aspiration.
Jose Maria MagrinaCEOArabian Cement Company
What Our Customer Has to Say
Cemtech Dubai, 5-8 March 2011
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