Training Review 2015

Training Review
2015
,
and First Deputy Prime
Minister
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At Alba, we consider people our most valuable resource and in today’s
competitive world we must continue to push the envelope on training
and development.
We believe that it is through dedication and an enduring commitment
to education that our company and employees will continue to grow
and prosper for future generations.
The Training and Recruitment Department plays a major role in
developing the future generations of leaders at Alba. We focus on
finding the right development paths for the employees and providing
them the right tools for success. Through our training and development
programmes we strive to improve employee capabilities and
organisational competences, which in turn leads to a more productive
and satisfied workforce.
At Alba, we are very proud that to have achieved an 87% Bahrainisation
level. Working together with our education partners, we take pride in
developing the future generation of Bahraini leaders. Alba strives to
ensure that we provide a unique and excellent place for our employees
to work and we understand the pivotal role that we play within the
Kingdom of Bahrain.
Alba is in the “People Business” and the success of our people is linked
directly to the bottom line.
Tim Murray
Chief Executive Officer
MESSAGE
FROM THE CEO
5
Total Training Hours
2012
2013
2014
2015 (as of July)
COMPUTER
16
3,060
4,064
1,323
SAP
1,638
1,236
2,873
2,236
VEHICLE
92,649.6
74,800.5
38,069.6
15,670
SAFETY
15,860
26,982
22,113
13,879
MANAGEMENT
0
5,140
14,543
6,835
TECHNICAL
121,249
66,701.6
143,614
81,228
SKILL MATRIX
43,012
53,713
35,743.6
21,188
TDP
36,054.5
56,278.7
138,264
93,591
TOTAL
310,479.1
287,911.8
399,284.2
235,950
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TRAINING
STATISTICS
Number Of Employees Trained
2012
2013
2014
2015 (as of July)
COMPUTER
4
300
478
136
SAP
157
217
383
255
VEHICLE
1,593
1,264
980
436
SAFETY
2,872
3,707
4,736
5,416
MANAGEMENT
0
293
1,270
911
TECHNICAL
1,651
1,731
4,027
3,224
SKILL MATRIX
339
492
476
363
TDP
37
69
112
110
TOTAL
6,653
8,073
12,462
10,851
CHAPTER 1
EXECUTIVE AND MANAGEMENT SERIES
Course Title: “Leadership” Programme based on Robert E. Lee book.
Duration: 1 Day
Speaker: Speakers Karyn Williams Sykes & Adnan Butt from Bahrain
Institute
Overview:
Robert E. Lee was a leader for the ages. He was an American soldier and
was known as an exceptional officer, a brilliant strategist and combat
engineer in the United States Army for 32 years. The man heralded by
Winston Churchill as “one of the noblest Americans who ever lived”
inspired an out-manned, outgunned army to achieve greatness on the
battlefield.
The course highlighted the life of Robert E. Lee, which taught many
important lessons and helped people triumph over challenges faced
every day in business and other walks of life.
Course Title: “Public Speaking” Programme for Management
Duration: 2 days
Speaker: Andrew Card, Simon Doyle and Davind Rendall from EMIC Institute
Overview:
Of all the skills employers’ desire in employees, oral communication skills
rank the highest. Many surveys reveal that oral communication skills are
considered even more important than writing and math skills as well
as a number of other job-related qualities, such as initiative, technical
competence, and organisational abilities.
Focusing on oral communication can help employees gain an edge. Effective
oral communication skills help people to improve their performance, enhance
their subsequent professional competence and improve their own personal
effectiveness.
The course helped all attendees to gain an insight on oral communication and
public speaking and further develop these skills.
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CHAPTER 1
EXECUTIVE AND MANAGEMENT SERIES
Course Title: “Coaching & Mentoring” for Executives and Managers
Duration: 1 day
Speaker: John E Skladan, a well-known trainer with over 45 years’
experience of working with corporates such as Honeywell, Navistar and
Arc Automotive at Leadership levels.
Overview:
Coaching and mentoring are often the key elements of good capacitybuilding practice. In the past decade, coaching and mentoring have
increasingly been practised within the civil society sector, which are in
line with the trend towards ongoing capacity-building processes rather
than one-off events.
The course addressed the topics of coaching and mentoring, which are
popular capacity-building tools, especially in the area of leadership
development. It gave a detailed understanding on what coaching and
mentoring really involve, and where and when they work.
Course Title: “LPI 360 Feedback” for all Executives and Managers
Duration: 3 days
Speaker: Prof. Richard Daft from Vanderbilt University
Overview:
Conducted in coordination with Vanderbilt University, the 360
Feedback was an objective and aggregate rating of each leader’s skills
from all directions - direct reports, boss, and peers who work with that
leader.
The objective of this 360 feedback exercise was to aid Alba’s leaders
learn how others perceive their behaviour, and help them identify their
strengths and areas for improvement to build a positive culture at Alba.
CHAPTER 2
SOFT SKILLS COURSES
Course Title: Leadership and Influence - Based on Gen. Colin Powell
Leadership Style
Duration: 1 day
Speaker: John David Sicilia & Don Lee Redinius, BIHR Training
Overview:
This course sought to enhance the participants’ leadership skills and
performance by learning and applying proven leadership methods,
principles and rules developed by Colin Powell throughout his career. It
included understanding of leadership and its impact on organizational
performance and highlighted current and future leaders with proven
leadership principles, methods and rules.
Course Title: The Six Sigma Green Belt Training Programme for Management
Duration: 5 days
Speaker: In-house Master Black Belt Specialist Waleed Tamimi and his team
Overview:
The Six Sigma methodology was selected as a base for sustainable continuous
improvement. Alba has successfully implemented eight Six Sigma projects.
As part of a capability building model, continuous Six Sigma training sessions
were held during the year.
The objectives of the courses held were to:
• Reduce Operational Cost
• Increase Revenue
• Increase Throughput
• Eliminate Waste
• Minimise/Eliminate variations in processes
• Improve Sustainability
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CHAPTER 2
SOFT SKILLS COURSES
Course Title: Supervisory Management Development Programme for
Management
Duration: 5 days
Speaker: EMIC Training by Simon Doyle
Overview:
The course aimed to develop all Alba’s supervisors and 1st line
staff in supervisory management and team development areas to
perform improved activities in required areas of the organisation. It
also looked at ways to improve performance of supervisors through
planning, resource allocation and managing time effectively, as well as
building skills needed to develop efficient work relationships linked to
performance management in order to meet agreed business objectives.
Outline:
• Building Self Esteem and Assertive Skills
• Effective Communication Techniques
• The Art of Delegating Effectively
• Solving Simple Workplace Problems and making Routine Decisions
• Building Better Teams
• Conflict Resolution Techniques
• Business Coaching Techniques
CHAPTER 2
SOFT SKILLS COURSES
Course Title: High Performance Leadership Training for 2nd Line
Management
Duration: 4 days
Speaker: EMIC Training by Andrew Card and Simon Doyle
Overview:
The course covered vital aspects of leadership such as effective time
management, planning and delegation, advanced management and
leadership principles and techniques. In addition, it also involved a
unique pre-assessment of leadership qualities at the beginning of the
course and 3 months after.
Course Title: Industrial and Employee Relationship programme
Duration: 4 days
Speaker: Robert Coates, a management consultant with experience in
conducting programmes in UK and UAE.
Overview:
The objective of this programme was to provide an engaging workshop to
all 1st and 2nd Line management staff in order to create a positive industrial
relation and employee relation culture in Alba.
Course Title: Leadership & Change Management Programme for Management
Duration: 1 Day
Speaker: John Skladan
Overview:
Change is an ongoing and important process. For a successful organisation,
change management in the role of leadership is essential for the healthy
growth of any business. Change is impossible without the active participation
of management.
The course allowed attendees to understand the aspects of change
management and its importance for successfully running an organisation.
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CHAPTER 2
SOFT SKILLS COURSES
Course Title: Miracle Team Building Programme for Non-Management
Duration: 1 Day
Speaker: Karyn Williams Sykes and Adnan Butt, BIHR Training
Overview:
The course aimed at creating the culture of One United Team across
Alba and comprised a short movie presentation along with a number of
team building activities, which promoted team work, trust, appreciation,
decision making, objective and goal setting.
Course Title: Workshop on “High Impact Leadership”
Duration: 1 day
Speaker: Shaun Harper, reputed leadership trainer of international
experience
Overview:
The course was based on the well-known book ‘Five Temptations
of a CEO’, and featured video clips on motivational quotes and on
temptations of leaders; role plays where delegates were randomly
selected to play characters with an objective to ensure that participants
understand basic principles in the book; questions and answers; and
case studies and group exercises to reinforce understanding of the 5
temptations faced by a leader. The book was also distributed to the
participants.
TIM’S BOOK CLUB
A new initiative by the Executive Management of Alba, Tim’s Book
Club has been established with the sole aim of developing a reading
culture in Alba. The approach behind introducing this new facility for
all Alba employees is that reading is one of the most fundamental skills
required to succeed in life. Through this Club, employees will have
access to well-known business/management books, which will help
them enhance their skills and capabilities.
Brining more value to the reading experience, books with the highest
reading rate will be converted into workshops, thus giving insights
about the author, the book and lessons from it. To assert the value
of reading, Tim’s Book Club was integrated into the Training &
Development Programme (TDP).
Starting with Silver followed by Gold and Platinum levels, members of
the Club will graduate to higher stages as they continue reading books.
The different levels established are based upon higher learning and
understanding of the various subjects.
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CHAPTER 2
SAFETY, HEALTH & ENVIRONMENT TRAINING
Developing its safety culture across the plant and achieving a zero
accident work environment has remained Alba’s priority in the past
year. This resoluteness translated into numerous training programmes
in Safety, Health and Environment within 2015, which ensured that
all employees were made aware on being responsible and safe in all
aspects of their life.
In 2015, among other standard SHE courses, various other topics are
also being covered such as Accident Investigation, JSP and Planned Job
Observation, Risk Assessment, Permit to Work, Working at Height, Be a
leader in Safety and one week in house made movie festivals. Courses
held covered both management and non-management employees, thus
ensuring that every employee becomes an ambassador of safety.
CHAPTER 3
Development Programmes- The MBA and TDP
As part of Alba’s education programme to develop its leadership, a total
of 22 employees are pursuing their Masters in Business Administration
(MBA) with 12 students in the ESSEC’s MBA Programme from French
Arabian Business School Bahrain, 3 students in UK and 7 in United
States. Some more will join very soon. The objective of the education
programmes is the overall professional development of Bahraini
leaders, which would enhance their knowledge, skills and leadership
driving Alba towards excellence among other smelters around the
world.
Strengthening the quality of Bahrainisation at all levels is part of
Training and Recruitment Department’s goal, and it is achieved via an
intensive programme called TDP (Training Development Programme).
Selected Bahraini employees with potential are identified and then
trained to become future leaders who will replace expatriate managers.
In addition to 2014 list, quest continued in 2015 also for talented and
potential employees to be able to make them future Alba Managers.
98 employees are undergoing targeted TDP program for higher
management positions presently.
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CHAPTER 3
Development Programmes- The Apprentice
Alba initiated the Apprentice Programme with the aim of identifying
individuals who will meet company’s business goals and objectives and
thereby, improve overall leadership skills of Alba employees.
The first season of the Apprentice Programme for management
employees kicked off in June 2014 with 10 participants being given
various tasks and challenges over a period of 3 weeks. The selected
candidates were divided into two teams, who then had to complete
a set of tasks. A panel of judges headed by CEO Tim Murray and
comprising executives and managers evaluated the candidates’
performance, and following a process of elimination, one successful
winner was selected.
In the second season of the Apprentice commenced in November 2014
and comprised non-supervisory level employees as the participants of
the programme.
The Apprentice Programme 2015 was kicked-off in April 2015 to
identify talented individuals who can fulfil Alba’s business goals and
objectives and thereby, enhance the leadership of the company. In this
year’s edition, a team from non-supervisory employees challenged a
team of supervisory employees.
Participants gained a lot from their interaction, the different projects
given and challenges faced. They will forever cherish this experience
and lessons learnt.
License Issuance and Renewal
Alba works with many types of heavy equipment and cranes, which are
especially designed for a smelter. A license ensures that all operators
are well trained and equipped with the skills to drive and operate the
vehicles and cranes.
Alba’s in-house facilities and experts provide the required training,
mentoring and assessment to its operators. The SAP system provides all
the records with respect to their general training, on–the-job training,
assessment and licensing both for provisional and operational. This
system allows the department to monitor and update their operator’s
license, and provides a safe environment where operators are working
safely for better efficiency and productivity
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CHAPTER 3
Development Programmes - VT’s
Alba’s Vocational Training scheme has been a vital part of the Company
for over 25 years with regular intake of vocational trainees. The
objective of this programme has been effective Bahrainisation of the
non-supervisory maintenance manpower of Alba.
The intake eligibility is a minimum of a technical National Diploma. The
duration has been optimised to 2 years resulting in speeding up of the
Bahrainisation process.
After successfully completing the programme, the trainee enters
the maintenance manpower with competence to work as skilled
maintenance staff in the relevant discipline.
The structure of the programme is modular. The duration of 2 years is
divided into 8 phases wherein each phase comprises two parts -- offthe-job component in Training Centre and on-the-job component as
plant attachment. In every phase, the on-the-job schedule is closely
linked to the associated off-the-job training input. The trainees as well
as the field mentors are able to be more objective because areas to be
covered during every on-the-job training period are clearly defined.
- Training Centre Input: - Plant Attachment: 42 weeks.
54 weeks.
The training areas focus specifically on the equipment and processes
the trainees will be required to work on. In addition, the trainees are
required to complete a project work during the programme enabling
them to apply the theoretical knowledge onto original technical project
with measurable results.
Chapter 4
Technical Courses
CHAPTER 4
TECHNICAL COURSES
Course Title: Oxy-Acetylene Cutting Process
Duration: 2 days
Speaker: Sr. Mechanical Instructor, Asterio Pavia
Overview:
This course, designed to enable participants gain essential knowledge
of gas cutting in the oxy-acetylene process, focused on providing skills
and knowledge required to service, maintain, repair or fabricate within
a metal work environment in order to improve productivity and quality
within the workplace or improve the participant’s own skills.
Outline:
• Understanding the oxy-fuel cutting process
• Prepare for the oxy-fuel cutting operation
• Visual identification of cutting defects due to cutting torch
manipulation, angle
• Caring for and storing cutting equipment, tools.
• Safe handling of oxy – acetylene
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CHAPTER 4
TECHNICAL COURSES
Course Title: Advanced Gas Turbine Operations PowerStation 4
Duration: 3 Days
Speaker: Sr. Instructor Power, T. Puranayya
Course Title: Advanced Gas Turbine Operations PowerStation 3
Duration: 3 Days
Speaker: Sr. Instructor Power, T. Puranayya
Overview:
This programme was designed for those who attended the 5-day course
on Basic Gas Turbine Operations PS-4. The course covers vital aspects
of operations in the Control Room and includes topics like operating
principles, operation techniques during start up, normal and shut down
instances and emergency situations and troubleshooting.
Overview:
This programme was designed for those who attended the 3-day course
on Basic Gas Turbine Operations PS-3. Its contents cover important
aspects of gas turbine operations in the Control Room and include
topics like operating principles, operation procedures for start-up and
normal and shut down including emergency operations.
It aims at providing senior operators with important information on
normal and emergency operations of gas turbine and associated
equipment as well as procedures involving start-up and shutdown. The
technical discussions, which include a number of aspects of gas turbine
operation are helpful to the operators.
The programme aims to allow senior operators gain a deeper
understanding of normal and emergency operations of gas turbine and
associated equipment as well as procedures involving start-up and
shutdown.
Outline:
• Analysis of Gas turbine operations
• Control and protection of gas turbines
• Control and protection of generator
• Reactive power and power factor
Outline:
• Analysis of Gas turbine operations
• Control and protection of gas turbines
• Control and protection of generator
• Reactive power and power factor
CHAPTER 4
TECHNICAL COURSES
Course Title: Virtual Machine (VM) ware Training
Duration: 5 days
Speaker: Samesh Dhankar, Training Plus Institute, Bahrain
Overview:
Power Station 4’s highly efficient 930 MW dual-fired combined cycle
plant has one of the largest HMI (Human Machine Interface) system
from ABB called OpIT. This has been upgraded to state-of-the-art ABB
800xA system for communicating with Advant Master, combined with
Power Generation Information Manager (PGIM), which is based on
Virtualization platform.
All new Human Machine Interface (HMI) servers are on VMWare ESXi
5.1 server technology to operate the combined cycle power plant
for the first time in the Middle East and third in the world. Each VM
(Virtualization machines) host is replacing four physical computers
and in total, both block 5 and block 6 are installed with 4 VM hosts in
redundant configuration connecting all new 25 clients.
The course defined and described the need for Data Center
Virtualization, and provided an overview of the features of vSphere
5.5. It also defined how VMware’s products help solve business and
technical challenges with regards to Data Center Virtualization.
Outline:
• Module 1: Introduction to Data Center Virtualization with VMware
vSphere – Overview & Examples.
• Module 2: Components of VMware vSphere.
• Module 3: Participants apply what is learnt about Data Center
Virtualization to overcome availability, scalability, optimization and
management challenges encountered by sample companies.
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CHAPTER 4
TECHNICAL COURSES
Course Title: Maintenance of Rotating Equipment
Duration: 3 days
Speaker: Sr. Mechanical Instructor, Asterio Pavia
Course Title: General Electric (GE) Remote Terminal Unit (RTU) Training
Duration: 5 days
Speaker: Dawood, JAL International, Saudi Arabia
Overview:
The course gave attendees an understanding of the process of shaft
alignment by application of the method as well as a detailed exposure
to key factors in the production of a good shaft alignment result.
The attendees were also taken through a bearing selection process
for the shaft previously designed and trained on how the original
design choices affects the use and care of the bearing and equipment
throughout its operating life.
Overview:
GE RTUs are used in the Power Plant to monitor the HT Power
Distribution and the XA/21 SCADA software is used for control and
monitoring. A total of 11 RTUs and BCUs (Bay Control Unit) are being
used for PS-1 to PS-4 and for Gas Compressors connected to 8 nos.
Oracle servers through Fibre optic network (Ethernet) for the Data
Acquisition, trending, alarms and events.
Outline:
• Anti-friction bearings and plain bearings, and the uses and limitations
of each
• Bearing lubrication and selection
• Bearing housings and construction
• Effects of shaft misalignment
• Standards and limits for alignment
• Methods of precision shaft alignment
This course provides hands-on training for the participants.
Outline:
• Detailed explanation on the D20 Hardware, troubleshooting and
maintenance
• Detailed explanation on D20 RTU functions
• Detailed explanation on D20 RTU to SCADA system communication
• RTU Configuration using Configpro version 5
• Practical training on the configuration and maintenance
CHAPTER 4
TECHNICAL COURSES
Course Title: ECM (CM 850) Familiarization
Duration: 2 Days
Speaker: Sr. Instructor Automobile, Danilo A. Perez
Overview:
The course enables participants to get familiarised with the Cummin’s
Electronic Control Module (ECM – CM850) design, components and
operations. It also provides trainees with the required skills and
knowledge to conduct minor trouble shooting activities on Cummins
Engine Electronic system.
Outline:
• Review on Cummins QSB 4.5/6.7 Familiarization and Maintenance
• ECM (CM 850) Design Concepts
• Input Devices: Sensors and Switches
• Output Devices: Fuel Injector Solenoid
• Testing the Electrical Equipment
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CHAPTER 4
TECHNICAL COURSES
Course Title: Basic Units, Measurement & Calculations
Duration: 5 days
Speaker: Mahmood, NIIT, Bahrain
Course Title: Hydraulics Proportional Valve Card Adjustment
Duration: 2 days
Speaker: Sr. Instructor Hydraulic & Pneumatics, Kamal K Jan
Overview:
The course was designed for Operators and Maintenance Fitters in order
to help them further develop and strengthen their overall knowledge
and performance.
Overview:
This was a specially designed course on proportional valves and
amplifier card fine-tuning of Casthouse 2 & 3 equipment. The technical
details and fine-tuning procedures are helpful to the maintenance
personnel and various practices, live demonstration is done in the
plant.
Outline:
• Introduction to Units in Measurement
• Basic Formulas
• Basic Electricity
• Basic Scientific Measurements
• Basic Mechanics
• Basic Constants
Outline:
• Introduction to Proportional & Servo Hydraulics
• Proportional Valves: Design and mode of Operation
• Proportional valves: Characteristic Curves and Parameters
• Amplifier and set Point Value Specification
• Switching examples using Proportional Valves
CHAPTER 4
TECHNICAL COURSES
Course Title: HERZOG M/C PLC (SIEMENS – S7)
Duration: 4 days
Speaker: Sr. Instructor Instrumentation, Venkata Murty
Overview
This course is for instrument maintenance personnel of CH to enable
them install every component and module, including wiring in a Herzog
Siemens S7 PLC system, and be able to program the processor for any
situation and requirement in the plant, including trouble shooting
problems by accessing software.
Outline:
• S7 – Family S7 – Software
• Create New Project
• Herzog PLC - Hardware
• Connecting to PLC
• Uploading / Downloading
• Memory Addressing
• Blocks Structure
• Basic Instructions
• Documentation
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CHAPTER 4
TECHNICAL COURSES
Course Title: Casthouse Burner Management System
Duration: 2 days
Speaker: Sr. Instructor Instrumentation, Venkata Murty
Course Title: Reduction Emission Monitoring Systems
Duration: 2 days
Speaker: Sr. Instructor Instrumentation, Venkata Murty
Overview:
Especially beneficial for new trainees and CH Instrument personnel, the
course provided an introduction as well as a detailed description on
Casthouse Burner System.
Overview:
This course was designed to provide an introduction and detailed
description of HF and Dust analysers used in Reduction Lines and Stack.
This course was especially useful for the new trainees and Reduction
Lines personnel.
Outline:
• Introduction to CH Furnaces
• Safety while working with Gas Burners
• Introduction to Burner system Interlocks
• Start-up & Shut down Sequence
• Burner Controller & flame supervision
• Adjustment of Gas/Air Ratio
• Troubleshooting
• PLC Program
Outline:
• Introduction to Gas Analysers
• Introduction to Principle of Analysis (LASER)
• Different Types of sensors used
• Hardware & System Components
• Calibration of the analyser
CHAPTER 4
TECHNICAL COURSES
Course Title: EOT Crane Electrical Controls & Brake
Duration: 2 Days
Speaker: Sr. Electrical Instructor, Ravi
Overview:
This course - designed for all electrical and instrument skilled fitters,
technicians, supervisors working in Maintenance section - provides
knowledge and skills required to maintain Electrical equipment and
controls of Electrical Overhead Travelling cranes in safe operational
condition. It familirizes trainees on crane controls, brakes, various
modes of operation, various safety devices and protections used in
cranes.
Outline:
• Different types/makes of EOT cranes in Alba
• Crane Terminology & Specification
• Crane current collecting system
• Understand the various modes of operation
• Crane duty motors and speed control
• Different types of electrical braking system
• Understand the various electrical control requirement
• Study of power & control schematic diagram
• Study of PLC programs
• Understand the various safety devices.
• Crane Interlocks / Alarms & Protections
• Plant visit
• Maintenance and Troubleshooting
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CHAPTER 4
TECHNICAL COURSES
Course Title: Line 4 Dual Pot-Control System Maintenance
Duration: 2 days
Speaker: Marcin Puchalski, Rio Tinto Alcan, RTA Alesa Ltd.
Course Title: Cummins Engine Fundamentals QSB 4.5 / 6.7
Duration: 2 Days
Speaker: Sr. Instructor Automobile, Danilo A. Perez
Overview:
This course is designed for instrument maintenance personnel to get
familiar with the basic operations, troubleshooting and fault finding on
the new Dual pot Micro of Reduction Line 4.
Overview:
The course enables participants to familiarise themselves with the
Cummin’s Diesel Engine System design, construction and operations.
It also provides trainees with the required skills and knowledge to
conduct proper preventive maintenance activities on the Cummins
engine.
Outline:
• Introduction of process and explain setting of process parameters
• Guidelines of DC Hazard inside Pot Room & Super Structure
• Explain Micro Pot Function (Site Visit)
• Explain Block Diagram on Micro Pot
• Explain Functions of Keyboard and how to test it
• Explain Functions of Boards and Method of Testing
• Communication Theory and Micro pots Communication
• Network Communication (Visit Automation Site)
• Normal Problems encountered in Micro pots & their Solution
• Significance of Various Alarms Generated and Action to be taken
Outline:
• Review diesel engine’s theory of operation
• Construction and application of Cummin’s Diesel engines
• Major operating systems of Cummin’s Diesel engines
• Air, Fuel, Lubrication and Cooling System
• Conducting Cummin’s Maintenance
CHAPTER 4
TECHNICAL COURSES
Course Title: Casthouse Screw Compressor & Air Dryer
Duration: 1 day
Speaker: Sr. Instructor Hydraulics & Pneumantics, Kamal K Jan
Overview:
This course enables participants to familiarise themselves with
the operation and systematic procedure for servicing, overhauling,
troubleshooting and failure analysis of screw compressor and air dryer
units. It also provides the trainees with extensive skills and knowledge
to eliminate the problems and failures. Moreover, It provides them with
case studies.
Outline:
• Basic Principles of operation
• Replacement of parts
• Lubrication system/Bearing Maintenance
• Gear Units
• Servicing & Overhauling
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CHAPTER 4
TECHNICAL COURSES
Course Title: Micro Motion – Mass Flow Meter
Duration: 2 days
Speaker: Sr. Instructor Instrumentation, Venkata Murty
Course Title: Fuel Injection (Common Rail) System
Duration: 1 Day
Speaker: Sr. Instructor Automobile, Danilo A. Perez
Overview:
This course is designed to assist instrumentation maintenance
personnel to understand the principle of Mass flow measurement
and working of Micro-motion mass flow meter used in Carbon and
Casthouse. The attendees were given information on the procedures for
calibration, characterisation and parameterisations of the flow meter.
Overview:
This course enables participants to familiarize with the Cummin’s
Fuel Injection System, its design, construction and operations. It
also provides trainees with the required skills and knowledge to
conduct proper maintenance procedures on the fuel system and
troubleshooting on engine failures due to the fuel system.
Outline:
• Principles of Mass Flow
• Coriolis principle
• Features of Micromotion F series
• Procedure for Calibration
• Procedure for Characterization
• Parameters of Micro –motion
• Communication with HART HHT
• Connection & Communication with PC
• Troubleshooting using PC based software
Outline:
• Review on Fundamentals of Fuel Injection System
• Advantages of the Common Rail System
• Components Overview
• High Pressure Pump and Transfer Pump
• Fuel Metering Control Valve
• Common Rail
• Fuel Injectors
• Discussion on Engine Problems related to Fuel Injection System
CHAPTER 4
TECHNICAL COURSES
Course Title: Aluminium Production Technology
Duration: 3 Days
Speaker: Halvor Kvande, Renowned Professor from Norway for
Aluminium Technology
Overview:
Held in coordination with Gulf Aluminium Council (GAC), this training
enables trainees get familiarized on global updates from a renowned
consultant, who is famous for his research work on the process of
primary production of aluminium and gain updates in this field as well
as participate in practical exercises training.
Outline:
• Hall – Heroult Process & Prebaked Anodes
• Heat Balance in Aluminium Electrolysis Cells
• Work Practices and Cell Operation
• Bath Compositions and Properties in the cell
• Current Efficiency & Energy Consumption
• Alumina and its properties & Feeding Technology
• Amperage Increase Projects
• Modernization of Prebake Cells
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CHAPTER 4
TECHNICAL COURSES
Course Title: SOLIOS GTC / FTC Technology & Control System
Duration: 2 Days
Speaker: Jeremy Neveu, Solios, USA
Course Title: ALPSYS Dual Pot control system on Reduction Lines
Duration: 8 days,
Speaker: Bernard Molinier, Rio Tinto Alcan Operation Specialist
Overview:
The training on Reduction Gas Treatment Technology is in line
with Alba’s management initiative to use the resources of original
equipment manufacturers and technology providers for providing
important technological know-how on GTC / FTC Technology & Control
System defects simulation and troubleshooting, technical consultancy
and training to our Reduction Lines GTC / Carbon FTC operation staff.
Overview:
The training on Reduction Technology is in line with Alba’s management
initiative to use the resources of original equipment manufacturers and
technology providers for providing important technological know-how
on ALPSYS Dual Pot Control system, technical consultancy and training
to our staff.
Alba has taken particular interest in this endeavour since last three
years and rich dividends are already visible in terms of improved
knowledge and competency of our operating staff.
Course Outline:
• Fume Collectors
• Dry Scrubbers & its Modules
• Alumina Handling, distribution and storage
• Fans & Blowers and Water cooling systems
• Emergency Bypass & Assessment Test
• Routines Inspection
• Defect Simulation
Course Outline:
• In depth knowledge of Pot Process Control
• Pot Alumina feeding Control
• Thermal Regulation & Control
• Thorough understanding of Level-2 Reports & Status
• Usage of New Dual Pot Micro
• in operation
CHAPTER 4
TECHNICAL COURSES
Course Title:Induction Furnace Control and Maintenance
Duration: 3 days
Speaker: Sr. Electrical Instructor, Ravi
Overview:
This course aims to provide electrical &instrument skilled fitters,
technicians, supervisors and engineers working in Carbon Rodding
plant and cathode sealing E & I Maintenance section with knowledge
and skills required to maintain Induction Furnace in safe operational
condition. This course familiarises trainees on Furnace controls,
Furnace coil Insulation Monitoring, rebuilding of coil insulations and
reassembling of furnace including Furnace cooling system and different
protections
Outline:
• Working principle of Induction Furnace
• Different types / makes of Induction Furnace used in Alba
• Study of power & control schematic diagram
• Converter, Inverter &Melt Manager controls
• Furnace Earth leakage monitoring
• Cooling system
• Furnace Interlocks / Alarms & Protections
• Rebuilding of Coil insulation & Furnace assembly
• High voltage & Furnace operational safety
• Plant visit
• Maintenance and Trouble shooting
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CHAPTER 4
TECHNICAL COURSES
Course Title: LV MCC Maintenance Course
Duration: 5 Days
Speaker: Schneider Electric UAE - Dr. Nabil & Krishnan
Overview:
This course, which was delivered in collaboration with Alba Training,
was held for Electrical Maintenance staff as an initiative towards
improving their overall knowledge and skills to carry out safe
maintenance of Motor Control Centres (MCCs) in the plant.
Outline:
• Better personal confidence in approach to working safely with power
switchgear
• Understanding “competence” and Safety & Health at work
• Awareness of the fault level and fault currents within equipment
• Detailed understanding of the various interrupting mediums, air,
vacuum and SF6
• Understanding protection, isolation and switching
• Understanding the following types of faults: Over current, Short
circuit, Ground fault, and Arc Fault
• Appreciating the differences between earthing and bonding.
• Understanding the need to carry out appropriate maintenance,
inspection, test & certification of installations, equipment and
appliances
• Familiarise with the different types of MCCs at Alba
Course Title: Rockwell: Maintaining and Troubleshooting a Device
Network
Duration: 5 Days
Speaker: Sr. Electrical Instructor, Ravi
Overview
This course prepares participants, who are mainly technicians,
supervisors and engineers from electrical and instrumentation field
to return a malfunctioning Device Net network to normal using RS
Networx for Device Net software operation and complete basic
hardware and software maintenance tasks with minimum downtime.
Outline:
• Identifying Device Net Network Components
• Maintaining and Troubleshooting a DeviceNet Cable system
• Maintaining and Troubleshooting a DeviceNet Power Supply
• Connect / Add / Replace Device to a DeviceNet Network
• Troubleshooting a DeviceNet Network
• using RSNetworx for DeviceNet Software
• using Hardware indicators
• using RSLogix 5000 Software
• Troubleshooting duplicate nodes on a DeviceNet Network
• Macros, Symbols and Security
• RSView SE Client and SE Administration Console
Chapter 5
Training Workshops
CHAPTER 5
Training Workshops- Then and Now
Before
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After
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CHAPTER 5
Training Workshops- Then and Now
Built in the early 1970’s, Alba’s Training Centre had an administration
office and training was imparted at different areas around the plant.
Within the next few years, the centre owned the training administration
block with few class rooms and offices, and then, four workshops were
built for conducting technical programmes and equipment training.
Technical training revolved around basic skills in mechanical, electrical,
welding and automotive trades. The trainees were imparted with skills
to enable them to work as fitters in maintenance functions. Over the
years more equipment was received from plant areas; maintenance
training now focused equally on theory and practical skills.
The new training workshop, built in 2015 near the Training and
Recruitment building, is bringing about a radical change in the methods
of technical training. There are five workshops dedicated to each of
the five maintenance disciplines - Automotive, Mechanical, Electrical,
Instrumentation and Hydraulic & Pneumatic – and comprise state of the
art equipment, simulators, workbenches and cranes.
Every trainee gets a spacious work area for carrying out his practical
activity, thus improving safety during training. The workshop area
is centrally air conditioned and has a well-designed lighting. Each
workshop is also provided with a separate store to house the tools and
spares used during training. The theoretical training will take place in
the nine Smart Classrooms with networked computers, projectors and
tablets. The trainees will also have the benefit of an amenity facility
with locker rooms, dining hall and prayer room.
For any large organisation with high reputation it is vital to have
training facilities which would help prepare its employees for high
standard skills and techniques to run different processes and maintain
sophisticated machines and equipment. Since Alba started 1971, the
company had this advantage.
A unique working environment coupled with hazards and risks posed
continuous challenges to the Alba management, which had to then
modify and improve the existing facilities.
At Training and Recruitment Workshops there are various sections and
equipment to meet maximum need of the smelter:
• Instrumentation Workshop
• Automotive Workshop
• Mechanical Workshop
• Electrical Workshop
• Hydraulic & Pneumatic Workshop
CHAPTER 5
Instrumentation Workshop
PRESSURE CONTROL TRAINER
This trainer assists the trainee to understand pressure principles,
regulation and control, usage of pressure relief valves and pressure
control valves
MICROMOTION FLOW TRANSMITTER
This special instrument is used in Carbon for measuring liquid pitch
flow accurately. The principle of measurement is unique and the same
principle is also used in Casthouse 3 for Billet casting speed control, in
Carbon 3 for liquid pitch control and in Calciner for CO2 dosing control.
WEIGHING SIMULATION PROJECT
This project developed by Alba VTs team aids in training Load cell and
weighing principles, measurement, diagnose problems associated with
weighing systems and calibration of the same.
MIXER SIMULATION PROJECT
This project developed by Alba VTs using PLC-5 assists the trainees
to understand the usage of various types of controls like pneumatic
motors, photo sensors, load cells, solenoids, level sensors, etc.
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CHAPTER 5
Instrumentation Workshop
INSTRUMENT CALIBRATION BENCH -1
This calibration Bench is based on Beamex MC5P host module and
is equipped with other necessary modules to calibrate any type of
Pressure transmitters and temperature transmitters.
INSTRUMENT CALIBRATION BENCH -2
Similar to Bench-1, this calibration Bench is based on Beamex MC5P
host module and is equipped with other necessary modules to calibrate
any type of Pressure transmitters and temperature transmitters.
INSTRUMENT CALIBRATION BENCH -3
This calibration Bench is a multipurpose calibration and testing Bench
for instruments other than pressure & temperature. This also features a
temperature controlled Soldering Station.
INDUSTRIAL VALVES TRAINER -1 & 2
Cut–away models of different types of valves are provided for better
understanding of function of various valves and their inner parts for
maintenance and replacement.
CHAPTER 5
Instrumentation Workshop
SLC Trainer
Simulator for training participants on existing SLC 500 controls. Input/
output simulator is provided to simulate both analog & digital signals
for testing small programs.
AUTOMATIC ASSEMBLY TRAINER
This automatic assembly plant simulator has two parts, one plastic and
another metallic are sorted separately and the assembled together. If
any part of the assembly is missing, it is detected and automatically
rejects the part.
Instructor can simulate faults on the field side, enabling trainees to
learn troubleshooting and find the faulty sensor / device and replace
the same in a running plant environment.
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CHAPTER 5
Instrumentation Workshop
DISTILLED WATER PRODUCTION PROJECT
This project designed and developed by Alba VTs helps trainees
understand heat exchange principles by producing steam using PLC
digital controls with level sensors and also usage of remote Input /
Outputs.
TANK WATER LEVEL CONTROL PROJECT
This project designed and developed by Alba VTs empowers trainees
with understanding of process control using PLC PID (Proportional,
Integral & Derivative) and also helps them to understand practically
about level measurement, flow measurement, pressure measurements.
PLC CLASS ROOM
PLC-5 TRAINER & I/O SIMULATOR
Two nos. simulators for training participants on existing PLC-5 controls
in Carbon & Reduction plants. Input/output simulator is provided to
simulate both analog & digital signals for testing small programs.
CHAPTER 5
Automotive Workshop
Drilling Machine A drilling machine (also known as drill press, pedestal
pillar drill, or bench drill press) is a fixed type drilling machine to open,
enlarge and to finish holes by drilling, reaming, boring, counter boring,
counter sinking, and tapping.
Parts Washer The Parts Washer is a recirculating machine used for
cleaning / degreasing parts or components. It is equipped with a
pump that recirculates the cleaning solutions and a brush that helps to
remove stubborn greases.
Engine (Cummins QSB 4.6) Cut Away Assembly This assembly is to be
used to train participants on familiarising themselves on the Cummins
QSB 4.6 Engine. The cut away construction of the engine can allow
them to appreciate the operations of the engine and identify the
different parts and components.
Differential (Kessler) Assembly This assembly is to be used to train
participants on familiarising themselves on the Automotive Differential
Assembly. The Kessler Differential is used in almost all of Alba heavy
industrial vehicles. The training module will include disassembly, parts
familiarisation and inspection, differential operating principles and
assembling procedure.
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CHAPTER 5
Automotive Workshop
Hydraulic System Fundamentals Trainer and Hydraulic Valves
Components The Hydraulic System Fundamentals Trainer teaches on
the basic principles of hydraulics and familiarization on the operations
of hydraulic system. Through the use of different hydraulic valves
and actuators, we are able to design and construct intended hydraulic
system operations. This would allow that participants to work through
a hydraulic circuit drawings.
Hydraulic Valves Trainer The Hydraulic Valves Trainer teaches on the
design principles and operations of hydraulic control valves (such as
directional control valves, flow control valves and pressure control
valves). It is equipped with a transparent model of the valves to show
the internal components of the valves and the flow of fluids in the
hydraulic components.
Electro- Hydraulic Excavator Simulator The Electro- Hydraulic Excavator
Simulator teaches the operating principles of the hydraulic system of
an excavator. Training would start on the manual operations of the
machine moving towards solenoid operations wherein relay logics are
being utilized. Finally working with advanced hydraulics that deals
already with a programming logic controls (PLC).
Engine Exhaust Emission Analyzer The Bosch Emission Analyzer 850
is equipped to meet all current and known future requirements of
exhaust gas analysis on petrol and diesel engine vehicles. This would
help in enabling complete vehicle system analysis for advanced fault
diagnosis. This equipment is installed on the exhaust system of an
engine wherein the outgoing gas is analysed
CHAPTER 5
Automotive Workshop
Hydraulic Variable Piston Pump Cut Away Project The Hydraulic
Variable Piston Pump is a mechanical device that converts mechanical
energy to fluid power energy. This component is to be used to train
participants on familiarising themselves with the Hydraulic Variable
Piston Pump. The cut away construction of the Hydraulic Variable
Piston Pump can allow the participants to appreciate its design
construction, operations and identify the different parts.
Common Rail System Project The Common Rail System is one of the
fuel delivery system of an engine. This component is to be used to
train participants on familiarising themselves with the Common Rail
Fuel Injection System. The cut away construction of the Common Rail
High Pressure Pump can allow the participants to appreciate the design
construction, operations and identify the different parts.
Auto PLC (Compact Logix) Trainer A number of our heavy vehicles
workon a PLC system (Compactlogix by Allen Bradley). This component
is to be used to train participants on familiarising themselves with the
Compactlogix System, its hardware and wirings. This will also be used
for training uploading and downloading programs, as well as rewriting
programs.
Lifting Tackles This is a display stand is to be used in conducting
training on Overhead Crane (lifting tackles). The training will cover the
different types of lifting tackles, its proper inspection and correct usage
(rigging). This will also provide samples of lifting tackle failures and
rejects.
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CHAPTER 5
Automotive Workshop
Hydraulic Cylinder Cut Away Project This component is to be used to
train participants on familiarising themselves on the Hydraulic Cylinder.
The cut away construction of the Hydraulic Cylinder can allow them to
appreciate the operations of the different parts and seals used.
Starter Cut Away Project A Starter is used to initially start an engine. This
component is to be used to train participants on familiarising themselves
with the engine starter motor. The cut away construction of the starter
can allow the participants to appreciate its design operations and
identify the different parts.
Alternator Cut Away Project An Alternator is used to charge the
automotive batteries and to supply the required electrical power on
the vehicle. This component is to be used to train participants on
familiarising themselves with the engine alternator. The cut away
construction of the alternator can allow the participants to appreciate its
design construction, operations and identify the different parts.
Turbo Charger Cut Away Project The Turbo Charger is used to increase
the power of the engine utilizing the exhaust system to run a compressor
that will increase the volume of air to the engine. This component is to
be used to train participants on familiarising themselves with the Turbo
Charger Component of an Engine. The cut away construction of the Turbo
Charger can allow the participants to appreciate its design construction,
operations and identify the different parts.
CHAPTER 5
Mechanical Workshop
Lathe Machine The lathe is a machine tool used principally for shaping
articles of metal (and sometimes wood or other materials) by causing
the work piece to be held and rotated by the lathe while a tool bit is
advanced into the work causing the cutting action.
Milling Machine The milling machine removes metal with a revolving
cutting tool called a milling cutter. With various attachments, milling
machines can be used for boring, slotting, circular milling dividing, and
drilling. This machine can also be used for cutting keyways, racks and
gears and for fluting taps and reamers.
Radial Drilling Machine A drilling machine to open, enlarge and to
finish holes by drilling, reaming, boring, counter boring, counter sinking,
and tapping. Because of its angular and radial movement, it is able to
cover the entire working surface of the entire table and its precints,
a property which renders this machine much more versatile than the
upright type of drilling machine with its fixed spindle.
Drilling Machine A drilling machine (also known as drill press, pedestal
pillar drill, or bench drill press) is a fixed type drilling machine to open,
enlarge and finish holes by drilling, reaming, boring, counter boring,
counter sinking, and tapping.
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CHAPTER 5
Mechanical Workshop
Combined Mechanical Trainer 1 (Coupling/Shaft Alignment) This
mechanical training equipment combines the mechanical maintenance
training in one hands-on workstation relating to Couplings Drives, and
Shaft Alignment.
Combined Mechanical Trainer 2 (Belt & Chain Drive) This mechanical
training equipment combines the mechanical maintenance training in
one hands-on workstation relating to Belt & Chain Drives.
Combined Mechanical Trainer 3 (Pump Maintenance/Gear Drives &
Shaft Alignment) This mechanical training equipment combines the
mechanical maintenance training in one hands-on workstation relating to
Pump Maintenance, Gear Drives, and Shaft Alignment.
Bearing Maintenance This mechanical training equipment combines the
mechanical maintenance training in one hands-on workstation relating to
Care & Maintenance of Bearings.
Arc Welding Simulator The welding simulator teaches welding without
the use of base material, shielding gas, welding electrodes as well as
other supplies and consumables. The system also does not require weld
fume removal. Other costs that can be reduced through the use of virtual
reality welding are electrical consumption, scrap and waste. System
includes software and modem for connection to PC for results.
CHAPTER 5
Electrical Workshop
Electrical Lab Bench-1 This is a modular and multipurpose electrical
work station for service/repair, troubleshooting and testing of electrical
and electronic components and devices. Includes all voltage supplies
and measuring devices typically required for testing purpose.
Electrical Lab Bench-2 This is a modular and multipurpose electrical
work station for testing protection relays through secondary injection
and a current leakage tester for all electrical appliances.
Electrical Lab Bench-3 This is a modular and multipurpose electrical
work station for service/repair, troubleshooting and testing of electrical
and electronic components and devices. Includes Hi-pot tester for
transformers and models.
A.C. Motor Trainer In this trainer, motor wiring is accomplished through
banana jack receptacles on the control enclosure’s front panel face. This
unit equipped with an appropriate voltmeter and ammeter to monitor
the motor voltage and load current.
Four instructor fault insertion switches are provided on motor module.
An optional motor loading module attaches to motor unit using a
flexible coupling provided with the loading module.
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CHAPTER 5
Mechanical Workshop
Pedestal Grinder A pedestal grinder is a larger version of a bench grinder
that is mounted on a pedestal, which is bolted to the floor. These types
of grinders are commonly used to hand grind cutting tools and perform
other rough grinding. Depending on the grade of the grinding wheel it
may be used for sharpening cutting tools such as lathe tools or drill bits.
Alternatively it may be used to roughly shape metal prior to welding or
fitting.
Lapping Table Is a machining process, in which two surfaces are rubbed
together with an abrasive between them, by hand movement or using
a machine to obtain surface flatness and surface roughness. Though
flatness is the most common goal of lapping, the process is also used to
obtain other configurations such as a concave or convex surface.
Lay-out Table Is a bench table, with a smooth and flat surface where
a work piece is to be laid out in order to establish a reference lines or
planes, to outline the surfaces that are to be machined or to locate the
position of the holes to be drilled, etc.
Hydraulic Bench Press A Hydraulic Press, is a device using a hydraulic
cylinder to generate a compressive force. These presses use the pressure
generated by the pistons and the hydraulic fluids to assemble and
maintain the parts or components of an equipment.
CHAPTER 5
Electrical Workshop
Motor Manager Trainer- MM120 This Trainer developed by Alba VTs is
designed to provide in-depth knowledge of Motor Manager Operation
and Maintenance with respect to different protections and its immunity
towards various transients and harmonics with a view to enhance
availability, reliability and safety of the plant equipment.
Motor Manager Trainer- MMII This Trainer developed by Alba VTs is is
designed to provide in-depth knowledge of the Motor Manager II (MMII)
In one package combines control functions and comprehensive motor
protection, providing sophisticated control and protective relaying of
LV Motors.
VFD – Altivar 66 Trainer This Project developed by Alba VTs. A Variable
Frequency Drive (VFD) is a type of motor controller that drives an
electric motor by varying the frequency and voltage supplied to
the electric motor. Other names for a VFD are variable speed drive,
adjustable speed drive, adjustable frequency drive, and inverter.
VFD – Altivar71 Trainer This trainer is designed to provide in-depth
knowledge of Schneider make Altivar 71 AC Motor Speed Controller.
The Course should enable the participants to get familiarsed with
hardware as well as software of Altivar-71, including troubleshooting &
fault management.
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CHAPTER 5
Electrical Workshop
Motor Control Trainer A system of task-specific, motor-related training
devices allowing for training in the operational principles, wiring, fault
troubleshooting and application of industrial motor control devices. All
wiring is accomplished through banana-jack connections on the front
panel face, rather than directly to individual components. Four fault
switches for creating common component faults are provided.
Electrical Control Circuit Troubleshooting Trainer This Trainer allows for
in-depth hands-on training in industrial motor control wiring, operation
and troubleshooting. This device, provided with a comprehensive student
manual, creates a complete, self-paced learning system. Performancebased testing is provided through the use of 80 fault creation switches
and a built in testing timer. The student’s proficiency is established by
the number of faults covered within a given period of time.
Industrial Sensor Trainer A comprehensive training system allowing
for training in the design, application and control of commonly used
industrial sensors. The device can be used in conjunction with optional
sensor packages, and related automation equipment.
The training aid can be outfitted with a variety of photoelectric sensors
and proximity sensorsup on which the sensors can be mounted. Control is
performed though an on-board, “smart relay” controller.
Electrical Generation Fundamentals Trainer A training simulator
designed to demonstrate the principles of electrical power generation.
The device illustrates the relationships that an operator must master in
order to confidently operate modern generating equipment. This includes
the paralleling of generators, and connecting to a larger power grid.
CHAPTER 5
Electrical Workshop
AC Induction Motor Load test Trainer By conducting the load test on
three phase induction motor, the performance of the motor viz. slip,
power factor, input, efficiency etc. at various loads can be studied.
Automation Project - Anode Conveyor: This Project developed by
Alba VTs. This project deals with real work simulation scenario similar
to one in Carbon department Paste plant. It consists of 2 conveyors
and a cooling control system. First conveyor is the Anode Cooling and
Transporting Conveyor. At the end of the cooling conveyor, a crane
picks the anode and transports it to the second conveyor which is the
sorting conveyor according to anode size.
The complete sequence of operation is the integration of automation
by PLC5 control with Panel view HMI , and Variable frequency drives for
motor speed control.
Drivers / Automation Class Room
Control Logix simulator – 4 Nos. This Control Logix workstation is
intended for trainees who want to practise those job tasks that are
frequently performed on the plant floor. The workstation is designed
to be used as an aid for strengthening and maintaining skill sets and is
equipped with latest controllers from Rockwell automation.
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CHAPTER 5
Electrical Workshop
Soft Starter Trainer A motor soft starter is a device used with AC
electrical motors. The soft starter makes use of the fact that when the
motor voltage is low during start of the motor, the starting current and
starting torque is also low. This reduces the mechanical stress on the
motor and shaft, as well as the electro dynamic stresses on the attached
power cables and electrical distribution network, extending the lifespan
of the system.
AC Slip ring Induction Motor Trainer Slip ring or Wound rotor motors
are usually started with full line voltage applied across its terminals. As
these motors have external resistance connected to its rotor circuit, the
value of starting current is adjusted or kept minimum, by increasing the
resistance of the rotor circuit. This external resistance, connected in star,
thus kept at maximum when the motor starts and gradually cut-out as the
motor gathers speed. Slip Ring Induction Motors that increasing the rotor
resistance, not only reduces the rotor current, but the stator current too.
This implies that the starting current of the motor is reduced when an
external resistance is added in the rotor circuit
AC Induction Motor Star/Delta Starter Trainer The star delta starting is
a very common type of starter and extensively used, compared to the
other types of the starters. This method uses reduced supply voltage in
starting. The method achieved low starting current by first connecting
the stator winding in star configuration, and thenafter the motor
reaches a certain speed, throw switching contactor changes the winding
arrangements from star to delta configuration. By connecting the stator
windings, first in star and then in delta, the line current drawn by the
motor at starting is reduced to one-third as compared to starting current
with the windings connected in delta.
CHAPTER 5
Hydraulic & Pneumatic Workshop
Hydraulic Trainer 1 & 2 and Valve Stands The Hydraulic Trainer teaches
on the basic principles of hydraulics and familiarization on the operations
of hydraulic system. Through the use of different hydraulic valves and
actuators, we are able to design and construct intended hydraulic system
operations. This would allow the participants to work through a hydraulic
circuit diagram.
Students learn about:
Principles of Hydraulics, Basic symbols, Functional symbols, Hydraulic
pumps and motors, cylinders, accumulators, Directional control valves,
servo valves, pressure control valves, flow control valves measuring
devices and indicators, Open and closed loop control of energy.
Pneumatic Trainer 1, 2, & 3 The Pneumatic Trainer teaches on the
basic principles of Pneumatics and familiarization on the operations
of Pneumatic system. Through the use of different Pneumatic valves
and actuators, we are able to design and construct intended pneumatic
system operations. This would allow that participants to work through a
pneumatic circuit diagram.
Students learn about:
Principles of Pneumatics, Basic symbols, Functional symbols, motors,
cylinders, Directional control valves, pressure control valves, flow control
valves, measuring devices and indicators, Open and closed loop control
of energy.
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CHAPTER 5
Electrical Workshop
Remote I/O / Network Simulator – 3Nos
This workstation simulates connections between industrial devices
like sensors, actuators, Remote digital & analog I/Os and higher-level
devices, including Control Logix controllers and computers. Using the
Control and Information Protocol standard, this workstation makes it
easy to practice control, configuration, and data-collection processes for
industrial devices.
VFD Power Flex700 Simulator – 3 Nos.
With the VFD Power Flex700 simulator participants will learn how to
recognise Power Flex standard control drive hardware and properly
wire the drive, Also they will learn to diagnose specific load related,
environmental, and equipment faults.
Introduces techniques and instructions that will assist the participants
in successfully configuring and starting up a Power flex 700 Ac drive
using LCD HMI Drive Explorer software or Drive executive software.
Panel View plus Trainer - 6 Nos.
This Panel View Plus Trainer is designed to provide in-depth knowledge
and hands-on practice on operator interface terminal (HMI). Panel
View plus with Rockwell R.S. View ME software enable the participants
to design, modify, test application files and troubleshooting. PLC
programming options are also covered.
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CHAPTER 5
Hydraulic & Pneumatic Workshop
Industrial Sensor Trainer 1 & 2 This Sensor training equipment teaches
on the operating principles of inductive, capacitive, ultrasonic, and
photoelectric sensors and describe differences and similarities.
Students learn and describe advantages, disadvantages, and
applications of limit switches, photoelectric sensors, inductive sensors,
capacitive sensors, and ultrasonic sensors.
Cut-away for Hydraulics & Pneumatics Components This cut-away
view for the hydraulics and pneumatics components teaches the
students to identify the inner parts of the components, and pilot
lines for easy understanding of the functions what happens exactly
during the operation. They could also visualize the running checks and
maintenance point of view.
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Looking
Ahead
Alba’s Training & Recruitment Department constantly endeavours
to provide our employees with a compressive range of new training
programmes as well as opportunities for development and education
that will enable all levels of Alba layers to be the best in their
profession and in personal life. We intend to provide employees with
the required tools and skills, which will empower them to stretch their
capabilities and aim for opportunities that will create a bright future.
Aluminium Bahrain B.S.C.
P.O. Box 570
Kingdom of Bahrain
Tel: +973 17 830000
Fax: +973 17 919001
albasmelter.com