World Class Plant Performance with NLS O&M

Ferdinand A. Pecson Ph. D, MBA, BS ME

Cemtech Dubai, 5-8 March 2011

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/S
has contracts in four other countries:
Iran, Libya, Angola and Tunisia
Cemtech Dubai, 5-8 March 2011

NLSupervision Company A/S

Hffdingsvej 34
DK-2500 Valby
Denmark
Tel.: +45 3618 3780
Fax: +45 3645 6415

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

Our Mission: Sustained Excellent Performance

Cemtech Dubai, 5-8 March 2011

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

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

Delivering Results by Engaging our People

Action areas

Result areas
Perception

Reputation

Behaviour

Satisfaction

Senior Management

Retention
Satisfaction
& Motivation

Immediate Superior

Loyalty

Co-operation
Motivation

Daily Work

Commitment

Remuneration
Development

Employees continued to run Ramliya Plant all throughout the Egypt Crisis!

Cemtech Dubai, 5-8 March 2011

Delivering Results through State-of-the Art O&M Systems

Measures of
Performance

Communication

Continuous
Improvement

Production &
Maintenance
Planning

Quality of
Execution

Failure
Reporting &
Root-cause
analysis

O&M
Organization

Training/
Coaching

Preventive
Maintenance

Celsius
160.0 94.7
90.0
85.0
80.0

WINDING JUNCTION
95.1

75.0
70.0
65.0
60.0
55.0
50.0

WINDING JUNCTION
100.3

45.0

-20.0

38.9

Thermoteknix VisIR 3:32:01 PM 2/16/2007 e : 1.00 Bg : 25.0C

Cemtech Dubai, 5-8 March 2011

Delivering Results through Continuous Improvement

Raw Mill Situation

Improvements

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

Switched to sintercast roller

segments
Increased nozzle ring area
Raised lower housing of separator by
2m
Installed densit lining at outlet duct
& cyclones

Cemtech Dubai, 5-8 March 2011

Delivering Results through Continuous Improvement

Kiln Situation

Improvements

High wear of refractory of tertiary air

damper
Alkali attack on kiln nose ring area
Process control by Operator

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

Improvements

Cross-bar cooler designed for 6000

tpd
Recurring red rivers

Upgraded cross-bar cooler to

seagull design, which increased
kiln output to 6700 tpd
After upgrade

Before upgrade

Cemtech Dubai, 5-8 March 2011

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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

13

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

15

Actual Results

Kiln Average Production Rate, %

of design capacity
Kiln Net Availability, %
Kiln MTBF, hrs
Safety LTIFR

Cemtech Dubai, 5-8 March 2011

2,009
103%

2,010
106%

92%
301
6.9

92%
256
2.81

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What Our Customer Has to Say

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 Magrina
CEO
Arabian Cement Company
Cemtech Dubai, 5-8 March 2011

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