Chairman message:

It is with great pride and honor to present our advanced Training Center held by Abu Qir
Fertilizers and Chemical Industries to be a model providing all support for new
generation of young cadres capable of assuming responsibility in the future.

Youth are half of the present and all the future, that’s why our duty is to give them
support and to help them bear the leadership as incurred earlier generations and remain
a beacon of hope without any doubt or reduce.

The Training Center has the pleasure to provide services and support for aspiring young
cadres for a best ever future.

Welcome in our advanced Training Center that represents a module for everyone looking for privileges.

Eng. Ahmed El Gayar

Chairman & CEO AFC.
Abu Qir Map:

Abu Qir Fertilizers and Chemical Industries is situated in El Tabia- Rasheed Road in the north-east side of Alexandria
Training Center Location:

The TC is located in the 5th floor of the Company administrative building on approximately 850 m2.
 AFC. Training Center History

In March 2005 AFC Training Center was established.

AFC Training Center is the leading center in the field of vocational training and human

development in all fertilizers & petrochemical companies in Egypt and in the Middle East.

After 8 months AFC Training Center was able to create a great success story by creating a wide

base of clients across the Delta, whole Egypt and the Arab companies.

In August 2009, the second phase of the Training Center was inaugurated.
Training Facilities:
Six lecture halls equipped with the latest Audio Video Technology.
Well equipped Workshops for practical training.
Simulator.
IT Center.
Printers.
Library.
High Speed Internet.
Our Mission
Providing effective technical training, human development and managerial programs and
services for fertilizer &petrochemical companies through controlling the operating process
and to cope with the dynamic life and business challenges

Our Vision
Our vision is to become the benchmark in effective technical training, human and managerial development in Egyptian and Arab
companies

Core Values
Customer Focus
Comprehensive Service
Methodological Thinking
Dynamism and Flexibility
Continuous Learning
Achievement and Ownership

AFC Training Center Approach and Methodology

AFC training center has a proven methodology in client’s consultancy.
We do not sell our service as many training companies, but rather we aim at solving our client's problems through fulfilling the
training needs of our clients
We have Nine Steps for Training Consultancy in our Methodology as follows:

1. Client Contact
• The first step for training consultancy.
• Client's situation should allow the application of comprehensive training to be able to transform the business through technology.
2. Corporate Presentation
• In the first meeting , the consulting team presents the profile of AFC training center and explains to the client its unique consulting approach
3. Training Needs Assessment
• In order to be able to define the needs of the client, a full fledged business diagnosis is performed to define the problems and the needs of the
client from a completely business perspective.
• Such diagnosis helps highlight the real problems that face the business of the clients.
4. Training Prioritization
• Based on the identified needs resulting from business diagnosis, the business needs of the client are further assessed and the approach for
fulfilling such needs is identified.
• The different training needs are then prioritized in terms of urgency and easiness of implementation.
5. Customized Program Design (scheduled trainings – customized trainings)
• To guarantee positive results at the end, a full fledged roadmap for the whole solution is designed showing the different phases of the project,
the approach for each phase, the costs of each phase as well as the expected results for each phase.
6. Program Objectives Definition
• Based on the customized program design, each phase will require different training programs. In this respect, AFC training centers its best to
integrate the different options available.
7. Training Implementation
• After customizing the needs of the topics and development phase, AFC training course undergoes the implementation of the needs of topics
and ensures the integration of the needs of the topics with the other internal systems.
8. Follow Up
• During and at the end of the training to guarantee that we get to the best results, AFC. Training center make a periodic follow up for the
client to know the average of the change which happened after the training to raise it up gradually in the other trainings.
9. Evaluation
• AFC Training center uses its tools to evaluate the trainees to ensure the maximum benefits after customizing the needs of the topics and
development phase, AFC TC course undergoes the implementation of the needs of topics and ensures the integration of the needs of the
topics with the other internal systems
Development:
AFC and the training center play together an ever increasing role in developing Egyptians and Arab Nations, by providing
the best and highest training quality.
Educational institutions will work together to identify and serve present and future needs through a continuous improvement
program.
In addition , the Training Center provides equipments , professional instructors , and course’s material prepared with highest
standard to allow both AFC T.C and the trainee to achieve aims and ambitious.

Accreditation:
Upon the successful completion of the course, the trainees receive a certificate in process operations from AFC.

Registration:
On the first day, you will fill in a personal data form to be saved in the training center as a customer data base.

Induction:
All trainees have an induction program on the first day of training. They will be introduced to the management team,
trainers. Then they will be shown the training center and the company working areas to identify the dangerous areas and
emergency exits.

Stationary:
AFC T.C provides stationary during the training course and issue an elegant clipboard and files.

Trainers Responsibility:
The AFC T.C provides a high quality training and educational service to trainees, customers and companies through a wide
range of professional trainers.
Consulting and Technical Support:
Abu Qir Fertilizers Company have a technical support to sister Companies through the specialized team work on technical
consultancy for fertilizers and petrochemical Companies , because of their mechanical workshops able to manufacture
some parts in a short period , which save time and effort .

Heat
Exchanger

Isolation Valves
Some of the services provided by the center and work sites:

Presentation of the Center and its procedures.

Related work through the support and praise the associated work during your training.
Programs details relevant your needs and abilities.
Information about the objectives and content of the training course.
Information about qualifications awarded to the successful trainees at the session.
Information and advice from the trainers on any difficulties in learning, supervision
and evaluation of the course.
Details of any work or employment experience that are an integral part of your track.
Opportunities to discuss any problems or difficulties.
Facilities scheduled training with the crew to discuss your development.
Complaints / Comments / suggestions:
The TC has several formal complaints for any one wishing to make a complaint. All complaints are treated fairly &
confidentially.
Training center management welcomes any comments or suggestions that can help to improve the service provided to
trainees, customers & client representatives.
In accordance with the TC complains procedures, trainees, customers and client representatives are invited to make their
views known.

Catering:
AFC provide free refreshments and drinks at cafeteria (Not in classroom) and also meals provided from the company's
restaurant.

Note: Overalls and workshop footwear cannot be worn while consuming food at the cafeteria
Accommodation:
Abu Qir Fertilizers provide the trainee the opportunity to choose his lodging place either in AFC Residential City or it can
help you to book rooms at any of the best Alexandria’s Hotels at special rates.

Transportation:
Abu Qir Fertilizers offer the transportation for trainees to and from Alexandria in order to spend the training period easily

Information:
Electronic Notice boards are available in the training center and should be checked by the trainee
daily for information about the Company.
Also you could check the web site: www.abuqir.com as a good source of information.

Lost Property:
Any items found within the TC should be handed to a member of staff who will ensure its safe keeping until claimed.

Telephones:
Trainees may use telephones that are available in the corridors within the TC.
Mobile Phones are prohibited inside lecture’s hall during the training session.

Note: The office phones are not for trainee’s use.

Course Advisors and Trainers:
In case you face any difficulties related to your studies, you should discuss it with your group tutor to avoid small problem.
All matters are dealt with confidentially. Trainees can also air-out their opinions at the
end of training courses.

Support:
Trainees can consult their training coordinator / technical instructor at any time. So
please don't hesitate to contact a staff member if you have anything to discuss. You will
be directed to the correct person to help in resolving your problem.
If you feel you have a particular support needed, let your technical instructor knows as soon as possible, so measures can be
identified and implemented.

Managing your studies:

You will be given a variety of learning methods during your time in the training center.
These will include lectures, tutorials and practical sessions.
Although your assessor / technical will assist you most of the time, you must take responsibility for your own learning. If
you have difficulty while studying your course assessor / technical will be on hand to offer assistance.
Introduction to Vocational Qualifications:
A vocational qualification is part of your training. VCs are based on competence and grated according to the type of nature
and description of the job as follows:

Level 1 :
Routine and predictable
Level 2 :
More demanding, individual responsibility
Level 3 :
Board range of varied work mostly complex and none – routine with
considerable responsibility and some supervision.
Level 4 :
Complex technical or professional includes management and supervision.
Level 5 :
Senior management / professional activities, significant responsibility

Why Vocational Qualification’s (VQ)?

VQ's are internationally recognized
Standards are developed by employers and national training bodies.
There are no pre-entry requirements
Any one can be assessed and registered through a registered assessment center.
VQ's assess more than skills and knowledge. They assess competence.
VQ's develop the whole person to become a valuable employee.
 Assessment:
The system of assessment is organized in 5 stages using the following cycle of events;
Stage 1:
Trainee and instructor plan a work activity which can be used to demonstrate
competence and agree the elements to be assessed.
Stage 2:
Trainee and instructor need to collect and gather all evidence about the work activity
Stage 3:
The monitor the evidence to make sure that it meets the occupational standards.
Stage 4:
The instructor judges the evidence to check it meets all requirements of the occupational standards, reaching an
assessment decision. Further actions when necessary are agreed.
Stage 5:
The instructor records wither the trainee is competent.
Performance Criteria Knowledge Requirements:
You must tell the instructor and demonstrate that you can:
Comply with the relevant legislation
Follow approved codes of practice and operating procedures.
Understand environment, safety and health policies.
Deal with accidents and incidents according to law.
Identify breaches of safety and take action.
Identify hazards and risk.
Know your individual responsibilities and limitations.
Know the employee and employer responsibilities within the relevant legislation.
Appeals:
If the trainee thinks the assessments process has been unfair, the following
procedures are available to you:

1. Question and clarify the decision with the assessor

2. Appeal in writing to the head internal verifier. He will record the details and
acknowledge the appeal in writing.
3. Your appeal will be investigated by the lead internal verifier and he will arrange a
second assessment with another suitably qualified assessor.
4. If agreement cannot be reached, the trainee can appeal to the awarding body external verifier.

AFC Policy Statement:

It's AFC' policy to manage all its activities so as to avoid causing any unnecessary or unacceptable risk to the safety of
its employees , customers , trainees and members of the public who may be affected by its operations.

Health, Safety & Environmental Policy:

In carrying out its activities, AFC TC will Conduct its business responsibility in a manner
that protects the health and safety of its employees,
Contractors and the public AFC will also seek to protect and conserve the natural
environment.
AFC recognizes that effective health, safety & environment management is critical to
continuing business growth.
Effective application of its policy is in line with the company's ingoing commitment to and
the satisfaction of the general requirements placed on the Company under Egyptian labor laws.
It is AFC Policy to ensure that:
Providing emphatically instructions and a suitable training to ensure the implementation of policies and
procedures.
Every person visiting or attending the center should be aware of applicable safety procedures.
Every person must wear his PPE and be provided with essential equipment and noting the way of use.
All equipment is maintained to a standard that ensures its safe operation.
All safety procedures are routinely reviewed and revised, where necessary, to ensure continued compliance to
health and safety Egyptian labor laws.
Work areas are maintained to ensure safely access and exit of the Center .
Necessary information are available to every person to accomplish his job safely.

Our Policy towards Workers in our Company:

Investment in training our staff to improve their performance for the
implementation of work assignments efficiently and effectively.
Promote education and self training.
Supply of skills and knowledge to develop the personal capacity to reach
the highest levels of performance through training in accordance with
work requirements.
The use of actual methods and inventing new ways to provide training
needs through conferences , programs , workshops and seminars…etc.
Accidents / First Aid / Facilities:
All accidents and incidents must be referred regardless of how minor they are.
Investigations are carried out to prevent the same accident happening again.
Remember, an investigation is not carried out to blame someone.
The instructor will ensure that the person involved is treated and that no-one
else is at risk following safety instruction.
First aid may be given at the scene of using a first aid box.
Further medical assistance may be obtained by dialing 241 or 242
A personal accident investigation must be completed as soon as possible.
If the accident / incident results in damage or less of equipment /materials, investigation must be completed.
No attempt must be made to clean up the area where the accident / incident took place unless authorization to do
or the area is too dangerous to leave.

Training Center Properties:

Care must be taken with all training center property. This includes buildings, furniture, fittings & equipment.
Equipment must be used as instructed by staff.
Use litter bins provided.
Lecture Halls:
The lecture rooms must be kept tidy.
Use litter bins.
No drinks & snacks may be consumed in the lecture halls.
Technical Workshops:
Be aware of dangers in the workshop.
All workshops are potentially dangerous.
Common sense must prevail at all times.
No pranks will be tolerated at any time.
Concentration while working is vital.
Personal hygiene & self discipline are needed at all time.

Working Environment:
A clean & tidy area is a safer area.
Use proper containers for waste.
Remove debris & waste as you go. Heat Exchanger
Keep tools & equipment clean & tidy. Workshop
Use proper storage facilities
Access ways should be clear at all times, especially fire exists & access to first aid.

General Cleanings:
All trainees are responsible for their own work area.
Personal Protective Equipment (PPE):
It’s necessary for every trainee to have his own PPE.
Overalls & safety footwear must be worn at all times in the workshop.
Only approved PPE will be issued
All PPE must be kept in good condition by the trainee.

Style / Mode of dress:

Long hair must be tied back safely.

No loose clothing to be worn around rotating equipment
No jewelry to be worn around rotating equipment

Emergency Equipment:
Emergency equipment such as fire extinguishers, hexes and fire alarm
points are situated thought out the workshops & training center.
Fire extinguishers should only be used in an emergency & by trained personal.
During the induction you will be shown the location of the emergency equipment

**Remember: The Emergency Number is 240

 Games:
Games are strictly forbidden in the training center premises.
Any offender may face disciplinary action.
Smoking:
Smoking is not permitted in the lecture hall and in only permitted in the designated area for the
workshop.
Remember:
- During your stay in the TC you should listen and learn avoid facing accidents
- While in the workshop you will work with equipments you had only learned or heard
about in your class room.
Investment in Human Beings:
All the possibilities mentioned previous become Abu Qir Fertilizers
Training Center one of the specialized Center in a various fields which
attention to the human element through the available possibilities and the
accrued expertise over thirty years .

Cooperation Agreements:
Through the good attribute and the potential of Abu Qir Fertilizers Company, we have signed a cooperation
protocol between the Company and the Leadership & Management Development Center for the human
cadres training in various field and disciplines.

It’s also being held to discuss a cooperation protocol between Abu Qir fertilizers Company and the Faculty
of Engineering - Alexandria University – to get a diploma create a capable cadre of managing such
industries in added value to the technology of fertilizer industry in the Arab Republic of Egypt and Arab
Companies .

And also the under-coordination with the accredited training such as the University of Alexandria
represented in the College of Engineering, Science and the Arab Academy for science, technology and
maritime transport and specialized sciences, and ports training institute for providing best ways of training
in superior levels .
 FIRST: AFC TRAINING DIRECTORY FOR
ARAB COMPANIES & ORGANIZATIONS

The Participant Company The Country

1. Ruwais Fertilizers industries (Fertil ) Emirates
2. Petrochemical Industries Kuwait
3. Gulf Petrochemical Industries Bahrain
4. State Co. of Fertilizers / South Region Iraq
5. State Co. of Fertilizers / North Region Iraq
 SECOND: AFC TRAINING DIRECTORY FOR
EGYPTIAN COMPANIES & ORGANIZATIONS

The Participant Company

6. Egyptian Fertilizers Company
7. Alexandria Fertilizers Company (ALEXFERT)
8. Helwan Fertilizers Company
9. Mopco
10. .El Delta Company for Fertilizers & Chemical Industries
11. Egyptian Chemical Industries ( Kima – Aswan )
12. Enppi Engineering Petrochemicals Industries
13. Polyserve Fertilizers & Chemicals ( Abu Zaabal Fertilizers Chemicals )
14. Egyptian Petrochemicals Company
15. Sidi Kreir Petrochemical Company (SIDPEC)
16. Western Desert Petroleum Company (WEPCO)
17. Petroleum Maintenance Company (PETROMENT)
18. Amreya Petroleum Company
19. Badr El DEEN Petroleum Company
20. Egyptian Gas Company ( GASCO )
21. Middle East for Refining Petrol ( MEDOR )
22. Alexandria National For Refining & Petrochemicals (ANERPEC)
 SECOND : AFC TRAINING DIRECTORY FOR
EGYPTIAN COMPANIES & ORGANIZATIONS

23. Heliopolis Chemicals Industries

24. El-Nasr Company for Chemicals
25. Middle East for Operating & Maintenance the Hydrocarbon Industries ( MEDOM )
26. Alexandria Mineral Oils Company (AMOC)
27. Egyptian Financial & Industrial Company
28. Mansoura Polymers & Wood
29. Asiout Cement Company
30. Egypt Maintenance Company (SAN MISR)
31. Sogic Company
32. Alexandria Water Organization
33. Egyptian Company for Starch , Yeast & Cleansers
34. Tanta for Flax & Oils
35. Plastics Pipes industries Company
36. Middle East Water Company (MID WATER)
37. El Oboor for Metal industries
38. Suez Steels Company
39. Papers National Company
40. Misr Hegaz Group
41. E Methanex
 THE PREVIOUS WORKS OF THE NEW EGYPTIAN FERTILIZERS CO.

The new Fertilizers Company Participants number man / week

Egyptian Fertilizers Co. 82 328

Alexandria Fertilizers Co. 76 224

Helwan Fertilizers Co. 57 84

Mopco 75 721
 1- DISTRIBUTED CONTROL SYSTEM (DCS)

OBJECTIVE:
To demonstrate the basic concepts, components, architecture, practices, diagnostics & guidelines associated with DCS systems

DURATION: 5 Days (20 H)

COURSE OUT LINE:

1. Introduction and historical background.

2. Main benefits of DCS.
3. Basic components and structure of DCS.
4. Input / Output modules.
5. Power supply modules.
6. Advant ABB Open Control System OCS.
7. Advant ABB Products Process Controllers.
8. Advant Controller 450 Hardware.
9. Operator station interface.
10. Engineering station interface.
11. Communication network
12. Redundancy.
13. System diagnostics and maintenance.
 2- TURBO COMPRESSORS

OBJECTIVE
This course provides the results of 29 experience years with compressors used in industrial field operation, monitoring, evaluation, diagnoses and problems
with its solution supported by case studies.

DURATION: 5 Days (20 H)

COURSE OUT LINE

1. Compressors- general descriptions and key features.

2. Gas bath.
3. Abnormal operating conditions overview.
4. Compressor performance curves.
5. Lube oil system.
6. Sealing system.
7. Maintenance Scope (Assembly and disassembly).
8. Maintenance philosophy.
9. Trouble Shooting with Case Studies
 3- VIBRATION MEASUREMENTS AND INSTRUMENTATION

OBJECTIVE:
He course is developed for managers, engineers, supervisors and technicians who need the application of vibration analysis in their maintenance activities
The participants will be able to understand the fundamental physical information concerned with vibration analysis and the necessary
Also they will learn the fundamental techniques to carry out vibration analysis to diagnose the most typical problems

DURATION: 5 Days (20 H)

COURSE OUT LINE:

Vibration measurements
Purpose of vibration measurement
When does Vibration happen?
Time wave from signal
Gain form use Vibration frequency
Gain form use Vibration amplitude
Vibration amplitude units
Phase measurements
Choosing the measurement point
External influences on measurements
Vibration transducers
Non-contact (proximity probe) theory of operation
Velocity pickup theory of operation
Accelerometers theory of operation
Piezoelectric accelerometer characteristics
Transducer selection
Vibration parameters
Vibration analysis
General analysis procedure
Diagnostic machinery Vibration
Applied cases
On conditioning monitoring
short overview
 4-WORKSHOP BASIC SAFETY HEALTH AND ENVIRONMETAL / OPERATIONS [English]

OBJECTIVES:
To enable delegates of being informed of general safety and environment.
WHO SHOULD ATTEND
Engineers, Supervisors and Technicians in different fields of safety operations,
Process, maintenance and environment.
DURATION: 5 Days (20 H)
COURSE OUTLINE:
1. Introduction
2. Safety and Organization
3. The Nature and Cause of Accident
4. Incident Reporting
5. Accident Prevention
6. Personal Protection
7. Production Safety
8. Static Electricity and Electrical Hazards
9. Fire Prevention and Protection
10. Color Coding and Signs
11. Chemicals and Gases
12. Elementary First Aids
13. Safety Factors in Production Equipment
14. Plant Visit
15. Exercises and SHE Meeting
 5-BASIC SAFETY AND LOSS PREVENTION
OBJECTIVES:
To enable delegates of knowledge of loss prevention and basic safety according to the previous aspects
WHO SHOULD ATTEND
Engineers, Supervisors and Technicians in different fields of safety operations,
Process, maintenance and environment.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1. Loss Prevention Aspects
2. Industrial Safety Role
3. Accident Prevention And Control
4. Analyzing Accidents
5. Accidents Investigation
6. Accident Reporting
7. Work Place Control And Development – Design Safety System
8. Safety Transportation And Handling
9. Safety Cloths And Personal Equipments
10. Work Permits Industrial Psychology
11. Area Classification
12. Emergency Management Planning
13. Fire Fighting And Prevention
 6- CONTROL VALVES

OBJECTIVE:
To provide the participants with the practical knowledge of sizing, selection, installation & testing practices of control valves used in process industries.

DURATION: 5 Days (20 H)

COURSE OUT LINE:

1. SLIDING STEAM CONTROL VALVE
Valve component
Calculate seat leakage

2. CONTROL VALVE DESIGN OPTION

Control valve components
Flow characteristic
Body stle options
Trim material options
Gaskets
Packing options
Bonnet options

3. EXERCISE
4. SLIDING STEAM ACTUATOR
5. BENCH SET CONCEPTS
6. CONTROL VALVE FLOW C/C
7. CONTROL VALVE NOISE
8. WORKSHOP
 7- HEAT EXCHANGERS MAINTENANCE DESIGN- OPERATION

OBJECTIVE:
The learning objective of this course is to present knowledge of the different types of industrial heat exchangers upon completion of this course, the
participant will have :
The ability to explain the basic principles.
Basic equations to design and rate heat exchangers.
The most important maintenance features

DURATION: 5 Days (20 H)

COURSE OUT LINE:
Basic design method of heat exchangers.
Introduction to industrial heat exchangers
Surface condensers.
Finned – tube heat exchangers.
Cooling towers.
Gasket - plate heat exchangers
Case studies
Work shop training.
 8- COMBUSTION

OBJECTIVE:
This course aim to increase the information about the firing problems in furnaces and boilers
DURATION: 5 Days (20 H)

COURSE OUT LINE:

1. Combustion principles.

2. Combustion efficiency calculation.

3. How to measure the combustion efficiency.

4. The control system in combustion.

5. The types of combustion in AFC I :

Combustion at primary reformers (A.F.C 1/2/3).

Combustion of Auxiliary boiler at A.F.C.
Package boilers at A.F.C 2/3.
6. Steam boilers

Combustion in boiler
Specification of bfw & ew
7. Boiler efficiency
 9-FIRE TRAINING FOR PETROCHEMICAL INDUSTRIES

OBJECTS:
The course is aimed to give a brief knowledge on all safety activities and how to manage the hazardous chemical, handle and store in addition to PPE study,
chemical and hazards. It goes through the experience in fertilizers industry and their hazards also; it is aimed to give the experience of fire safety activities.

WHO SHOULD ATTEND

Safety Engineers and Technicians
Process Engineers and Technicians
Maintenance Engineers and Technicians

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Why Maintain Good Standards Of Fire Safety
2. The Combustion Process
3. Causes Of Fire
4. Building Designs And Construction
5. Means Of Escape
6. Means Of Raising The Alarm
7. Means Of Fighting A Fire
8. Emergency Evacuation Procedures
9. Fire Risk Assessment
 10- INDUSTRIAL WATER TREATMENT

OBJECTIVE:
To know a new technology and chemicals for water treatment
To Focus the major troubleshooting, and how it solved.
WHO SHOULD ATTEND
Senior, junior production engineer and technicians.
DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Water treatment.
o Water source impurities & chemistry.
o Clarification.
o Filtration.
o Ion exchange.
o E.D.R. & R.O.
o Trouble shooting.
2. Boiler water systems
o Boiler feed water desecration.
o Boiler water treatment & monitor system.
o Case study & trouble shooting.
o Inspection
3. Cooling water
o Cooling water systems
o Cooling water treatment
o Monitor system & operational check.
o Inspection
4. Waste water treatment
5. Water analysis for all activities.
o Treatment, ion exchange - cooling water, boiler, condensate.
 11- PUMPS & FANS

OBJECTIVE:
To improve participants understanding of pumps for special applications in refineries and chemical plants.
DURATION: 5 Days (20 H)
COURSE OUT LINE:
1. ossification & application
2. Basic concepts
3. Types of pump
Centrifugal pump.
- principle of operation
- construction & basic elements
- impeller design
- centrifugal pump sealing
- centrifugal pump efficiencies
- troubleshooting
reciprocating pump
- principle of operation
- construction & basic elements
- Suction & discharge pulsation & pump capacity.
- Power consumption and efficiencies
- troubleshooting
axial flow pump
- principle of operation
- construction & basic elements
4. Maintenance and repair
5. Case study
6. Work shop
 12-KNOWLEDGE OF SAFETY NEEDS
(PETROCHEMICAL ORIENTATION PROGRAM)
TRAINING COURSE
OBJECTS:
The course is aimed to give a brief knowledge on all safety activities and how to manage the hazardous chemical, handle and store in addition to PPE study,
chemical and hazards. It goes through the experience in fertilizers industry and their hazards also; it is aimed to give the experience of fire safety activities.
WHO SHOULD ATTEND
Safety Engineers and Technicians
Process Engineers and Technicians
Maintenance Engineers and Technicians

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Introductions
2. General Occupational Safety Management Concepts
3. PPE
4. Electrical Safety
5. Mechanical Safety – Machine Guarding
6. Chemical Safety – Hazcom And MSDS
7. Earthling For Flammable Liquid Containers
 13- LUBRICATION AND GREASING TECHNOLOGY

OBJECTIVE:
This course is introducing engineers to the nature of friction and to be able to decide proper solution for friction.
Different industries applications will also be discussed audio - visual materials are available.
DURATION: 5 Days (20 H)

COURSE OUTLINE

1. Introduction
2. Friction
3. Theory of lubrication
4. Characteristics lubrication & effect of contamination on oil characteristics.
5. Additives.
6. Importance of oil analysis for new & used oils.
7. Type of lubrication oils.
8. Engine oils.
9. Fundamentals of lubrication for mechanical units.
10. Selection of lubricants for bearings.
11. Accessories of lubrication.
12. Greases.
13. Storage & handling of petroleum products.
14. Case study.
 14-SIX SIGMA AWARENESS WORK SHOP
OBJECTIVES:
Delegate will be able to
Understand Six Sigma Methodology
Continual process improvement of services for each department
Guide, Define and measure and analysis and improve and implement and control processes applying Six Sigma quality tools
Recognize improvement through Six Sigma implementation
1. Matrices and essential static process control tools
2. Develop action plans for implementation
3. Approve implementation schedule
WHO AHOULD ATTEND
Process managers and engineers, safety and environment engineers and quality assurance and safety, environment and quality auditors
DURATION: 3 Days (12 H)
COURSE OUTLINE
1. Introduction
2. Six Sigma Overview
3. Process Improvement
4. SIPOC – Process
5. DMAIC Methodology
6. Roles And Responsibility
7. Six Sigma Implementation In Some Organizations
8. Change Management
9. Wrap – Up
 15- ELECTRIC MOTORS

OBJECTIVES:
Provides participants with detailed knowledge on all types of electric motors and the critical factors affecting motor selection and the fundamentals of their operation.

WHO SHOULD ATTEND

Elec. Engineers and technicians.

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. introduction:
2. motor design and protection
Designs of motor frames
Types of protection
3. maximum temperature rise
4. theory of operation of three phase induction motor
5. torque , power and current input
Torque curves
Run up time
Type of duty
6. motor starting characteristics
7. operating values for electric motors
8. the protection of three phase unduction motored
9. the periodic maintenance for electric motors
 16- BAGGING UNITS
OBJECTIVE:
The objective of this course aim to help engineers and technicians to be familiarized with aspects of operating and maintenance in bagging units.
WHO SHOULD ATTEND
Engineers & technicians in bagging field.
DURATION: 5 Days (20 H)
COURSE OUT LINE
1. Bulk Storage.
2. Conveying Machines: Continues Machines

Conveying Belts Bucket Elevators

Vibrating Conveyor Screw Conveyor
Vibrating Screens
Intermittent Machines
Bulk Storage Machines (scraper- reclaimer Trucks Loader Machines
Trucks Loader Machines Railways Loading Machines
Prime Machines, Trucks and Loaders
3. Interlock System for Conveying Machines.
4. Deducting System
5. Special Study Course for Special Materials and Handling.
6. Safety Aspects & Corrosion.
7. Operation & Maintenance of Bagging Units.
8. Practical Training In Bagging Units.
9. How To Manage the Losses
10. Conveying machines maintenance view.
11. Warehouse machines & interlocks system.
12. bagging machines instruments
 17-BEHAVIORAL BASED SAFETY (BBS)

OBJECTIVES:
Delegate will be able to
Observe & asses behavior at work
Know how to change at risk behavior (latent and active)
Know what is a safety culture and how it can be measured and improved
Know how to conduct a safety culture survey and develop action plans and create continuous improvement
WHO AHOULD ATTEND
Safety, process and maintenance engineers, supervisors and technicians.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1. Introduction
2. Understanding BBS
3. Assessing Behavior At Work
4. Latent And Active Failure
5. Changing Safety Behavior
6. Categories Of Human Failure
7. Improving Safety Culture
8. Conduction Of Safety Culture
9. Aspects Influencing Human Factors
10. Accident Causation
11. Case Studies For Accident Analysis
 18 - PROFESSIONAL MANAGERS

OBJECTIVE:
The participants will be able to:
Know the various management functions and the type of management activity associated with each.
Decide when to use coaching and counseling
Define the relationship between attitude an behavior and use if to motivate self and others
Use logical and creative approaches to solving problems
Differentiate between leadership and management

DURATION: 5 Days (20 H)

WHO SHOULD ATTEND?

Department heads, senior supervisors, managers & others who need to develop their managerial skills
COURSE OUT LINE
1. Management :
Management an science Changes impacts the manager's job Managerial Competencies
2. Coaching :
To coach or to manage Coaching core Competencies What does a coach do and how he does it
3. Motivation:
The hierarchy of needs Various motivational theories How to motivate a multicultural workforce
4. Problem solving :
Barriers that get in our way A rational approach to problem solving Problem analysis supplementing tools
The 6 Thinking hats for creative problem solving
5. Leadership :
Leaders born or made Leadership versus or management Characteristics of a leader
The 6 leader ship styles The 7 habits of highly successful leaders.
 19-PRODUCTION TROUBLESHOOTING

OBJECTIVES:
At the end of the training session operational staff will be able to understand the following items
Who is the trouble shooter?
How orders are communicated

WHO SHOULD ATTEND

Process supervisors and operations.

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Process Upset Due To Loss Or Change In Feed Stock Properties
2. Behavioral Reasons In Improper Plant Control
3. Foam In Process Absorbers And Regenerators (Causes And Remedy)
4. Heat Exchangers Fouling, Water Coolers, Air Coolers, etc
5. Carry Over And Hold Up Liquids In Absorbers (Gas / Liquid Conditions)
6. Channeling In Gas Distribution Through Catalytic Vessels
7. Snowball Effect Of Reactive Chemicals (Detection And Control) To Check For Abnormal And Unsafe Observations In The Walk Through (Corrosion,
Pipe Creeping, Abnormal Noise Or Presence Of Vibration)
 20 - FURNACES TECHNOLOGY

OBJECTIVES:
The course provides overview about furnaces for engineers and supervisors who working in production and maintenance fields.

WHO SHOULD ATTEND

Engineers and supervisors in production and maintenance fields.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1- Main components of furnaces.
2- Furnaces classification: according draft/according to types.
3- Furnace attachment: burners/soot blowers/air preheating.
4- Design considerations: general/tubes/stack, duct and breeching.
5- Design limitation/tubes design/stack, duct and breeching design.
6- Furnace material:
Radiant tube material/ Convection tube material/ Header material
Piping, terminal material/tube support material / refractoriness and
Insulation/ structure material / stack material.
7-furnace performance
8- Instrument and auxiliary connection
9- Inspection.
10- Furnace maintenance.
11-Examination and testing.
 21-WORKING IN NORMAL CONDITIONS

OBJECTIVES:
Delegates will be able to know the normal conditions of process.
WHO SHOULD ATTEND
Process engineers, supervisors and technicians.
Maintenance engineers.
DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Principles Of Heat Transfer
2. Heat Exchange Equipment Operation
3. Fired Heaters Operation
4. Separation By Difference In Density
5. Separation By Difference In Boiling Point “Fractionation”
6. Liquid Transportation (Pumps)
7. Gas Transportation (Compressors)
 22- CASE STUDY IN AMMONIA PLANT

OBJECTIVES:
This course provides the experiences and focus the main problems which happened in Ammonia plants and how can be avoid.

WHO SHOULD ATTEND

Ammonia process & maintenance engineer.

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Revamp of Ammonia converter.
2. Revamp of Ben field unit and condensate recovery unit.
3. Revamp of product Gas cooler.
4. Reformer tube failure in Ammonia plant 2.
5. Gallery tray failure in top desorber.
6. Investigation and repair of Ammonia converter basket after 10 years in service.
7. Bad design of combustion air problem.
8. Internal leakage from P.G.C 303E001.
 23- BOILERS OPERATION & MAINTENANCE

OBJECTIVES:
Understand the principles how boiler operated, maintenance & control.
Be able to control and operate generic models of boilers
WHO SHOULD ATTEND
This subject will be very useful for engineers, chemists and operators who work at boilers fields.
Duration: 5 Days (20 H)

COURSE OUTLINE
1. Types of boilers.
2. Boiler components
3. Drum water circulation & heating system
4. Super heater and heat recovery system
5. Combustion system
6. Steam distributions system
7. Burner characteristics
8. Fuel characteristics
9. Steam temptation control
10. Fuel, Combustion and Oxygen control
11. startup and shutdown operations
12. Maintenance philosophy of boilers.
 24-CHEMICAL HAZARD COMMUNICATION PROGRAM

OBJECTIVES:
The delegate will be able to deal with hazardous chemicals.
WHO SHOULD ATTEND
Process, maintenance and safety and laboratory engineers, supervisors and technicians

DURATION: 4 Days (16 H)

COURSE OUTLINE
1. Basic Chemistry
2. Hazard Communications
3. NFPA, HMIS And GHS Labeling
4. Control Approach And Prevention Actions
5. Disaster Plan And Evacuation Plan
 25- CASE STUDIES IN UREA PLANT

OBJECTIVE:
To enhance the experiences and focus the main problems which happened in urea plants and how can be avoid.
WHO SHOULD ATTEND
Process and maintenance engineers.

DURATION: 5 Days (20 H)

COURSE OUT LINE

1. Replacement of H.P. stripper
2. Replacement of H.P scrapper.
3. Relining of top of reactor.
4. Desorber flooding.
5. Corrosion & thickness decrease in the elbows of steam lines outlet H.P.C.C.
6. Corrosion in the upper tube sheet of H.B.C.C.
7. Increasing the liquid level in H.P. scrapper overflow line .
8. Cutting in the tubes of L.P.C.C. and the tubes of reflux condenser
 26- AMMONIA INDUSTRIAL TECHNOLOGY
FOR SUPERVISORS AND OPERATORS

OBJECTIVES:
This course provides the experiences and focus the main problems which happened in Ammonia plants and how can be avoid
WHO SHOULD ATTEND
Supervisors, ammonia technicians & maintenance manpower in ammonia plants.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1. Introduction of Ammonia plants.
2. Reforming & steam system.
3. Natural gas & instrument air compressors.
4. Ammonia (synthesis-refrigeration-storage).
5. Trip system& safety in ammonia plants.
6. Case studies in turbines and compressors.
7. Case studies in ammonia plant.
8. Types of control in ammonia plants.
9. Production calculations & how to prepare unit for maintenance.
10. Technical report writing.
 27- STATIONARY AND ROTOR EQUIPMENTS FOR OPERATORS

OBJECTIVES:
The course provides a reasonable background for operators about more mechanical equipment used in the oil, chemical, and fertilizers
industries.
WHO SHOULD ATTEND
Operators and technicians at both production and maintenance fields.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1-Heat transfer.
2-Heat exchangers :( size/types/shell and tube heat exchanger/use different types of shells/types of tubes/fouling factor).
3-Combusion
4- Steam boilers.
5- Types of pumps and which one used in our field and why?
6- Gas compressors.
7-Gas turbines.
8- Steam turbines.
9- Furnaces.
10- Valves.
11-how to operate or do maintenance to your machine or Equipment safely.
12- Chemicals handling safely.
 28 - HYDRAULIC TECHNOLOGY

OBJECTIVES:
The aim of this course to provide the participants with basic knowledge in hydraulic field , further it covered main important points as design ,
analysis, operating and maintenance hydraulic circuits, .

WHO SHOULD ATTEND

Design, technical support engineers and maintenance and supervisors.

DURATION: 5 Days (20 H)

COURSE OUTLINE
1- Hydraulic fluids and tanks.
2- Pipes and fittings.
3- Hydraulic pumps.
4- Control valves, pressure / flow.
5- An application of hydraulic circuit.
6- Gear pumps / Vane pumps / Piston pumps.
7- Hydraulic cylinders.
8- Hydraulic motors, gear motors / Vane motors / Piston motors.
9- Hydraulic transmissions.
10- Applications: loaders, cranes.
11- Maintenance and trouble shooting.
 29- UREA INDUSTRIAL TECHNOLOGY FOR SUPERVISORS AND OPERATORS

OBJECTIVES:
To enhance the experiences and focus the main problems which happened in urea plants and how can be avoid.

WHO SHOULD ATTEND

Supervisors, urea technicians & maintenance manpower in urea plants.

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Process description for urea plant in AFC.
2. Case studies in urea synthesis section.
3. Case studies in urea recirculation section.
4. Description for different types of granulation.
5. Case studies in granulation section.
6. Cooling water system.
7. Basic water chemistry & ion exchange unit.
8. EDR unit and its troubleshooting & waste water treatment.
9. Boiler water treatment & steam boiler.
10. Production calculation & Technical report writing.
 30- CORROSION PROTECTION
OBJECTIVES:
The goal of this course to provide participants with an over view off the deal theoretical aspects of corrosion control and gives detailed explanations
for corrosion monitoring methodology and techniques.
WHO SHOULD ATTEND
This subject will be very useful for field workers how deal with corrosion and corrosion control.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1- Corrosion definition.
2- Factors cause corrosion.
3- Chemistry of corrosion.
4- Uniform corrosion.
5- Pitting corrosion.
6- Dissimilar metal couple corrosion & galvanic corrosion.
7- Stress corrosion cracking.
8- Intergranular corrosion.
9- Corrosion fatigue.
10- Crevice corrosion.
11- Types of corrosion atmosphere.
12- Passivity.
13- Cathodic protection.
14- Material up cording.
15- Painting and coatings.
16- Metallurgical factors affecting corrosion.
 31 - PREVENTIVE MAINTENANCE

OBJECTIVES:
Participants will be able to: Describe the function of inspection and scheduled maintenance as the basis of preventive maintenance.
Discuss the causes, effects, and goals of a successful preventive maintenance program.

WHO SHOULD ATTEND

This subject will be very useful for maintenance engineers who plan maintenance programs and field maintenance engineers.

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Introduction to preventive maintenance
2. Why perform preventive maintenance.
3. Scheduling preventive maintenance.
4. Preventive maintenance program personnel.
5. Preventive maintenance program goals.
6. Computerized preventive maintenance programs.
7. Fitting preventive maintenance into day-to-day emergency-driven maintenance operation.
8. Finding a balance between maintenance an item or replacing it.
9. Calculation cost for repairs and cost for preventive maintenance.
 32- BLOW OUT AND PRESSURIZED CONTROL

OBJECTIVES:
The participants learn how to assist in planning of a successful blow out operation by choosing right blow out method and by carefully planning the
logistics of blow out operation.

WHO SHOULD ATTEND

Chemistry, engineers and technicians in fire fighting field.

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. A special type of fire. The pressurized fire. Examples of pressurized fires.
2. Oil well fires: typical scenarios and examples.
3. Gas well fire: typical scenarios and examples.
4. Multiple oil well/gas well fires: war impacts, terrorist attacks.
5. Necessary equipment and appropriate fire fighting methods.
6. Materials: water, foam, dry chemical powder. How to choose the right blow out control method, depending on the circumstance.
7. How to prepare a blow out control operation: water supply for cooling, foam demand calculation for ground fire control.
8. Applications of case studies and troubleshooting.
 33 - EMERGENCY DIESEL GENERATOR
OBJECTIVES:
The participants learn the basic principals of diesel engineers.
WHO SHOULD ATTEND
Engineers and technicians in both fields of electricity and maintenance.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1. INTRODUCTION
2. DIESEL ENGINES
Layout, arrangement and construction principles
Operation and monitoring of slow and medium speed propulsion diesel engines
Medium speed generator diesel engines
High speed auxiliary and emergency generator diesel engines.
Diesel electric drives
3. DIESEL ENGINE SUPPORT SYSTEM
Layout and arrangement
Operation and monitoring of Starting system
Fuel oil service systems fuel injection equipment
Charge air and exhaust systems
Fresh water and sea water cooling systems
Crankcase ventilation systems
4. DIESEL GENERATOR AUTOMATION
Layout and arrangement
Operation of Engine operating controls
Diesel engine governors
Automation sequencing and auto transfer switching
Voltage regulation system
Self protection and alarms
 34 -TECHNICAL REPORT WRITING

OBJECTIVES:
By the end of the program, participants will be able to:
Write clear an (reader friendly) technical reports
Understand the structure of technical reports
Produce various types of technical reports
DURATIONS: 5 DAYS (20 HRS)
WHO SHOULD ATTEND
Engineers, safety officers, technicians and accountants
COURSE OUT LINE
1. Writing technical reports:
Purpose Findings Methodology
Conclusions and recommendations

2. Preparing technical visual aids :

Line graphs Gantt Charts Bar graphs
Pie Charts Tables

3. Purpose of technical reports:

Recording work done Validating information Assessing situations
Indicating future actions

4. Interpreting statistics :
Use of Statistics in technical writing Explaining statistics in a readable language

5. Types of technical reports :

Investigation Forms Progress
Proposals Financial Accident
 35 - PROFIBUS TECHNOLOGY & DCS SYSTEM FOR CONTROL SYSTEM ENGINEERS

OBJECTIVE:
To enhance the knowledge and skills of participants in profibus technology and DCS for control system engineers.
WHO SHOULD ATTEND
Instrumentation engineers.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1. communication in automation
2. Profibus at glance
3. profibus transmission & communication
4. General application profiles.
5. Specific application profiles.
6. System profiles.
7. device management.
8. Implementation.
9. profinet.
10. profibus international.
11. New automation systems.
12. Distributed control systems.
13. advent open control system ( DCS )abb. product
14. Advent controller 450 hardware.
15. Engineering stations.
16. Safeguard 400 series.
 36 - PAINTING PLANT INSPECTION COURSE
OBJECTIVES:
To enhance the knowledge and skills of participants in the inspection of painting during application for new construction and maintenance.
WHO SHOULD ATTEND
All engineers and tech. working in the fields of welding technology & Quality assurance of welding joints.
DURATION: 5 Days (20 H)
COURSE OUTLINE
1. Corrosion theory.
Course of corrosion
Chemistry of corrosion.
The galvanic series.
Mill scales.
2. Surface preparation.
Blast cleaning.
Abrasives.
Surface finish specification.
Wire brushing
Needle gunning.
Pickling
Flame cleaning
Water cleaning (blasting )
3. Standard of surface preparation.
Swedish standard
Surface characteristics
4. Paint
Consist of paint
Paint system
Paint drying
Viscosity
Density
5. Measurement of dry film
Paint data sheet ( painting quality control)
 37- GAS PROCESSING TEGHNOLOGY

OBJECTIVES:
Participants will learn about the fundamental concepts and principles on which most gas processing plants operate.

WHO SHOULD ATTEND

Chemical engineers
Plant engineers
Production chemists

DURATION: 5 Days (20 H)

COURSE OUTLINE
1. Desulphurization Unit
2. Reforming Unit
3. Steam System
4. CO Conversion Unit
5. CO2 Removal Unit
6. Methanation Unit
7. Ammonia Synthesis Unit
8. Refrigeration Unit
9. Ammonia Recovery Unit
10. Hydrogen Recovery Unit
11. Condensate Stripping Unit
12. Methanation Unit
 38 - HIGH PERFORMANCE TEAM

OBJECTIVE:
Participants will be able to:
Identify team strengths and blind spots after analyzing their personal styles and performances
Distinguish between groups and teams and list the major characteristics of effective teams.
Make decisions by consensus through participating in a number of team building activities.

DURATION: 5 Days (20 H)

WHO SHOULD ATTEND?

Managers, supervisors and staff whose job involves building teams as well as working in teams

COURSE OUT LINE

1. Identifying the strengths and blind spots of the team
2. Groups & teams
3. Group process
How groups work?
Including the task & maintenance functions of groups
4. Team roles and the team development cycle ( stages of team development )
5. Team leadership and laws :
The right team for the right challenge
Dealing with weak members
Development good communication between tem mates and leaders
Role of team leaders
 Contacts
Acc / Teleb El Bassiouny Chemist / Tarek Rezk Mr. Adel Abd El Hakim Acc. Magdy Habiba
Aministrative Sectors Head Training Sector Head Training General Manager Training Department Manager
: 03/ 5603037 : 03/ 5603086 : 03/ 5603053 : 03/ 5603053

: 0103407095 : 0101437751 : 0105858935 : 0105736987

E-mail: afctrainingcenter@yahoo.com
Web Site : www.abuqir.com

Abu Qir Fertilizers Company

Tel: +2 03 560 30 53 (7 lines) Fax: +2 03 560 30 86 - +2 03 5603032