Mohammed Mustaq

Industries: Feed & Bio-Fuel

Digital Solution: IDEAS Simulation Software, Metris Platform

Equipment: Dryer, Extruder, Palletizer, Cooler, Hammer MIll, Vacuum Coater

• Process Design and Engineering Validation: Utilize IDEAS software to simulate and validate engineering designs at early stages, ensuring that any potential issues are identified and addressed efficiently.
• Control Strategy Development: Collaborate with control engineering teams to integrate and test control logic within the simulation to ensure optimal plant operation.
• Design Concept Testing: Use simulation outcomes to make informed decisions on design modifications or enhancements with minimal risk.
• DCS Logic Checkout and Validation: Stage, test, and validate Distributed Control System (DCS) logic within the IDEAS environment to ensure control systems are error-free and fully functional before implementation.
• Operator Training and Simulation: Develop and implement operator training simulators using IDEAS, providing a safe and effective environment for training plant operators on both normal and emergency procedures. Update and refine training modules based onEvolvingEvolvingving plant designs and operational strategies.
• Continuous Learning and Improvement: Stay updated with the latest developments in simulation technology, particularly enhancements to the IDEAS software, to continuously improve simulation accuracy and effectiveness. Share knowledge and best practices with colleagues to foster a culture of continuous learning and improvement within the organization.

Industries: Cement, Pulp & Paper

Digital Solution: Deltum XMC Controllers. MPC controller

Equipment: Rotary Kiln, Vertical Roller Mills, Ball Mills

• Conducting process & quality analysis to estimate potential of improvement.
• Site visit for process study and formulate control strategy for process control loops and to identify bottlenecks.
• Networking and Data communication setup between plant automation server and APC servers using OPC, control system driver interface.
• Design and process modelling for different sections during engineering phase.
• Model identification with offline/real time data using step test.
• Designing and tuning of Model predictive controller (MIMO) for process control loops of cement and minerals applications.
• Fine tuning of MPC/Fuzzy/PID controllers and implement innovative technical ideas.
• Program to handle different upset conditions or process behavior and to keep less operator intervention while achieving maximum run factor.
• Achieving performance guarantee parameters for production, Reduction in energy and standard deviation.
• Optimizing main fuel and maximizing alternate fuel while keeping emission levels under target.
• Site closure with utmost customer satisfaction.
• Provide training and prepare site specific manual to ensure continuous operation of APC.
• Remote optimization for commissioned sites.
• Training new graduates, assess and develop skills.

• Reporting to Production Manager and Plant Works Manager.
• Acting Head of Production dutyand Acting Head of Quality control in their absence.
• Responsible for daily production activities from Reclaimer to Cement Mill.
• Conducting energy auditing for cement plant (heat and mass balances).
• Periodical calculation of specific power and fuel consumption to improve plant efficiency.
• Maintaining daily production report, energy, and power reports.
• Production Planning in weekly, monthly, and yearly basis.
• Inventory control of all the materials.
• Supervising all operational parameters of the entire plant and advising operators and shift supervisors to extract full capacity of the equipment.
• Periodical monitoring of pollution control equipment.
• Carrying out activities to reduce down-time of equipment.
• Improvement in efficiencies of the equipment.
• Shutdown activities and supervising refractory activities in kiln and preheater.
• Coordinating with maintenance, quality, and quarry to carry out a smooth operation of the plant and to reduce stoppage time of the equipment.

• Pre-Commissioning Checks of all FLS supplied equipment.
• Performing FAT test along with automation team before approving of interlocks.
• Checking all the instruments in the field along with the P&ID diagrams.
• Commissioning (first time load trial) and optimization & auditing of major equipment like pyro process, VRM, Cooler, Burner and its auxiliaries, Ball Mills and HRP.
• Plant audit & Optimization of entire cement plant.
• Performing audit of cement plant and making heat balance and calculating specific heat and specific power consumption.
• Obtaining the performance guarantee for the supplied equipment.
• Trouble shooting – After sales service.
• Documentation of all protocols for no load trials of the supplied equipment.
• Preparation of complete report on commissioning activities and Performance test done on a project.