Advanced Process Control Engineer

RESPONSIBILITIES:• Process auditing for APC implementation• Project implementationImplementation of RamcoOPTIMA advanced process control system in process industries:Project implementation done:1. Madras Cements ltd, Jeyanthipuram - Power plant I & II2. Madras Cements ltd, Alathiyur - Power plant I & II3. Sterlite industries ltd, Tuticorin - Sulphuric acid plant I & II4. Birla copper ltd, Dahej - Sulphuric acid plant I & III5. Madras Cements ltd, Alathiyur - Rawmix Blending Control for Line I & II6. Madras Cements ltd, RR Nagar - Rawmix Blending Control for Line Ia. Installing RamcoOptima APC solutions in workstation and communicating it with the OPC server in process DCS/PLC systems.b. Configuring the required controlled variables, manipulated variables, measured input disturbances and measured output disturbances in RamcoOptima, so as to get and set values to corresponding variables in DCS/PLC.c. Discuss the control logics, process constraints and safety constraints for the said process, in detail with the client.d. Create model between the controlled variables and manipulated variables using AI tools such as Fuzzy logic builder, system identification, control charts, Regression analysis, etc.e. Use the created model in strategies controller / Model predictive controller to get the control moves.f. Tune the models and controller settings to get the optimum control of the said process.g. Project sign off with the client with the improvements and benefits achieved.APC Knowledge:a. Fuzzy logicsb. Neural networksc. Genetic programmingd. Model predictive control

Responsibilities:Co-ordinates and controls the process in the Reduction Plant, by:a. Monitoring the process/production parameters using statistical process methods and standard procedures.b. Investigating deviations and initiating corrective action.c. Coordinating with Production Shift Supervisor and providing expertise regarding monitored process/production parameters, deviations and recommended corrective actions.d. Investigating technical problems and recommending solutions.e. Conducting and initiating non-routine and specialized technical analysis, evaluating results and providing reports thereon.Maintains and optimizes processes equipments, by:a. Monitoring and ensuring production/process quality in the potroom is maintained.b. Recommending modifications with respect to quality, safety, training procedures and standards.c. Recommending modifications to technical parameters.d. Providing adequate and relevant information to management so that corrective action can be taken when deviations from process parameters occurs.e. Keeps abreast of trends and developments and technology improvements in the relevant field.Provide and implements training strategies, by:a. Explaining/demonstrating techniques and methods to production personnel.b. Monitoring production performance by conducting audits on procedures and equipment usage.c. Discussing and explaining technical issues. (Technical information sharing).Provides input and technical expertise with respect to the implementation of Process Projects undertaken in the Reduction Plant, by:a. Assisting with the evaluation and acceptance of new plant and equipment.b. Defining and compiling standard operating procedures and monitoring their effectiveness.c. Instructing and assisting Production Personnel on various techniques and methods used.

Responsibilities:a. Achieving production targets, quality targets, sp. Cons of foil, CGM, dewatering aid, tray flocculants as per BPb. Maintaining the process parameters such as Liquor productivity, weak soda C.R, seeding temperature, seeding quantity, soda gpl in hydrate and alumina, moisture in hydrate, calcined alumina LOI etc as per the norms.c. Troubleshoot for process deviations and take actions to rectify it. d. Manage the operations, manpower allocation and resource management.e. Train new Operators, GETs.Continual Improvement projectsa. Reduction fines in Alumina and improving liquor productivity of Aluminate. b. Furnace Oil consumption reduction

a. Project management - Erection and commissioning of 320 KA Pot room.b. Preheat monitoring and smooth start up of Cells.c. Normalizing the new pots by tuning all the process parameters to achieve the target Current Efficiency.d. Analyzing the process parameters to find out the root cause for the major problems like hot running pots, mucky pots, low purity metal production and pot failure and given necessary corrective action and preventive measures for the same.e. Preparation of Smelter monthly targets like metal production, current efficiency, specific energy consumption and all other process parameters etc.f. Involved in making the department world class by practicing SOP’s, proper housekeeping methods and safety procedures.g. Team co-coordinator for pot room Technical departmenth. Train up (theoretical and shop floor level) trainee engineers, operators and etc.