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Nigeria
Leading Commissioning Activities at One of Africa's Largest Cement Operations
Industrial commissioning is where engineering plans are tested against real-world operating conditions. At Dangote Cement's Ibese Plant in Nigeria, Rajesh Shah played a key leadership role during one of the most critical phases of the project — the transition from construction to successful plant operation.
Working as Deputy Manager (Electrical & Instrumentation), he led a multidisciplinary team of engineers while coordinating activities between FLSmidth, Dangote Cement and Petron Engineering. The role extended far beyond instrumentation alone. Responsibilities included planning and tracking commissioning schedules, coordinating electrical testing activities, verifying equipment readiness and ensuring smooth integration between electrical, instrumentation and automation systems.
Particular attention was given to the commissioning of process equipment, field instrumentation and plant automation systems that would ultimately control and monitor the entire cement manufacturing process. The project required constant coordination between equipment suppliers, contractors and plant personnel to ensure all systems were tested, calibrated and commissioned safely before startup.
In addition to commissioning responsibilities, Rajesh Shah later contributed to a major automation modernization initiative at the Ibese facility involving the migration of the control system from the original SINOMA platform to the FLSmidth ECS control system.
This project demanded careful planning and execution to ensure reliable process control while supporting long-term operational efficiency.
Key Contributions
Led a team of 8 engineers
Coordinated commissioning between client, contractor and OEM
Managed electrical testing schedules
Supported startup and operational stabilization
Automation migration from SINOMA to FLS ECS
Instrumentation and automation integration
Dangote Cement, Ibese, Nigeria
Edo Cement, Nigeria
Commissioning Nigeria's First 6000 TPD FLSmidth Cement Plant for BUA Group
The successful commissioning of a greenfield cement plant requires precise coordination between hundreds of interconnected systems. At Edo Cement, Rajesh Shah contributed to the commissioning of Nigeria's first 6000 TPD cement plant supplied by FLSmidth for the BUA Group.
The project involved supporting the integration and commissioning of instrumentation systems critical to plant operation and environmental compliance. A major focus of the project was the installation and commissioning of gas analyzer systems and stack emission monitoring equipment designed to support process optimization and regulatory requirements.
The work required close coordination with equipment suppliers, contractors and plant personnel to ensure all instrumentation systems were accurately calibrated, tested and integrated into the plant's automation architecture. The successful startup of the facility represented a significant milestone in Nigeria's industrial development and reinforced valuable experience in modern cement plant commissioning.
Key Contributions
Commissioning of 6000 TPD cement plant
Gas analyzer system installation
Stack emission monitoring systems
Instrument calibration and testing
Automation system integration
Startup support activities
Lafarge Cement, Calabar, Nigeria
Improving Process Reliability Through Instrumentation & Drive Systems
At Lafarge Cement's UCC Calabar facility, Rajesh Shah supported projects involving instrumentation and process control equipment critical to plant performance.
The scope included:
Pfister feeder systems
Schenck belt weighers
Field instrumentation
Low-voltage switchgear
Variable frequency drives
These systems play a vital role in maintaining process accuracy, stable material flow and reliable plant operation. The experience strengthened practical understanding of process measurement, electrical distribution systems and drive technologies used throughout cement manufacturing operations.
Key Contributions
Pfister feeder systems
Schenck belt weighing systems
Instrumentation integration
LV switchgear systems
VFD applications
Water Injection System Commissioning for Cement Mill Optimization
Efficient cement grinding operations depend heavily on maintaining proper process temperatures and mill operating conditions. At Lafarge Cement's Shagamu Plant, Rajesh Shah supported the commissioning of water injection systems for two cement mills. The project involved integrating instrumentation, control systems and process equipment required to maintain optimal mill operating temperatures and improve grinding performance.
The successful commissioning of the system contributed to improved process stability, enhanced mill efficiency and reliable operation of critical grinding assets.
Key Contributions
Water injection system commissioning
Cement mill process optimization
Instrumentation integration
Control system verification
Operational performance improvement
Lafarge Cement, Shagamu, Nigeria
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