PF Instrument Kiln Clr CoalM
PF Instrument Kiln Clr CoalM
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Job Description
Job Purpose
To carry out regular & planned maintenance & necessary modifications in Kiln Work for optimization of Kiln Ensure no breakdown should occur because of Instrument Failure.
Job Context & Major Challenges
Job Context:
UltraTech Cement Ltd. is the largest manufacturer of grey cement Ready Mix Concrete (RMC) and white cement in India. It is also one of the leading cement producers globally. The company has a consolidated capacity of 132.45 Million Tones Per Annum (MTPA) of grey cement. UltraTech Cement has 23 integrated plants 1 Clinkerization plant 27 grinding units and 7 bulk terminals post the Century merger. Its operations span across India UAE Bahrain Bangladesh and Sri Lanka.
UltraTech Rawan Cement plant started its Line 1 operation in early 90s with the capacity of 1 MTPA commissioned in March 1995 as Grasim Cement Unit. This was setup to capture the Eastern Cluster deficit market. In March2013 Line 2 Clinkerization unit was commissioned along with clinker bulk loading facility currently consolidated capacity of Rawan Cement is 6.5 MTPA. Rawan Cement Works also has Captive Thermal Power Plant with a total capacity of 55 MW Waste Heat Recovery System with capacity of 20.4 MW and 10.8 MW Solar Power Plant. The plant has a state of art technology viz. Vertical Roller Mills from Loesch Germany for grinding limestone and coal Kiln and cooler from L&T/FLS Denmark CombiGrinding Cement Mill with Roller Press from KHD Germany Finish Grinding Slag Grinding Roller Press from Krupp Polysius Germany Cross belt analyser from Gamma Metrics USA for online analysis of Limestone XRay analyser Cem Scanner from FLS Denmark.
As the largest cement producer in India we continually strive to play a key role in finding effective and responsible ways to preserve the environment a Cement Sustainability Initiative. We as a company are committed to improving our sustainability footprint in the identified areas of waste management energy reduction water conservation biodiversity management afforestation and emission reduction which are relevant to the cement industry.
Major challenges
Reduce the 20 break down in Kiln from Last Year.
100 availability of equipment in above mentioned sections.
Completion of project jobs within schedule time for increasing the productivity better quality and lowest power.
Zero accident.
Planning to control the ideal inventory and maintain all spare parts
Responsible for Plant Instrument shift operation (Pre & Post Clinkarisation) .
Maintenance and trouble shooting of Instrumentation systems i.e. Weighing system Gas analyzers CCTV schenck SFF Trans weith feedersCoriolis Cooler Hydraulics Roller press Hydraulic VVFD & DC Drive and other field instruments
Experience on Siemens DCS PCS7 simatic manager Wincc S7400 S71500 & TIA
Experience on Smart MCCs Simocode Profibus/Profinet FO Communication and networking.
Experience on Raw Material handing systems stacker/ reclaimer/ wagon tippler etc
Exposure of ISO/ WCM/ Safety systems
Key Result Areas
Supervise and coordinate for smooth trouble free operation of instruments by providing maximum equipments availability in Cement Mill Slag & Mixing section as per requirement and satisfaction of internal customer.
Corrective preventive actions with timely monitoring.
Plan & organize required resources for the job.
Coordinate maint. Jobs related to preventative shutdown & modification / upgradation .
Preparation of proposals for modification / upgradation and take approvals.
Interact with OEMs / Consultants for typical plant maintenance problems.
Facilitate and reorganize required manpower within the existing. manpower available within the unit.
Meet regularly internal customers to take feed back & communicate to concerned for corrective action.
Extending help required to internal customer.
Monitor and control the of maint. Jobs of the section as the budget allocated to keep the cost under control by effective utilization of resources.
Monitor consumption of resources with respect to budget.
Carry out whywhy analysis to prevent recurrence.
Studies Provide interlocks for minimizing idle running of equipments.
Standardization of Instruments in the section.
Review material requirements and inventory.
Control contractor cost & overtime.
Alternate material / design change development and trials.
Organize timely calibration of field instruments for measurement accuracy to reduce losses and improve to customer satisfaction.
Coordinate with stores for calibration certificates.
Organize the baseline of instruments to know the test status.
Study the existing systems and process requirements and identify improvement/ modifications and ensure implementation of approved proposals for completion in time / as per for continuous improvement in the section.
Identify improvement / problematic areas.
Brainstorm for alternatives.
Discussion with superiors OEMs
Review of available resources
Formulate proposal & seek approval
Monitor implementation progress
Plan for revisions of specifications / drawings
Monitor & carryout all the activities required to maintain good house keeping & safety standards of section.
Insist for following safety systems/safe practices.
Guide / interact for effective implementation.
Impart training to workmen/contract workmen.
Identification & rectification of unsafe points/leakage points.
Regular checking of level sensing instruments.
Regular checking of tools & tackles.
Analyze accident/near miss cases.
Carryout safety/environment audits.
Regular checks of dust collector solenoids.
Monitor working of pollution control equipment.
Organise and implement ISO/ OHSAS/SA 8000 and WCM systems in the section through involvement of Team members for improvement of sections working & quality standards.
Identify & get rectify.
Abnormalities.
Spillage/leakages.
Unsafe conditions/practices.
5S activities.
Points emerged in campaigns..
Execute implementation plan for
Quality improvement objectives.
Improvement of WCM practices.
Internal customer rating improvements.
ISO system improvement.
Statutory compliance.
Improvement of OEE/MTBF/MTTR
Elimination of MUDA.
Prepare/present weekly/monthly WCM presentation.
Development & implementation.
Update WCM activity boards.
Develop Model area.
Create awareness in team members.
Visual controls development & implementation.
Monitor working of pollution control equipments.
Employment Type
Full Time
