Associate Manager - BOP

Job Title:

Department:

Function:

Reports to:

Job Purpose

To ensure the Unit/Station availability as per the AOP plan by adhering to 100% statutory compliance, adopting safe and trouble-free technology, and ensuring value addition to all stakeholders. The goal is to convert the maintenance wing into a profit center from a cost center.

Organization Chart

Key Accountabilities and Performance Indicators

1. Mechanical Maintenance Responsibilities

• Responsible for maintenance planning, scheduling of preventive & breakdown maintenance of

  Turbine & auxiliaries

  .
• Responsible for maintenance planning, scheduling of preventive & breakdown maintenance of

  Air compressors and dryers

  .
• Execute emergency shutdown work like

  feed pump bearing failure, generator rotor thread out, hydrogen seal replacement, turbine bearing inspection, major steam leakages, tube leakage tests in condenser, HP/LP heater issues

  .
• Carry out daily maintenance during

  HP/IP control & stop valve failures, safety valve failures

  , etc., on a war footing to minimize downtime.
• Maintain unit availability for

  maximum running hours

  from the mechanical side.
• Execute maintenance activities based on

  defect notifications

  .
• Coordinate with the

  condition monitoring team

  to maintain

  oil quality and pump vibration

  within limits.
• Assist in

  major overhauls

  of turbines and auxiliaries.
• Involved in

  condenser flood tests and HP heater hydro testing

  .
• Perform regular maintenance and overhauling of

  BFPs and booster pumps

  .
• Improve the performance of

  air compressors and dryers

  .
• Support

  erection and commissioning

  of turbines and auxiliaries.

Key KPIs:

• Turbine & auxiliaries availability
• Generation loss due to equipment failure
• Maintenance budget adherence
• Zero accidents
• Zero stock-out
• 3S Score > 90%
• 100% preventive maintenance compliance
• Statutory certification of lifting tools, tackles, and EOT cranes as per schedule
• 100% TNI compliance
• Knowledge sharing and idea implementation

2. Spare Management & Inventory Control

• Identify

  critical and other spares

  for various equipment to avoid zero stock situations.
• Develop spares through

  reverse engineering

  .
• Develop

  Indian and alternate vendors

  for spares.
• Effectively manage inventory to avoid any

  emergency delays

  .
• Plan and procure spare parts within

  AOP budget

  with a target of utilizing

  80% of the budget

  .

3. Safety & Compliance

• Ensure

  safety implementation

  in all daily maintenance activities.
• Develop safety skills for agency workforce (working at height, confined spaces, hot zones, etc.).
• Identify and eliminate

  unsafe acts/conditions

  .
• Ensure compliance with all

  EHS audits

  and execution of improvement plans.
• Conduct

  toolbox talks and regular safety meetings

  to promote behavioral safety.

Key KPI:

4. System Improvements & Cost Optimization

• Identify and implement

  system improvements for reliability and cost savings

  via brainstorming and root cause analysis.
• Examples of successful modifications:

1. Dosing line modification to allow initial dosing without CEP.
2. JOP supply line isolation for individual bearing maintenance.
3. CRH pot drain common line connection.
4. BFP balancing pressure gauge installation.
5. MDBFP cartridge reconditioning.
6. Air compressor performance enhancement.

5. Continuous Operations & Troubleshooting

• Apply

  preventive, proactive, and condition-based maintenance

  to ensure uninterrupted operation.
• Continuously monitor systems for

  reliability improvements

  .
• Target station availability > 98.5%.

Team Development & Knowledge Transfer

• Conduct expert training on

  air compressors

  .
• Deliver

  refresher courses

  based on TNI needs.
• Build team motivation, proactive behavior, and ownership.
• Address performance challenges through

  daily discussions and technical sessions

  using problem-solving methods.

Stakeholder Management

• Maintain healthy working relationships with internal departments and vendors.
• Ensure smooth job execution via proper coordination.
• Guide

  Graduate Engineers

  and build their confidence to manage activities 24x7.
• Maintain transparent and effective communication with

  superiors and senior management

  .

External Interactions

• Third-party vendors
• Contractors
• Equipment and spare part suppliers

Internal Interactions

• Department colleagues
• Interdepartmental teams
• Stores, Finance, and Commercial teams
• Senior management

Financial Dimensions

• Responsible for managing the

  maintenance and spare procurement

  budget.
• Contribute to

  cost-saving initiatives

  and optimize resources.

Educational Qualifications

• Bachelor's Degree

  in Mechanical Engineering (or related field)

Relevant Experience

• Minimum 5 years

  of experience in a power plant (preferably thermal).
• Extensive hands-on experience in

  erection, commissioning, preventive, predictive, breakdown, and opportunity-based maintenance

  .

Core Competencies

• Personal Effectiveness
• Social Awareness
• Entrepreneurship
• Problem Solving & Analytical Thinking
• Planning & Decision Making
• Capability Building
• Strategic Orientation
• Stakeholder Focus
• Networking
• Execution & Results
• Teamwork & Interpersonal Influence