Job Purpose Objective of this role is to ensure smooth operation of the plant in the assigned shift by operating the DCS control console to coordinate and regulate process variables and to direct flow rates of various process and utility streams according to prescribed schedules. Coordinate the start-up, shutdown (normal & emergency). Set controls to adjust process variables, such as furnace magnetite, copper loss, matt grade, blister quality, lag chemistry, sulfur in blister, and bearing temperature etc. . This role is also responsible for recording and documenting operating data, and monitoring process indicators. Dimensions: Business/SBU/Unit Revenue Business Workforce Number Permanent workmen – 1750 employees LMS – Management Cadre – 350 Contract labor - Unit Workforce Number Permanent workmen – 1500 employees LMS – Management Cadre – 350 Contract labor - Function Workforce Number Permanent workmen – 550 LMS – 35 Management Cadre – 85 Contract labor - 1000 Department Workforce Number 92 Other Quantitative and Important Parameters for the Job: Budgets/Volumes/No. of Products/Geography/Markets/ Customers or any other parameter DCS Familiarization with regulatory loop, graphic, faceplate, trend & controller Peripheral skills - handling keyboard & mouse Alarm Handling- prioritized acknowledge response Ability to handle Emergency Shutdown and coordination with the concern area person Co-ordinating with the Automation Team for setting up different alarm sound for critical and non critical alarms Ability to handle emergencies in plant like power failure, high temperature of furnaces etc Observation skills to identify the abnormalities in the instruments and parameters like temperature, furnace magnetite, slag chemistry and leakages blister quality etc in the plant Knowledge of the Standard Woking procedures and safe working practices Knowledge of process controls to adjust process variables such as temperatures, air and oxygen blowing, water PH, etc. Basic computer skills like Microsoft office Knowledge of slag making and granulation system Operational knowledge of feed tank and its circuit Thorough Knowledge of furnace chemistry Knowledge of material Dryer system including bag filter and dog fan bearing temperature etc Knowledge of additives being used in process like flux, silica etc Job Context & Major Challenges: Job Context Bi rla Co pp er has a c o pper smelting a nd r e fi ning co mpl ex a t D ahej producing copper cathodes, cast copper rods, precious metals such as gold silver and selenium, fertilizers, and other bi-products such as s ulphur ic a ci d, phosp ho ric acid etc . in multiple plants with different technologies requiring diverse competencies. There are approximately 1500 employees, across functions at the Dahej unit of which about 350 are in the management cadre. This role is responsible operation of S, CL and C Furnaces, Lance, Feeding system, ASCM, ARM of Copper Smelter 3 supplied by Mitsubishi, achieving targeted production and ensuring preventive maintenance. The key element of this role is maintaining furnace chemistry, monitoring furnace health and controlling copper loss in discarded slag. It involves ensuring optimum liquidation of WIP through C slag, dust and lumpy consumption in S Furnace. The operation involves hazardous processes and generation of corrosive and toxic intermediate products which need to be monitored to be able to keep emissions such as SO2 within permissible limits. The role involves strict compliance of statutory stipulations and compliance of quality, safety, health and environment parameters. It requires continuous process improvement and training. Job Challenges Smelter 3 is a continuous process that is highly complex in nature requiring 1 Stringent process control at high feed rate (TPH). 2 Rigorous preventive maintenance to eliminate breakdown of the single line equipment and prevent the whole plant from stopping. - Molten metal in launder tend to solidify if not monitored closely, blocking WIP and cash flows - Processes hazardous with corrosive, toxic emissions, minimizing emissions within PCB norms and meeting other environmental and safety norms difficult. Key Result Areas/Accountabilities: Key Result Areas/Accountabilities Supporting Actions Planning Giving inputs for Planning shutdowns and routine preventive maintenance to improve uptime of S, CL and C Furnaces Employee Relation Discuss with team members every day to develop better team Operational Excellence Achieving the targeted production of Copper Anodes as per specifications during the assigned shift - Restricting copper losses within norms during the assigned shift - Implementing SOPs and WIs during the assigned shift - Implementing good housekeeping practices and maintaining a clean work environment during the assigned shift Basic knowledge of various quality parameters like oxygen purity, air, blister quality, sulfer containt in blister, matt grade quality Knowledge of equipment- like compressor, bearings, feed tank, dryer, burner, bag filter,dog fan, dumper, belt conveyor etc Material- coal, lime, silica, copper concentrate, Proficient skills in recording, compiling, and documenting operating data and process indicators from DCS Budgetary Controls Implementing optimum utilization of resources is a vis consumption norm to minimize cost of production - Maximizing liquidation of WIP during the assigned shift to ensure minimum blocking of funds and consumable controls Compliance Implementing compliances of Integrated Management Systems, health, safety environment norms Follow the basic know how’s and do and don’ts about and below safety task force knowledge and know how about all these mentioned below . Behaviour Based Safety Electrical Safety, Electrical for Non-Electrical persons, Use of Hand power Tools Lock out / Tag out / Try out system Process Safety Management and Permit To Work System Management of Change, SOP, SWI, HIRA & JSA Emergency Preparedness and Mock drills, Fire prevention and control Material Handling (Hydra, Crane, FLT), Lifting and supporting of loads, Type of Tools, Tools and Tackles, Safe use of Hand tools Road and Transport safety Chemical Handling Safety (Plant Specific) Working at height and fall protection, Safety in Roof sheathing, Scaffolding, Etc Gas Cylinder Management Machine Guarding Safety Confined space Safety Molten metal safety Contractor Safety Management Hot work Safety Basic First Aid and Corona, occupational health, HIV, Maleria Customer-centricity Minimizing response time for all internal customers issues Sustainability and Process Improvement Implementing best practice for process improvement - Keeping assets under jurisdiction in good condition - Implementing good housekeeping during assigned shift - Participating in improvement initiatives such as Kaizens, Quality Circles etc. - Implementing good housekeeping practices in area of operation - Partnering in the creation and maintenance of green belt Contract Labor management Ensuring training of S, CL and C Furnace team members to enhance technical and behavioral competencies and increase safety awareness - Implementing 5S and autonomous maintenance culture People development and engagement Monitoring and improving performance of team members - Ensuring training of S, CL and C Furnace team members to enhance technical and behavioral competencies and increase safety awareness - Implementing 5S and autonomous maintenance culture Role Specific Competencies Technical competencies the knowledge and abilities required to apply specific technical principles and information in a job function or role. Knowledge of equipment- like compressor, bearings, feed tank, dryer, burner, bag filter, dog fan, dumper, belt conveyor etc Material- coal, lime, silica, copper concentrate, Behavioral competencies Can assess the impact - understands the value/ implications a change will have on a given function/ process Job Purpose of Direct Reports: Position Title Job Purpose Position No. Support operation Objective of this role is to ensure smooth operation of the plant in the assigned shift by operating the DCS control console to coordinate and regulate process variables and to direct flow rates of various process and utility streams according to prescribed schedules. Coordinate the start-up, shutdown (normal & emergency). Set controls to adjust process variables, such as furnace magnetite, copper loss, matt grade, blister quality, lag chemistry, sulfur in blister, and bearing temperature etc. . This role is also responsible for recording and documenting operating data, and monitoring process indicators. 00242200 Show more Show less
