Requirement in Producer Gas Plant

Job Description

We have various position in below department 1. Project 2. Operation 3. Maintenance (Mechanical) 4. Maintenance (Electrical) Experience Range: 4-25 years Education: BE/B.Tech./Diploma/B.Sc. Job Purpose: To manage the complete lifecycle of the Producer Gas Plant, including project planning and execution, daily operations, and maintenance activities. Ensure consistent and safe producer gas supply, optimize performance and cost, and ensure environmental and statutory compliance. Key Responsibilities A. Project Planning & Execution Lead the setup of a new Producer Gas Plant or expansion projects from concept to commissioning. Conduct feasibility studies, load calculations, and sizing of the gas plant based on production requirements. Finalize plant layout, PFDs, P&IDs, equipment specifications, and integration plans with consultants and internal teams. Coordinate with purchase for vendor selection, RFQs, technical evaluations, and commercial negotiations. Supervise civil, mechanical, electrical, and instrumentation works at site. Monitor project schedules, budgets, and resource allocations using project management tools (MS Project/Primavera). Drive pre-commissioning and commissioning activities, including safety trials, gas testing, and interlock checks. B. Operations Management Ensure continuous, reliable, and safe operation of the Producer Gas Plant. Monitor critical process parameters such as temperature, pressure, flow, gas quality, and fuel feed rate. Manage and optimize fuel consumption (coal) and maintain ash handling systems. Ensure smooth functioning of gasifiers, scrubbers, blowers, filters, and pipeline systems. Coordinate with consuming departments (e.g., rolling mill, furnace, forging) for gas demand and supply synchronization. Maintain shift-wise production logs, daily generation and consumption reports. C. Preventive & Breakdown Maintenance Develop and implement preventive maintenance schedules for all mechanical, electrical, and instrumentation components. Lead troubleshooting of plant breakdowns to ensure minimum downtime. Maintain inventory of critical spares and consumables. Coordinate with AMC vendors and internal teams for predictive and condition-based maintenance. Maintain equipment history records and reliability improvement initiatives. D. Safety, Quality & Compliance Ensure adherence to all safety protocols, interlocks, gas leak detection systems, and fire-fighting equipment functionality. Conduct hazard analysis (HAZOP), job safety assessments, and safety audits periodically. Comply with environmental regulations for emissions, ash disposal, and water usage. Ensure statutory approvals and liaison with authorities (e.g., PCB, Energy Dept.) as required. Train the team on safety practices, SOPs, and emergency preparedness. E. Performance Monitoring & Continuous Improvement Track KPIs like gas yield, thermal efficiency, specific fuel consumption, downtime, and plant availability. Implement energy-saving and cost-reduction projects. Analyze plant performance and drive improvements in reliability, capacity, and efficiency. Benchmark best practices from the industry for performance optimization. F. Team Management & Documentation Lead a multidisciplinary team of operators, technicians, and support staff. Plan shift deployment and ensure skill development and training. Conduct regular team briefings, performance reviews, and motivation activities. Maintain all documentation: SOPs, O&M manuals, logbooks, inspection reports, MIS reports, and audit records. Qualifications & Experience Education : B.E. / B.Tech in Mechanical / Chemical / Energy / Electrical / Industrial Engineering Experience : 418 years in gasification-based utility systems with proven experience in project execution and plant operations Preferred Industry : Steel, Foundry, Refractories, Forging, Biomass/Energy plants Key Skills & Competencies End-to-end project management of utility systems (preferably gasifier plants) In-depth technical knowledge of gasification processes (fixed bed, downdraft, updraft) Strong troubleshooting skills in mechanical and instrumentation systems Safety leadership and statutory compliance Strong leadership and man-management skills Knowledge of SCADA/PLC systems (preferred) Strong data analysis and reporting capabilities Vendor and contractor management Working Conditions Site-based role with presence required during commissioning and critical operations May involve shift working and on-call duty Exposure to high temperature and dusty environment; use of PPE mandatory Requires coordination across departments and with external stakeholders