Job
Description
Job Context & Major Challenges: Write the specific aspects of the job that provide a challenge (internal and external) to the jobholder in the context of the Business/Unit/Function/Department/Section Job Context Birla Copper Unit at Dahej has a captive power plant complex with potential to generate 95MW of power through three coal based thermal power plants catering to the captive power requirement of the complex. (CPP 1& 2 is a 71.95 MW Power Plant and CPP 3 is a 60 MW Power Plant) These plants also supply steam to the process plants. CPP 1 &2 the complex consists of one CFBC type boiler, five Steam Turbines of capacity 24.5 MW, 24.45 MW, 12.5 MW,10.5 MW (Total 71.95 MW), 2 no of Diesel Generating Sets (2.5 MW each), 5 no of Plant air and Instrument Air Compressors, & Ash Handling plant. CPP3 complex consists of two CFBC type boilers, one Steam Turbines of capacity 60 MW, Ash and Coal Handling plants. The most critical element of this role is ensuring the uninterrupted supply of power, steam and compressed air for production of copper cathode and anode as well as fertilizer. This role is responsible for operation and maintenance of the assigned power plants (CPP 1& 2 or CPP 3) and generation of power as per monthly and annual target within the budgeted cost, supplying steam to process plants (Smelter and Refinery) and supply of compressed air. It is critical to match generation of power with the demand of internal customers as closely as possible through planning so as to provide reliable Power steam and compressed air and reasonable cost. This involves optimum resource utilization and continuous training to improve efficiencies so as to comply with statutory stipulations, company norms as well as quality and environment certification specifications. Job Challenges CPP 1 & 2 equipment is more than two decades old and CPP 3 equipment is about than one decade old and needs upgradation. Their ability to operate at required efficiency levels and meet environment norms is a major challenge There is no margin for shutdown and maintenance Fluctuation of power and steam demand by operations result in back feed without payment and unplanned import of power costing money. Sustaining uptime of plant and instrument air compressor due to very corrosive atmosphere causing corrosion to the vital parts of the compressors and piping system and structures Aging of the major capital equipment like Boiler and Turbine DG sets, Compressors. Cooling Tower maintenance effectiveness due to timber cooling tower. Availability of skilled manpower and capability building. High imported coal cost and increasing completion in Copper business. Contract Manpower safety awareness and behavioral change. High Manpower attrition rate Space constraints for turbine and boiler and cooling tower area for maintenance work and store room. Cyclone prone area lead to damage may high rise structure. Stringent pollution control norms by GPCB/ CPCB. Growth opportunities and new learning opportunity for employees. Adaptation of digital mindset and developing digitalization competency. Obsoleting equipment like compressor and DG sets. Low performance of small capacity turbine. Timely Spare parts availability of different make Turbines ( LMZ Russia, Skoda Germany, Shin Nippon Machinery Co., Ltd Japan, BHEL India) Single stream coal handing plant conveying system. Poor Fire water spray system in CHP and Power plant. Nearby hazardous chemical plant lead to environment and life hazards Connectivity issue with major cities like Bharuch and Vadodara for emergencies. Key Result Areas: Write the key results expected from the job and the supporting actions for each of these key result areas (For a majority of jobs typically there could be 4- 7 key result areas) Key Result Areas Supporting Actions Daily Asset Care Ensure overall maintenance planning i.e., identification, prioritization & scheduling of maintenance work / jobs (Monthly / Weekly basis) and ensure schedule adherence & PM quality, escalation of non-compliance to AET / PBU / VST Develop resource, time & cost estimates of planned maintenance and collaborate with AET maintenance members to plan schedules, manpower & other resources for the most effective outcomes. Tracking and execution of predictive maintenance schedule. Implementing SOPs and WI for the departmental activities Equipment health monitoring. Ensure spares & consumable planning by setting up proper mechanism, maintain optimum inventory and standardize vendors in collaboration with purchase Ensure up-keep of equipment performance parameters database, maintenance history and job records Plan & schedule shutdown jobs / overhauling work and execute them along with AETs & DMTs Knowledge of CPP related MIS work. Ensure that AETs & DMTs are adhering with maintenance schedules without compromising on quality by providing feedback and through regular audits. Knowledge of Power Plant Philosophy and its optimum operation and performance gap monitoring. MIS Coal Management MIS Ash Management Liaoning works with Directors of Boiler for IBR Statutory Inspection. Compliance monitoring for all Statutory Inspection of Pressure Vessels and EOT as per schedule. Report generation and modification Daily Monitoring Plant Performance. Providing awareness on Statutory work and complete statutory inspection of IBR ( CPP) Monitoring of Coal Stock & Biomass Management. Ash Management and keep record of Generation & Dispatch. Daily monitoring KPI of CPP. Carbon foot print data tracking Monitoring of TG Performance and daily Heat rate. Customer Centricity Co- Ordinate with Operations, Maintenance related to improve plant performance and cost effectiveness Statutory work and complete statutory inspection of IBR. Generate MIS reports of KPI analysis with respect to Power cost and process & equipment performance for the reference of all internal customers. Co- Ordinate with MIS ( Finance ) department for CPP related KPI and cost monitoring. Reliability Centered Maintenance & Asset Life Improvement Supporting the Implementation RLA (Residual Life Analysis) and thickness monitoring practices to assess equipment / structural stability and sustainability of the plant & equipment. Participate plan and schedule for shutdown & overhauling work and execute them along with AETs & DMTs. Audit the work of all planned jobs and provide feedback to respective departments in terms of quality assurance & process compliance. Ensure that corrective actions as per the performance gap analysis are incorporated and implemented, for continuous improvement. Asset Life Cycle Management Review, analyze and monitor trends & systems in Operation management framework to recommend actions for continuous improvement and achieving customer satisfaction. Institutionalize maintenance management system for various maintenance practices (PM planning & scheduling, Predictive & Condition monitoring, RCM, etc.) and achieve sustainable asset care. Reducing working capital and improving profitability. Implement Predictive maintenance practices & condition monitoring for increasing the asset life span as well as reliability across its lifetime. Review, analyze and monitor trends & systems in maintenance management framework to recommend actions for continuous improvement and achieving customer satisfaction. Value Creation & Asset Leadership Monitoring overall cost of Power by following measures: track Maintenance cost and Operation cost by conducting regular reviews, Capability Building & People Engagement Develop Pre & Post Shutdown report for gap identification and remedial actions and share the lessons learned with O&M team for future shutdowns. Training of juniors & help to learn about the plant for the new engineers HSE & Sustainability Implement safety standards to achieve zero harm during Mechanical & Electrical maintenance and Automation & Digitalization activities. Role Specific Competencies Technical competencies Degree in Engineering Preferably mechanical, Power Engineering, Electrical, with adequate relevant & troubleshooting experience Project Management. Vibration Analysis certification NDT certification Understanding of Power plant and related operation. Analytical problem-solving skills Behavioural competencies ABG Leadership Competencies- Vision and strategy Business acumen Financial Know-how External stakeholder management Show more Show less
