Job Description

:Job PurposeMonitor and supervise the operation of WHRS. Responsible for safe, continuous and efficient startup and operation of Boiler, Turbine and its auxiliaries in order to keep 100% availability of WHRS. Collection of data for MIS report as per requirement. Implement & Monitor ABG safety standards & procedures in being followed in WHRS.Job Context & Major ChallengesThe Unit is located in Tonki Village, Tehsil - Manawar, District - Dhar (M.P.). Located at a distance of 139 kms from the city of Indore.
Unit has 2 lines with capacity 6MTPA located at the prime location to capture market of high potential. Total raw material transportation and dispatch is through road transportation with a turnaround of average 600 trucks per day.
Clinker at Dhule and other GUs are being transported from Dhar.
Job Context :
Dhar Cement Works is integrated cement plant equipped with modern technology with an installed capacity of 6 MTPA, cement production capacity of 5.2 MTPA with WHRS for power generation (33 MW) and open cast mines. It manufacturers OPC 43, OPC 53 ,PPC , PPC Special grade of cement. Our Unit have AFR processing facilities to support our TSR.Unit has always maintained high level of operational performance and stands tall, as a symbol of Sustainable Industrial Development. It is acknowledged as one of the efficient, vibrant, productive, profitable, technologically updated and state-of-the-art unit. For sustainability units environmental cell monitors air and water quality, audits, and conducts ecological studies and environmental studies of mines and nearby villages.Waste Heat Recovery System consists of 33 MW (13+15 MW), condensing type steam turbine with single Injection top Exhaust steam Turbine.Having 2 boiler WHRS type,After Quenching Cooler boiler having steam generation capacity of 50 TPH in final superheater and 25 TPH in HP primary superheater with Working Pressure 18.94 Kg/cm2,LP Boiler of AQC circuit having steam generation of 3.4 TPH with working pressure 7 kg/cm2 and Unit-2 Preheater Boiler type having steam capacity 25.6 TPH with working pressure -18.94 Kg/CM2 and LP boiler with 11.5 TPH capacity with working pressure 7 kg/cm2. The auxiliaries system for steam turbine comprises high pressure boiler feed pumps having working pressure 30 Kg/CM2, and Air cooled condensers consisting of total 6 Nos. of forced draft fans for 1 units having dia. Of fan-9.75 Mtrs, Steam jet air ejectors, gland steam condensers, 01 Nos of Deaerator system etc.The water treatment system consists of R O & D M plant. Waste water will be treated in waste water treatment plant. Auxiliary cooling water system with induced draft cooling towers and raw and fire water system.The operation of entire WHRS would be a challenge for all engineers with parallel operation of unit without grid (island mode). Also the Air cooled type condensers is a new technology which needs proper attention for efficient operation as it is changing with the quality of atmosphere air.
system.
Major Challenges:Operation :

• Inspite of availability of grid, maintaining the 100% availability & reliability of boiler TG set in any case by fulfilling IBR statutarty requirements, GPCB norms and WCM & ISO practices for uninterrupted quality power provision to cement plant & keeping minimum Load in the Grid
• Over the years, the Boiler and Turbines componants have started showing deterioration in their performance due to ageing factor. Challenges of best operation & maintanace practices are needed to sustain performance of Boiler-TG set.
• To prepare and provide immediate real time data related to plant performance, budget, flash provision report, power cost budget, etc

Key Result Areas KRA (Accountabilities) (Max 1325 Characters) Supporting Actions (Max 1325 Characters)
KRA1 Responsibility of Plant operation:
Coordinate operational activities for power generation from WHRS in order to supply uninterrupted power to cement manufacturing plant. Review operating instructions and tailor them to site specific requirements
Review of operational strategy and philosophy as per instruction of superior
Internal Energy audit and cost optimization at plant level
Forced Outage Analysis per instruction of superior
Co-ordinate conduction of Operations Team Review daily Meetings
Identification of plant abnormality, operational losses & coordinate with maintanace department to resolve issues.
Interact with service department for day-to-day operational work requirement.
Assist in shutdown plan execution from operational side.
KRA2 Plant Performance
Improved the plant performance in operation and work environment Monitor day to day operation of the plant and its deviation from the optimum value.
Identify factors resulting in low availability, high partial loading and deviation of critical performance parameters from standard norms and take corrective actions
Assessment of critical performance parameters and performance optimization
Visit and verify functioning of each equipment to be at its optimum stage.
Monitor false air in system monthly basis.
Heat rate break-up with all factors contributing it.
Analyse Boiler Performance & find out abnormal parameter, losses and take action to control it.
Monitor equipment wise power consumption & find out the abnormality with root cause, daily auxiliary comparision (Equipment wise) and immediate action plan generation for its optimisation.
KRA3 WHRS Reports Generation, Budgeting & Billing Root cause analysis of tripping, failures, outages, low availability, and partial loading
Prepare unit performance of all UTCL units to identify DHCW position.
Assistance in generation of COO, CSI, GRI & Manufacturing council PPT reports.
Daily and Monthly Power Cost monitoring with break-up of all factors contributing it.
Real-time data provision related to WHRS as per requirement of WCM & production department.
Assistance in maintaining PAT & EDB data.
Monthly Reports:
a. Cross checking of WHRS performance reports wrt SAP
b. RPM Flash Provision
c. Loss cost matrix
d. QCDIP
e. WCM Board updation
f. Updating history of WHRS Performnace Reports
g. Contratual Billing.
h. Service entry of jobs done & Material PR & PO.
Assistnce in maintaining statutary reports related to IBR & GPCB.
MOM of Third party services and assisting them carrying out WHRS services.
Annual Budgeting:
a. Budgeting WHRS annual performance as per forecast of Cement plant and filling in TM1
b. Real time budget provisions as per requirements of MIS
KRA4 System implementation :
Ensure effective implementation of all quality systems e.g. WCM, TQM, ISO, ENMS etc., in all the section of operations to attain excellence Preparation of SOPs for each system and equipments and ensures adherence to it for safe and reliable operation.
To assist superiors to Identify and execute improvement study and kaizen, identify and get rectified abnormalities spillage/leakages, unsafe condition/practices.
ISO system improvement.
Execute implementation plan for strategic quality projects. Improvement in ABEF Score, EMS target, internal customer rating improvement, SO System Improvement, statutory compliance. Elimination of Muda, does why-why analysis, develop model Area. Create awareness in team member
PAT data collection and submission to Govt. Bodies within time frame.
Identify and executive improvement study and kaizen.
Execute implementation plan for Quality improvement objectives.
Improvement of WCM criteria score.
KRA5 SAFETY To assist superiors to Carryout timely inspection of all jobs required as per statutory guidelines and ensure their timely compliance.
Complete task specific Risk Assessments and to ensure proactive adherence to Health and Safety at all times.
Follow safety practices in work methods and ABG procedures; (rules, regulations, codes, safe work habits and potential hazards presented by the work environment).
Maintain all safety rule and regulation as per the company norms.
Take everyday safety tool box talk for the awareness of safety among the workman.
Report regular Near miss so that no major accident take place.
Maintain statutory records of the observations
Take corrective measures for deviations.
Identify & rectify unsafe points & unsafe practice in the area.
On the job training to staff &workmen on safety & treatment.

Aditya Birla Group