Pf tpp (instrument btg) - engineer/ sr. engineer/ asst. manager

Job Purpose

To maintain the Instrumentation and control systems of Boiler, Turbine and Generator sets of TPP/DG to run power plant and to ensure smooth and trouble free operation of the power plant in order to produce uninterrupted power supply.

Job Context & Major Challenges

Andhra Pradesh Cement Works (APCW): a unit of UltraTech Cement Limited, a flagship company of the Aditya Birla Group is situated at Tadipatri, District - Anantapur. APCW has 2 Lines. Line-1 was commissioned in 1998 with an installed capacity of 2 million tons (2 MTPA) cement annually, which has been enhanced to 2.7 MTPA over a period of six years through several improvements and modifications. Line-2 was commissioned in August 2008 with an installed capacity of 3.4 MTPA. The total cement production capacity of APCW, along with the associated Units, is 11 MTPA. The integrated plant is associated with two grinding units and one bulk terminal - Arakkonam Grinding Unit (ARCW) in Tamil Nadu, Ginigera Grinding Unit (GICW) in Karnataka and Shankarapalli Bulk Terminal (SBT) in Hyderabad. The unit has also established a thermal power plant of 4 X 25 MW capacity to cater the plant's power requirement. The APCW Mine is located near Tummalapenta Village, Kolimigundla Mandal, Kurnool District at Andhra Pradesh. It has a production capacity of 9.20 MTPA. The mine lease extents up to 844.939 hector. It was opened in the year July 1997. The general geology falls in Narji Limestone formation of Kurnool system, age of 800 Mio years old. As per UNFC classification, mine has got the limestone reserves of 181.65 Mio MT as on 31 March 2012. It is one of the largest mines producing 9.20 Mio MTPA limestone at single location.

Job Challenges

Location of the plant posses a challenge to get the skilled manpower and proper responses from some vendors.

Key Result Areas KRA (Accountabilities)

KRA1 Plant Availability: Timely Completion & implementation of maintenance activities for maximum availability Instrumentation department of BTG 1 & 2 for achieving targets with respect to downtime, maintenance work and customer satisfaction. Instrumentation Cost Optimization: Plan, monitor and control cost (spares, Inventory & manpower) of Electrical & Instrumentation maintenance activities in BTG 1 & 2 to optimize maintenance cost within the budget.

• Troubleshooting of Instrument and control Related problems in time for achieving the plant availability.
• Timely calibration for accuracy of field instruments as per standards.
• Execute maintenance plans.
• Timely Completion of PM schedule.
• Timely Completion of jobs in shutdown.
• Review breakdowns & carryout analysis for problems.
• Take corrective actions.

KRA2 Continuous Improvement: Study and identify projects, coordinate and monitor implementation of up-gradation/modification/de-bottle necking/improvement projects to improve the availability & reduce cost of Electrical & Instrumentation maintenance.

• Collection of data on failures and bottlenecks & identification of improvements projects.
• Analysis of failures.
• Identify improvement actions.
• Formulate proposal i.e., equipment specification, drawings etc.

KRA3 SHE (Safety, Health & Environment) along with Sustainability initiatives: Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area. Educating team about “I know my job”, “I know the hazards associated with my job and I applied control measures” & “I escalate to my senior” among manpower deployed in sections/department manpower including peer, WB & CL manpower.

• Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.
• To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP.
• Active participation in safety training, safety sub committees, standard champions meeting and any safety event.
• Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action.
• Adhering of all safety precautions on the site and off the site.
• Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.

KRA4 System Management: Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards.

• To implement improvement project to reduce repetitive problems/breakdown or losses.
• Timely submission of Kaizen, OPL, Good to fine, suggestion on system.
• Developing and sustaining Model area in respective sections.
• 100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity.
• Conduct awareness programmes down the level team.
• To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments.
• Implementation of critical spares & consumable SOP without any defilement.
• Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.