PF Instrumentation (DCS & Automation)

Supervise, co-ordinate & attending of Instrumentation operations & activities in Coal Mill , Coal Reclaimer ,Coal Stacker and Coal Transport systems for smooth operation of plant .

 

Job Context:
Hirmi Cement is one of the single largest cement plants with an installed capacity to produce 2.5 million tons of cement /annum. The plant consists of 1 units. Unit was commissioned in the year 1994.
The Technical know how and main equipment has been obtained from M/s F L Smidth Ltd., Denmark. It has also supplied the ball mill technology, which is one of the latest equipment in cement grinding process. The unit has also bulk Clinker/cement loading arrangement through Rail and Truck.
The plant consists of 1 Kiln. The Kiln producing 8500 TPD, commissioned in 1994. The plant operation is 24 hours/day and 345 days in a year.
The plant runs on EXPERT CONTROL SYSTEM and Modicon Unity Pro PLC, continuously 24 hrs/day and 345 days per annum.

Job Challenges:

To restrict down time on account of instrumentation stoppages for each area 12 hours / year for Coal Mill & Coal Transport /Handling systems
As per the above requirement the supporting departments to be run to achieve the Production targets ( Coal providing to Kiln & Calciner ,Raw Coal handling systems operations and maintenance in short duration-bin full condition ).
Develop and increase confidence level of Technicians and Supervisors to attend the problems independently through know How. Zero Incident reports, Zero Stoppage ,Zero Break down ,Zero Tolerance at minimum Inventory .

 

Key Result Areas KRA (Accountabilities) (Max 1325 Characters) Supporting Actions (Max 1325 Characters)

 

KRA1 Plant Availability: Supervise and coordinate for smooth, trouble free operation of instruments
for achieving optimum equipments availability and PLC system in-house Engineering jobs. Analyze stoppages
Suggest corrective actions
Coordinate predictive / preventive maintenance, shutdown / modification.
Supervise implementation progress
Ensure smooth operations of the plant

 

KRA2 Calibration: Organize timely calibration of all field instruments, Tripping Relay, for measurement with
accuracy to reduce losses and improve customer satisfaction. Carry out calibrations as per schedule.
Maintain relevant documentation.

 

KRA3 Plant Improvement /Modifications: Study the existing systems and process requirements and identify,
improvement/ modifications and ensure implementation of approved proposals for completion in time / as per continuous improvement in the section. Modifications jobs implementation & completion in time / as per continuous improvement in the section.
Data collection & analysis

 

KRA4 Instrumentation Services: Coordinate and monitor annual maintenance contracts for instruments of Coal mill section to reduce downtime & improve equipment availability as well as customer satisfaction. Routine maintenance of field instruments & cabling trouble shooting.
Plan adequate spare parts for instruments. Regular calibration of instruments for consistent accuracy.

 

KRA5 Environment & Safety: Monitor & carryout all the activities required to maintain good house keeping & safety standards of section. Provide resources required Ensure proper safety interlocks Environment & Safety.
Carryout all the activities required to maintain good housekeeping & safety standards of section.
Review the jobs / systems for following safety systems/safe practices.
Impart training to workmen/contract workmen.
Identification & rectification of unsafe points/ leakage points.
Regular checking of level sensing instruments/other safety interlocks.
Regular Checking of tools & tackles.
Report near miss cases. Carryout safe operation as per the standards. environment systems upkeeping.
Upkeep & Monitor working of pollution control equipments.

 

KRA6 System Implementation: Organise, and implement ISO/ EMS/ systems in the section through involvement of Team members for improvement of
sections working & quality standards. Execute improvements identify and kaizen Identify & rectify abnormalities.
Spillage/leakages. Unsafe conditions/practices.
5S activities: implementation & improvement objectives. Improvement of ABGE criteria Score.
EMS monitoring.
Internal customer service support as per the target given.
ISO system improvement. Maintaining Statutory compliance. Improvement of OEE/MTBF/MTTR Elimination of muda. Does Why-Why analysis. Self Maintenance.

Qualifications:

Diploma

Minimum Experience Level:
3-8 Years

Report to:
Senior General Manager