Chief Engineer -Projects and Maintenance

Role & responsibilities

• Approvals & Coordination Liaising: Liaising with statute agencies i.e. Chief factory inspector, Pollution control board officers for plan approval, air, water and hazardous waste consent approval etc.
• Barrel Loading system: To design system for loading of 20ft and 40ft container with minimum manpower.
• Civil Construction, Structural Consultant: Getting Construction RCC drawing from Structural Engineer and to plan all civil activities – SOP and take confirmation from the RCC Consultant / Contractor , make Quality Assurance plan, take target date from the contractors (i. e. Factory Shed, Foundation, RCC, PCC Work, Flooring, Cable Trenches, Roofing, M/c Foundation Work etc. etc.) Structural work (i. e. Fabrication of Factory Sheds, Column, Trusses, Purlins, Bracings, M/c Base Frames etc. etc.).
• Completion Certificate: Coordinate with suppliers and vendors for project completion.
• Cost Control – Improving efficiency: Preparation of departmental yearly budget and ensuring expenditures are within the budgeted norms.
• Designing of New Plant Layout : Design as per the Land Availability, to plan layout of Storage tank with factory shed, barrel stacking, IBC stacking, layout for 20 ft container, ISO tank loading & unloading, sufficient space for safe movement of road tankers, 40 ft containers, planning for internal movement of cranes to lift and shift the reactors as per the need, getting all the consultant coordination for civil, electrical, mechanical, automation, corrosion engineering to minimize rusting of plant, minimize corrosion, food & drug approval, designing of AHU system in clean room etc.
• Designing Total Greenfield project for storage of Base Oils: To have tank from storages with capacity of 3000 kl, 2000 kl, 1000 kl and underground storage tanks for storage of explosive material – solvents, planning for packaging – barreling of base oil, of solvents and filling of ISO tanks, IBCs etc.
• Documentation – SOP: Standard operating procedure preparation for each work as per the requirement for fabrication, erection of reactors, civil work, electrical work, instrumentations and to also make process description documents.
• Drawing: Review and provide input on P&IDs, getting detail engineering done before execution of plant, equipment layout drawings, fabrication drawings, As build drawings.
• Effluent Treatment Plant: To get effluent treatment plant designed as per the parameters, getting the samples checked from the Lab, Effluent treatment plant commissioning and operations. Getting the Plant monitored on on-line basis and installation of required instrumentations, designing of effective scrubber for SO3 gases.
• Electricals: Load Calculations and giving inputs to electrical consultants for designing of single-line diagram and load division, designing of all Safety equipment required - MCB, ELCB, Earthing Pits as per the load of the plant, Checking performance of all electrical cables - Power Transmitting Loss, checking of Transformer efficiency, Power Capacitor Banks which are installed and the performance achieved, rechecking the load and cables installed and required.
• Electrical Electrical Transformer, Kios, Electrical Breaker – Re-designing of entire electrical transformer system and ensure there should be no power and electrical losses, designing proper layout of the system.
• Energy Conservation & Energy Efficient Equipments: Experiments on Energy Consumption.
• Enquiry – Technical Comparison & Cost Comparison: Raise enquiry for all engineering goods, make technical comparison, take approval from basic engineering, structural engineer, details engineering competent person and finalize the same.
• Environment – Scrubber Designing: To design scrubber for Oleum tanks, and fumes and to generate Spend Acid, to select good MOC Pump with Mechanical Seal.
• Explosive, Liaising, Coordination & Approval: To take permission from explosive department for storage of material – Underground tanks, Overground tanks, Plan, Storage facility of Solvents – A Class, B – Class, 200 MT. and above and to take permission for solvent recovery in existing plant, plan all electrical fittings flameproof and plan for safety requirement.
• Fabrication Work: To plan fabrication work for modification work, new project work, structural modification, erection of reactors, storage tank height wall of 10 mtrs. and coordinating with structural engineers, safety inspectors, safety consultants and planning the same by giving training to the entire team, mock-drill before carrying out the work etc.
• Factory Inspector – Testing & Examination of all Capital Equipment: To take approval from Factory Inspector before start of erection of project and take the reapproval and inform the Factory Inspector. Inspector office and the working of the plant in extended hours. Hydro Testing of all Reactors, Pipeline, Steam Boiler, Thermic Fluid, Cooling Towers as the preventive maintenance check-up to maintain zero defect in the system.
• Factory Inspector: To appoint Agency for get plan approval, making respective drawings and carryout submission 6 months before the project is taken up for civil work, structural modification, electrical modifications etc.
• Factory Building Plan approval from Corporations & Statutory Authorities: To get the plan submitted to factory inspectors office time-to-time before the changes done and get the same approved from auditors who carry Hassop Study on site emergency plan.
• Fire Hydrant System: To design the fire hydrant system, take permission from explosive department, give work order to the experts in the industry, call for comparison of material required for installation of Fire Hydrant system, to appoint agency for preventive and yearly maintenance, to carry out mock-drill operations every quarter in the plant and give training to the team.
• Fixed Asset List: Maintain Equipment List – to take photographs and load it in software on yearly basis, upload all the invoice of the equipment purchased, purchase order, inspection report, installation document, major maintenance and overhauling done etc..
• Food & Drug Approval: – Designing of Clean room system. Installation of AHU, ventilation system required in clean room. Implementing all the facilities as per the guidelines given.
• Grease Reactor: Designing of Reactor for mfg of various Grease – open kettle, pressurized kettle, planning for for Barrel filing of various types of Greases, with automation – load cell, with filling line for small packing 500 gm, 1kg, 2kg, 3kg, 5kg, 18 kg, 200 kg.
• Instrumentation: Maintain hourly report of production and calculate productivity. Alarm & Trip List
• Issue of Purchase Order with terms condition, Inspection stages, Issue of Performance Bank Guarantee, Advance Bank Guarantee, delay penalty: Ensure technical requirements defined in the contract are properly incorporated in the engineering deliverables.
• Issue of specifications for fabrications: Control project plan by reviewing design, specifications, documentations of purchase item, 3rd party testing, inspection, making fabrication plans, installation, erection etc.
• Logistics: Coordinate with sales and customer for despatch of panels. Supply chain management and product logistics.
• Lube Oil Filling Machine: To plan for filling of 250 ml, 500 ml, 1 ltr. Lubricants filling with nitrogen filling, filling of 3 ltr, 3.5 ltr. 5 ltr engine oil, gear oil, Hydraulic Oils, Cutting Oils in small pack with automation – Wad System Sealing, Capping, Labeling and Filling in Cartons
• Lubricants Blending: To design Lube oil blending, mixing of base oil with additives, waxes – automation plan designing – with load cell and getting accuracy in manufacturing.
• Monitoring, Supervision & Planning Independently of Project Work: Estimation, Rate analysis & finalizing specifications for the Project. Lesioning with the concerned Govt. Authorities. Also responsible for plant setup & commissioning of the infrastructure with selection of consultants & Co-ordination as per Govt. norms.
• New Project Scale up with Basic Engineering: Coordination with R & D for new product development: To collect data from production team, coordinate with basic engineering team – process engineering and to scale up the process – improve the product quality, optimize the production to better level.
• Performance Bank Guarantee: Project close outs and warranties required for final acceptance.
• Plant Budgeting & Costing: Also, additional charge of plant & capital project's procurement as expediter.
• Preventive Maintenance & Breakdown Maintenance: T investigate Preventive work done and reason for Break-down f Pumps, Motors, Agitator, Mixing System, Blowers, Centrifuges etc.
• Process Engineering – Basic Engineering: Coordinate with Process Engineer for carrying out Basic Engineering and doing the estimation of Utility services required and optimizing of present equipment – process time required, present batch cycle and reduction in the same.
• Product Filling Line: To design Lube Oil filling system 210 ltr, 235 ltrs, IBC, ISO tanks with proper filtration systems.
• Project Monitoring & Review: Project Meetings to monitor progress and corrective actions to meet timelines
• Project Review Meeting: Conduct weekly engineering project meetings.
• Project Management: Maintain project schedule by monitoring project progress; coordinating activities; resolving problems. To ensure all the teams are given proper SOP for working and they are committed to work with their own planning, keep friendly atmosphere, do not pressurize the contractors, allocate the work in win-win situations, make Quality Assurance Plan etc.
• Production Planning & Time Reduction: To make production planning and handover the same to the production department, supervisor, discussing and supervising the operation and reducing the time etc.
• Product Yield Improvement: Waste reduction and improving the process by alternate solutions – selection of process technology.
• Protective Coatings: Shot Blasting, Surface preparation and to apply coating
• Purchase Coordination – Logistics: Coordinate with sales and customer for dispatch of panels.
• Quality Assurance Plan – For Erection, Commissioning, Maintenance: Monitor the execution of the quality assurance program for conformance to project requirements.
• Quality Assurance Plan: Produce good quality output within specified time.
• Rain Water Harvesting: To plan collection of all the Rain Water Harvesting and utilizing the same during the monsoon period and to recharge the land with water.
• Safety – Acid & Alkali: To design dyke, have eyewash installed, purchase of required safety gown, PVC suit, eye protective goggles, helmet, and to plan purchase of all kind of required personal protection equipments as per the operation criteria.
• Safety – Hazzop Study, Onsite Emergency Plant, Safety Audit: Safety procedures implementation as per Du Pont standards. Task based risk assessment preparation. HAZOP and 3D Model reviews. Review of safety during construction and HSE in transition with EPC/PMT.
• Safety – No Loss of Time: Achieving record of no lost time, accidents. Process – Sulphonation: To design SO3 Sulphonation plant and its automation, scrubbing SO3 gas and making Spend Acid as a b—product which can be sold to industries.
• Safety - Investigation: Key responsibility in incident investigation.
• Safety – Solvent Processing and Storage: To plan to take safety approvals from explosive department and build up the approval for all solvent, preventing static charge, purchase of flame proof equipments, fire alam system, purchase of safety Personal Protective Equipments as required.
• Safety – Housekeeping: Maintain safe and clean working environment by enforcing procedures, rules, and regulations.
• Safety: To plan for disposal of Spent acid to Mumbai waste management or to any other institute or to do value addition by carryout centrifuge operations.
• SHE management: To implement the same in the organization
• Solar System - Load Calculation, Designing, Installation, Maintenance & Operation: To invite quotation for installation of solar panels which will ghet connected with the grid, designing of solar system layout - as per the location suitable for maximum yield, to check the performance of Solar Panel every 3 months.
• Storage System: To design storage system for Barrel stacking – Capacity 210, 235 ltr, open mouth barrels, Carbouys, pails and general stacking material.
• Sulphonation Process: To design SO3 Sulphonation plant and its automation, scrubbing SO3 gas and making Spend Acid as a b—product which can be sold to industries.
• TQM: To implement the same in the organization.
• Training: Coordination of internal and external engineering activities and the interdisciplinary interfaces in close coordination with the discipline team leaders.
• Training to Project Team, Operators, Supervisors, Foreman: To share the drawing, Layout of the equipment, Plant capacity announcement and reduction in Batch. CSU training to all employees.
• Trouble Shooting: To carry out brain-storming session, team in-charge, production supervisor, Lab various persons in the company and take up troubleshooting activities.
• Utility – Boiler: Preparing boilers for annual IBR inspection & to offer inspection including hydraulic test, steam, test etc. Installation of Steam Boiler, Thermic Fluid, Cooling Tower – design chemical dossing for maintaining the water quality, Weigh Bridge, Platform Weighing Scale, Electrical – Transformer, Kios, Electrical breakdown, voltage stabilizer. Ground inspection for various steam lines and its fittings for new project with IBR documentation.
• Utility Equipments: P. M. & Break Down Maintenance of Heavy Machines & Equipment’s like Overhead Cranes, Compressors, Generators, Chilling Plants etc.
• Utility: Barrel filling system: To install and re-engineer the existing barrel filling machine, to have optimum capacity of filling line – with minimum manpower,- automatic sealing, capping and labeling.

Preferred candidate profile

Perks and benefits