Support CHP Engineer

Role & responsibilities

Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

1. Capex Projects:

• To prepare the CAPEX plan in consultation with team members, draft Capital Proposal, and obtain its approval in conjunction with Head CHP
• To assess and forecast technological obsolescence and timely plan for up gradation, replacement or alternative strategy.
• To analyze critically the repetitive failures, major breakdowns, unit trip outs; to interpret predictive test results and to develop an action plan for preventing failures.
• Freezing the scope of work both for consultant and service provider in consultation of dept Head 
• To ensure Safe working environment by implementing and practising good construction practises through agency with an aim of zero Loss Time Injury.
• To benchmark the efficiency parameters of CHP with the operational parameters.

1. Material management, Planning & Monitoring
2. To ensure Implementation of maintenance plan the completion of targets and to maximize plant availability.
3. To   ensure      excellent   upkeep    and maintenance of the equipments to maximize plant availability and smooth operation of the plant. Major equipments are;

Conveyors                   -   66 Nos.

Secondary crusher    -      06 Nos.

Primary crusher         -      04 Nos.

Truck Tippler            -    02 N0s

Shuttle Carriage         -      02 Nos

Coal sample room:

Jaw crusher                 - 1Nos.

Roll crusher                 - 1 Nos.

Disc Grinder                  -1 Nos

Auxiliaries:

            DE System     -      17 Nos.

            Fire Pump     -        02 Nos                                                                                                                                    

             DSS Pump      - 02 Nos.

             Sump pump -   06 Nos.

Zero discharge pump- 01 no

             Compressor-   04 Nos.

             Air Vessels   -      03 Nos.

All discharge chutes. 

 Coal Weigh Bridge Maintenance. - 3nos.

Workshop Maintenance- Gear Box O/H, fluid coupling O/H, Idler making, pulley making, bar grid fabrication, other fabrication jobs.

• To plan and establish the annual preventive maintenance schedule, predictive maintenance schedule, overhauling schedule ,
• To fix risk-based strategy for keeping spare inventory, spare standardization, import substitution, etc.
• To extend technical expertise & support to team members on maintenance execution.
• To provide   technical      and   administrative supports to minimize outages of equipments to ensure Budgeted / Bench   Marked      Plant Availability Factor.
• Ensure maintenance planning based on requirement.
• Prepare monthly planned/ preventive maintenance plans.
• Ensure implementation, performance review & direct for corrective/ preventive actions.
• Get feedback from external / internal customers.
• Review maintenance problems with operation teams

1. Analysis & Action Plans

• Preparation of various deviation in KPIs
• New cost saving project implementation.
• Physical checking & inspection of worn out gearbox, fluid coupling, for root cause analysis
• Physical checking & inspection of all spare items at workshop.
• Preparing Action Plan based on root cause analysis
• Implementation of Action Plan and adherence monitoring

1. Maintenance

• Equipment availability in unit-1,2,3, 4 & 5 to carryout regular maintenance.
• Workshop maintenance job (Gear box O/H, fluid coupling O/H, Idler making, pulley making, bar grid fabrication, other fabrication jobs).
• Manpower distribution & field supervision for maintenance job
• Compliance of Ekaayan kpi , Daily log sheet maintain.
• Ensuring healthiness of firefighting & detection system
• Implementing Safety standards and developing safety mechanism to achieve zero reported incident.
• Compliance of observation of safety task forces to eliminate unsafe conditions & behaviours
• Maintain all ISO, IMS document as per requirement.
• Maintain the CHP workshop for doing the job safely with availability of all spare.
• Availability of all DE, DS & sprinkler systems to maintain good work environment.
• Availability of coal lab equipment (jaw crusher, roll crusher, disc grinder) with proper maintenance schedule.
• Making of service bill of all maint vendors
• Review all spares, purchase requisition of materials & service, new item code creation in eam.
• Ensure bunker cleaning of all boilers
• Maintaining different operational parameter of coal i.e. coal sieve size, as per the operational requirement.
• Weight bridge maintenance job.
• All hoist maintenance 
• Update & maintain load test certificate of all hoist, chain pulley block & air receiver.
• New belt replacement, open belt joint job
• Maintain crusher tonnage & conveyor run hour data for timely bearing O/H.
• All conveyor & crusher guarding as per safety guideline .

1. People Development:

• To plan the proper manpower deployment on specified job for better & timely execution.
• To identify the critical areas where technical expertise is supreme requirement, identify suitable persons and groom them well. Also involve in the behavioural grooming of subordinates
• To ensure continued up-gradation of knowledge by imparting regular training on New systems/technologies, best maintenance practices and literatures.
• To motivate people by using the Praise system, Instant Sabasi, nominating for employee of month, rewarding in gate safety meeting etc. thereby increasing their involvement in job.
• Communicate on continuous basis, regarding the plant performance, challenges to the subordinates in order to make them aware about the current situation of plant so that they can give their best for the betterment of the organization.
• Ensure systematic goal setting for the subordinates to improve productivity, growth and motivation levels of employees and develop a performance oriented work culture.

1. Cost Management:

optimum utilization of equipment’s, resources & reduce cost to enhance efficiency.

• Identify potential cost saving areas.
• New cost saving project implementation (Pulley lagging, idler pulley modification, re used of old conveyor belt & crusher V belt).
• Control operation such that minimum shutdown, minimum Moisture content at plants          increase its use and utilization of Ash

1. Statutory and Legal Compliances

Continuously maintaining maintenance systems to ensure compliance of various statutory and Legislative requirements related to legal, Electrical, Safety and Environment.

• Ensuring adherence of all environmental, health, safety, revenue and all legal aspects.
• Implementation of best practices in Safety, Hygiene and Environmental Management.
• Study of statutory requirements/ review audit reports/ review inspection reports from statutory bodies.
• Review departmental implementation status in the department.
• Coordinate with concerned department
• Ensuring 100% compliance with safety standards and all applicable statutory norms.
• To fulfill all statutory requirements as per State/Central Pollution Control Board.

1. System Management:

To ensure for effective implementation of WCM concepts, IMS and oracle systems.

• To establish and ensure management practices on quality, environment, and safety. 
• To decide on the practicability and implement ability of EOHS Committee
• Review & monitor implementation of HMF WCM practices, IMS & Energy management system etc.
• Implement Autonomous Maintenance.
• Extend technical assistance for implementation of ERP for Plan to Produce (P –P) programme.
• Study of statutory requirements/ review audit reports/ review inspection reports from statutory bodies. Implementation of ERP.
• Continuous improvement in best practices & 5S standards support.

8. Environment & Safety

      Ensure adherence of Environment and Safety norms & Statutory requirements related to all aspects of plant operations.

1. To Plan & establish safe work practices and to target for achieving ZERO accident and ZERO incident.

• By constant counselling to the people. 
• Ensure all DE & DSS system availability.
• Ensuring use of PPE by the workmen. 
• Ensuring coal yard sprinkle system.
• Establishing the Housekeeping standards and monitor the implementation of the same in the work area.  
• Review all operating conditions & Audit reports & ensure compliance to all regulatory norms.
• Promote best practices in operational safety and monitor plan for improvements.

9.    New Projects

        Provide technical support in commissioning of new projects in CHP

• . Co-ordinate in shift maintenance activity for commissioning of the new projects as per schedule with planning and technical cell dept.