Support Engineer

Role & responsibilities

Maintenance Management :

1. To ensure Implementation of maintenance plan the completion of targets and to maximize plant availability.
2. To      ensure   excellent   upkeep       and maintenance of the equipments to maximize plant availability and  smooth operation of the plant

Boilers (CFBC)      -      5 Nos.

Capacity    -     165 TPH X 5 nos.

Heat Transfer area-    26925 Sq.mtrs.

Refractories                - 730 MT

Pressure-part length(Tubes and Sheilds)-                         >56000 mtr

ESP Systems                                           -   13 Nos.

Ash Conveying system                        -   143 Nos.

Auxiliaries :

ID,FD & PA Fans                  30 Nos. 

Bed Ash Cooler                -   10 Nos.

DCC                                -    10 Nos.

Ash Silos                          -   04 Nos.                                                             

Ash screw Feeders           -  10 Nos

Safety Valves                  -   20 Nos.

HP Valves                       - 1000 Nos

LDO Station                     -   2 Nos Insulation & cladding -   53000 Sq.mtrs.

• Planning, scheduling and execution of the maintenance of AHP,Silos r & Aux. equipments, safety & protection of equipments and maintain them in the best of health to ensure uninterrupted power availability 
• All Equipments maintenance planning, scheduling, execution with spares planning and report generation.
• To provide   technical   and      administrative supports to minimize outages of Boiler & Aux. equipments, T/G & Aux. 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 of operation departments.
• Ensure the Preventive and predictive Maintenance of every equipment’s.

Operation & Maintenance of 

Mechanical Workshop

Review,Monitor and Control Job Planning and Scheduling, onsite quality of service, operation of Engineering Workshop machines effectively.

• Monitoring of new jobs, pending jobs and quality of jobs.
• Review importance and requirement of different jobs & maintenance activities.  
• Review Man, machine and material planning for timely completion of jobs.

Technology up-gradation:

Up gradation of old technology equipment/generating units to achieve desired (targeted) generation at optimum operating parameters. Modifications and improvement of machines for Energy Conservation.

• Review and monitor for up-grading & de-bottlenecking of generating units to achieve targets.
• To interact and arrange the inputs for technology up-gradation and to maintain environment protection and pollution control standards as per international norms.

People Development :

Planning & implementation of departmental structure for effective man- power utilization, Build & sustain conducive work culture by effective management of people to improve productivity, growth and motivation levels of employees, ensure subordinate development and develop a performance oriented work culture.

• To monitor the manpower deployment at various units and various levels.
• To identify training need and plan training of personnel and ensure training man days of all subordinates.
• 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.
• Subordinates development to fill up the gap generated/to be generated, by lack of experienced staff.
• Ensure systematic goal setting for the subordinates to improve productivity, growth and motivation levels of employees and develop a performance oriented work culture.

Spares and Inventory management

• Developing alternate vendors & spares through reverse engg. To minimize spares cost & dependency on OEM. 
• Develop indigenous vendors for imported components, wherever possible
• Employing JIT to minimize spares inventory. 
• To plan and Control the inventory of the spares and their consumption.
• To Identify and take action against Non moving items to control the inventory.
• Optimize the availability of Spares for maintenance.

Cost & Efficiency

To finalize the P&B for availability and R&M Cost. To Benchmark the maintenance indices.

To Ensure optimum utilization of resources, monitor & reduce cost to enhance efficiency.

• Identify potential cost saving areas.
• Drive Import substitution projects to minimize cost.
• Plan and monitor key cost drivers and ensure optimization of power consumption.
• Formulate improvement proposals & their implementation.
• Control inventory of spares & their consumption.
• Benchmarking the availability, utilization, replacement of key equipment with other group thermal plants and other plants in India and abroad. 
• Optimizing spares inventory, and identifying availability of similar spares in group units and neighbor plants.
• Encouraging in-house expertise and minimizing OEM / External support.
• Preparation, monitoring and review     of annual R&M budget of the deptt.
• Recommending and deploying optimum contract labour resources.

Quality Control

To ensure the use of best quality materials and services in order to have reliable operation of equipments.

• To ensure the quality of maintenance jobs and materials used in maintenance of equipments by utilizing tools like NDT(RT, UT, MPT, Replica, Dimension checking, visual inspection, fibroscopic inspection, hardness, oxide scale etc.), material composition testing in lab and using XRF machine etc. and to record the findings for future reference.
• To arrange for testing of material composition before accepting any ferrous & nonferrous materials and to record the findings for future reference and audit purpose To conduct interviews before deploying any high skilled/skilled technicians/supervisors of contractors in order to have quality and reliable maintenance of equipments.
• To prepare quality assurance plan (QAP) required during procurement of any material and to get it approved.
• To prepare the guarantee certificate and to get it signed by approving authorities after completion of overhauling of critical equipments and to record it for reference.

Adherence to Statutory Compliances and Standard

CONTINUOUSLY MONITOR AND REVIEW MAINTENANCE SYSTEMS TO ENSURE COMPLIANCE OF VARIOUS STATUTORY AND LEGISLATIVE REQUIREMENTS RELATED TO FACTORIES & BOILERS, INDUSTRIAL SAFETY AND ENVIRONMENT.

TO CO-ORDINATE WITH STATUTORY AUTHORITIES. TO IMPLEMENT SYSTEMS ON QUALITY, ENVIRONMENT, SAFETY, AND WCM.

• Arrange the annual and periodic inspections of equipments by statutory authorities like Factories & Boilers Inspector and other statutory government agencies as per the requirement. 
• Head the EOHS Committee for Mechanical department. Facilitate the identification of areas of improvement and implement those. Arrange budget allocation, when capital investment is required.
• Arrange periodic visit of team members to other industries for acquiring best practices.
• Lead and guide the Committee for Confined Space Task Force 
• To ensure adherence of best practices in Safety, Hygiene and Environmental Management as per the guidelines by state/central Govt. agencies.
• To fulfil all the statutory requirements as per the direction of statutory authority
• To ensure renewal of test certificates of all lifting tools and tackles by competent persons before due date without fail.