Tm Plang

**Designation**:Deputy Engineer

**Updated**:May 29, 2025

**Location**:Gujarat, India

**Organization**:Metals

**3) Job Context & Major Challenges**:Write the specific aspects of the job that provide a challenge (internal and external) to the jobholder in the context of the Business/Unit/Function/Department/Section**:
Job Context:

- Birla Copper Unit at Dahej has a captive power plant complex with potential to generate 95MW of power through three coal based thermal power plants catering to the captive power requirement of the complex. (CPP 1& 2 is a 71.95 MW Power Plant and CPP 3 is a 60 MW Power Plant) These plants also supply steam to the process plants. CPP 1 &2 the complex consists of one CFBC type boiler, five Steam Turbines of capacity 24.5 MW, 24.45 MW, 12.5 MW,10.5 MW (Total 71.95 MW), 2 no of Diesel Generating Sets (2.5 MW each), 5 no of Plant air and Instrument Air Compressors, & Ash Handling plant.

CPP3 complex consists of two CFBC type boilers, one Steam Turbines of capacity 60 MW, Ash and Coal Handling plants. The most critical element of this role is ensuring the uninterrupted supply of power, steam and compressed air for production of copper cathode and anode as well as fertilizer.
- This role is responsible for operation and maintenance of the assigned power plants (CPP 1& 2 or CPP 3) and generation of power as per monthly and annual target within the budgeted cost, supplying steam to process plants (Smelter and Refinery) and supply of compressed air.

It is critical to match generation of power with the demand of internal customers as closely as possible through planning so as to provide reliable Power steam and compressed air and reasonable cost. This involves optimum resource utilization and continuous training to improve efficiencies so as to comply with statutory stipulations, company norms as well as quality and environment certification specifications.

Job Challenges:

- CPP 1 & 2 equipment is more than two decades old and CPP 3 equipment is about than one decade old and needs upgradation. Their ability to operate at required efficiency levels and meet environment norms is a major challenge
- There is no margin for shutdown and maintenance
- Fluctuation of power and steam demand by operations result in back feed without payment and unplanned import of power costing money.
- Sustaining uptime of plant and instrument air compressor due to very corrosive atmosphere causing corrosion to the vital parts of the compressors and piping system and structures
- Aging of the major capital equipment like Boiler and Turbine DG sets, Compressors.
- Cooling Tower maintenance effectiveness due to timber cooling tower.
- Availability of skilled manpower and capability building.
- High imported coal cost and increasing completion in Copper business.
- Contract Manpower safety awareness and behavioral change.
- High Manpower attrition rate
- Space constraints for turbine and boiler and cooling tower area for maintenance work and store room.
- Cyclone prone area lead to damage may high rise structure.
- Stringent pollution control norms by GPCB/ CPCB.
- Growth opportunities and new learning opportunity for employees.
- Adaptation of digital mindset and developing digitalization competency.
- Obsoleting equipment like compressor and DG sets.
- Low performance of small capacity turbine.
- Timely Spare parts availability of different make Turbines ( LMZ Russia, Skoda Germany, Shin Nippon Machinery Co., Ltd Japan, BHEL India)
- Single stream coal handing plant conveying system.
- Poor Fire water spray system in CHP and Power plant.
- Nearby hazardous chemical plant lead to environment and life hazards
- Connectivity issue with major cities like Bharuch and Vadodara for emergencies.

**4) Key Result Areas**:Write**the key results expected from the job and the supporting actions for each of these key result areas (For a majority of jobs typically there could be 4- 7 key result areas)**:
**Key Result Areas**

**Supporting Actions**

Daily Asset Care
- Ensure overall maintenance planning i.e., identification, prioritization & scheduling of maintenance work / jobs (Monthly / Weekly basis) and ensure schedule adherence & PM quality, escalation of non-compliance to AET / PBU / VST
- Develop resource, time & cost estimates of planned maintenance and collaborate with AET maintenance members to plan schedules, manpower & other resources for the most effective outcomes.
- Tracking and execution of predictive maintenance schedule.
- Implementing SOPs and WI for the departmental activities
- Equipment health monitoring.
- Ensure spares & consumable planning by setting up proper mechanism, maintain optimum inventory and standardize vendors in collaboration with purchase
- Ensure up-keep of equipment performance parameters database, maintenance history and job records
- Plan & schedule shutdown jobs / overhauling work and execute them along with AETs & DMTs
- Knowledge of CPP related MIS work. Ensure that AETs & DMTs