Pf Mechanical

**Designation**:Engineer

**Updated**:December 10, 2024

**Location**:Himachal Pradesh, India

**Organization**:Cement

**Job Purpose**:
To support SH Mechanical (Post Clinker) in Planning, Organizing & Coordinating the implementation of Field Operation &maintenance activities (Preventive/Predictive) in Cement Mill for optimum plant availability within optimum cost to meet production target.

**Job Context & Major Challenges**:
Job Context: UltraTech Cement Ltd. is the largest manufacturer of grey cement, Ready Mix Concrete (RMC) and white cement in India. The company has consolidated capacity of 138.39 Million Tons Per Annum (MTPA)* of grey cement. UltraTech Cement has 23 integrated plants, 1 clinkerisation plant, 29 grinding units and 8 bulk terminals.

Baga Cement Works was acquired by UltraTech Cement Limited from erstwhile M/S Jaiprakash Associated Limited in the year 2017. Baga Cement Works is located at around 155 Km from Chandigarh, 67 km from Shimla and 37 km from Bilaspur (HP). The nearest National Highway is NH-88 which is 17 Km from the plant. The plant has 10,000 TPD clinker production capacity & 250/300 TPH OPC/PPC cement grinding capacity. The preheater consists of four strings, each with 6 stages of LP cyclones, with two pyroclones supplied by M/s KHD. This is a unique feature of this cement plant due to which the plant operates at lower heat and electrical energy. The preheater has a height of 155 mtrs, with top floor at 135 mtrs. The preheater has been constructed out of tubular steel structure.

The Cement Plant is based on lime stone deposits in Baga '“ Bhalag hills which are adjacent to plant area. Limestone requirement of the plant is around 15000 TPD. For raw material grinding, two vertical roller mills of 420 TPH each have been installed with a C.F. Silo having a capacity of 24,000 MT.
The unit is equipped with state-of-the-art pollution control systems, and operating emission norms are much lower than the permissible standards of 30 mg/Nm3. Two continuous ambient air quality monitoring stations have been installed which are hooked up to CPCB and PCB and transmit real time data's.
For emergency electrical power, 8 x 1800 KVA, DG sets have been installed.
The township for the plant is located near the plant and has a residential complex for 300 families. 10+2 school and 30 bed hospital has been built. For transporting clinker and cement from plant a fleet of about 4000 trucks have been engaged.ar.
'¢ Space constraints at the unit location.
'¢ Land and possession related disputes regarding ML area falling in different villages is proving to be the bottleneck for scientific development and expansion of mines.

**Key Result Areas**:
**KRA (Accountabilities) (Max 1325 Characters)**

**Supporting Actions (Max 1325 Characters)**
- KRA1
- PLANT AVAILABILITY:
Plan, Organize and monitor implementation activities for optimum plant availability
- Execution of preventive & corrective maintenance activities.
- Ensure periodic checking.
- Manpower planning one day in advance for daily jobs.
- Proper Job planning for shutdown jobs.
- Spare parts planning for major shutdown jobs as well as fulfilling day to day basic requirements.
- Interaction with OEM and suppliers for elimination of critical equipment problems.
- Execution of all the major jobs during shutdowns.
- Planning of contractor jobs to be carried out and raise service work order accordingly.
- Proper coordination with other departments.
- Daily monitoring of equipment health and maintaining records.
- Avoiding idle running of equipment's
- KRA2
- I) COST CONTROL:
Plan monitor and control spares and lubricants inventory and manpower cost as per budget in Mech maintenance activities in coal mill in order to optimize the maintenance cost.
- Reduction in section cost by reducing breakdowns.
- Reduction in section cost by avoiding idle running of equipment.
- Avoid over time and optimum utilization of contract manpower
- Control the handling cost by avoiding Spillage.
- KRA3
- System Management
(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards)
- To implement improvement project to reduce repetitive problems/breakdown or losses.
- Timely submission of Kaizen, OPL, Good to fine, suggestion on system
- Developing and sustaining Model area in respective sections
- 100% active participation in respective KFA & GRT meetings and giving inputs related to bring new technology, innovation and improvements towards productivity. Conduct awareness programs down the level team
- To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments.
- Implementation of critical spares & consumable SOP without any defilement
- Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.
- KRA4
- Focus on SHE