Pf Process

**Designation**:Engineer

**Updated**:January 04, 2025

**Location**:Himachal Pradesh, India

**Organization**:Cement

**Job Purpose**:
To monitor process parameters i.e. draft, temperatures, power etc. along with process trends for production optimization and quality control of Coal Mill and Cement Mill and take corrective, preventive action for abnormal situation /alarms in coordination with concerned maintenance department for resolving shift related issues for smooth operation of plant adhering with highest level of safety standards and to manage, supervise and coordinate the laboratory working to ensure quality checks of raw material and finished goods and also ensuring compliance to statutory requirement to avoid any penalties / actions due to noncompliance.

**Job Context & Major Challenges**:
Job Context:

- Bagheri Cement Works was conceptualized in 2004 for setting up a blending unit for manufacturing of PPC. This is done by blending OPC from Baga unit and fly ash from power plants of Punjab State. Subsequently, a grinding unit was also installed along with blending unit for making PPC cement.
Cement manufacturing capacity: 2 Million Ton Per Annum
Grinding unit has been designed and supplied by M/s KHD, Germany with a combination of pre-grinding by roll press and finished grinding through ball mill.
Unit has fly ash separator and dryer supplied for separating fine fly ash for blending and drying wet fly ash. System supplied by M/s LNVT
Multi compartment silos of 15500 MT of flyash silo, 10000MT of Gr clinker silo & 16500 MT of cement silo for storage. Clinker storage silos of capacity 24,000 MT
Four packers have been installed: Two rotary packers of capacity 120 TPH and two rotary packers of 90 TPH supplied by M/s Enexco Engineering Ltd
Construction work of blending unit started on 26th Dec 2005 whereas the installation of grinding section was in early 2007. Grinding and blending unit was commissioned on 14th Oct 2010 and the first cement truck was dispatched on 25th January 2010.
Major Challenges '“
1. To create Pollution free environment
2. To ensure sustainable improvement in plant operational parameters by consistently improving upon existing processes.
3. To sustain fly ash to bring cost effectiveness in production.
4. Quality Control during processes & Quality Assurance in products consistency with cost control, on time and Meeting strength criteria of products.

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

**Supporting Actions (Max 1325 Characters)**
- KRA1
- Operational Management: Operation and optimization of VRM/coal mill as to achieve the targeted production and Power.
- 1.Continuously check operation and quality parameters of equipment's and Identify abnormalities if any Inform SH Process and CCR Operators for corrective actions
2. Implementation of daily activities as per production planning
3. Automise and track VRM/coal mill circuit to avoid idle running of equipment
4. Implementation of PM checklist in the section,
5. Why-why & PM analysis for process break downs and take corrective measures.
7. Daily Trends review and checklist execution Record day wise production and Power Consumption and prepare comparative data for study/analysis.
8. Monitoring of power consumption and take corrective action to reduce power consumption.
9. Ensure grade wise production as per requirement and correct changeover of circuit ensuring product quality.
10. Cross checking of cement blaine whenever it comes abnormal.
11.Planning and monitor smooth changeover of cement grade as per requirement
12. Monitor and ensure timely replacement of grinding media make-up charge
13. Assisting SH P&QC in day to day operation activities to ensure smooth operation to meet the company target with proper coordination with respective departments.
- KRA2
- Cost Control: Process expenses to
operate in budgeted norms and
implementation of improvement
actions for cost optimization.
- 1 Identifying and bringing to the notice of Section Head for unnecessary interlocks / idle running of equipment's. Continuous monitoring of trends along with process parameters. Ensure running of power saving equipment in SPRS. Running Raw Mills / Cement Mills in Fuzzy logic control.
2.Implement the action suggested to reduce the variance after comparing actual and budgeted cost.
3. Use of grinding media within the budgeted norms.
4. Evolve schemes resulting in reduction and power cost.
5. Monitor false air and idle running of equipment and take corrective action.
6. Ensure running of power saving equipment to optimize and reduce power consumption.
7.Initiate procurement of grinding media with shutdown planning to optimize idle inventory level.
8. Making shutdown PRs and MRs, Indent / Issue the material and coordinate with Contractor
9. Control utilisation of contractor manpower & overtime.
- KRA3
- Continuous improvement & Process Maintenance Jobs:
Identify areas for improvements,
conduct focused studies, and
executio