Pf Process

**Designation**:Engineer

**Updated**:October 09, 2024

**Location**:Gujarat, India

**Organization**:Cement

**Job Purpose**:
Supervise and monitor operation of Cement Mills of Line No. I & II along with fly ash unloading, Gypsum and clinker system by optimisation of process parameters, to meet the production, power and quality targets at optimum cost maintaining environment and safety standards.

**Job Context & Major Challenges**:
Job Context: UltraTech Cement Limited has an annual capacity of 52 million tonnes. It manufactures and markets Ordinary Portland Cement Portland Blast Furnace Slag Cement and Portland Pozzalana Cement. It also manufactures ready mix concrete RMC. The company has 11 integrated plants one white cement plant one clinkerisation plant in UAE 15 grinding units 11 in India UltraTech Cement is the country largest exporter of cement clinker. The export markets span countries around the Indian Ocean Africa Europe and the Middle East.2 in UAE one in Bahrain and Bangladesh each and five terminals four in India and one in Sri Lanka. UltraTech Cement is the country largest exporter of cement clinker. The export markets span countries around the Indian Ocean Africa Europe and the Middle East. Sewagram Cement Works was commissioned in 2009. The plant has clinker capacity of 3.6 MTPA and cement capacity of 2.4 MTPA. The Unit has two captive power plants (CPP) CPP-I with 35 MV and CPP-II with 22.5 MV capacity. The Unit has mines with reserve of 246.45 MT, a captive jetty, a desalination plant that can filter around 20 lakh litres of water every day and a bag-making plant. The plant also has an environmental cell which monitors air and water quality, audits, and conducts marine ecological studies and environmental studies of mines and nearby villages.

Job Challenges:Reduction of mill power consumption by improving mill output (rate of cement mills).Increase percentage of fly ash of up to 30%.

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

**Supporting Actions (Max 1325 Characters)**
- KRA1- Accountability:Production & Quality:
Monitoring Cement Mill optimization for process operating conditions to achieve the targeted Production, Power & Quality as per dispatch schedule.- Monitor Daily production, operating parameter and trends and take corrective action for improvement.
- Monitoring of line wise power consumption and take corrective action to reduce power consumption.
- Ensure grade wise production as per requirement and correct change over of circuit ensuring product quality.
- Implementation of PM checklist in the section.
- Attend daily gain-loss meeting, why-why & PM analysis for process break downs and take corrective measures.
- To monitor calibration of clinker / Gypsum / SSF offly ash weigh feeders.
- Daily Trends review and checklist execution.
- Cross checking of cement blaine whenever it comes abnormal.
- Planning and monitor smooth changeover of cement grade as per requirement and minimize fly ash bulkers turn around time.
- Monitor and ensure timely replacement of grinding media make-up charge.
- KRA2- Cost Control:
Process expenses to operate in budgeted norms and implementation of improvement actions for cost optimization.- Implement the action suggested to reduce the variance after comparing actual and budgeted cost.
- Use of grinding media within the budgeted norms.
- Evolve schemes resulting in reduction and power cost.
- Monitor false air and idle running of equipment and take corrective action.
- Take corrective action to maintain targets of power consumption.
- Ensure running of power saving equipment to optimize and reduce power consumption.
- Initiate procurement of grinding media with shutdown planning to optimize idle inventory level.
- KRA3- 3.Modifications and Improvements

Identify areas for improvements, conduct focussed studies, and execution of proposals on modifications /improvements for Productivity Improvement.- Assist in data collection, analysis of data and implement corrective action based on action plan.
- Execute action for modification in new proposals.
- Process flow measurement.
- Identification of source of leakage and ensure corrective action.
- KRA4- .System implementation:
Compliance of WCM (ISO, EMS, OHSAS, SA 8000) in the section.- Daily Jishu-Hozen and Fuguais/ abnormality registration and corrective action.
- Execution of countermeasures recommended during inter-departmental observation.
- Identification of near-misses and ensure its corrective action
- Monitor implementation of safety
- Close watch on pollution control equipments ( ESP and Bag Filter )
- Execution of Kaizen Schemes.
- Develop One-Point Lesson and impart training to work man.
- On the job training given to attendant for safe working
- Monitor & ensure effective working of pollution control equipment like ESP, Bag Filters & co-ordinate with service department for optimum operation of the equipment.
- KRA5- 5.Process Maintenance Jobs:
Implementation of va