Process (kiln) Engineer/Senior Engineer/Assistant Manager

Job Purpose
Work Location:
Rawan Cement Works
Job Band: 11

Designation: Officer / Engineer / Senior Officer / Senior Engineer / Assistant Manager

Education: Diploma in Chemical/Diploma in Cement Tech/BE/BTech Chemical

Minium Experience Required: 6 Years and above

Supervise & monitor to ensure running of Kiln operations without any trouble at optimized cost with defined parameter for uninterrupted plant production and quality.

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. It is also one of the leading cement producers globally. The company has a consolidated capacity of Million Tones Per Annum (MTPA) of grey cement. UltraTech Cement has 23 integrated plants, 1 Clinkerization plant, 27 grinding units and 7 bulk terminals, post the Century merger. Its operations span across India, UAE, Bahrain, Bangladesh and Sri Lanka.

UltraTech, Rawan Cement plant started its Line 1 operation in early 90's with the capacity of 1 MTPA, commissioned in March, 1995 as Grasim Cement Unit. This was setup to capture the Eastern Cluster deficit market. In March'2013, Line 2 Clinkerization unit was commissioned along with clinker bulk loading facility, currently consolidated capacity of Rawan Cement is 6.5 MTPA. Rawan Cement Works also has Captive Thermal Power Plant with a total capacity of 55 MW, Waste Heat Recovery System with capacity of 20.4 MW and 10.8 MW Solar Power Plant. The plant has a state of art technology viz. Vertical Roller Mills from Loesch, Germany for grinding limestone and coal, Kiln and cooler from L&T/FLS, Denmark, Combi-Grinding Cement Mill with Roller Press from KHD, Germany, Finish Grinding Slag Grinding Roller Press from Krupp Polysius, Germany, Cross belt analyser from Gamma Metrics USA for on-line analysis of Limestone, X-Ray analyser, Cem Scanner from FLS, Denmark.

As the largest cement producer in India, we continually strive to play a key role in finding effective and responsible ways to preserve the environment - a Cement Sustainability Initiative. We as a company are committed to improving our sustainability footprint in the identified areas of waste management, energy reduction, water conservation, biodiversity management, afforestation and emission reduction which are relevant to the cement industry.

Major Challenges

• Reduction of Kiln & mill power consumption by improving mill output .
• Quality Compliance
• Reduction of plant stoppages by conteneous monitoring Of Operational and quality data
• Reduction of Specific heat consumption by operating plant in optimized mode with respect to productivity.

Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)
Supporting Actions (Max 1325 Characters)
KRA1 1) Operational management (Operation of Kiln

to achieve the targeted production and quality). 1.Check operation parameters of all equipments in the beginning of the shift.

• Identify abnormalities if any Inform PF process and site attendants for corrective actions
• Continuously monitor process parameters of kiln and operate kiln 4.Register operational parameters of Kiln in log book as per the specified timelines with remarks if any
• Check quality parameters for operation of Kiln, coal mill.
• Inform PF/ SH for any major abnormality / breakdown
• Perform Corrective action as per instructions of SH (Process) / HOD (process)
• Coordinate with all service departments & communicate plan problems if any for corrective actions.
• Record shift wise production of Kiln Inform SH / HOD (Process) for production at the end of the shift.

KRA2 2) Cost Control 1.Sp.Power consumption To avoid Idle running of the circuit,

• Optimizing operation by reduction in RPM cost along with Reduction in Stores & spares cost
• Delivery Specific Heat Reduction and Reduction in Specific Heat consumption
• Reducing breakdown by early detection of abnormalities
• Timely completion of kiln shut down activity.

KRA3 3) Continuous improvement 1. Increasing output rate

• Reduction in breakdown, Process trend analysis, Field visit and observation, Reducing abnormalities.
• Compliance to SAP PM module for shutdown activities, orders booking and history updation Improvement in productivity of Kiln by optimising the operations and consistency.
• Improvement in productivity of Kiln by optimising the operations and consistency.

KRA4 4) Plant Availability
Plant Shutdown Check & Inspect

the equipments during shutdown and carry out repair jobs at Preheater /Kiln / Decoloriser 1.Check equipment status before give shutdown of equipment.

• Take trial of all equipments in coordination with all service departments from CCR.
• Follow and perform job instruction of PF/SH related to shutdown activity.
• Carry out specific job with 100 % safety compliance during shutdown.

KRA5 5) SHE (Safety, Health & Environment) along with Sustainability initiatives Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area.

Educating team about "I know my job", "I know the hazards associated with my job and I applied control measures" & "I escalate to my senior" among manpower deployed in sections/department manpower including peer, WB & CL manpower

Timely conducting scheduled SO round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system.

To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP

Active participation in safety training, safety sub committees, standard champions meeting and any safety event

Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action

Adhering of all safety precautions on the site and off the site

Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.

KRA6 6) 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 programmes 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.