PF Process

Job Purpose

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. The company has consolidated capacity of 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.

Key Result Areas KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)KRA11) 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.
2.Identify abnormalities if any Inform PF process and site attendants for corrective actions
3. 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
5. Check quality parameters for operation of Kiln, coal mill.
6. Inform PF/ SH for any major abnormality / breakdown
7. Perform Corrective action as per instructions of SH (Process) / HOD (process)
8. Coordinate with all service departments & communicate plan problems if any for corrective actions.
9. Record shift wise production of Kiln Inform SH / HOD (Process) for production at the end of the shiftKRA22) Cost Control1.Sp.Power consumption To avoid Idle running of the circuit,
2.Optimizing operation by reduction in RPM cost along with Reduction in Stores & spares cost
3. Delivery Specific Heat Reduction and Reduction in Specific Heat consumption
4.Reducing breakdown by early detection of abnormalities
5. Timely completion of kiln shut down activity.KRA33) Continuous improvement1. Increasing output rate
2. Reduction in breakdown, Process trend analysis, Field visit and observation, Reducing abnormalities.
3. Compliance to SAP PM module for shutdown activities, orders booking and history updation Improvement in productivity of Kiln by optimising the operations and consistency.
4. Improvement in productivity of Kiln by optimising the operations and consistency.KRA44) Plant Avialability:
Plant Shutdown Check & Inspect
the equipments during shutdown and carry out repair jobs at Preheater /Kiln / Decoloriser1.Check equipment status before give shutdown of equipment.
2.Take trial of all equipments in coordination with all service departments from CCR.
3. Follow and perform job instruction of PF/SH related to shutdown activity.
4. Carry out specific job with 100 % safety compliance during shutdown.KRA5SHE (Safety, Health & Environment) along with Sustainability initiativesEnsuring 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 , WTI 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.KRA6System 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.

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