PF Process (CRO/Kiln/CoalMill) || Kotputli Cement Works

Aditya Birla Group

India

Fresher

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Posted 23 hours ago
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Job Description

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:

Kotputli Cement Works was originally setup in the year 2009 with state-of the art plant with rated capacity of 2.5 MnTPA (8000 TPD) clinekrization line and 2.5 MnTPA (8000 TPD) cement production mills. With systematic de-bottlenecking and asset squeezing clinekrization line ramped up to 3.3 MnTPA capacity (10000 TPD). With installation of new clinkerzation line in FY 24, the plant capacity is ramped up to 6.6 MnTPA clinker production and 4.5 MnTPA Cement gridning capacity- making it second largest IU in North cluster.

Job Holder is responsible for Supervise & monitor Kiln & Coll mill operations for trouble free running at optimized cost & ensure maintenance as per ISO standards. Operate & maintain process parameters as per total quality IMS for Kiln as to ensure uninterrupted plant production.

Job Challenges:
1. Maintain targeted quality and production of Product.
2. Maintain coal ratio in coal mill as desired for coal firing in kiln.
3. Avoid tripping by taking pre corrective action during operation.
4. Ensuring 100% safe and quality jobs during annual shut downs.

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. 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 shift
KRA2	2) Cost Control 3) Continuous improvement 4) Plant Avialability: Plant Shutdown Check & Inspect the equipments during shutdown and carry out repair jobs at Preheater /Kiln / Decoloriser	1.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. 1. 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. 1.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.
KRA3	5) SHE (Safety, Health & Environment) along with Sustainability initiatives	1. Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area. 2. 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 3. Timely conducting scheduled SO, WTI round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system. 4. To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP 5. Active participation in safety training, safety sub committees, standard champions meeting and any safety event 6. Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action 7. Adhering of all safety precautions on the site and off the site 8. Replicating good practice for saving environment for long run sustainability and creating awareness among manpower to save guard natural resources.
KRA4	6) System Management (Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards)	1. To implement improvement project to reduce repetitive problems/breakdown or losses. 2. Timely submission of Kaizen, OPL, Good to fine, suggestion on system 3. Developing and sustaining Model area in respective sections 4. 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 5. To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments. 6. Implementation of critical spares & consumable SOP without any defilement 7. Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.
KRA5	5) SHE (Safety, Health & Environment) along with Sustainability initiatives	1. Ensuring 100% compliance of all safety standards and all applicable recommendations related to their concerned area. 2. 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 3. Timely conducting scheduled SO, WTI round and reporting of accidents, incidents and near misses on occurrences in the area of concern in system. 4. To conduct daily Tool Box Talk as schedule and before start the job any critical job along with SWP 5. Active participation in safety training, safety sub committees, standard champions meeting and any safety event 6. Ensure good housekeeping, limited use of power, no leakage of water, oil, air etc and reporting concerned if any abnormalities for corrective action 7. Adhering of all safety precautions on the site and off the site 8. 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)	1. To implement improvement project to reduce repetitive problems/breakdown or losses. 2. Timely submission of Kaizen, OPL, Good to fine, suggestion on system 3. Developing and sustaining Model area in respective sections 4. 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 5. To know about IMS and other systems requirement and documents for Non-Conformity in section during internal and external audits or assessments. 6. Implementation of critical spares & consumable SOP without any defilement 7. Identify & arrange rectification of leakage points/unsafe points along with monitor & take corrective action for emission levels.