PF Process (CRO & Cem Mill)

Job description

**Job Purpose** To support SH Post Clinkerisation in Operation of Cement Mills of Line No. I & II along with feeding circuit and fly ash dossing system, as well as identify and reporting of any abnormality in operation for Smooth operation to meet the production, specific power consumption targets and quality targets at optimum cost maintaining environment and safety standards. **Job Context & Major Challenges** **Job Context** Nathdwara Cement Plant was commissioned with the manufacturing capacity of 4.8 MTPA and clinker capacity of 4.81 MTPA. The first unit was installed in 1997 and second unit was installed in 2007. Grinding Unit, Neem ka Thana was commissioned in 2007. Limestone requirement of the plant is 4.5 MTPA. To meet the limestone requirement, limestone mines are spread over 724.7 Ha having deposits sufficient for around 50 years. Limestone crusher including wobblers having capacity of 1000 TPH, located inside the plant. Material is transported from mines to plant through dumpers. The Unit has three captive thermal power plants of 24 MW & 2X23 MW i.e. a total of 70 MW. WHRS of 23 MW and Solar Plant is also there. The Cement & Power Plant is located at strategic location on Highway Cement is more than requirement and 40% manpower is Land Sellers who got job in consideration of Land. The skill & competencies are very less. The attitude towards work and job is not very appreciating. Job Holder is responsible for Smooth Mill Operation, Ensure Good Quality, Mill Optimization, safety implementation, New system implementation, Minimum Power Consumption **Job Challenges** - Reduction of mill power consumption by improving mill output (rate of cement mills). - Reduction in mill tripping specially in rainy season and to maintain optimum production. **Key Result Areas** **KRA (Accountabilities) (Max 1325 Characters)** **Supporting Actions (Max 1325 Characters)** KRA1 1.Production & Quality cement (Supervise Cement Mills operation for smooth optimum process operating conditions to achieve the targetted Production & 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 raw mill and Register operational parameters of raw mill in log book as per the specified timelines with remarks if any - Check quality parameters for operation of raw 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 and quality of raw mill and Inform SH / HOD (Process) for production at the end of the shift - Preparing daily production report and filled up in SAP. KRA2 2.Cost Optimisation and Control (Identify and analyse various process inputs and parameters like power etc., for cost reduction and ensure cost effective plant operation.) 1.Sp.Power consumption To avoid Idle running of the circuit, - Optimizing operation - Reducing breakdown by early detection of abnormalities - Daily monitoring of trends. - Take corrective action to maintain the consumption. Coordinate with Electrical / Instr./Mech. maintenance departments for related jobs. - Ensure running of power saving equipments. KRA3 3.Continuous improvement- Assist the SH for studying areas of improvement, implementation of improvement actions for optimisation of process. 1. Increasing output rate - Reduction in breakdown, Process trend analysis, Field visit and observation, Reducing abnormalities. - Identification of source of leakage and ensure corrective action. **KRA4 4.Process Maintenance Jobs** (Supervise & monitor timely execution of repairs in CM section and readiness of standby equipments for improvement of equipment availability.) 1. During mill maintenance /shutdown VRM internal inspection, separator inspection, any material accumulation, hot gas chamber, damper calibration, roller position calibration. - Jointley with concern deparment take equipment trial after shutdown. - Take no-load trials of standby equiments and Changeover when required - Take maintenance of problematic equipment. Execute PM work order **KRA5 5.System Implementation** (Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards) Execution of counter measures recommended during inter-departmental observation. Tracking on pollution control equipments ( ESP and Bag Filter ) Practices. -5S activities Monitor & ensure effective working of pollution control equipment like ESP, Bag Filters & co-ordinate with service department for optimum operation of the equipment. 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. KRA6 6.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