PF-Process

Job description

Job Purpose To support SH Post Clinkerisation in operation and optimization of Cement Mill by daily monitoring & routine inspection of cement mill TPH, power rate loss in cement mills area in field to avoid breakdowns and co-ordination with other department for corrective action of any abnormalities or minimizing downtime of the equipment. Job Context & Major Challenges Job Context UltraTech Cement Limited is the cement flagship company of the Aditya Birla Group. A USD 7.9 billion building solutions powerhouse, UltraTech is the largest manufacturer of grey cement, ready mix concrete (RMC) and white cement in India. It is the third largest cement producer in the world, excluding China. UltraTech is the only cement company globally (outside of China) to have 100+ MTPA of cement manufacturing capacity in a single country. The Company's business operations span UAE, Bahrain, Sri Lanka and India. UltraTech has a consolidated capacity of 138.39 Million Tonnes Per Annum (MTPA) of grey cement. UltraTech has 23 integrated manufacturing units, 29 grinding units, one Clinkerisation unit and 8 Bulk Packaging Terminals. UltraTech has a dealer network of over 30,000 and retailer network of over 84,000 across the country, with a market reach of more than 80% Indian cities and towns. In the white cement segment, UltraTech goes to market under the brand name of Birla White. It has one White Cement unit and three Wall Care putty unit, with a current capacity of 1.98 MTPA. With 230+ Ready Mix Concrete (RMC) plants in 100+ cities, UltraTech is the largest manufacturer of concrete in India. It also has a slew of speciality concretes that meet specific needs of discerning customers. Our Building Products business is an innovation hub that offers an array of scientifically engineered products to cater to new-age constructions. Narmada Cement - Jafarabad Works was established in 1982 as Narmada Cement Company Limited and merged with UltraTech in 2006. The installed capacity of 1 MMTPA clinker has been gradually increased to 1.50 MTPA (4,300 – 4,500 TPD). Cement capacity is 0.50 MTPA (1,150 TPD). heater, in-line flash calciner, reverse air bag house dust collector, vertical roller mills besides to be the first to unload imported South African coal at plant jetty. It transports 100% clinker to grinding units is in bulk by sea route. The special feature of this plant is ‘Just in Time’ design for raw mill circuit. As against conventional norms of 20,000 MT silo for raw meal storage it has 2,000 MT silo. The grinding units associated with Jafrabad Cement Works are Magdalla Cement Works and Ratnagiri Cement Works. All three coast-based split location clinker manufacturing units have jetties. Narmada Cement was the prime supplier of fly ash-based Portland Pozzolana Cement (PPC) to Sardar Sarovar Dam on river Narmada, which is the World’s second largest concrete gravity dam (by volume). Narmada Cement Mine is the captive mine for Jafarabad plant having a production capacity of 2.30 MTPA. It is situated near coastal village of Babarkot, 7 km from Jafarabad port. Out of the total 565.94 hector lease area. Job Challenges Reduction of mills power consumption by improving mills output (rate of cement mills). Increase percentage of flyash of up to 35%. 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. 1. Maximise the productivity by ensuring smooth and continuous operation of cement mill Ensure quality maintained as per standard • Monitoring of mill 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. – • 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. 9.Planning and monitor smooth changeover of cement grade as per requirement3 • 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. 1.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. • 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. • making shutdown PRs and MRs. KRA3 Modifications And Improvements Identify areas for improvements, conduct focussed studies, and execution of proposals on modifications /improvements for Productivity Improvement. 1.Assist in data collection, analysis of data and implement corrective action based on action plan. • Analysis of data and feasibility study (Cost benefit analysis) by application of PM analysis. • Execute action for modification in new proposals. • Process flow measurement and parameter cross check if found abnormal. • Identification of source of leakage and ensure corrective action. KRA4 4.System Implementation (Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition & quality standards) 1. Execution of counter measures recommended dur