Support E&I DC1,2 & Caster

Aditya Birla Group -
Orissa

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Job details

12 hours ago

Qualifications

Oracle
Programmable logic controllers
Electrical experience
Apache Pig
Kaizen

Full job description

Designation:

Location: India Orissa Hindalco, Hirakud

Organization: Metals

Job Description:

Job Purpose

To execute Electrical and Instrumentation maintenance in three shift operation of DC1,DC2&Caster & to ensure their reliability and continuous availability towards smooth operation of DC1,DC2 &Caster.
Electrical Isolation of 415V and up to 11KV voltage level as per statutory guideline.
Strictly follow PTW, LOTOTO, HIRA, JSA, SMP and all safety standards of M/S HIL.
To continuously facilitate upgradation skills of the team and embed a culture of quality, safety, and sustainability.
Review daily work orders, ensure compilation & provide reports.
Participating in equipment improvement plans using historical data on breakdowns as the tool, capturing and tracking actions to completion.
Reporting on down time and entering this data into the MIS and logbook.
Thorough knowledge of all applicable policies, rules, regulations, and codes, in a specific engineering field.
Modification to existing controls for improved process control, reliability, safety, and compliances with OSHA requirements.
Develop & maintain good working relationship with production team to formulate the best cost-effective manufacturing process and present a good image of the E&I.
Recommend replacement for old or faulty electrical equipment to the management
Keep record of all stock and supplies, store items & inventory control.
Support the company in increasing profitability by managing resources efficiently and making necessary recommendations.

3) Job Context & Major Challenges:

The Smelter of the Aluminium Production Unit of Hindalco Industries Limited at Hirakud has a Potroom, a rodding plant with a carbon unit, and Cast houses. Molten aluminium is tapped out in ladles and supplied to cast houses where they are cast into Rolling Ingots, Cast Coils, pig ingots as well as Sow Ingots, utilizing entire liquid metal & Aluminium scrap from FRP. The products of Cast House are supplied to downstream plants of Hindalco or directly to external customers.

Hirakud has 3 cast houses linked to dedicated downstream FRPs- Belur,Taloja & Mouda as stated below.

DC1- It produces rolling ingots for Belur FRP unit & Sow Ingot for inter plant sale /3rd party sale in domestic/export.

DC2- It produces rolling ingots for Taloja and Belur FRP units and primary sow for 3rd party sale in domestic /export or inter plant.

Continious Caster- It produces continuous cast coil for Belur FRP unit.

This involves collaboration with other maintenance teams for plant availability and with the commercial and support functions for resource availability. Critical aspect is to embed right blend of maintenance practices such as preventive, predictive and reliability centred maintenance, breakdown maintenance as and when required as well as planned shutdown and overhauling

This role ensures all statutory compliances related to health, safety, energy and environment. This role is also required to focus on continuous improvement through capability building, improvement initiatives, performance monitoring as well as improvement of efficiency parameters, quality, safety and sustainability.

Key equipment includes

DC-1

DC Casting machine- 1Nos
Holding Furnaces- 2 Nos
Cooling Tower- 1 Nos
MCC & PCC
EOT Crane- 2 Nos( 15T)
Weigh Bridge- 2 Nos(20T)
Forklift- 2Nos
Motors- 40 Nos
Lathe manchine-1 nos
Spectrometer- 1nos
HFO
MTT system

DC-2

DC casting Machine
Holding Furnaces- 2 Nos
Cooling Tower- 1 Nos
MCC & PCC
EOT Crane- 2 Nos( 15T)
Weigh Bridge- 2 Nos(20T)
Forklift- 2Nos
PLC System
Instrument Calibration
Lathe Machine- 1nos
Alpur system-1nos
CFF system-1Nos
Rod feeder-1Nos
HFO

Continuous Caster(CC)

MCC & PCC
PLC system
Holding cum tilting furnace( 20T)-2Nos
Continuous casting Machine-1 set
Alpur System
Rod feeder system
Cooling tower
Compressor & Dryer-3 Nos
EOT crane- 15T & 20 T- 2Nos
Bailing Press machine-1 no
Grinding machine-1 no
Lathe Machine-1 no
HFO system

Other common Area

Calibration of all Instrumets
LPG detector system
Weights & measure(calibration weigh bridge, Flow meter)- 6 Nos weighbridges
Lighting System

The criticalities of the role are reducing the meantime between failures (MTBF) and improving meantime to repair (MTTR). This role must also drive system improvement besides preventive maintenance and to improve equipment reliability and availability. Apart from these the role includes maintenance & upkeep of advanced PLC system at all the Cast houses along with taking care of C&I related issues & digitalization projects.

In order to ensure timely maintenance of all equipment spread across the five cast houses, this role must undertake maintenance planning in oracle system and data monitoring. The scope includes breakdown analysis and control, root cause analysis (RCA) and corrective and preventive action (CAPA)

Other important aspects of the role are vendor development for modifications of equipment and substitution of spare parts. It also involves awarding annual job contract for maintenance and service contracts.

The role involves statutory compliance with respect to annual approval of Chief electrical inspector and calibration of weighbridge.

Job Challenges:

Vast number imported spare parts with long lead time making inventory management difficult.
Old machines with old technology, where in many cases OEMs have close.
Ensure to follow statutory regulation like-

1)IE rule-1956 section-29-46,47-59,60-62,63-73,74-93,

2)NFPA-70 E, OSHA 29,

3)FD system,

4)LPG detector system

5)IMS system.

Upkeep of Basic Electrical Hygiene at workplace.
Zero return base Pilog code creation.
Monitoring of process parameter.
Monitoring & capturing energy reading as per desire data base.
Spare move order & Spare parts monitoring.
Cable scheduling, cleaning, covering.
Illumination study with action plan.
Completing of carry forward General shift work within timeline.
Action to close of all walkdown safety observation
Upkeep of all statutory & maintenance related documentation.
Calibration of all measuring instruments.
Upkeep of critical equipment like Furnaces, EOT cranes, Cooling towers, Compressor, Transformers etc.
Maintaining best practices for reliability improvement of MCC, Substation, DCP,Alpur,Caster equipments etc.
Implementing best practices to develop motor maintenance & storage area.

4) Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

Business Excellence

Ensuring continuous equipment availability at DC1,DC2, Caster through preventive, predictive, breakdown maintenance as well as shutdown and overhauling with respect to electrical aspects of the equipment
Undertaking maintenance planning in oracle system and data monitoring through breakdown analysis and control, root cause analysis (RCA) and corrective and preventive action (CAPA)
Formulation of standard maintenance practices as well as reviewing and monitoring implementation of the same in all aspects of maintenance under jurisdiction

Cost

Planning and budgeting with respect to CAPEX and R&M for the next financial year as well as monitoring implementation with respect to the cast house
Awarding annual job contract for maintenance and service at the best possible rates
Partnering planning and budgeting with respect to all technical upgradation and regular maintenance for the next financial year
Implementing budget through strategic planning of Electrical & Instrumentation maintenance activities
Partnering in alternate vendor development and ensuring reduction in rework
Achieving cost saving without compromising delivery by driving continuous process improvement across area of operation

Cash

Optimizing inventory of spares and consumables so as to optimize working capital and improve profitability and cash flows
Improving profitability through spare part substitution where OEMs are closed and the cost of replacement is high
Partnering cost projections for working capital and cash flow management for the next financial year with respect to area of operations
Contribute to profitability through optimizing working capital by reducing the cost of maintenance by developing internal resources for testing and calibration, maintenance of optimum spares inventory and eliminating breakdown

Customer

Reducing meantime to repair (MTTR) and improving the meantime between failures (MTBF) in order to maximize internal customer satisfaction.
Partnering commercial teams in vendor development.
Ensuring response time in providing information and solutions to all internal and external customers is minimized
Ensuring execution of breakdown maintenance activities with minimum downtime
Reviewing and monitoring maintenance of critical spares having longer lead time of procurement.

Sustainability & Compliance

Driving WCM, Kaizen and improvement projects for continuous improvement and greater sustainability
Ensuring good housekeeping practices in area of operation
Leads energy saving initiatives
Ensuring compliance of Integrated Management system and Energy Management System
Partnering in green initiatives:
- Maintaining of instrumentation equipment to achieve reliability and availability of pollution control equipment to maintain environmental norms.
Ensuring ISO 45001, ISO 50001 or any other energy of safety management certification compliance

Safety

Implementing Safety standards and developing safety mechanism to achieve zero reported incident
Ensuring a culture of safety as per standards through actively participating in safety walk downs and monthly celebration of lack of incident to embed safety culture
Reviewing and monitoring implementation of Health, Safety, Environment norms in area of operation:
- Implementation of safety standards such as LOTOTO, MSDS, 5S
- OHSAS standards & compliance
- fire safety mechanism
- HAZOP study
- Risk assessment
- HIRA.
- Compliance of all safety observation &implementation of safety task forces to eliminate unsafe behaviour.
Ensuring safety related training is imparted to all sections of Electrical & Instrumentation maintenance teams including contractual workmen
Undertaking Consequence Management.
Ensuring emergency handling readiness through continuous recording of special events, failure analysis, efficiency improvement, benchmarking, efficiency evaluation

People development and engagement

Monitoring and improving performance of team members
Ensuring competency building through training need identification, training initiatives to enhance technical and behavioural competencies
Driving mobility across various sections of Instrumentation maintenance team through multiskilling
Improving team engagement scores
Monitoring intake and deployment of appropriately trained contractual workforce and ensuring their continuous training and wellbeing as per company guidelines.

Digitization

Implementing digitization and digitalization projects - leading upgradation of PLC and SCADA system to mitigate obsolescence.

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Job Description:

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