PF Process (CRO & Raw Mill )

Job Purpose

Supervise and monitor operation of Raw Mills of Line No. I & II as well as helping hand for kiln operator for smooth running of plant and ensure to handling Raw material & coal feeding system by optimisation of process parameters, to meet the production, power 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.

Nathdawara has always maintained high level of operational performance and stands tall, as a symbol of Sustainable Industrial Development. Today, unit is acknowledged as one of the most efficient, vibrant, productive, profitable, technologically updated and state-of-the-art unit of Nathdawara Birla Group's UltraTech Cement Business

The job holder resposbile for wmooth raw mills Operation, Ensure Good Quality, Mill Optimization, safety implementation, New system implementation, Minimum Power Consumption.

Major Challenges

• Reduction of mill power consumption by improving mill output (rate of raw 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.Accountability:Production & Quality:

Monitoring raw Mill optimization for process operating conditions to achieve the targeted Production, Power & 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 Optimiasation And Control

Process expenses to

operate in budgeted norms and

implementation of improvement

actions for cost optimization. 1.Sp.Power consumption To avoid Idle running of the circuit,

• Optimizing operation
• Reducing breakdown by early detection of abnormalities
  
  

KRA3 3. Improvements & 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.
• Conduct other studies as per requirement, compile data and analyse data
• Eexcution on recommend actions required take corrective action.
  
  

KRA4 4.Process Maintenance Jobs

Implementation of various process

maintenance jobs in coordination with other maintenance department to improve 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.
• Indent / Issue the material and Coordinate with Contractor
• Implementation & execution of procedures incase of new process equipment/products installation.
• Check availability of standby equipments and take noload trials of standby equiments.
• Changeover when required & take maintenance of problematic equipment. Execute PM work order
  
  

KRA5 6.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 7.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 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 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.