Senior Engineer

Job Description: Maintenance Engineer Kiln / Pyro Section (Cement Plant)

Position

Maintenance Engineer – Kiln / Pyro Section

Department

Mechanical Maintenance / Pyro Maintenance

Location

Plant Site – [JSW Cement Nandyal]

Reporting To

Manager – Mechanical Maintenance / Head – Pyro Maintenance

Job Summary

We are looking for a skilled and proactive Maintenance Engineer for the KHD Kiln/Pyro section of a cement plant. The candidate will be responsible for ensuring reliable operation, preventive maintenance, shutdown planning, and troubleshooting of rotary kiln and pyro-processing equipment including IKN Clinker Cooler systems to achieve maximum plant availability, safety, and operational efficiency.

Key Responsibilities

Mechanical Maintenance

• Execute preventive, predictive, and breakdown maintenance activities for:
• Rotary Kiln
• Preheater & Calciner
• Clinker Cooler (IKN Cooler preferred)
• Kiln Drive System
• ID/FD Fans
• Pyro Conveying Equipment
• Burner Systems
• Hydraulic & Lubrication Systems
• Roller crushers
• Belt bucket elevators
• Blowers

Shutdown & Planning

• Plan and execute annual/major kiln shutdown activities.
• Prepare maintenance schedules, manpower plans, and spare requirements.
• Coordinate with production, refractory, and cooler OEM teams during shutdowns.
• Ensure timely completion of maintenance jobs within planned downtime.

Reliability & Improvement

• Conduct root cause analysis (RCA) for major equipment failures.
• Implement reliability improvement initiatives to reduce breakdowns.
• Monitor vibration, temperature, alignment, and cooler performance parameters.
• Optimize spare parts consumption and maintenance cost.
• Improve cooler efficiency, clinker handling reliability, and equipment availability.

Safety & Compliance

• Ensure strict adherence to plant safety procedures and permit systems.
• Conduct risk assessments and safety inspections in pyro areas.
• Ensure compliance with environmental and statutory standards.

Documentation & Reporting

• Maintain maintenance history, inspection records, and equipment logs.
• Prepare daily maintenance and shutdown reports.
• Update SAP/CMMS maintenance records and spare inventories.

Required Qualifications

• Bachelor’s Degree / Diploma in Mechanical Engineering.
• Additional certification in maintenance or reliability engineering preferred.

Experience

• 5–12 years of experience in cement plant mechanical maintenance, preferably in Kiln/Pyro section.
• Mandatory experience in maintenance and operation support of IKN Clinker Cooler systems.
• Hands-on experience with:
• Cooler grate maintenance
• Hydraulic systems
• Cooler fans and roller crushers
• Kiln alignment and pyro equipment maintenance
• Experience in large cement plants (8500 - 12000 TPD) preferred.

Required Skills

• Strong knowledge of rotary kiln and clinker cooler mechanical systems.
• Expertise in IKN cooler maintenance and troubleshooting.
• Knowledge of alignment, lubrication, bearings, hydraulics, and gear systems.
• Familiarity with SAP/CMMS systems.
• Strong shutdown planning and troubleshooting skills.
• Ability to lead maintenance teams and contractors.

Key Performance Indicators (KPIs)

• Equipment availability (%)
• Kiln & cooler downtime reduction
• MTBF (Mean Time Between Failures)
• Shutdown completion within schedule
• Cooler reliability and efficiency
• Maintenance cost control
• Breakdown frequency reduction
• Safety compliance performance

Preferred Candidate Profile

• Strong technical troubleshooting capability in pyro equipment.
• Experience handling critical shutdown jobs independently.
• Good communication and team coordination skills.
• Result-oriented and safety-focused professional.

Top of Form

Bottom of FormRole & responsibilities

Preferred candidate profile