Thermopac Operator

Job Summary

The Thermopac Operator will be responsible for the safe and efficient operation, monitoring and routine maintenance of Thermopac and associated utility equipment used for process heating in the chemical manufacturing plant. The position will ensure continuous and reliable heat supply to production while maintaining operating parameters, fuel efficiency, equipment reliability and compliance with safety and statutory requirements.

Role & responsibilities

• Operate and monitor Thermopac systems, circulation pumps, burners, fuel systems, expansion tanks, heat-transfer systems and associated equipment.
• Monitor operating parameters such as temperature, pressure, fuel consumption, flow, circulation and other relevant process parameters and maintain them within prescribed operating limits.
• Carry out Thermopac start-up, normal operation, shutdown and changeover activities as per approved SOPs.
• Conduct routine inspection of burners, pumps, valves, pipelines, gauges, safety devices, expansion systems and other associated equipment.
• Identify abnormal conditions such as unusual temperature/pressure variations, leakage, vibration, burner malfunction or circulation problems and take immediate corrective action.
• Respond promptly to alarms, equipment abnormalities and emergency situations and follow established emergency operating procedures.
• Ensure proper fuel handling and monitor fuel consumption to support efficient operation and minimize unnecessary losses.
• Coordinate with Maintenance, Electrical and Instrumentation teams for preventive maintenance, breakdown maintenance and rectification of equipment issues.
• Carry out routine housekeeping, cleaning, lubrication and basic operator-level maintenance activities as required.
• Maintain proper operating logs, shift reports, fuel consumption records, temperature/pressure readings, maintenance records and equipment checklists.
• Ensure availability and proper functioning of safety devices, interlocks, alarms and emergency systems.
• Follow all plant safety procedures, PPE requirements, permit-to-work systems, SOPs and chemical-industry safety practices.
• Support statutory inspections and maintain required records related to utility operations and safety compliance.
• Monitor water quality and treatment parameters for systems, where applicable, and coordinate with the concerned team for corrective action.
• Conduct regular rounds of the Thermopac area and report abnormalities immediately to the Shift In-charge / Utility In-charge.
• Maintain good housekeeping and ensure the Thermopac area remains clean, safe and free from unnecessary material.
• Participate in emergency drills, safety training and toolbox meetings.
• Ensure proper shift handover and communicate equipment status, abnormalities, pending maintenance and operational issues to the next shift.
• Follow environmental and statutory requirements applicable to utility operations within the chemical manufacturing plant.

Required Skills

• Hands-on experience in Thermopac operation.
• Knowledge of industrial heating systems and utility equipment.
• Knowledge of burners, pumps, valves, fuel systems and circulation systems.
• Ability to read and understand operating parameters, gauges and instruments.
• Knowledge of preventive and breakdown maintenance coordination.
• Basic troubleshooting and emergency-handling skills.
• Knowledge of industrial safety practices and PPE.
• Good communication and shift handover skills.
• Ability to work in rotational shifts.

Preferred candidate profile

Experience in chemical, specialty chemical, pharmaceutical, petrochemical or other process manufacturing industries will be preferred. Experience with high-temperature Thermopac systems,utility operations and associated equipment will be an advantage.