PF Process; Kiln Operation

Position: PF Process (Kiln Operation)
Location: Nāthdwāra

Job Description  Job Purpose  Supervise & monitor to ensure running of Kiln operations without any trouble at optimized cost with defined parameter for uninterrupted plant production and quality.
Job Context & Major Challenges  Job Context:
Ultra Tech Cement Limited has an annual capacity of 52 million tonnes. It manufactures and markets Ordinary Portland Cement Portland Blast Furnace Slag Cement and Portland Pozzalana Cement. It also manufactures ready mix concrete RMC. The company has 11integrated plants one white cement plant one clinkerisation plant in UAE 15 grinding units 11 in India Ultra Tech Cement is the country largest exporter of cement clinker.

The export markets span countries around the Indian Ocean Africa Europe and the Middle East.
2 in UAE one in Bahrain and Bangladesh each and five terminals four in India and one in Sri Lanka. Ultra Tech Cement is the country largest exporter of cement clinker. The export markets span countries around the Indian Ocean Africa Europe and the Middle East. Nathdawara Cement Works was commissioned in 2009. The plant has clinker capacity of 3.6 MTPA and cement capacity of 2.4 MTPA.

The Unit has two captive power plants (CPP) CPP-I with 35 MV and CPP-II with 22.5 MV capacity. The Unit has mines with reserve of 246.45 MT, a captive jetty, a desalination plant that can filter around 20 lakh litres of water every day and a bag-making plant. The plant also has an environmental cell which monitors air and water quality, audits, and conducts marine ecological studies and environmental studies of mines and nearby villages.

Job Holder is responsible fors Supervise & monitor Kiln & Coll mill operations for trouble free running at optimized cost & ensure maintenance as per ISO standards. Operate & maintain process parameters as per total quality IMS for Kiln as to ensure uninterrupted plant production.

Job Challenges:
1. Maintain targeted quality of Product
2. Maintain coal ratio in coal mill as desired for coal firing in kiln.
3. Avoid tripping by taking pre corrective action during operation.
Key Result Areas      KRA (Accountabilities) (Max 1325 Characters)  Supporting Actions (Max 1325 Characters)    KRA1
1) Operational management (Operation of Kiln
to achieve the targeted production and quality)  1.Check operation parameters of all equipments in the beginning of the shift.
2.Identify abnormalities if any Inform PF process and site attendants for corrective actions
3. Continuously monitor process parameters of kiln and operate kiln
4.Register operational parameters of Kiln in log book as per the specified timelines with remarks if any
5. Check quality parameters for operation of Kiln, coal mill.
6. Inform PF/ SH for any major abnormality / breakdown
7. Perform Corrective action as per instructions of SH (Process) / HOD (process)
8. Coordinate with all service departments & communicate plan problems if any for corrective actions.
9. Record shift wise production of Kiln Inform SH / HOD (Process) for production at the end of the shift    KRA2
2) Cost Control  1.Sp.Power consumption To avoid Idle running of the circuit,
2.Optimizing operation by reduction in RPM cost along with Reduction in Stores & spares cost
3. Delivery Specific Heat Reduction and Reduction in Specific Heat consumption
4.Reducing breakdown by early detection of abnormalities
5. Timely completion of kiln shut down activity.
KRA3
3) Continuous improvement  
1. Increasing output rate
2. Reduction in breakdown, Process trend analysis, Field visit and observation, Reducing abnormalities.
3. Compliance to SAP PM module for shutdown activities, orders booking and history updation Improvement in productivity of Kiln by optimising the operations and consistency.
4. Improvement in productivity of Kiln by optimising the operations and consistency.
KRA4
4) Plant Avialability:
Plant Shutdown Check & Inspect
the equipments during shutdown and carry out repair jobs at Preheater /Kiln / Decoloriser  
1.Check equipment status before give shutdown of equipment.
2.Take trial of all equipments in coordination with all service departments from CCR.
3. Follow and perform job instruction of PF/SH related to shutdown activity.
4. Carry out specific job with 100 % safety compliance during shutdown.
KRA5  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…