PF TPP (Operation- Desk Engr) - Engineer/Sr.Engineer/Asst Manager

Designation: Senior Engineer

Location: India Andhra Pradesh APCW Tadipatri Dedicated Plant

Organization: Cement

• *Job Description:**
• -------------------

#### **Job Purpose**

To ensure safe \& smooth TPP desk operation while start up\- shutdown of boiler and turbine along with economic, uninterrupted and quality power generation by co\-ordination with other agencies in the plant to rectify the abnormalities and report to Shift Incharge and SH operation. Ensuring Process optimisation, Handling of emergencies \& Safe operation of boiler and turbine on most economic fuel mix efficiently.

#### **Job Context \& Major Challenges**

Job Context: Andhra Pradesh Cement Works (APCW) : a unit of UltraTech Cement Limited, a flagship company of the Aditya Birla Group is situated at Tadipatri, District \- Anantapur. APCW has 2 Lines. Line\-1 was commissioned in 1998 with an installed capacity of 2 million tons (2 MTPA) cement annually, which has been enhanced to 2\.7 MTPA over a period of six years through several improvements and modifications. Line\-2 was commissioned in August 2008 with an installed capacity of 3\.4 MTPA. The total cement production capacity of APCW, along with the associated Units, is 11 MTPA. The integrated plant is associated with two grinding units and one bulk terminal \- Arakkonam Grinding Unit (ARCW) in Tamil Nadu, Ginigera Grinding Unit (GICW) in Karnataka and Shankarapalli Bulk Terminal (SBT) in Hyderabad. The unit has also established a thermal power plant of 4 X 25 MW capacity to cater the plant's power requirement.

The APCW Mine is located near Tummalapenta Village, Kolimigundla Mandal, Kurnool District at Andhra Pradesh. It has a production capacity of 9\.20 MTPA. The mine lease extents up to 844\.939 hector. It was opened in the year July 1997\. The general geology falls in Narji Limestone formation of Kurnool system, age of 800 Mio years old. As per UNFC classification, mine has got the limestone reserves of 181\.65 Mio MT as on 31 March 2012\. It is one of the largest mines producing 9\.20 Mio MTPA limestone at single location.

Major Challenges: Operation

Maintaining maximum economic and quality power generation with respect to fluctuating power demand from the cement plant with Maintaining full loading, careful operations, avoiding wastages of steam, water, fuel, and auxiliary power for optimise the cost of generation inspite of no greed availibility.

Ensure the safe start up, operation \& shutdown to minimise the delay \& smooth functioning of all auxiliaries systems in context of high pressure \& temperature parameters.

To run the boiler successfully on various (multi fuel) fuel mix such as Lignite, Mozambique, SAB, US \& Petcock with maximum availability \& without affecting the optimum boiler efficiency with maintaining parameters within specified limits.

• *Professional Experience description:** (state key experiences required): Power plant operation of boilers and turbines

• *Critical Job competencies / Mandatory Skills:**

• Operation of Boiler \& Turbine its auxiliary systems
• Optimise the auxiliary power and PHR
• Shift operations through DCS and ensuring field observations and its safe controls.
• Explore to shut down jobs like boiler \& turbine and its auxiliaries, other safe work procedures.
• Maintain the plant performance data (MIS) and records for future,

Subordinate Team: Direct reports (nos.): 3 Indirect reports (nos.): 7

• *JOB PROFILE** \- (Please select the most essential points \& supporting actions of the role).

1\) Experience of field \- desk operating of boilers \& turbine during normal \& emergency time, safe start\-up \& stoppage of plant, like to come in round the clock shifts.

2\)Operational knowledge in CFBC Boilers, Steam turbines, water chemistry, and material handling system (Ash and coal handling plant) Operation.

3\) Awareness about SAP, MIS, WCM, ISO \& UTCL Safety standards.

4\) Knowledge to collect performance parameters and calculate equipment efficiency and maintain record data.

5\) Good coordination shift team members \& cross function team member.

#### **Key Result Areas**

• *KRA (Accountabilities) (Max 1325 Characters)** **Supporting Actions (Max 1325 Characters)**

KRA1 Plant operation

Execute all Desk \& supervise field operational activities for smooth operation of all equipments, in turn to give uninterrupted \& quality power to customer. - Continuous monitoring of all operational parameters and track the deviation followed with immediate corrective actions.

• Maintain Log Sheets and Records.

• Ensures smooth and safe plant operation through continuous interactions with field Operators as and when required.

• Visit to equipments and ensure the smooth functioning.

• To run the Boiler efficiently by optimizing percentage of excess air and minimizing other losses and to optimize turbine operation parameter to minimize turbine heat rate.

• Initiate immediate actions in any emergency by taking decision in consultation with SCE and other operation engineers.

• Set and establish efficient operation of boilers on various fuel mixes such as Lignite, coal \& petcock by maintaining SOx, Nox and SPM as per emission norms.

KRA2 Shift management

Monitoring of all operational activities \& housekeeping - Monitor all parameters and find out any abnormalities and report to Shift Incharge

• Coordinate with Field Operators during normal \& Emergency situations

• Ensure filling of Field Operator’s Check list, \& Log sheets and regular verification of datas.

• Ensure all Standby Equipment availability.

• Ensure House keeping of Stream\-2 Turbines.

KRA3 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.

KRA4 System Management

(Effective implementation of all IMS and other systems requirements through involvement for continuous improvement in plant working condition \& quality standards) - Ensuring proper safety precautions for working at height especially in boilers and sea water pump maintenance for

sustenance of zero accident.

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.

KRA5 Safety, WCM \& ISO implementation.

Maintaining the standard safety practices and participation in WCM / ISO activities. To look after the daily job activity by strick follow up of the safety practices to prevent the occurrence of any unwanted incident / accident

To increase the safety awareness among the workers and supervisors.

To take active participation in various WCM / ISO activities \& implementation of some concepts like visual management etc. in field area.