Support Shift R/M BLR

Job Purpose

Job Purpose

To ensure the smooth functioning and mechanical upkeep of boilers and their auxiliaries during the assigned shift. This includes timely execution of routine, preventive, and corrective maintenance activities, attending breakdowns, and ensuring readiness of critical components like oil guns, soot blowers, and high-pressure valves. The role also involves coordination with operation and instrumentation teams to ensure continued and reliable steam supply to turbines for uninterrupted power generation.

Job Context

Job Context

The Captive Power Plant (CPP) at Renusagar is a critical backbone for Hindalco’s aluminium operations, supplying uninterrupted power to the smelter at Renukoot. Continuous availability and mechanical reliability of 11 high-pressure boilers and their auxiliaries are vital for meeting the plant’s load demands. Within this operational framework, the role of the Shift – Running Maintenance becomes crucial, as the person is directly responsible for ensuring the smooth functioning of boiler equipment during the assigned shift.

This position operates in a dynamic and high-pressure environment, where timely identification and resolution of equipment issues directly impact power generation reliability. The job involves working on aged and diverse machinery installed over different phases of plant expansion. It demands a strong grasp of mechanical systems like oil firing units, soot blowers, high pressure valves, and high-pressure steam/feedwater pipelines. Coordinating with operations and instrumentation teams under time-bound conditions, while ensuring safety compliance and permit procedures, adds to the complexity of the role.

Operating at the frontline of maintenance, the Shift In-Charge plays a direct role in ensuring boiler reliability, minimizing forced outages, and upholding the performance standards of the CPP.

Job Challenges

Managing maintenance of ageing and diverse boiler systems during the shift with limited time and resources is a key challenge. Quick response to breakdowns while ensuring safety compliance and coordination with operations, E&I teams, etc is critical. Supervising permanent and contract manpower and maintaining accurate shift documentation under pressure adds to the complexity.

Dimensions

Business / SBU / Unit Revenue

Business headcount

Unit headcountMgmt-299, LMS-258, Workmen-839, Contract Labour-1510

Function headcount

Department headcountMgmt-9, LMS-7, Workmen-54

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Job Description

Other Quantitative & Important Parameters

Key Result Areas/Accountabilities Supporting Actions

Business ExcellenceMaintenance Planning and Execution: Implement and oversee preventive and predictive maintenance schedules in collaboration with E &I maintenance and CPP operations teams.

Manage breakdown maintenance activities, such as addressing coal dust leakages and minor water and steam leakages to ensure reliability and continuous availability of mechanical equipment across all aspects of maintenance under jurisdiction

CostEfficient Manpower Utilization: Ensure optimal deployment of available manpower, including contract workers, to complete maintenance jobs without delays or idle time.

Control Material Wastage: Avoid unnecessary use of spares or consumables by proper job planning, checking actual equipment conditions before part replacement.

Support Cost-Saving Initiatives: Participate in cost-reduction efforts by suggesting repairable items, using refurbished parts where feasible, and improving work methods.

Minimize Rework: Ensure jobs are done right the first time to avoid rework, which leads to additional material, time, and manpower costs.

Feedback on Actual Costs: Provide feedback to the Area Head on material usage and recurring issues that lead to cost escalation.

Efficient Manpower Utilization: Ensure optimal deployment of available manpower, including contract workers, to complete maintenance jobs without delays or idle time.

CashJudicious Spare Usage: Ensure critical and long lead time spares are used only when genuinely needed, to avoid stockouts and emergency purchases.

Monitor Consumption Patterns: Track spare parts and consumables used during each shift, and highlight abnormal or excessive consumption for review.

Promote Repair Over Replacement: Identify and suggest equipment or components that can be repaired or reconditioned instead of fully replaced, preserving cash.

Inventory Coordination: Communicate shift-level requirements to the stores team or Area Head to support accurate inventory planning and avoid excess or obsolete stock.

Avoid Emergency Procurements: Ensure preventive maintenance and advance planning are followed, reducing the need for urgent and often costlier material procurement.

Customer Timely Support to Operations: Provide immediate mechanical support to the boiler operations team during the shift to ensure continuous and stable plant operation.

Quick Resolution of Issues: Respond promptly to any operation-related mechanical complaints or abnormalities to minimize impact on power generation.

Coordination with E&I and Lab Teams: Work closely with Electrical & Instrumentation and Chemical Lab teams to ensure smooth execution of interdependent activities like isolation, testing, and sample collection.

Job Closure and Feedback: Ensure maintenance tasks are completed to satisfaction and communicate job status clearly to operations for safe equipment handover.

Sustainability Energy Efficiency Support: Ensure proper operation and maintenance of systems like soot blowers and oil guns to support efficient combustion and reduced fuel wastage.

Support Green Initiatives: Participate in plant-level energy-saving and emission-reduction initiatives (e.g., reducing steam leaks, minimizing equipment idling).

Timely Statutory Compliance: Assist in maintaining readiness of lifting tools, pressure parts, and safety equipment as per statutory norms and internal audit requirements.

Safety Implementing good housekeeping practices.

Obtaining permits for regular maintenance of running maintenance.

operation including implementation of safety standards such as

LOTOTO, MSDS, 5S, OHSAS compliance, fire safety mechanism, HAZOP study, Risk assessment, HIRA job safety

analysis / PEP talks in spirit in all aspects of maintenance under jurisdiction.

Implementing compliance of observation of safety task forces to eliminate unsafe behaviour.

Conducting or facilitating safety related training is imparted to teams including contractual workmen.

Implementing emergency handling readiness through continuous recording of special events, failure analysis, efficiency improvement .

People development and engagementFacilitating competency building through training need identification, training initiatives to enhance technical and behavioural competencies and promote multitasking

identification, training initiatives to enhance technical and

behavioural competencies and promote multiskilling

Monitoring intake and deployment of appropriately trained

contractual workforce and ensuring their continuous training

and wellbeing as per company guidelines.