Front Line Engineer-Instrumentation (Caustic Soda Plant-Karwar)

Job Purpose

Implement maintenance activities of control & instrumentation equipments of membrane based Caustic soda plant & Value added products so as to maximize plant availability at minimum maintenance cost while also maintaining safety & environmental standard with available resources to meet daily and monthly production as per budget.

Job Context & Major Challenges

There are Seven Units of ABG in India manufacturing Chlor-Alkali products : Grasim Chemical Division Nagda (M.P.), Grasim Chemicals Vilayat (Gujarat) Grasim Chemicals Veraval (Gujarat) Grasim Chemicals Gharwa Road (Jharkhand), Grasim Chemicals Renukoot (UP), Grasim Chemicals Karwar (Karnataka) & Grasim Chemicals Ganjam (Orissa). ABG Chlor-Alkali Business (India) is headed by SBU Head.

The Unit Grasim Industries Limited Chemical Division Karwar Facility operates Phosphoric Acid manufacturing plant of 24000TPA & 59400TPA Chlor Alkali Chemicals Plant with Mercury Cell Technology in the name of Solaris Chemtech since 1975. For implementing CREP Recommendations for Chlor - Alkali Sector operation of Mercury Technology plant was stopped in Dec 2012.Thereafter, this plant was taken over by Aditya Birla Chemicals ( India ) Limited in September 2013 & replaced old Mercury Cell process of 59400 TPA of Caustic Soda plant by latest state of Art Membrane Cell technology from M / s Uhde Germany .The other By-products are Hydrochloric Acid which is consumed for the manufacturing of Phosphoric Acid ,Liquid Chlorine & Sodium Hypo Chlorite. Caustic Soda manufacturing is power based Industry and unit requires 22MW power (Approximately 65% manufacturing cost is power cost) The business environment is multifaceted involving different technologies, various qualities of products for fragmented markets.

The Unit is also responsible for procurement of various raw materials and marketing and sales of its products. Initially, after meeting the requirements of Phosphoric Acid Plant, the excess material sold in the market at premium prices because there was a protected market and less supply of material in the market. With the changing time, the demand and supply position has completely been changed. There are as many as 38 players and total market suffers from excess supply of caustic soda.

The Indian Chlor-Alkali industry is facing a competition from global market and dumping of Caustic by other nations. By virtue of its strong commitment towards quality management, company has made efforts to setup Energy Efficient latest Membrane Cell Technology , New Chinese Brine purification Ceramic Filtration ,Variable Frequency Drive for critical Equipment to make the unit more Energy Efficient , Energy Conservation, Quality, Safety, Health & Environment.

The job holder is responsible for planning, monitoring, implementing and control Production& Maintenance activities of Caustic Soda Plant and VAPs so as to optimize plant effectiveness and power consumption to ensure that targeted production achieved with the budgeted cost and adherence to safety and environment including downstream products Liquid Chlorine, Hydro Chloric Acid, Phosphoric Acid and Sodium Hypo in alignment with business mission and EVA targets.

Major Challenges

• Equipments are of different technology & makes. This requires high technical competency to maintain the equipment performance & healthiness.
• Maintaining instruments healthiness in highly corrosive atmosphere.
• Manpower : The availability of skilled manpower is a challenge. The local manpower is low on both capability and commitment. Hence managing these resources is a constant challenge.
• Ensuring healthiness of stack monitoring instruments for accuracy and uninterrupted stack monitoring data transfer to CPCB & SPCB .
• C&I is the eye for plant operation. Ensuring intruments healthiness, logics & protection interlocks is prime focus of C&I deptt.

Key Result Areas

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

KRA1 1. Plant Maintenance

Implement all maintenance activities in the plant 11. Follow schedules and timely implement daily maintenance activities in the concerned areas

KRA2 2. Cost Control & improvements

Act on cost reduction and process improvement plans within budgeted time and cost 1. Implement measures in design modification for cost reduction

KRA3 3. Reports and Documentation : Timely update all documents of the section 1. Timely preparation all relevant reports, MIS and update all systems

KRA4 4. System Management (Safety, Sustainability & WCM) : Adhere to statutory compliance related to Safety, Health and Environment & Sustainability and systems like IMS, WCM and ISO 1. Adhere to quality systems in the section for improving performance as per quality and environmental standards

KRA5 People Development

Maintain a congenial work culture by effective communication with workmen both permanent & contractual 1. Maintain proper communication with workers and contract labour, their shift activities and resource requirements

Skills Required

Safety Health Environment, Quality Management