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

UltraTech Cement

Andhra Pradesh

On-site

INR 500,000 - 900,000

Full time

2 days ago

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Job summary

UltraTech Cement is seeking an experienced Power Plant Operator to manage the safe operation of boilers and steam turbines at APCW in Andhra Pradesh. You will supervise desk and field activities, optimize fuel mixes, and coordinate with cross-functional teams to ensure continuous, compliant power generation.

The role demands vigilance in safety, process control, and accurate data logging. The candidate should be proficient in DCS-based operations, MIS data handling, and SAP environments, with a

Qualifications

Field and desk operation of boilers and turbines in a cement plant.
Experience in multi-fuel boiler operation and safety checks.
Familiarity with SAP, MIS and plant information systems.
Ability to manage shift operations and respond to emergencies.

Responsibilities

Operate boilers and turbines during normal and emergency time.
Optimize auxiliary power usage and fuel mix.
Monitor process parameters and ensure safe, compliant operation.
Record MIS data and prepare performance reports.
Coordinate with cross-functional teams and ensure safe start-up/shutdown.

Skills

Boiler operation

Turbine operation

DCS & plant controls

Shift management

Safety & compliance

Tools

DCS

MIS

SAP

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.

Job Purpose

Job Context & Major Challenges

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).

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.
Operational knowledge in CFBC Boilers, Steam turbines, water chemistry, and material handling system (Ash and coal handling plant) Operation.
Awareness about SAP, MIS, WCM, ISO & UTCL Safety standards.
Knowledge to collect performance parameters and calculate equipment efficiency and maintain record data.
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 escape 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