Senior Engineer

JSW Cement; Nandyal; On-site; INR 1,200,000 - 2,200,000; Full time

Job summary

JSW Cement is seeking a Maintenance Engineer for the Kiln/Pyro section at its Nandyal plant. The role focuses on reliable operation, preventive maintenance, and proactive troubleshooting of rotary kiln and pyro equipment to maximise plant availability and safety.

The candidate will lead shutdown planning, coordinate with production and OEM teams, and drive reliability improvements across the kiln and cooler systems, leveraging SAP/CMMS to maintain logs and spare inventories.

Qualifications

• Bachelor’s Degree / Diploma in Mechanical Engineering.
• Additional certification in maintenance or reliability engineering preferred.

Responsibilities

• Execute preventive, predictive, and breakdown maintenance for Rotary Kiln, Preheater & Calciner, Clinker Cooler (IKN Cooler preferred), Kiln Drive System, ID/FD Fans, Pyro conveying equipment, Burner systems, Hydraulic & Lubrication systems, roller crushers, belt bucket elevators, and blowers.
• Plan and execute annual/major kiln shutdown activities.
• Coordinate with production, refractory, and cooler OEM teams during shutdowns to ensure timely completion within planned downtime.
• Conduct root cause analysis (RCA) for major equipment failures and implement reliability improvements to reduce breakdowns.
• Maintain maintenance history, inspection records, and equipment logs; update SAP/CMMS records and spare inventories.

Skills

Rotary kiln

Clinker cooler maintenance

IKN cooler maintenance

Shutdown planning

Troubleshooting

Hydraulic systems

Education

Bachelor’s / Diploma in Mechanical Engineering

Tools

SAP/CMMS

Job description

Job Description: Maintenance Engineer Kiln / Pyro Section (Cement Plant)

Position

Maintenance Engineer – Kiln / Pyro Section

Department

Mechanical Maintenance / Pyro Maintenance

Location

Plant Site – [JSW Cement Nandyal]

Reporting To

Manager – Mechanical Maintenance / Head – Pyro Maintenance

Job Summary

We are looking for a skilled and proactive Maintenance Engineer for the KHD Kiln/Pyro section of a cement plant. The candidate will be responsible for ensuring reliable operation, preventive maintenance, shutdown planning, and troubleshooting of rotary kiln and pyro-processing equipment including IKN Clinker Cooler systems to achieve maximum plant availability, safety, and operational efficiency.

Key Responsibilities

Mechanical Maintenance

• Execute preventive, predictive, and breakdown maintenance activities for:
• Rotary Kiln
• Preheater & Calciner
• Clinker Cooler (IKN Cooler preferred)
• Kiln Drive System
• ID/FD Fans
• Pyro Conveying Equipment
• Burner Systems
• Hydraulic & Lubrication Systems
• Roller crushers
• Belt bucket elevators
• Blowers

Shutdown & Planning

• Plan and execute annual/major kiln shutdown activities.
• Prepare maintenance schedules, manpower plans, and spare requirements.
• Coordinate with production, refractory, and cooler OEM teams during shutdowns.
• Ensure timely completion of maintenance jobs within planned downtime.

Reliability & Improvement

• Conduct root cause analysis (RCA) for major equipment failures.
• Implement reliability improvement initiatives to reduce breakdowns.
• Monitor vibration, temperature, alignment, and cooler performance parameters.
• Optimize spare parts consumption and maintenance cost.
• Improve cooler efficiency, clinker handling reliability, and equipment availability.

Safety & Compliance

• Ensure strict adherence to plant safety procedures and permit systems.
• Conduct risk assessments and safety inspections in pyro areas.
• Ensure compliance with environmental and statutory standards.

Documentation & Reporting

• Maintain maintenance history, inspection records, and equipment logs.
• Prepare daily maintenance and shutdown reports.
• Update SAP/CMMS maintenance records and spare inventories.

Required Qualifications

• Bachelor’s Degree / Diploma in Mechanical Engineering.
• Additional certification in maintenance or reliability engineering preferred.

Experience

• 5–12 years of experience in cement plant mechanical maintenance, preferably in Kiln/Pyro section.
• Mandatory experience in maintenance and operation support of IKN Clinker Cooler systems.
• Hands-on experience with:
• Cooler grate maintenance
• Hydraulic systems
• Cooler fans and roller crushers
• Kiln alignment and pyro equipment maintenance
• Experience in large cement plants (8500 - 12000 TPD) preferred.

Required Skills

• Strong knowledge of rotary kiln and clinker cooler mechanical systems.
• Expertise in IKN cooler maintenance and troubleshooting.
• Knowledge of alignment, lubrication, bearings, hydraulics, and gear systems.
• Familiarity with SAP/CMMS systems.
• Strong shutdown planning and troubleshooting skills.
• Ability to lead maintenance teams and contractors.

Key Performance Indicators (KPIs)

• Equipment availability (%)
• Kiln & cooler downtime reduction
• MTBF (Mean Time Between Failures)
• Shutdown completion within schedule
• Cooler reliability and efficiency
• Maintenance cost control
• Breakdown frequency reduction
• Safety compliance performance

Preferred Candidate Profile

• Strong technical troubleshooting capability in pyro equipment.
• Experience handling critical shutdown jobs independently.
• Good communication and team coordination skills.
• Result-oriented and safety-focused professional.