Support E&I DC1,2 & Caster

3) Job Context & Major Challenges:

The Smelter of the Aluminium Production Unit of Hindalco Industries Limited at Hirakud has a Potroom, a rodding plant with a carbon unit, and Cast houses. Molten aluminium is tapped out in ladles and supplied to cast houses where they are cast into Rolling Ingots, Cast Coils, pig ingots as well asSow Ingots, utilizing entire liquid metal & Aluminium scrap from FRP. The products of Cast House are supplied to downstream plants of Hindalco or directly to external customers.

Hirakud has 3 cast houses linked to dedicated downstream FRPs- Belur,Taloja & Mouda as stated below.

DC1-It produces rolling ingots for Belur FRP unit & Sow Ingot for inter plant sale /3^rd party sale in domestic/export.

DC2- It produces rolling ingots for Taloja and Belur FRP units and primary sow for 3^rd party sale in domestic /export or inter plant.

Continious Caster-It produces continuous cast coil for Belur FRP unit.

This involves collaboration with other maintenance teams for plant availability and with the commercial and support functions for resource availability.Critical aspect is to embed right blend of maintenance practices such as preventive, predictive and reliability centred maintenance,breakdown maintenance as and when required as well as planned shutdown and overhauling

This role ensures all statutory compliances related to health, safety, energy and environment. This role is also required to focus on continuous improvement through capability building, improvement initiatives, performance monitoring as well as improvement of efficiency parameters, quality, safety and sustainability.

Key equipment includes

DC-1

1. DC Casting machine- 1Nos
2. Holding Furnaces- 2 Nos
3. Cooling Tower- 1 Nos
4. MCC & PCC
5. EOT Crane- 2 Nos( 15T)
6. Weigh Bridge- 2 Nos(20T)
7. Forklift- 2Nos
8. Motors- 40 Nos
9. Lathe manchine-1 nos
10. Spectrometer- 1nos
11. HFO
12. MTT system

DC-2

1. DC casting Machine
2. Holding Furnaces- 2 Nos
3. Cooling Tower- 1 Nos
4. MCC & PCC
5. EOT Crane- 2 Nos( 15T)
6. Weigh Bridge- 2 Nos(20T)
7. Forklift- 2Nos
8. PLC System
9. Instrument Calibration
10. Lathe Machine- 1nos
11. Alpur system-1nos
12. CFF system-1Nos
13. Rod feeder-1Nos
14. HFO

Continuous Caster(CC)

1. MCC & PCC
2. PLC system
3. Holding cum tilting furnace( 20T)-2Nos
4. Continuous casting Machine-1 set
5. Alpur System
6. Rod feeder system
7. Cooling tower
8. Compressor & Dryer-3 Nos
9. EOT crane- 15T & 20 T- 2Nos
10. Bailing Press machine-1 no
11. Grinding machine-1 no
12. Lathe Machine-1 no
13. HFO system

Other common Area

1. Calibration of all Instrumets
2. LPG detector system
3. Weights & measure(calibration weigh bridge, Flow meter)- 6 Nos weighbridges
4. Lighting System

The criticalities of the role arereducing the meantime between failures (MTBF) and improving meantime to repair (MTTR). This role must also drive system improvement besides preventive maintenance and to improve equipment reliability and availability. Apart from these the role includes maintenance & upkeep of advanced PLC system at all the Cast houses along with taking care of C&I related issues & digitalization projects.

In order to ensure timely maintenance of all equipment spread across the five cast houses, this role must undertake maintenance planning in oracle system and data monitoring. The scope includes breakdown analysis and control, root cause analysis (RCA) and corrective and preventive action (CAPA)

Other important aspects of the role are vendor development for modifications of equipment and substitution of spare parts. It also involves awarding annual job contract for maintenance and service contracts.

The role involves statutory compliance with respect toannual approval of Chief electrical inspector and calibration of weighbridge.

Job Challenges:

1. Vast number imported spare parts with long lead time making inventory management difficult.
2. Old machines with old technology, where in many cases OEMs have close.
3. Ensure to follow statutory regulation like-

• 1)IE rule-1956 section-29-46,47-59,60-62,63-73,74-93,
• 2)NFPA-70 E, OSHA 29,
• 3)FD system,
• 4)LPG detector system
• 5)IMS system.

1. Upkeep of Basic Electrical Hygiene at workplace.
2. Zero return base Pilog code creation.
3. Monitoring of process parameter.
4. Monitoring & capturing energy reading as per desire data base.
5. Spare move order & Spare parts monitoring.
6. Cable scheduling, cleaning, covering.
7. Illumination study with action plan.
8. Completing of carry forward General shift work within timeline.
9. Action to close of all walkdown safety observation
10. Upkeep of all statutory & maintenance related documentation.
11. Calibration of all measuring instruments.
12. Upkeep of critical equipment like Furnaces, EOT cranes, Cooling towers, Compressor, Transformers etc.
13. Maintaining best practices for reliability improvement of MCC, Substation, DCP,Alpur,Caster equipments etc.
14. Implementing best practices to develop motor maintenance & storage area.

4) Key Result Areas/Accountabilities:

Key Result Areas/Accountabilities

Supporting Actions

1. Business Excellence

• Ensuring continuous equipment availability at DC1,DC2, Caster through preventive, predictive, breakdown maintenance as well as shutdown and overhaulingwith respect to electrical aspects of the equipment
• Undertaking maintenance planning in oracle system and data monitoring through breakdown analysis and control, root cause analysis (RCA) and corrective and preventive action (CAPA)
• Formulation of standard maintenance practices as well as reviewing and monitoring implementation of the samein all aspects of maintenance under jurisdiction

1. Cost

• Planning and budgeting with respect to CAPEX and R&M for the next financial year as well as monitoring implementation with respect to the cast house
• Awarding annual job contract for maintenance and service at the best possible rates
• Partnering planning and budgeting with respect to all technical upgradation and regular maintenance for the next financial year
• Implementing budget through strategic planning of Electrical & Instrumentation maintenance activities
• Partnering in alternate vendor development and ensuring reduction in rework
• Achieving cost saving without compromising delivery by driving continuous process improvement across area of operation

1. Cash

• Optimizing inventory of spares and consumables so as to optimize working capital and improve profitability and cash flows
• Improving profitability through spare part substitution where OEMs are closed and the cost of replacement is high
• Partnering cost projections for working capital and cash flow management for the next financial year with respect to area of operations
• Contribute to profitability throughoptimizing working capital by reducing the cost of maintenance by developing internal resources for testing and calibration, maintenance of optimum spares inventory and eliminating breakdown

1. Customer

• Reducing meantime to repair (MTTR) and improving the meantime between failures (MTBF) in order to maximize internal customer satisfaction.
• Partnering commercial teams in vendor development.
• Ensuringresponse time in providing information and solutions to all internal and external customers is minimized
• Ensuring execution of breakdown maintenance activities with minimum downtime
• Reviewing and monitoring maintenance of critical spares having longer lead time of procurement.

1. Sustainability & Compliance

• Driving WCM, Kaizen and improvement projects for continuous improvement and greater sustainability
• Ensuring good housekeeping practices in area of operation
• Leads energy saving initiatives
• Ensuring compliance of Integrated Management system and Energy Management System
• Partnering in green initiatives:
  1. Maintaining of instrumentation equipment to achieve reliability and availability of pollution control equipment to maintain environmental norms.
• Ensuring ISO 45001, ISO 50001 or any other energy of safety management certification compliance

1. Safety

• Implementing Safety standards and developing safety mechanism to achieve zero reported incident
• Ensuring a culture of safety as per standards through actively participating in safety walk downs and monthly celebration of lack of incident to embed safety culture
• Reviewing and monitoring implementation of Health, Safety, Environment norms in area of operation:
  1. Implementation of safety standards such as LOTOTO, MSDS, 5S
  2. OHSAS standards & compliance
  3. fire safety mechanism
  4. HAZOP study
  5. Risk assessment
  6. HIRA.
  7. Compliance of all safety observation &implementation of safety task forces to eliminate unsafe behaviour.
• Ensuring safety related training is imparted to all sections of Electrical & Instrumentation maintenance teams including contractual workmen
• Undertaking Consequence Management.
• Ensuring emergency handling readiness through continuous recording of special events, failure analysis, efficiency improvement, benchmarking, efficiency evaluation

1. People development and engagement

• Monitoring and improving performance of team members
• Ensuring competency building through training need identification, training initiatives to enhance technical and behavioural competencies
• Driving mobility across various sections of Instrumentation maintenance team through multiskilling
• Improving team engagement scores
• Monitoring intake and deployment of appropriately trained contractual workforce and ensuring their continuous training and wellbeing as per company guidelines.

1. Digitization

• Implementing digitization and digitalization projects - leading upgradation of PLC and SCADA system to mitigate obsolescence.