FLO WTP/ETP_Harihar

BE/B.Tech - Chem Eng.Job Purpose
Plan, Organize, monitor and execute production activities of WTP& ETP to supply targeted quantity of Filtered water, DM water, Soft water to Pulp plant, Fibre plant, Energy centre and Colony, treat & discharge the effluent to stipulated regulatory discharge standards at desired quality while maintaining budgeted cost, ensuring compliance to safety & environmental norms.
Job Context & Major Challenges
Harihar Polyfibers was started in 1972 with 100 TPD production using indigenous machinery and technology. This is the only integrated Pulp & Fibre units in the business, which demands for continuous availability of Pulp for our Fibre plant. Currently plant is operating at 210 TPD production. The basic raw material for Pulp Plant is eucalyptus wood. Pulping process is water intensive.
Harihar is the only integrated plant having both pulp & fibre operation together. Many facilities are common for both plants. Water for both the plants in drawn from common river intake well located 1.5 km from plant and required filter water and DM water for fibre plant is supplied from pulp plant.
The Pulping process requires water at various stages of process. River water is treated with chemicals to produce Filter water, soft water & DM water of specified quality. The process involves high degree of safety requirements because of the use of pressure vessels, Handling of Biogas and manual intensive equipment. Pulp industry is categorised as highly pollutant industry & thus there are stringent environmental requirements & regulations to be complied.
Pulp industry is categorised as highly pollutant industry & thus there are stringent environmental requirements & regulations to be complied. Increased awareness among surrounding villagers and stringent upgradation of discharge standards has helped industry to continuously upgrade environment monitoring and measurement devices.
Other Major Challenges

• Achieving required Filter water quality at optimum cost during the rainy season and adverse conditions when input variations are high.
• Achieving efficiency of demineralized water at optimum cost during summer
• Meeting stipulated ETP discharge quality during process upsets.
• Achieving effluent treatment cost within norms during plant upsets.
• Supply of uninterrupted filter & DM water to fibre plant during HPF power interruption/ water plant interruption.
• Ever increasing awareness of surrounding society and stringent regulations calls for very close monitoring and control of ETP
• Due to intensive manual operations it’s a challenge to ensure safety of employees
• Encroachment of boundaries by villagers
• Movement of castles/animals in the lagoon area
• Large effluent treatment lagoons without fencing requires vigilant monitoring
  

Key Result Areas
KRA (Accountabilities) (Max 1325 Characters)Supporting Actions (Max 1325 Characters)
KRA1 Ensure supply of Filter, DM and Soft water to Pulp plant, fibre plant, Energy Centre and Colony

• Plan & control required water quantity
• Organize and ensure to shift chemicals to work spot
• Coordinate for major maintenance activity / breakdown for early availability of equipment
• Plan and isolate equipment for preventive maintenance as per maintenance plans
  

KRA2 Achieving First Pass Yield (FPY) and Up time (UT)

• Monitor and control FPY and Up Time parameters on daily basis
• Prepare corrective and preventive actions against deviations
• Deploy action plan implementation in shifts
• Prepare monthly review report of FPY, Up Time parameters of the section
  

KRA3 Ensure treatment of effluent

• Monitor & control individual effluent streams
• Organize and ensure to shift chemicals to work spot
• Optimize aerators/diffusers running based on DO level
• Coordinate for major maintenance activity / breakdown for early availability of equipment
• Plan and isolate equipment for preventive maintenance as per maintenance plans
• Analyze deviation in ETP operations on daily/weekly basis and implement corrective/preventive actions
• Ensure proper sludge handling in each shift
  

KRA4 Achieving treated effluent quality to meet KSPCB discharge norms

• Monitor & maintain the process parameters of ETP plant
• Analyze quality deviations & initiate corrective actions/preventive action
• Train shift engineers and operators in ETP SOP
• Monitor and review SOP adherence on daily basis and initiate corrective/preventive actions
• Trouble shooting of process/equipment related problems with Maintenance team
• Prepare corrective and preventive plan for deviations and deploy action plans in shifts
• Prepare RCA for process upsets as assigned
  

KRA5 Ensure Environment Regulations Compliance

• Implement internal/external environment audit observations
• Develop greenery around plant premises to meet regulatory requirement and maintain record
• Ensure timely maintenance and availability of online pollution measurement and monitoring devices
  

KRA6 Cost Optimization

• Monitor and control ETP chemicals, WTP chemicals on daily basis within specified quality limits

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• Plan and optimize energy and chemicals by effectively deploying in shifts without affecting quality
• Analyze deviations(RCA) w.r.t targets and prepare corrective and preventive actions and deploy implementation plan in shifts
• Monitor and control overtime & initiate effective deployment/actions to minimize overtime
• Improve productivity by eliminating Non Value Adding activities in the section.
• Monitor & ensure SOP compliance to avoid equipment stoppage/breakdown
  

KRA7 Implementation of improvement projects

• Identify improvement opportunities
• Evaluate risks and prepare MOC for incorporating improvement schemes
• Co-ordinate with maintenance teams and Technical Cell in improvement/project execution
• Plan and implement approved plant scale trails
• Incorporate changes in SOP and safety documents w.r.t change
• Train shift engineers and operators on modified SOP and deploy in shifts
  

KRA8 Ensure Safe plant Operation

• Issue work permit and JSA for all maintenance and breakdown jobs as per unit PTW & JSA guidelines
• Implement risk mitigation actions identified in your area
• Train shift engineers and operators on applicable safe operations in your section
• Ensure Isolation of pressure vessels and equipment’s as per procedure before handing over for maintenance
• Execute personal safety action plan and compliances
• Implement internal and external audit observations in Biogas plant, conduct SO rounds, report near mIss
  

KRA9 System Implementation

• Prepare and maintain QMS, EMS, EnMS & OHSMS documentation as per standards
• Implement departmental objectives & targets
• Co-ordinate internal and external system audit in the department
• Comply audit observations in the department
• Implement SAP activities for the section
• Execute other assigned tasks
• Prepare and maintain documentation