Associate Manager - Mechanical

Date: 19 Dec 2024

Location:

Angul, Angul (KL03AD01), IN

Company: GMR Kamalanga Energy Ltd.

JOB PURPOSE

To Ensure the Unit/Station availability as per AOP plan ,stick to 100% statutory compliance adopting safe and trouble free technology ensuring the value addition to all stake holders converting maint wing into a profit center from cost center

ORGANISATION CHART

*Accountabilities*	*Key Performance Indicators*
Key responsibility in maintenance work. • Responsible for Maintenance Planning, scheduling preventive & breakdown Maintenance of Turbine & auxiliaries. • Responsible for Maintenance Planning, scheduling preventive & breakdown Maintenance of Air compressors and dryers. • Executing emergency shutdown work like feed Pump Bearing failure, generator rotor thread out, Hydrogen seal replacement, main turbine bearings inspection major steam leakages, tubes leakage test in condenser, HP/LP heater • Carry out day to day maintenance activity during HP/IP control and stop valves failures, safety valve failures in war foot basis and bring back the system in minimum time • Responsible for units’ availability for maximum running hours in Turbine and auxiliary’s mechanical maintenance side. • Involved in day to day planning & execution of maintenance against defect notifications. • Maintaining the oil quality and vibration of pumps within limit in co-ordination with conditioning monitoring team. • Associated with major overhauling job of Turbine and its auxiliary. • Involved in condenser flood test and HP heater hydro test activity. • Associated with maintenance works of BFP’s, Booster pump’s in regular maintenance and overhauling • Involved in Air compressor and dryer’s maintenance work and improving efficiency thereon. • Involved in erection and commissioning of Turbine and auxiliaries. • Association in preparing departmental AOP budget. • Responsible for implementing improvement initiatives w.r.t. 5S in TG & Aux. Zone.	• Turbine & auxiliaries Availability • Generation Loss due to Equipment Failure • Maintenance Budget as per Approved AOP • Zero Accident • Zero Stock out • 3S > 90% • 100% Prev. Maint. • Statutory Certification of Lifting Tools & Tackles incl. EOT Cranes in TG Building as per Schedule • 100% TNI • Knowledge sharing. • Idea implementation
Spare management and inventory control. • Identifying all the critical and other spares for different equipment to avoid zero stock out. • Development of spares through reverse engineering process • Developing Indian & alternate vendors for suppling of spares • Maintain inventory effectively to avoid any type of emergency due to spare. • Spare parts’ planning & procurement within the AOP Budget scope and targeting to 80% of the Budget.

Accountabilities

Key Performance Indicators

Key responsibility in maintenance work.
•   Responsible for Maintenance Planning, scheduling preventive & breakdown Maintenance of Turbine & auxiliaries.
•   Responsible for Maintenance Planning, scheduling preventive & breakdown Maintenance of Air compressors and dryers.
•   Executing emergency shutdown work like feed Pump Bearing failure, generator rotor thread out, Hydrogen seal replacement, main turbine bearings inspection major steam leakages, tubes leakage test in condenser, HP/LP heater
•   Carry out day to day maintenance activity during HP/IP control and stop valves failures, safety valve failures in war foot basis and bring back the system in minimum time
•   Responsible for units’ availability for maximum running hours in Turbine and auxiliary’s mechanical maintenance side.
•   Involved in day to day planning & execution of maintenance against defect notifications.
•   Maintaining the oil quality and vibration of pumps within limit in co-ordination with conditioning monitoring team.
•   Associated with major overhauling job of Turbine and its auxiliary.
•   Involved in condenser flood test and HP heater hydro test activity.
•   Associated with maintenance works of BFP’s, Booster pump’s in regular maintenance and overhauling
•   Involved in Air compressor and dryer’s maintenance work and improving efficiency thereon.
•   Involved in erection and commissioning of Turbine and auxiliaries.

• Association in preparing departmental AOP budget.
• Responsible for implementing improvement initiatives w.r.t. 5S in TG & Aux. Zone.

•   Turbine & auxiliaries Availability
•   Generation Loss due to Equipment Failure
•   Maintenance Budget as per Approved AOP
•   Zero Accident
•   Zero Stock out
•   3S > 90%
•   100% Prev. Maint.
•   Statutory Certification of Lifting Tools & Tackles incl. EOT Cranes in TG Building as per Schedule
•   100% TNI
•   Knowledge sharing.
•   Idea implementation

Spare management and inventory control.
•   Identifying all the critical and other spares for different equipment to avoid zero stock out.
•   Development of spares through reverse engineering process
•   Developing Indian & alternate vendors for suppling of spares
•   Maintain inventory effectively to avoid any type of emergency due to spare.
•   Spare parts’ planning & procurement within the AOP Budget scope and targeting to 80% of the Budget.

KEY ACCOUNTABILITIES

*Accountabilities*	*Key Performance Indicators*
Ensure safety at work place & compliance of all permits to work: • Take responsibility and implementation of all safety aspects in day to day maintenance work. • Involvement in developing safety skill of the agency work force to work in height, confined spaces, hot zone etc. • Identification of unsafe actions / conditions at workplace and attempting to eliminate the defects. • Compliance to all internal / external EHS audits and safe execution of the Improvement action plan. • Addressing regular safety and tool box talk with agency work force and update them about unsafe conditions and unsafe acts before starting the assigned job. This activity is focused on to improve the behavioral safety of the work force.
Major modifications for system reliability improvement and cost saving: - • Involved in identifying opportunities for improvement in system for reliability enhancement and cost saving by brain storming and root cause analysis. • Few are already implemented resulting in significant gains. 1- All units dosing line modification for initial dosing without starting of CEP. 2- JOP supply line modification in all three units for isolation of individual bearing supply line for easy maintenance. Installation of new globe valve in down comer drain and stop high energy steam loss from boiler. 3- Common drain line connection for CRH pot drain in all three units. 4- Pressure gauge installation in All BFP’S for monitoring the balancing pressure. 5- MDBFP Cartridge reconditioning & installation. 6- Air Compressors’ performance inmprovement.
Ensure for uninterrupted operation. • Responsible in carrying out proper maintenance practices such as preventive, proactive, condition based maintenance as well as close monitoring of the systems in order to ensure cost effective and uninterrupted power generation (Station availability > 98.5%). • Trouble shooting of different problems of equipment for reliability improvement.

KEY ACCOUNTABILITIES - Additional Details

EXTERNAL INTERACTIONS

Team Development.
•   Carrying out subject expert trainings on Air Compressors.
•   Meeting TNI needs and provide additional refresher classes to the peers & subordinates on need basis.
•   To buildup proactive, positive attitude, motivation, team spirit & can do approach among the team members to meet known / unknown challenges.
•   Understand and address all concerns in getting desired result in terms of output;
•   Developing team member technical skill by daily discussion of each technical points by adopting a question why, how & when as well as give their solution with a suitable case study.

5.   Stakeholder Relationship.
•   Maintain good relation among departmental colleagues and with interdepartmental personal for carrying out maintenance activities smoothly.
•   Maintaining good relationship between third party vendor to carry out on time job completion.
•   Follow up with all the service providers like C & C, F & A and stores to ensure the availability of all resources all the time without affecting the work.
•   Guiding & developing the Graduate Engineers in the Department and building confidence in them for handling the maintenance activities 24X7 basis.
•   Proper information management and building trust with the reporting boss & senior management.

INTERNAL INTERACTIONS

FINANCIAL DIMENSIONS

OTHER DIMENSIONS

EDUCATION QUALIFICATIONS

Bachelor Degree in with 5 years of experience in Power Plant.

RELEVANT EXPERIENCE

Having extensive experience in all phases Maintenance activities like erection commissioning and maintenance etc. Extensive exposure to Preventive, Predictive, Breakdown & Opportunity Maintenance activities in Mechanical Maintenance Department.

COMPETENCIES

Personal Effectiveness
Social Awareness
Entrepreneurship
Problem Solving & Analytical Thinking
Planning & Decision Making
Capability Building
Strategic Orientation
Stakeholder Focus
Networking
Execution & Results
Teamwork & Interpersonal influence