A. BASIC INFORMATION

Position/Role/Job Title Head - Mechanical

Grade/Job Band

Department Fertilizer

Reporting to HOD - Fertilizer

B. JOB PURPOSE

To lead the entire Mechanical Section, guide & direct the team members and effectively support in all Mechanical activities, during project and operation phases.

C. DIMENSIONS

Risk Authorisation:

Identify and mitigate risks related to all Mechanical activities during project and operation phases.

Budgetary Control:

Monitor and Control cost associated with all Mechanical activities during project and operation phases.

Supervisory Control:

Responsible & accountable for personnel management in Mechanical Section.

D. KEY RESPONSIBILITIES AND DELIVERABLES

List primary duties and responsibilities and expectations for the role holder

- List the essential duties required to carry out this job. - Use complete sentences. - Start sentences with verbs. - Use the present tense.

Financial:

Project Phase:

- Continuous monitoring & control of all costs associated with mechanical project activities

Operations Phase:

- Optimising Spares procurement & inventory

- Optimising consumables usage

- Annual budget preparation of Mechanical section and compliance to approved budget.

Customer (Internal/External):

Extending timely support to Operations and other functions within Fertilizer during project and operation phases

Process:

Project phase:

- Timely completion of all mechanical related project activities including engineering, procurement, construction, pre-commissioning and commissioning.

- Reviewing Technical & Engineering Specifications, Equipment Datasheets, PIDs, Equipment & Piping Layouts, Equipment Inspection & Test Plans, Piping Line lists, Isometrics, Support drawings, 3D model, etc. for detailed engineering phase of the Project.

- Participate in HAZOP, etc.

- Review of Tender documents, Procurement specifications, Commissioning, Capital & 2-years Spare parts lists, Technical calculations as necessary, for equipment & piping.

- Supervision of the Construction, Pre-commissioning and commissioning activities of Mechanical equipment (Rotating & Static Equipment), Ancillaries and Piping.

- Project Progress monitoring and initiate necessary actions to meet the project completion schedules.

- Mechanical Inspections & clearance of equipment and piping during various stages of the project.

- Support in controlling effluents and emissions discharges,, project waste discharges.

- Develop, implement and comply to the project procedures.

Operations Phase:

- Ensure effective Maintenance of Mechanical equipment & Piping of the plant

- Preventive, Predictive, Corrective Maintenance and trouble shooting.

- Technical Decision making on Plant Equipment as and when required.

- Optimum Inventory of Spares & Consumables.

- Development and implementation of CMMS (Centralized Maintenance Management System)

- Procurement of equipment, spares, items as necessary and inspections of the same.

- Preparation of Scope of works for Service Contracts, tendering, review of contract bids, Contract awarding and implementation.

- Day-to-day coordination with user sections for prioritising scheduled and un-scheduled maintenance activities

- Shutdown & Plant Turnaround Planning and Execution.

- Ensure and maintain safe working practices and procedures in the section.

- Support in controlling effluents and emissions discharges

- Maintenance Performance monitoring and improvement.

- Suggest and follow-up on improvements.

- Develop, implement and comply to the procedures.

Other responsibilities:

- Develop and implement the best maintenance management systems & practices.

- Prepare MIS reports and other non-routine reports, as required.

- Develop, implement and comply to the management systems with respect to Quality, Health, Safety, Environment.

Compliance Safety Governance (CSG):

- In-depth understanding and knowledge of QHSE requirements during Project and Operation phases.

- Familiar with Job Safety Analysis (JSA).

People:

People management for the Section, including recruitment, training & development, leave management and other administrative activities.

E. REQUIRED COMPETENCIES

Functional:

Competent in Engineering and maintenance aspects of:

- Static equipment such as Reformer, Ammonia Converter, Heat Exchangers, Pressure Vessels, Columns, etc.

- Refractory application

- Rotary equipment such as Turbines, Compressors, multi-stage pumps, centrifugal & reciprocating pumps, fans, blowers, etc.

- MMS

- Material handling equipment such as conveyors, reclaimer, ship loader, bagging machines, etc.

- Different types of materials used in fertilizer industry, their welding processes along with the filler materials and electrodes.

- Lifting practices, Tools & appliances used in the fertilizer Industry

- Codes and Standards like API, ASME, ASTM, NACE, TEMA, etc.

- 3D model

- Understanding of HAZOP and QRA

Trouble shooting:

- Should have basic idea of design criteria, working principle, application for different types of rotary equipment used in process plant.

- Should have knowledge of RCA methodologies to analyse & co-relate observations to evolve solution.

Cost optimization:

- Should be familiar with budget preparation and optimization

Behavioural:

- Personnel management skills

- Communication skills

- Negotiation skills

- Analytical skills

- Conflict resolution skills

- Leadership skills

Any other specific attributes:

Desirable competencies:

- MS-Project for scheduling of critical activities

F. BASIC QUALIFICATION

Bachelor of Engineering in Mechanical

G. MIN. YEARS OF EXPERIENCE

15 years

H. CERTIFICATION/LICENSES REQUIRED (if any)

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