Staff TPP Op (BTG FLD)

About the Role

This role involves ensuring safe and smooth field operations during the startup, shutdown, and ongoing operation of AFBC and CFBC boilers, turbines, and their auxiliaries. The position requires coordination with shop floor working agencies, identification and reporting of field abnormalities to CCR and Shift Incharge, and ensuring field process optimization while adhering to all safety standards.

Job Context & Major Challenges

The Thermal Power Plant (TPP) has a total capacity of 57.5 MW, comprising a 1x35 MW and a 1x22.5 MW condensing type steam turbine. It features two boilers: Unit-1 (CFBC, 170 TPH steam generation) and Unit-2 (AFBC, 110 TPH steam generation), operating at 85 Kg/CM² pressure. Auxiliaries include HP/LP heaters, high-pressure boiler feed pumps (95 Kg/CM²), and air-cooled condensers with 14 forced draft fans. The primary fuel is lignite, with an approximate daily consumption of 900T. The fuel handling plant includes screening, belt conveyors, and hydraulic truck unloaders. Limestone, ash, and water treatment systems (RO & DM plant, wastewater treatment) are also part of the infrastructure. The plant uses screw air compressors for pneumatic and instrument air.

Major Challenges

• Maintaining maximum economic and quality field work while running both units simultaneously.
• Handling field casual manpower.
• Ensuring safe field startup, operation, and shutdown of AFBC and CCFBC boilers and auxiliaries under high pressure and temperature conditions.
• Maintaining housekeeping of the allocated field area.
• Providing operational support to working agencies, minimizing waste of steam, water, fuel, and auxiliary power to optimize generation cost.
• Efficient field operation of air-cooled condensers, which are sensitive to atmospheric air quality.
• Managing parallel field operations of two units without grid connection (island mode).
• Handling various fuel types and proportions requiring continuous field operation and process monitoring.

Key Result Areas (KRAs)

KRA1: SHE (Safety, Health & Environment) along with Sustainability Initiatives

• Ensuring 100% compliance with all safety standards and applicable recommendations.
• Educating team members on job knowledge, associated hazards, and control measures.
• Timely conducting scheduled SO rounds and reporting accidents, incidents, and near misses.
• Conducting daily Tool Box Talks and pre-job safety briefings for critical tasks.
• Active participation in safety training, subcommittees, and meetings.
• Ensuring good housekeeping, efficient use of power, and reporting leakages.
• Adhering to all on-site and off-site safety precautions.
• Replicating good environmental practices and promoting awareness for natural resource conservation.
• Ensuring no unsafe work occurs in the Boiler Turbine field during the shift.
• Reporting near misses to prevent major accidents.
• Coordinating with Casual Manpower and reporting to CCR Shift Incharge.

KRA2: System Management

• Effective implementation of all IMS and other system requirements for continuous improvement.
• Implementing improvement projects to reduce repetitive problems or losses.
• Timely submission of Kaizen, OPL, and suggestions for system improvements.
• Developing and sustaining Model areas in respective sections.
• Active participation in KFA & GRT meetings, providing inputs on new technology, innovation, and productivity.
• Conducting awareness programs for the team.
• Understanding IMS and system requirements for Non-Conformity during audits.
• Implementing critical spares & consumable SOPs.
• Identifying and rectifying leakage points/unsafe points.
• Monitoring and taking corrective action for emission levels.

KRA3: Shift Management

• Monitoring all field operational activities records and housekeeping.
• Monitoring all field physical parameters and maintaining readings in the logbook.
• Maintaining the Field Record Logbook for boiler and turbine activities during the shift.
• Ensuring daily status of equipment using CLIT Checklists.
• Ensuring availability of all standby equipment.
• Maintaining housekeeping of both Boiler House and Turbine Building.
• Managing Casual Manpower attendance and shift schedules.

KRA4: Field Operation

• Executing all field operational activities for smooth operation of both units.
• Continuous monitoring of all operational field processes and tracking deviations.
• Implementing immediate corrective actions.
• Maintaining Log Books and Records.
• Ensuring smooth and safe plant field operations through continuous interaction with CCR- Shift Incharge.
• Daily physical inspection of all field equipment and reporting abnormalities to working agencies through CCR.
• Initiating immediate actions during leakages or emergencies in consultation with CCR Shift Incharge and Desk Engineers.

Requirements & Tech Stack

• AFBC boiler operation
• CFBC boiler operation
• Turbine operation
• Air-Cooled Condenser operation
• Coordination with shop floor working agencies
• Identification and reporting of field abnormalities
• Field Process optimization
• Adherence to safety standards
• Handling manpower
• Monitoring physical parameters
• Maintaining logbooks and records
• IMS
• Kaizen
• OPL
• KFA
• GRT
• CLIT Checklist
• CCR