Mechanical Maintenance Engineer Sponge Iron (DRI) Plant

Role & Responsibilities

- Plan, execute, and monitor preventive, predictive, and breakdown maintenance of mechanical equipment across the DRI plant (Rotary Kiln, Cooler, ABC (After Burning Chamber), ESP, Dust Handling System, Raw Material Handling, and Product Handling systems).
- Ensure trouble-free operation and maximum uptime of critical rotating equipment such as kiln support rollers & tyres, girth gear & pinion, cooler, ID/FD fans, blowers, compressors, and conveyor systems.
- Carry out condition monitoring (vibration analysis, thermography, lubrication analysis) to predict and prevent equipment failures.
- Plan and execute kiln shell alignment, tyre-roller clearance checks, and girth gear-pinion backlash/alignment during shutdowns.
- Coordinate and supervise annual/periodic shutdowns — planning job lists, manpower, spares, and contractor resources for kiln, cooler, and auxiliary equipment overhauls.
- Troubleshoot mechanical failures in real-time during plant operation and minimize downtime through quick diagnosis and corrective action.
- Maintain and repair material handling equipment — belt conveyors, bucket elevators, screw feeders, rotary feeders, vibrating screens, and crushers.
- Ensure proper functioning of refractory-related mechanical systems (kiln shell, cooler shell) in coordination with refractory teams.
- Maintain equipment history, failure analysis records, and prepare RCA (Root Cause Analysis) reports for major breakdowns.
- Plan and control spare parts inventory (critical & insurance spares) for kiln, cooler, and auxiliary mechanical systems.
- Ensure compliance with safety standards (permit-to-work, LOTO, working at height, hot work) during all maintenance activities.
- Coordinate with production, electrical, instrumentation, and refractory departments for integrated maintenance planning.
- Drive continuous improvement initiatives to reduce breakdown frequency, MTTR, and improve overall equipment effectiveness (OEE).
- Liaise with OEMs/vendors for technical support, spares, and equipment upgrades (e.g., kiln drive systems, ESP, fans).
- Ensure proper documentation of maintenance job cards, checklists, and shutdown reports.




- Train and guide technicians/junior engineers on safe and effective maintenance practices.

Preferred Candidate Profile
- BE/B.Tech in Mechanical Engineering.
- 3–10 years of relevant maintenance experience in a Sponge Iron/DRI plant, or similar process industry (steel, cement, or pellet plant).
- Solid hands-on knowledge of rotary kiln, cooler, ESP, and material handling systems maintenance.
- Good understanding of kiln alignment, tyre-roller wear patterns, girth gear-pinion maintenance, and refractory-related mechanical issues.
- Experience in planning and executing plant shutdowns/overhauls independently.
- Working knowledge of predictive maintenance tools (vibration analyzers, thermography guns, lubrication analysis).
- Familiarity with rotating equipment such as fans, blowers, compressors, gearboxes, and couplings.
- Strong troubleshooting skills with the ability to take quick decisions during breakdowns.
- Knowledge of safety systems, permit-to-work procedures, and statutory compliance in mechanical maintenance.
- Good coordination skills to work with cross-functional teams (production, E&I;, refractory, safety).
- Willingness to work in rotational shifts and be available for emergency breakdowns.
- Exposure to CMMS/SAP-PM for maintenance planning and spares management preferred.

Interview Questions – Mechanical Maintenance Engineer (Sponge Iron/DRI)
1. Basic Technical Understanding
2. Explain the DRI (Direct Reduced Iron) process and the role of the rotary kiln in it.
3. What are the major mechanical equipment in a sponge iron plant, and which have you directly maintained?
4. What is the difference between preventive, predictive, and breakdown maintenance? Give examples relevant to a DRI plant.
5. Explain the function of the cooler in the DRI process and its key mechanical components.
6. Kiln & Rotating Equipment
7.



What are the common causes of kiln shell deformation, and how do you detect it?
8. Explain tyre-roller clearance and why it's critical. How do you measure and correct it?
9. What is girth gear-pinion backlash? How do you check and adjust it?
10. What causes excessive vibration in ID/FD fans, and how would you troubleshoot it?
11. How do you check alignment of kiln support rollers, and what tools do you use?
12. What are the signs of bearing failure in kiln support rollers or major rotating equipment?

13. Material Handling Systems
14. What are common mechanical failures in belt conveyors, and how do you address them?
15. Explain maintenance practices for bucket elevators and rotary feeders.
16. How do you handle frequent chute chocking or material flow issues from a mechanical maintenance perspective?
17. Shutdown & Planning
18. How do you plan a kiln shutdown — what are the key job lists you prioritize?
19. Describe your approach to spares planning for a major overhaul.
20. How do you estimate manpower and contractor resources for a shutdown?
21. What safety precautions are critical during kiln/cooler shell hot work or internal inspection?
22. Troubleshooting & Root Cause Analysis
23. Describe a major mechanical breakdown you handled. What was the root cause, and how did you prevent recurrence?
24. If the kiln trips due to a mechanical fault during operation, what is your immediate action plan?
25. How do you use vibration analysis or thermography to predict equipment failure?
26. Safety & Compliance
27. What is your understanding of permit-to-work and LOTO procedures?
28. How do you ensure safety while working at height (e.g., ESP, ducting, kiln shell)?
29. Have you handled a mechanical safety incident? What corrective actions were taken?

30. Behavioral / Situational
31. Describe a time you had to make a quick decision during a breakdown under production pressure.
32. How do you coordinate with production and electrical teams when a mechanical issue affects plant output?
33. Tell me about a time you mentored a technician or junior engineer.
34. Are you comfortable with rotational shifts and being on-call for emergencies?

📌 Mechanical Maintenance Engineer Sponge Iron (DRI) Plant (Gandhidham)
🏢 Shreeyam Power And Steel Industries
📍 Gandhidham