: Maintenance Engineer Kiln / Pyro Section (Cement Plant)

Position

Maintenance Engineer – Kiln / Pyro Section

Department

Mechanical Maintenance / Pyro Maintenance

Location

Plant Site – [JSW Cement Nandyal]

Reporting To

Manager – Mechanical Maintenance / Head – Pyro Maintenance

Job Summary

We are looking for a skilled and proactive Maintenance Engineer for the KHD Kiln/Pyro section of a cement plant. The candidate will be responsible for ensuring reliable operation, preventive maintenance, shutdown planning, and troubleshooting of rotary kiln and pyro-processing equipment including IKN Clinker Cooler systems to achieve maximum plant availability, safety, and operational efficiency.

Key Responsibilities

Mechanical Maintenance

- Execute preventive, predictive, and breakdown maintenance activities for:

- Rotary Kiln
- Preheater & Calciner
- Clinker Cooler (IKN Cooler preferred)

- Kiln Drive System

- ID/FD Fans

- Pyro Conveying Equipment

- Burner Systems
- Hydraulic & Lubrication Systems

- Roller crushers

- Belt bucket elevators

- Blowers

Shutdown & Planning

- Plan and execute annual/major kiln shutdown activities.
- Prepare maintenance schedules, manpower plans, and spare requirements.
- Coordinate with production, refractory, and cooler OEM teams during shutdowns.
- Ensure timely completion of maintenance jobs within planned downtime.

Reliability & Improvement

- Conduct root cause analysis (RCA) for major equipment failures.
- Implement reliability improvement initiatives to reduce breakdowns.
- Monitor vibration, temperature, alignment, and cooler performance parameters.
- Optimize spare parts consumption and maintenance cost.
- Improve cooler efficiency, clinker handling reliability, and equipment availability.

Safety & Compliance

- Ensure strict adherence to plant safety procedures and permit systems.




- Conduct risk assessments and safety inspections in pyro areas.
- Ensure compliance with environmental and statutory standards.

Documentation & Reporting

- Maintain maintenance history, inspection records, and equipment logs.
- Prepare daily maintenance and shutdown reports.
- Update SAP/CMMS maintenance records and spare inventories.

Required Qualifications

- Bachelor’s Degree / Diploma in Mechanical Engineering.
- Additional certification in maintenance or reliability engineering preferred.

Experience

- 5–12 years of experience in cement plant mechanical maintenance, preferably in Kiln/Pyro section.
- Mandatory experience in maintenance and operation support of IKN Clinker Cooler systems.
- Hands-on experience with:

- Cooler grate maintenance

- Hydraulic systems
- Cooler fans and roller crushers
- Kiln alignment and pyro equipment maintenance
- Experience in large cement plants (8500 - 12000 TPD) preferred.

Required Skills

- Strong knowledge of rotary kiln and clinker cooler mechanical systems.
- Expertise in IKN cooler maintenance and troubleshooting.
- Knowledge of alignment, lubrication, bearings, hydraulics, and gear systems.
- Familiarity with SAP/CMMS systems.
- Strong shutdown planning and troubleshooting skills.
- Ability to lead maintenance teams and contractors.

Key Performance Indicators (KPIs)

- Equipment availability (%)
- Kiln & cooler downtime reduction
- MTBF (Mean Time Between Failures)
- Shutdown completion within schedule
- Cooler reliability and efficiency
- Maintenance cost control
- Breakdown frequency reduction
- Safety compliance performance

Preferred Candidate Profile

- Strong technical troubleshooting capability in pyro equipment.
- Experience handling critical shutdown jobs independently.
- Valuable communication and team coordination skills.
- Result-oriented and safety-focused professional.

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Preferred candidate profile

📌 Senior Engineer (Nandyala)
🏢 JSW Cement
📍 Nandyala