1) Job Purpose: Write the purpose for which the job exists ?

To check the quality of each and every equipment before box-up to ensure the quality and reliability of the equipment and data entry in Maintenance management system etc pertaining to Boilers overhauling.

2) Job Context & Major Challenges: Write the specific aspects of the job that provide a challenge internal and external to the jobholder in the context of the Business/Unit/Function/Department/Section ?

Hindalco Hirakud Complex, part of Hindalco Industries Limited, is located in Sambalpur District of Odisha. It is the oldest Aluminium producing unit operating in India. The unit was established in 1959 and was a part of Indian Aluminium Company, which was later acquired by Hindalco in 2004. The Complex consists of an Aluminium Smelter Unit which has an installed capacity of 215 Kilo Ton Per Annum (KTPA) and a Captive Power Plant with a capacity of generating 467 MW of Power. The Unit manufactures hot metal to Downstream Units.

Hirakud Complex has grown through several rounds of expansions down the years. It is one of the legacy units of Hindalco where there are still several manual processes and technology is not as advanced in comparison to new-age Smelter and CPP Plants. There is also significant influence of local community and Unions in the Unit, and restrictive practices still pose a major challenge in improving overall culture at shopfloor. With increasing focus being given to the manufacturing of Green Aluminium, sustainability is also a key challenge especially in areas related to waste disposal, carbon emissions, water consumption, etc.

There is an urgent need to transform the Unit to ensure it can perform in a highly competitive environment.

Major Challenges:

1.Planned manpower was not available, especially during night shifts, affecting productivity and work-front coverage.

2. Narrow lifting path due to cable trays, platforms, and limited access at higher elevations created coil handling difficulties

3. Daily coordination meetings, advance PTW planning,



and joint shutdown scheduling.

4. Additional defects identified during inspection increased work quantity beyond the original plan.

1. Asset Care & Equipment Reliability

- Manage shift activities for Pressure Parts (Boiler, Furnace, Cyclone) and related jobs.
• Permit management and issuance of ~5 permits per shift.
• Conduct pre-job safety inspections and hazard identification.
• Verify housekeeping, access & egress, barricading, signage, and safety compliance.
• Supervise tube replacement, cutting, welding, grinding, and pressure part repairs.
• Monitor furnace and header inspection activities.

2. Maintenance Planning & PM/PdM Optimization

- Prepare and update PM schedules for SH, Economizer, Water Wall, Evaporator, and other coils.
• Plan and execute predictive maintenance through UT, MPI, NDT, Boroscopy, Thermography, etc.
• Ensure readiness of manpower, tools, procedures, and materials before shutdowns.
• Track shutdown progress and resolve bottlenecks.
• Ensure availability of critical spares and IBR materials.
• Support elimination of recurring failures through planned maintenance improvements.

3. Reliability Engineering & Production Support

- Capture daily field observations on erosion, corrosion, hotspots, leakages, refractory damage, and abnormal conditions.
• Update maintenance checklists and job packs based on field learnings.
• Provide daily feedback on defects, manpower utilization, risks, and constraints.
• Coordinate overhaul activities and ensure integration of operational defect lists into maintenance scope.
• Verify hydro-test readiness and contractor mobilization.

4.



Asset Performance & Condition Monitoring

- Monitor boiler health through condition assessment programs.
• Improve quality and accuracy of equipment performance data.
• Detect defects early to reduce emergency shutdowns and tube leakages.
• Maintain asset history and condition monitoring records.
• Improve MTBF, Availability, Reliability, and Uptime.

5. Maintenance Quality & QMS Compliance

- Ensure compliance with IBR, ISO, and quality standards.
• Control welding quality and NDT acceptance rates.
• Verify fit-up, alignment, welding procedures, and inspection compliance.
• Maintain quality records and ensure adherence to SOPs.
• Drive zero quality deviation during pressure part maintenance.

6. Cost, Budget & Inventory Optimization

- Track daily consumption of tubes, coils, bends, electrodes, filler wires, and consumables.
• Monitor critical spare inventory and high-value materials.
• Support maintenance cost estimation and budgeting.
• Analyze historical maintenance costs and shutdown expenditure.
• Minimize emergency procurement and inventory shortages.

7. Process Standardization & Compliance

- Ensure adherence to approved maintenance procedures and workflows.
• Maintain weld records, NDT reports, welder traceability, and job completion records.
• Update CMMS/EAM systems with accurate maintenance information.
• Standardize maintenance documentation and record management.
• Support audit readiness and regulatory compliance.

8.Safety, Setting & Regulatory Compliance

- Ensure compliance with LOTO, PTW, HIRA, JSA, Hot Work, Confined Space Entry, and Working at Height requirements.
• Conduct daily safety inspections and audits.
• Deliver Toolbox Talks (TBTs) before critical jobs.
• Ensure proper PPE usage and safe work practices.
• Report and investigate near misses and incidents.
• Enforce 100% compliance during shutdown and pressure-boundary activities.

📌 Support CPP Mech Maint (Hirakud)
🏢 Hindalco Industries
📍 Hirakud