Job Description
Job Description: 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.
- Good communication and team coordination skills.
- Result-oriented and safety-focused professional.
Top of Form
Bottom of FormRole & responsibilities
Preferred candidate profile