Reporting to the Maintenance Manager, the Mechanical Technician is responsible for executing the maintenance schedules of the Air Products Kochi facility.
Working with the guidance of the Maintenance Manager and alongside the Shift engineer and Assistant Plant Manager to ensure the smooth and reliable operation and maintenance of all aspects of the plant, with the aim of achieving the highest plant reliability and availability, whilst controlling maintenance related costs within the budget.
Nature and Scope
The Kochi Plant is Air Products first fully owned and operated plant in India; it represents a significant investment and includes “State of the Art” technology which makes it the most advanced Hydrogen Plant within the Corporation.
The plant consists of 3 main elements: -
2 x Large Technip Steam Methane Reformers (SMR) with Air Products PSA’s for H2 purification.
An 18 MW Kawasaki Gas Turbine integrated with both reformers.
An Air Products Air Separation Unit (ASU) Producing Nitrogen and Oxygen.
A future expansion is expected for Syngas (H2/CO) production consisting of: -
Amine System for CO2 removal (aMDEA)
Cryogenic separation and purification of CO.
The scope of maintenance for the Production Plants, equipment and associated systems includes: -
Compressors, Gas Turbines, Generators, Motors, Fans, Pumps (cryogenic and other), Pressure Vessels and piping systems, Relief Valves, Heat exchangers, Furnaces, Burners, Cryogenic turbines, Computer control systems, Trip Systems, Analysis equipment etc.
The customer is Bharat Petroleum Corporation Ltd. (BPCL), Kochi refinery and the Air Products plant is located within the customer’s site. The products from the Air Products plants go directly to the customer as part of their refinery expansion. There is a high level of integration between BPCL and Air Products with respect to feedstock’s, products and utilities. The products are critical to refinery unit operations.
The plants run on continuous basis and there is a strong emphasis of high reliability and high efficiency with contractual penalties against Air Products for under performance.
Air Products owns, operates and maintains Hydrogen Plants and ASU’s around the globe with Operations in over 50 countries, in excess of 80 hydrogen plants and 350 ASU’s. As such we have a wealth of expertise and have well established work processes in place for the reliable and efficient operation of our plants. The Plant Manger will be expected to work closely with the Global Communities of expertise and ensure consistent compliance with these work processes.
Prior to facility operation the individual will have a period of training before plant commissioning begins, where they will have a role setting up the permanent site maintenance team, establishing site procedures and participating in plant commissioning.
Ensure to comply with AP and local safety, health and environment standard, fulfil the mandatory safety requirement and activities: safety training, safety meeting, and all other requirements by AP EH&S and local regulation.
Monitor the serviceability of plant equipment and facilities and ensure they adhere to safety, housekeeping and environmental requirements.
Responsible for maintenance for all rotating and static equipment such as: centrifugal and reciprocating compressors, fans, cryogenic pumps, heater exchangers, pipelines, centrifugal expanders.
Response to maintenance requirements that could be scheduled or unscheduled/emergency jobs, on 24/7 base, prompt response to requests for assistance and putting in the time and effort to meet our customer’s expectations.
To be familiar with all equipments in plants, maintain all maintenance equipments accurate documents integrity and equipment history database reachable.
Provide hand-on technical skills at the troubleshooting and all related maintenance work or supporting work responsible.
Perform preventive maintenance work and support to implement Mechanical Integrity work, troubleshooting, repair for all equipment.
Coordinate or assist of supervision the contractor’s work in the facility or shop to guarantee safety and quality and reliability.
Provide technical reports through the specified datasheet or checklist.
Reporting-Time entry weekly and assist supervisor to prepare technical reports.
Work with Air Products Materials Management Department to ensure that the correct spare parts are held in locations and quantities that meet the business needs of the Plant.
Operate in a culture in which work is done correctly first time and re-work is eliminated.
Ensure maintenance is executed in compliance with EH&S requirements.
Contribute to the development of EH&S related procedures in support of maintenance activities.
MINIMUM REQUIREMENTS AND QUALIFICATIONS
A diploma in mechanical engineering with minimum 10 years as a hands-on maintenance technician in refinery, ammonia, methanol, chemical process, power generation, marine industries or similar.
Should have knowledge of the construction and maintenance of large and complex rotating equipment (e.g. gas turbines, compressors, fans, steam turbines, pumps, expanders), a good working knowledge of pressurised systems, reformers and experience in some of the following, reciprocating, rotating, centrifugal machinery, pipe and welding techniques. Knowledge of shaft alignment checking and correction, fastening and retaining devices, rigging, hoisting and lifting, installing shafts, bearings and seals and couplings including alignments, fans and blowers, compressors and pumps.
The technician should be familiar with basic math, precision measuring, machinery, rigging, layout drawings.
Must have experience in major shutdown support, project work, plant operations and maintenance efforts.
Knowledge of vendor contracts and knowledge of shop support in the region is desirable.
Good Communication & coordination skills.
Fluent in oral and written English language.