Support Pumps

To ensure efficient, safe, and reliable maintenance of all Boiler Feed Pump (BFP) systems and their associated components such as booster pumps, suction strainers, Voith couplings, lubricating oil systems, and coolers. This role involves regular preventive and breakdown maintenance, alignment, reconditioning, and timely overhauling to maintain equipment health and uptime.

Job Context & Major Challenges

Job Context

The Mahan Captive Power Plant comprises 12 units, each having two sets of critical rotating equipment like Boiler Feed Pumps, Condensate Extraction Pumps, Gland Steam Fans, Chemical Dosing Skids, Cooling Water Pumps, and more. Each BFP system includes critical subcomponents—booster pump, suction strainer, Voith coupling, lubrication & working coolers—which need specialized and timely maintenance for seamless power plant operation.

Major Challenges

• Handling real-time operational issues like oil leakage, bearing temperature rise, water leakage, seal failures, etc.
• Complex alignment and vibration minimization efforts during opportunity shutdowns.
• Safe and efficient replacement and reconditioning of BFP cartridges.
• Managing PM schedules, maintaining spares inventory, and coordinating overhauling activities with OEMs or expert agencies.
• Responding to unit abnormalities during odd hours independently.

Key Result Areas & Supporting Actions

Daily Work Management

• Ensure safe and timely execution of all BFP maintenance tasks
• Coordinate with cross-functional teams for job completion
• Manage PTW (Permit to Work) processes before and after maintenance
• Record progress, maintain logbooks, PM checklists, and equipment history
• Identify and implement improvement initiatives
• Track and manage tool usage and oil/filter maintenance
• Plan inventory of spare parts, oil, filters, and critical consumables
• Handle abnormalities and emergencies independently during non-working hours

Systems

• Participate in WCM (World Class Manufacturing) small group activities
• Monitor equipment health through LLF (Low-Level Failures)
• Maintain basic conditions of assigned equipment as owner
• Use HMF (Health Monitoring Format) and quality systems effectively

Safety

• Ensure PPE compliance by all personnel
• Conduct toolbox talks and safety briefings before tasks
• Prepare and implement SWI (Safe Work Instructions) and HIRA (Hazard Identification and Risk Assessment)
• Report near misses and potential incidents promptly
• Comply with oil disposal and environmental norms
• Adhere to safety, environment, and sustainability policies

Competency Building (Self & Team)

• Participate in internal competitions like Kaizen
• Attend and conduct technical and safety trainings
• Promote suggestion schemes and Kaizen involvement among workers
• Conduct relay training of SWIs and promote a culture of learning