1)  Job Purpose

Plan, organize, co-ordinate & control all the short term as well as long term activities required during execution of major expansion projects for Captive Power Plant, which are being undertaken at Grasim Cellulosic Division Vilayat (Bharuch) to meet VSF and Chemical Division Business objectives.

Coordinate, monitor Capex (Planning and Budgeting) & other major schemes for timely completion within allocated budget.

2) Dimensions

What are the areas (in quantitative terms) the job has an impact on?

Function

Dept.

Section

Remarks

Projects

1.

Manpower (Nos.)

a.

Management

1

b.

Staff

0

c.

Worker

0

d.

Contract

250

Total

251

2.

Other Relevant Parameters (Capacity/Volumes/ Budgets)

a

Power Plant capacity Expansion

250 tph Capacity CFBC Boiler, 1 x 150 m3/hr. DM Plant and B.O.P.

b

Project cost                      

26 Million $

c

Capex Budget

26 Million $

BUSINESS:   PULP AND FIBRE

Grasim Pulp & Fibre business has grown over a period of last 50 years and has matured in terms of cost, quality & productivity. Today Grasim Viscose fibre is branded as `Birla Viscose’ and is considered as most environment friendly man-made cellulosic fibre known for its feel, comfort and biodegradability. Grasim has put up a new manufacturing facility to further strengthen the group’s market leadership in the fibre business and expand its share in the world market.

GRASIM CELLULOSIC DIVISION:

The Company’s plant is situated at G.I.D.C Vilayat Industrial Estate, commenced commercial production in 2013-14 with a modest capacity of 1,27,750 TPA. Grasim Cellulosic Division Vilayat has total six manufacturing lines; four lines with 135 TPD capacity each for Grey fibre production and two additional jumbo lines (first in business) with 300 TPD capacity each. Two of these lines are capable of making speciality modal/ micromodal fibre. GCD Vilayat also houses a captive power plant producing 171 MW Power to sustain the staple fibre production and the chemical division. There are two Sulphuric acid plants with capacity of 700 TPD acid production and 2 lines of CS2 plant of 180 TPD. Another 280 TPD acid manufacturing unit using Wet Sulphuric acid technology is also being installed.

In order to drive sustainability and compliance to EU-BAT norms, Gas Treatment Unit ( H2S scrubbing) and Carbon Adsorption Process ( CAP) plant has been installed. A fully operational WTP and ETP is available at site augmented to meet the increased production requirements. In order to recycle and reuse maximum water in process, state of the art ETP-RO has been added to recover water from treated effluent.  

The Company also produces chemicals like Anhydrous Sodium Sulphate and Sulphuric Acid. Anhydrous Sodium Sulphate is widely used in detergent, textile dyeing, glass, pulp and paper industries.

GCD has a 171 MW ( 3 X 32 MW, 1 X 30 MW & 1 X 45 MW) Capacity Co-generation Captive Power Plant which makes it self reliant for its requirement of steam and power of VSF, Chemical and Epoxy Division. The upcoming CPP expansion will cater additional requirement of Chlor-Alkali & ECH Plants of Chemical Division and capacity expansion of Epoxy plant.

Major Challenges

Job requires high level of technical expertise and utmost attention right from selection of technology, equipment, material of construction finalisation, guarantee norms with the vendors to quality of workmanship during erection stage, as wrong decision taken at the project stage becomes the liability for the unit till some major shut down and investment is planned.

• Selection of right technology and order finalization- To get details of existing technology with group CPPs, other recent technology available with machinery/technology supplier and to recommend the best technology which should meet the stringent requirement of Quality, cost, systems and productivity, needs ample amount of knowledge and experience of the processes.

      Thorough knowledge of equipment specification and its performance is

      required which is to be very well incorporated in the purchase order.

• Building, Equipment and Piping Layout Finalization- The Equipment Layout & Plot Plan  finalization keeping operational, maintenance, safety and aesthetic view becomes a challenging task.

      Similarly, preparation of PID, Isometric drawings for piping and keeping

      provision in building while all piping details from supplier may not be available

      from beginning, needs fair knowledge of all the power plant processes and expertise in

      similar job.

Coordination with all agencies – Job needs utmost level of coordination among various agencies involved, both internal & external for timely action like – all technical departments for feed back & requirements of common items for expansion, mechanical, electrical, instrumentation during coordinating civil activities and with purchase department for all procurement activities. Frequent feed backs and approvals from Superiors. Similarly, regular follow up with vendors & technology suppliers to get the details timely for smooth progress of  procurements & erection activities.

• Meeting Time Line- Job needs big expertise for timely execution of all the erection activities with bare minimum skilled man power for erection and commissioning with judicious use of resources, while activities running altogether in every section, which demands lot of innovative ideas at every stage of project. Simultaneously monitoring the quality of job, safety requirements during erection stage when about more then 400 persons are working at a given moment during peak erection period.
• Meeting target budget matching or lower than the industry standard. As requirement of equipment mostly keep on changing from good to best during time of budgeting to actual procurement, similarly price trends for many items & contractor rates keep on increasing during the project execution period, making of correct budget (should match Industry standard) and keeping budget under control is again a challenge and needs lot of cost cutting and rationalization during project execution.
• Consolidation & Rationalization – For such a large project with maximum imported items, it becomes very necessary to consolidate all the requirement of general nature items like steel, piping, pumps, cooling tower, valves, tanks& many such items to get quantity discount, reduction in freight & handling charges, which requires   fair understanding & knowledge of overall plant requirement & coordination with all departments.   Also, as full technical details for all the equipments are not available at the same time, job needs lot of expertise in estimating consolidated requirement to get the material timely.

4)  Principal Accountabilities

Accountability

Supporting Actions

Equipment & Technology Selection

To recommend the best Electrical equipments & technology for CPP expansion which will give expected benefits in terms of quality, cost, system & productivity.

• To get details of existing technology in unit, group unit & if possible, other CPPs.  

• To study & analyze the pros & cons of each technology.

• Based on suitability to our unit recommend the best technology to superiors for final selection.

Equipment Layout design

To plan and finalise best possible layouts

• To get details of equipments from suppliers.
• To get details of layouts, building design of group units.
• To select the best design suitable to our requirement of quality, cost, maintenance, operation ease, safety & aesthetic view.

Consolidation of common item required for expansion project.

• Estimating & collecting total requirement of common natures item
• Optimizing the quality, size & type based on available inventory & minimizing variety based on existing type, respectively.
• Sending technically clear requirement to purchase for getting offers.
• Evaluating offers & finalise ordering after techno commercial negotiation along with purchase dept.

4)  Principal Accountabilities

Accountability

Supporting Actions

Major equipment Specs finalization

• Finalization of technical details for negotiations based on overall experience for running equipment in unit & group units.
• Detailed techno commercial discussion with various vendors.
• Finalisation of order with purchase department with proper guarantee clauses & delivery schedules.

Coordination- Internal and External

Internal- with all technical departments along with purchase& stores

External- Machinery suppliers, vendors, contractors, group units.

• Coordination with all technical departments for their requirement for new plant & feed back (running equipments), Capex Schemes & for estimation of common item requirement.
• Coordination with purchase for finalizing the order after techno commercial discussion for main machinery & common items.
• Coordination with mechanical, instrument and civil departments for finalization of Equipment Layout, openings, insert plates & underground cable laying etc.
• Coordination with Vendors for foundation plan and loading details.
• Coordination with vendors, contractors during erection activity.

Erection & commissioning of plant in minimum possible time with optimized use of resources with best quality of work.

§  Making available skilled man power for specialized job & various contractors as per nature of job.

§  Making available resources like Crane, For lifts, specilaised tools& tackles to carryout the jobs efficiently

§  Ensuring quality of work, monitoring time guide line & safety norms.

4)  Principal Accountabilities

Accountability

Supporting Actions

Monitoring

§   Generating bar chart for complete projects right from ordering procurement, civil, mechanical erection, electrical instrumentation, installations, mechanical trial & commissioning activity.

§   Regular monitoring to identity the critical activity & allocating additional resources to minimize the duration of that activity.

Coordinating & Monitoring Capex (Planning & Budgeting) schemes.

§   Coordination for collection of proposed schemes from each department with budget.

§   Making summary & segregating the schemes based on nature of scheme.

§   Getting approval from Project Head based on justification for improvement & as per last years sanctions.

§   Sending to CPC for approval & getting preliminary offer clarifying the queries if any.

§   Coordinating with all dept. for making final approval papers with all dept for making final backup papers for investment & sending to CPC for final approval.

§   Monthly monitoring of Project for timely & within budget completion.

5)  Job Purpose of Direct Reports

Internal

Frequency

Nature

Senior President Director

Need based

For approvals and feedback

AVP (CPP) “O & M”

Need based

Major Interface of CPP Operations & Projects

Head Purchase, Unit & Central Procurement Cell

Regular

Procurement

CPP “O & M” Department

Regular

Project activities coordination

CPP “O & M” –Electrical and C &  I team.

Need Based

Matters related to interface activities coordination

Group Units Project and Technical team

Need based

Data requisition & general queries for project related matters

Finance department

Need based

Capex, project costing, insurance details

External

Frequency

Nature

Contractors

Regular

Erection, & commissioning jobs

Vendors

Regular

Procurement, product specifications

Main Equipment Supplier

Regular

Various specification details and feed backs

Technology supplier/consultants

Need based

Various equipment/supplier details and feed backs