CHP OPERATOR

Established in 1953, Shyam Steel Group is one of the leading TMT Bar producers in India, manufacturing TMT Rebar, Billets, Sponge Iron and Ferro Alloys. Shyam Steel has also expanded its business in Construction Solutions, FMCG, Infrastructure, IT & ITeS Solutions etc. Operating with cutting-edge technology in order to meet the stringent requirements of its reputed customers both in India and abroad. Shyam Steel has emerged as a large, growing, competitive and multi-product organization by delivering quality material & service through innovation, excellence, and dedication.

Key Responsibilities

• Operate and monitor CHP equipment from the field and/or control room as assigned.
• Ensure uninterrupted coal feeding to coal bunkers, crushers, and boiler coal-feeding systems.
• Operate and monitor:
  • Belt conveyors
  • Crushers
  • Vibrating screens/feeders
  • Wagon tippler
  • Stacker/reclaimer
  • Travelling trippers
  • Coal feeders
  • Magnetic separators
  • Belt weighers
  • Dust suppression systems
  • Dust extraction systems
• Monitor conveyor belt condition, belt alignment, loading, spillage, abnormal noise, vibration, and temperature.
• Start and stop CHP equipment according to the prescribed operating sequence/interlocks.
• Check equipment health during field rounds and immediately report abnormalities to the Shift In-Charge.
• Monitor coal flow, bunker levels, conveyor loading, and equipment running status.
• Attend to coal blockage, chute choking, belt misalignment, spillage, and other operational abnormalities in coordination with maintenance personnel.
• Ensure proper operation of dust suppression and dust extraction systems.
• Monitor and operate fire protection systems associated with the CHP.
• Coordinate with the Boiler/Turbine Control Room to maintain adequate coal availability.
• Carry out equipment changeover from duty to standby as per operating requirements.
• Maintain proper communication with field operators, control room operators, electrical/mechanical maintenance teams, and shift personnel.
• Follow PTW (Permit to Work), LOTO, and safety procedures during maintenance and equipment isolation.
• Maintain shift logbooks, equipment status records, coal consumption records, and abnormality reports.
• Assist maintenance teams during breakdowns, inspections, and shutdown activities.
• Ensure proper housekeeping around conveyors, transfer towers, crushers, bunkers, and other CHP areas.
• Report unsafe conditions, equipment defects, coal leakage, fire hazards, and abnormal operating conditions.
• Participate in emergency response activities such as belt fire, coal bunker fire, conveyor trip, chute blockage, and power failure.
• Follow all plant SOPs, safety standards, and environmental requirements.

Technical Knowledge

The operator should have working knowledge of:

• Coal conveying and handling systems
• Belt conveyor operation
• Crushers and screens
• Wagon tippler operation
• Stacker/reclaimer operation
• Coal bunkering system
• Conveyor interlocks and protection
• Belt sway and zero-speed switches
• Pull-cord/emergency-stop systems
• Metal detectors and magnetic separators
• Dust suppression/extraction
• Fire protection systems
• Basic electrical and mechanical equipment identification
• CHP operating SOPs and emergency procedures

Safety Responsibilities

• Never bypass equipment interlocks or safety devices without authorization.
• Ensure proper isolation before entering or working on conveyors/chutes.
• Follow LOTO and PTW procedures strictly.
• Maintain safe distance from moving belts, rotating equipment, and crushers.
• Use prescribed PPE: helmet, safety shoes, gloves, goggles, hearing protection, and dust mask/respirator as applicable.
• Immediately report fire, coal dust accumulation, belt damage, abnormal vibration, overheating, or unsafe conditions.

Key Performance Indicators (KPIs)

• Availability of CHP equipment
• Continuous coal supply to the boiler
• Reduction in CHP trips and interruptions
• Timely identification of equipment abnormalities
• Reduction in coal spillage
• Proper adherence to SOPs and switching sequences
• Preventive-maintenance support
• Housekeeping and 5S compliance
• Zero safety violations/accidents
• Accurate shift log and operational reporting

Typical Shift Duties

Before Shift

• Take proper shift handover.
• Check running/standby equipment status.
• Check coal bunker levels and coal availability.
• Review ongoing maintenance/isolation activities.

During Shift

• Monitor coal flow and equipment parameters.
• Conduct regular field rounds.
• Attend alarms/trips and coordinate with the control room.
• Change over equipment when required.
• Maintain housekeeping and safe operating conditions.

At Shift Handover

• Report equipment under maintenance.
• Communicate abnormal conditions and pending jobs.
• Record coal-system status, bunker levels, equipment trips, and important observations.

© ShyamSteel | Rights Reserved