DCS ENGINEER

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.

1. DCS-Based Plant Operation

• Operate and monitor the CFBC boiler, turbine, generator, and auxiliaries through the DCS.
• Maintain plant parameters within prescribed operating limits.
• Monitor trends, alarms, interlocks, and process deviations.
• Ensure safe and stable power generation as per load demand.

2. CFBC Boiler Operation

• Monitor:
  • Bed temperature
  • Furnace draft
  • Steam pressure and temperature
  • Bed inventory
  • Fuel and air flow
  • Flue gas parameters
• Control combustion efficiency and maintain optimum boiler performance.
• Coordinate boiler startup, shutdown, banking, and load changes.
• Handle emergency operating conditions.

3. Turbine and Generator Monitoring

• Monitor turbine operating parameters.
• Ensure synchronization and stable generation.
• Coordinate with electrical personnel regarding grid/load requirements.
• Monitor condenser vacuum, lubrication systems, and cooling water systems.

4. Alarm and Interlock Management

• Analyze alarms and abnormal operating conditions.
• Take corrective actions to prevent trips and equipment damage.
• Verify proper functioning of safety interlocks and protections.
• Assist in troubleshooting operational issues.

5. Auxiliary System Operation

Monitor and control:

• Fuel handling system
• Ash handling system
• DM water system
• Cooling water system
• Air compressors
• FD, ID, and PA fans
• ESP and pollution-control equipment

6. Performance Optimization

• Optimize combustion efficiency and heat rate.
• Minimize auxiliary power consumption.
• Reduce unburnt carbon and fuel consumption.
• Monitor emissions and ensure compliance with environmental norms.

7. Shift Operation Responsibilities

• Take and hand over shifts properly.
• Prepare shift logs and operating reports.
• Record major events, abnormalities, and corrective actions.
• Coordinate with field operators for plant inspections.

8. Safety and Compliance

• Follow SOPs, safety procedures, and statutory requirements.
• Ensure safe startup and shutdown practices.
• Participate in emergency response activities.
• Support safety audits and operational reviews.

9. Maintenance Coordination

• Coordinate with Mechanical, Electrical, and Instrumentation departments.
• Prepare equipment for maintenance through proper isolation and permit systems.
• Assist in commissioning and post-maintenance trials.

Key Parameters a CFBC DCS Engineer Monitors

• Boiler load
• Main steam pressure and temperature
• Bed temperature
• Furnace pressure
• Oxygen (O₂) levels
• Flue gas temperature
• Coal feed rate
• Air flow rates (FD/PA/ID)
• Turbine load and frequency
• Generator parameters

Required Skills

• Knowledge of CFBC boiler operation.
• Understanding of thermodynamics and power plant processes.
• Experience with DCS platforms such as ABB, Siemens, Honeywell, Yokogawa, Emerson, etc.
• Ability to analyze process trends and alarms.
• Strong troubleshooting and decision-making skills during abnormal conditions.

Typical Qualification

• Diploma/B.Tech/B.E. in Mechanical, Electrical, Instrumentation, or Power Engineering.
• Experience in thermal power plant or captive power plant operations is usually preferred.

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