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POSITION SUMMARY Purpose Reporting to the Facility Manager, the Junior machinery engineer is responsible for providing technical leadership and be a resource in analysing day to day machinery problems, troubleshooting of machinery issues, liaising with manufacturer or technical expertise to understand and improve reliability issues that affect plant operations of the Air Products Kochi facility. Working with the guidance of the Machinery Manager and alongside the Shift engineer and Plant Supervisor to ensure the smooth and reliable operation and maintenance of the plant machinery, with the aim of achieving the highest plant reliability and availability. 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 advanced Hydrogen Plant within the Corporation. The plant consists of 2 main elements: - 2 x Large Technip Steam Methane Reformer (SMR) with Air Products PSA’s for H2 purification. An Air Products Air Separation Unit (ASU) Producing Nitrogen 1 X Syngas unit 1 X Gas turbine generator power block The scope of maintenance for the Production Plants, equipment and associated systems includes: - Compressors, Motors, Fans, Pumps (cryogenic and other), Pressure Vessels and piping systems, Relief Valves, Heat exchangers, Furnaces, Burners, Cryogenic turbines, Gas Turbine. The customer is Bharat Petroleum corporation Ltd. (BPCL), 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 plant runs on continuous basis and there is a strong emphasis on high reliability and high efficiency with contractual penalties against Air Products for underperformance. Air Products owns, operates, and maintains Hydrogen Plants and ASUs around the globe with Operations in over 50 countries, more than 100 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. Air Products Internal Use Only Plant Products (Approximate): H2: 142 KTPA N2: 10,000 Nm3/h Job Dimensions Number of Direct Reports (approximate): Nil Provide machinery diagnostics services in troubleshooting and resolving machinery issues using vibration diagnostics tools and failure analysis techniques. This includes involving in root cause analysis investigations, issuing failure analysis reports and recommendations for reliability improvements. Carry out turbo-machinery health and performance assessment and provide assessment reports to stakeholder teams on a quarterly basis. Assist to develop machinery job-packs for all machinery inspections and overhauls. Involve in “bad actor resolution” program to resolve machinery bad actors to increase reliability and machinery availability. Provide installation and commission support for new machinery and new plants. Provide technical support and supervision in the overhaul of large machinery. Principle Responsibilities Ensure 100% machine reliability & plant availability. Work closely with other departments for Machinery troubleshooting. Develop and Maintain specific LLF and Machinery condition monitoring programs. Develop and implement initiatives to improve the safety, reliability, or efficiency of rotating equipment. Identify cost savings opportunities in spare parts by leveraging reverse engineering skills and experience to repair or make ourselves. Responsible for developing technical capabilities in the country maintenance organizations at the maintenance engineering level to allow for localized support for new plant commissioning. Implement, and/or maintain the current predictive and preventive maintenance programs in the base organization. Regularly evaluate effectiveness of maintenance programs and modify accordingly to insure optimum reliability and cost benefits. Analyse data to reduce operating and maintenance costs related to machinery performance using sound technical engineering review of data and processes. Actively participate in safety programs, promote, and enforce safety rules and good housekeeping methods. Promote an atmosphere of team spirit through good example, open communication, good listening, and timely problem resolutions. Equipments Support all rotating equipment (machinery) including and not limited to Gas Turbine, Gas compressors – centrifugal & reciprocating. Multistage pumps – water & flammables, Cooling Water system including colling water pumps, cooling tower fans, Cryogenic pumps, Gas expanders, Gas Turbine etc. MINIMUM EXPERIENCE AND QUALIFICATIONS Candidate must possess a bachelor’s degree in mechanical engineering from a recognized. university with minimum of 5 years’ experience in rotating equipment machinery engineering and maintenance from refinery, ammonia, methanol, chemical process, power generation, marine industries or similar. Air Products Internal Use Only Good working technical knowledge and experience in machinery installation, commissioning, and maintenance of large rotating equipments [e.g., centrifugal compressors, reciprocating compressors, gas turbine]. Familiar with major engineering Standards pertaining to machinery. Familiar with machinery vibration diagnostics skills and machinery troubleshooting skills and root cause analysis techniques. Knowledge of MS package such as Word, SAP, Excel, Microsoft project are essential. Good Communication & coordination skills. Fluent in oral and written English language. Knowledge of Hindi will be an added advantage. Strong English verbal and written communications skills are a must with the ability to work across cultures. Demonstrate the ability to work independently and make sound decisions as required. Willingness to travel within India and overseas to provide machinery support to AP Plants. MOST CHALLENGING PART OF JOB As this is a specialized job, we are looking for a candidate with a passion for machinery and is keen to build a technical career in machinery. Ability to provide 24/7 machinery support during machinery crisis which impacts plant reliability or availability. Willing to travel to other regions as required providing machinery support (during machinery commissioning or machinery outages) as and when required.
We are the world’s largest hydrogen producer with over 80 years of industrial gas experience. We are hydrogen and industrial gas experts delivering safe, end-to-end solutions, investing in real, clean energy projects at scale, and driving the industry forward to generate a cleaner future.
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