Purpose of the Role
The Shift In-Charge (Operations) is responsible for the safe, efficient, and uninterrupted operation of a 900 TPD Air Separation Unit (ASU), ensuring optimum production of Liquid Oxygen (LOX), Liquid Nitrogen (LIN), Gaseous Oxygen (GOX), Gaseous Nitrogen (GAN), and Argon as per quality and production targets. The role involves leading shift operations, monitoring process parameters, coordinating with maintenance teams, ensuring adherence to safety standards, and driving operational excellence.
Job Responsibilities (KRA)
Plant Operations & Process Control
- Operate and monitor the 900 TPD Air Separation Unit during assigned shifts.
- Ensure stable operation of compressors, cold box, purification systems, distillation columns, expanders, and cryogenic storage systems.
- Monitor and control critical process parameters such as pressure, temperature, flow, purity, and energy consumption.
- Optimize plant performance to maximize production efficiency and minimize losses.
- Ensure product quality specifications for Oxygen, Nitrogen, and Argon are consistently achieved.
- Monitor utility consumption and implement corrective actions for deviations.
Shift Management
- Lead and supervise shift operators, field operators, and technicians.
- Conduct shift handovers and ensure proper communication of plant status.
- Prepare and maintain shift reports, production logs, and operational records.
- Coordinate manpower deployment during normal and emergency operations.
- Ensure timely reporting of abnormalities and process upsets.
Safety, Health & Environment
- Ensure strict compliance with safety standards, SOPs, work permits, and statutory requirements.
- Promote a strong safety culture and conduct toolbox talks during shifts.
- Participate in HAZOP, risk assessments, incident investigations, and safety audits.
- Ensure compliance with cryogenic safety, oxygen handling safety, confined space entry, and emergency response procedures.
- Monitor environmental compliance and operational discipline.
Plant Start-up, Shutdown & Troubleshooting
- Execute plant start-up, shutdown, cooldown, and warm-up activities as per approved procedures.
- Identify process abnormalities and initiate corrective actions.
- Coordinate with maintenance teams during planned shutdowns and breakdowns.
- Troubleshoot process issues related to compressors, molecular sieves, distillation columns, turbo-expanders, pumps, vaporizers, and storage systems.
Maintenance Coordination
- Coordinate with Mechanical, Electrical, and Instrumentation teams for planned and breakdown maintenance.
- Ensure equipment isolation and permit compliance before maintenance activities.
- Participate in preventive and predictive maintenance programs.
- Monitor equipment health and report potential failures.
Continuous Improvement
- Identify opportunities for process optimization and energy conservation.
- Support implementation of operational excellence and reliability improvement initiatives.
- Participate in root cause analysis (RCA) and corrective action programs.
- Contribute to cost reduction and productivity improvement projects.
Key Equipment Exposure
- Main Air Compressors (MAC)
- Booster Air Compressors (BAC)
- Molecular Sieve Purification Units
- Cryogenic Cold Box
- High Pressure & Low Pressure Distillation Columns
- Argon Recovery System
- Turbo Expanders
- Cryogenic Pumps
- Vaporizers
- LOX/LIN/LAR Storage Tanks
- Product Compression & Distribution Systems
- DCS/PLC-Based Process Control Systems
Job Requirements (KPI)
Experience : 10+ Years of relevant experience in Air Separation Units (ASU), Industrial Gas Plants, Cryogenic Plants, Oxygen Plants, Nitrogen Plants, Ammonia Plants, Hydrogen Plants, Steel Plant Gas Units, or similar continuous process industries.
Minimum 2–3 years of experience in a shift supervisory role preferred.
Educational Qualification: Diploma / B.E. / B.Tech in Chemical, Mechanical, Electrical, Instrumentation, or related Engineering disciplines.
