DGM/Sr. Manager – Smelter Maintenance
Department: Projects
Education: B. Tech in Mechanical/Metallurgy Engineering
Experience: 12 to 18 years in the fields/s of Smelter
Maintenance
Job Role Description (in short):
·
Smelter maintenance experience encompasses the
Technical & Commercial skills and hands-on operational knowledge
·
required to maintain high-temperature furnaces
and complex industrial equipment in a metallurgical facility.
·
Smelter maintenance experience includes the
following areas:
Core Technical Skills
·
Furnace & Refractory Work: Experience in
rebuilding and maintaining furnaces (Flash Smelting, Arc, or Blast furnaces).
·
This includes brick masonry for refractory
linings and installing water-cooled copper elements.
·
Rotating Equipment: Proficiency in diagnosing
and repairing gearboxes, pumps, fans, and large industrial conveyor systems
(belt and drag chain).
·
Electrical & Automation: Maintenance of
high/low voltage motors, DCS/PLC control systems, and AC/DC drives.
·
Fluid Systems: Working with high-pressure
hydraulic and pneumatic systems, as well as cooling water reticulation.
Specialized Smelter Equipment
·
Maintenance experience often requires
familiarity with equipment specific to the smelting process:
·
Material Handling: Overhead cranes (10+ tons),
pneumatic dust conveying systems, and winches.
·
Heat & Gas Management: Waste heat boilers
(WHB), dry electrostatic precipitators (ESP), and acid plant systems.
·
Tapping Operations: Maintenance of ISA Tapping
machines, ladle equipment, and matte/slag tap-hole components.
Operational & Safety Standards
·
Shutdown Management: Executing planned shutdowns
(turnarounds) for major repairs and equipment overhauls while minimizing
production downtime.
·
Hazardous Environments: Working under extreme
temperatures (often exceeding 1000°C) and managing risks related to molten
metal, toxic fumes (SO2), and high-pressure steam.
·
Reliability Centered Maintenance (RCM): Applying
techniques such as vibration analysis, thermography, and non-destructive
testing to predict and prevent failures.
Please forward your updated resume
dharmendra@karmaasolutions.com
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