Senior Manager / AGM – Non-Recovery Coke Oven, Utilities, Hydraulics & Coal-Coke Handling Route

True Blue HR Consultants · Hospet, India

Designation: Senior Manager / AGM – Non-Recovery Coke Oven, Utilities, Hydraulics & Coal-Coke Handling Route.

Experience: 15 to 17 years

Budget: 15 LPA

Location: Hospet, Karnataka

NOTE:

Education: Bachelor of Engineering (B.E.) or Bachelor of Technology (B.Tech) in Mechanical Engineering from a recognized, AICTE-approved full-time university.

Non-Recovery Coke Oven Plant & Plant Utilities (O&M), Hands-on experience with non-recovery pusher machines, charging car, stamping machine, quenching car, EOT Cranes etc.

Proficiency in SAP PM or other CMMS platforms.

15 to 17 Years in Steel / Metallurgy / Heavy Process Industry

About the Role:

The role holds complete ownership of coke oven machinery, coal handling, coke handling, quenching system, conveyors, crushers, screens, pumps, fans, hydraulic systems, material handling equipment and associated mechanical systems, driving continuous improvement in plant reliability and maintenance practices.

Responsibilities

• Lead Preventive, Predictive, RCM and Breakdown Maintenance for Non-Recovery / Heat Recovery Coke Oven Batteries and associated thermal systems.
• Manage specialized non-recovery machinery and equipment, including Pusher-cum-Charging Car, Stamping Machine, Quenching Cars/Towers and Door Extractors.
• Maintain mechanical and refractory integrity of oven sole flues, secondary combustion chambers, damper mechanisms, and waste gas ducts.
• Oversee mechanical upkeep of Waste Heat Recovery Boilers (WHRB), waste gas fans, ID/FD fans, damper drives, expansion joints, and ducting networks.
• Lead maintenance for the entire mechanical Coal Route (unloading, crushing, blending, conveyor galleries, transfer towers, bunkers, and tripper cars) and Coke Route (coke wharf, primary/secondary screening, crushing units, silos, wagon/truck loading).
• Maintain heavy-duty material handling equipment including high-capacity belt conveyors, idlers, pulleys, belt cleaners, drive units, fluid couplings, heavy gearboxes, hammer mills, roll crushers, and vibrating screens.
• Manage Dust Extraction & Suppression Systems (bag filters, venturi scrubbers, dust collection blowers, water spray networks) to minimize spillage and control emissions.
• Serve as plant-wide Subject Matter Expert (SME) for all Industrial Hydraulic Systems, power units (HPUs), accumulators, manifolds, and hydraulic actuators.
• Oversee maintenance and troubleshooting of complex hydraulic circuits on heavy mobile coke oven machinery (Pusher machines, door extractors, charging cars).
• Implement strict oil cleanliness standards (NAS/ISO contamination codes), routine oil sampling, lab analysis, and proactive flushing/filtration programs.
• Expertise in hydraulic schematics reading, cartridge valves, manifold assembly, pressure & flow adjustments and root cause analysis.
• Maintain Sewage Treatment Plants (STP), ETPs, raw/treated water reservoirs, aerators, clarifiers, sludge mechanisms, and decanter centrifuges.
• Manage large-scale industrial pump houses, horizontal/vertical centrifugal pumps, mechanical seals, alignment, and non-return valves.
• Ensure 100% readiness of plant-wide fire networks, diesel/electric fire water pumps, jockey pumps, hydrants, deluge valves, and storage tanks.
• Formulate annual maintenance budgets, critical spare parts inventory (conveyor belts, idlers, gearbox assemblies, hydraulic cylinders) and implement RCFA for recurring failures using SAP PM Module.
• Drive predictive maintenance tools – vibration analysis, oil condition monitoring, thermography.
• Responsible for identification and management of critical mechanical spares, insurance spares, consumables, bearings, gearboxes, couplings, belts, hydraulic components, valves, pumps, mechanical seals, chains & sprockets.
• Maintain optimum inventory by applying ABC / VED / criticality analysis and develop standardization of components wherever feasible.
• Prepare and control annual maintenance budget, spare-parts budget, consumables budget, repair/reconditioning budget, AMC requirements and contractor maintenance cost.
• Monitor maintenance cost per ton of coke and identify opportunities for in-house repair, reconditioning, component standardization, life extension, energy reduction and spare consumption optimization.
• Manage mechanical maintenance contractors for routine maintenance, shutdown maintenance, fabrication, conveyor maintenance, equipment erection, refractory-associated mechanical work, heavy lifting and specialized maintenance.
• Ensure contractor compliance with safety requirements, quality standards, manpower competency, work permits, PPE and statutory requirements.
• Ensure stringent adherence to safety protocols for high-temperature zones, high-pressure steam/fluid injection hazards, conveyor safety (pull-cords/zero-speed switches), and confined space entry.
• Enforce Lockout/Tagout (LOTO), Permit to Work (PTW) systems, statutory environmental emission norms, and fire safety regulations at COP, Hospet.

Qualifications

• Education: Bachelor of Engineering (B.E.) or Bachelor of Technology (B.Tech) in Mechanical Engineering from a recognized, AICTE-approved full-time university.
• Experience: 15 to 17 years of post-qualification experience in heavy manufacturing / steel industry with deep hands-on expertise in Non-Recovery Coke Ovens, coal-coke material handling routes, industrial hydraulics, and utility infrastructure.
• Domain Knowledge: Comprehensive mastery of non-recovery / heat recovery coke oven battery design, bulk material handling, hydraulic system engineering, and high-capacity pumping systems.

Required Skills

• Specialized Non-Recovery Expertise: Hands-on experience with non-recovery pusher machines, charging car, stamping machine, quenching car, EOT Cranes etc.
• Coal & Coke Route Proficiency: Belt alignment, splice vulcanizing, gearbox/coupling troubleshooting, and dust extraction system maintenance under abrasive material conditions.
• Advanced Industrial Hydraulics: Schematics reading, troubleshooting of hydraulic systems, cartridge valves, manifold assembly, pressure and flow adjustment.
• Hands-on experience in maintaining STPs, large water reservoirs, industrial pump houses, and high-pressure fire hydrant networks.
• Strong diagnostic skills using predictive maintenance tools (vibration analysis, oil condition monitoring, thermography).
• Proficiency in SAP PM or other CMMS platforms.