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Reporting to the Facility Manager, the Maintenance Manager is responsible for leading the maintenance management and execution of the Air Products Barauni facility.

Working alongside the Plant Supervisors to ensure the smooth and reliable operation and maintenance of all aspects of the plant, with the aim of achieving the highest plant reliability and availability, whilst controlling maintenance related costs in line with the business needs.

Nature and Scope

The Barauni 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 scope of maintenance for the Production Plants, equipment and associated systems includes: -

Compressors, Electrical distribution systems, Switch gear, Generators, Motors, Fans, Pumps (cryogenic and other), Pressure Vessels and piping systems, Relief Valves, Heat exchangers, Furnaces, Burners, Cryogenic turbines, Computer control systems, Trip Systems, Analysis equipment etc.
The customer is Indian Oil Corporation Ltd. (IOCL), Barauni refinery and the Air Products plant is located within the customers 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 IOCL and Air Products with respect to feedstocks, products and utilities. The products are critical to refinery unit operations.
The plants run on continuous basis and there is a strong emphasis of 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, in excess of 100 hydrogen plants and 350 ASUs. 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. The Maintenance Manger will be expected to work closely with the Global Communities of expertise and ensure consistent compliance with these work processes.
Prior to facility operation the individual will have a period of training before plant commissioning begins, where they will have a role setting up the permanent site maintenance team, establishing site procedures and participating in plant commissioning.

Principle Responsibilities
Ensure that the plants are maintained in a safe and serviceable condition, so that they can consistently attain the reliability and performance targets necessary to meet the business needs.

Implementation of specific maintenance programmes such as statutory, condition based and Preventive Maintenance. Optimisation of these maintenance programmes.

Work with Air Products Materials Management Department to ensure that the correct spare parts are held in locations and quantities that meet the business needs of the Plant.

Comply with Key Performance Indicator (KPI) targets.

Be capable to take any corrective action required to ensure the continuity of production and the safety of the equipment and personnel by making use of all the available information. Ensure all site breakdowns are repaired and completed in a timely/prioritized manner.

Prepare the Maintenance Budget in conjunction with Plant, Line and Business Management.
Ensure that the agreed maintenance budgets are not exceeded and that year-on-year underlying cost reductions are delivered whilst reducing unplanned events and their consequential business costs.
Accountable for keeping maintenance expenditure within budget.
Provide leadership for and manage the maintenance organization that supports the Air Products Barauni Facility.

Ensure that the organization is staffed and developed to provide the required maintenance support and service level in support of the business objectives.

Drive a culture in which work is done correctly first time and re-work is eliminated.
Safety performance of staff and contractors. Ensure that a strong safety culture is developed and maintained.

Ensure maintenance is executed in compliance with EH&S requirements.

Contribute to the development of EH&S related procedures in support of maintenance activities.

Drive Contractor and Air Products Maintenance Health & Safety Excellence through actively participating in plants safety program, promoting and enforcing global safety procedures and good housekeeping methods, and by directing & administrating outside maintenance resources to meet and exceed all EH&S regulations, and company requirements.

Ensure adherence to Permit to Work system and contractor induction training is completed to maintain the high level of safety for all site work

Use SAP for managing maintenance and the spare parts associated with the Plant.




MINIMUM REQUIREMENTS AND QUALIFICATIONS


A bachelors degree in engineering with minimum 15 years in a maintenance related role in refinery, ammonia, methanol, chemical process, power generation, marine industries or similar.

A track record in which strong technical and practical engineering skills have been demonstrated. Should have an in-depth knowledge of the construction and maintenance of large and complex rotating equipment (e.g., Compressors, pumps, expanders), good working knowledge of Static Equipment, good working knowledge of control and instrumentation systems, good working knowledge of electrical equipment and systems and good working knowledge in Civil Maintenance. Must be a capable user of Computerized Maintenance Management Systems, ideally SAP.

Prior maintenance management experience is necessary with considerable management and leadership skills for:-

Management of a team that often performs in high intensity periods of site work such as maintenance shutdowns, in which a large number of outside contractors are employed, often having a different approach to Air Products normal expectation.

Development and motivation of staff to be prepared, at short notice, to work long and unsociable hours, in often difficult and pressurized situations, whilst maintaining enthusiasm, standards of safety, and work quality.

Budget Preparation, Cost Control and Budget Monitoring

Contractor Management

Spares Management

Knowledge of local Health & Safety , Labour law and Statutory Compliances.

Excellent Communication & coordination skills.

Fluent in oral and written English / Hindi Language.