JOB DESCRIPTION FOR THE MADHAVARAM LOCATION MAINTENANCE ENGINEER / EXECUTIVE
Department : Maintenance
Reporting To : Maintenance Manager & Warehouse In charge
Objective :
To ensure the safe, reliable, and uninterrupted operation of all mechanical, electrical, utility, material handling, and process equipment used in the storage, handling, repacking, loading, unloading, filling, cleaning, and transfer of hazardous chemicals, poisonous chemicals, flammable liquids (PESO & Non-PESO), acids, laboratory chemicals, and finished products while ensuring statutory compliance, preventive maintenance, and safe operational practices.
1. Inspection, Availability & Maintenance of Tools and Equipment
- Conduct routine inspections of all tools, equipment, and machinery used in chemical warehouse operations.
- Maintain adequate inventories of essential spare parts and identify minimum critical spares for all production and warehouse equipment.
- Carry out corrective maintenance and repair of defective equipment to minimize downtime.
- Maintain inspection records, maintenance history, and equipment logbooks.
- Ensure only calibrated and approved tools are used for hazardous chemical operations.
- Conduct periodic inspections of portable electrical tools and flameproof (FLP) equipment.
- Ensure all lifting tools, chain pulleys, slings, pallet trucks, forklifts, drum handling equipment, and lifting accessories remain in safe working condition.
- Provide operational and maintenance training for material handling equipment to authorized personnel.
2. Preventive Maintenance & Equipment Reliability
- Prepare and implement preventive maintenance schedules for all mechanical and electrical equipment.
- Renew Annual Maintenance Contracts (AMC) before expiry.
- Include newly installed equipment in the AMC scope, SOPs, preventive maintenance schedules, and inspection checklists.
- Review preventive maintenance reports submitted by service providers and ensure timely closure of observations.
- Arrange required spare parts based on maintenance reports and maintain critical spare inventories.
- Update the Preventive Maintenance Master List whenever equipment is added, modified, or replaced.
- Review preventive maintenance status weekly with the Maintenance Engineer and respective warehouse representatives.
- Ensure preventive maintenance activities are completed without affecting production schedules.
- Monitor equipment reliability and implement improvements to reduce breakdown frequency.
3. Maintenance of Chemical Handling & Repacking Equipment
Ensure safe operation, inspection, maintenance, and servicing of:
- Single Semi-Automatic PESO solvent filling machine
- Dual Semi-Automatic Non-PESO solvent filling machine
- Manual filling stations at PESO ,Non-PESO, Poisonous Chemicals and Lab Chemicals
- Drum transfer pumps
- Barrel unloading systems
- Drum lifters (Trolleys)
- Drum stackers
- Drum / Barrel washing and rinsing systems
- Gravity transfer systems
- Barrel-to-barrel transfer systems
- Chemical transfer pipelines
- Chemical unloading manifolds
- Flexible hoses
- Hose reels
- Pumps (Centrifugal, Diaphragm, Gear, Air Operated Double Diaphragm)
- Mechanical seals
- Valves
- Flameproof motors
- Compressors
- Vacuum pumps
- Air receivers
- Weighing systems
- Drum conveyors
- Roller conveyors
- Forklifts
- Reach trucks
- Battery chargers
- Hydraulic Pallet trucks
- Dock levellers
4. Maintenance of Chemical Storage Infrastructure
Maintain all infrastructures associated with hazardous chemical storage, including:
- PESO solvent storage areas
- Non-PESO chemical storage areas
- Flammable liquid storage warehouses
- Poisonous chemical storage locations
- Acid storage rooms
- Drug room
- Laboratory chemical storage areas
- Drum storage racks
- Intermediate Bulk Container (IBC) storage areas
- Underground storage tanks
- Above-ground storage tanks (Fire Hydrant Tank & Raw water Utilisation tank)
- Chemical transfer lines
- Spill containment systems
- Bund walls
- Ventilation systems
- Flameproof electrical systems
- Earthing and bonding systems
- Static discharge protection systems
- Raw water lines for the Eye wash shower
- Wash basin sinks
- Waste water after domestic use (Sewage) drain lines
- Waste water from Laboratories (Effluent) drain lines
- STP
- ETP
5. Regulatory Compliance & Statutory Maintenance
Ensure timely inspection, testing, certification, and documentation for:
- Weighing scales, test weights, and weighbridges.
- Forklift inspections and Competent Person certification.
- Pressure vessels, air receivers, and compressors.
- DG emission testing and documentation as per TNPCB requirements.
- Waste oil storage and authorized disposal.
- Water meters and utility meters.
- Fire protection systems, hydrants, extinguishers, sprinklers, and fire pumps.
- Electrical safety inspections.
- Earthing resistance testing.
- Lightning arrestor testing.
- Flameproof equipment inspections.
- Portable electrical equipment inspections.
- Calibration of pressure gauges, flow meters, temperature indicators, and level transmitters.
- Zero Breakdown of the STP & ETP
- Building Stability.
6. Support Safe Chemical Operations
Provide maintenance support for:
- Hazardous chemical unloading from tankers.
- PESO chemical unloading in UG Sump
- UG storage tank to Chemicals repacking in Barrels
- Loading of chemical tankers.
- Loading and unloading of intact barrels.
- Manual drum handling.
- Drum palletizing.
- Barrel stacking.
- Chemical repacking.
- Manual filling of laboratory chemicals.
- Automatic solvent filling operations.
- Drum cleaning.
- Drum rinsing.
- Barrel-to-barrel transfer.
- Decanting operations.
- Container filling.
- Intermediate storage operations.
Ensure all equipment is suitable for handling such following chemicals :
- Formic Acid
- Acetic Acid
- Hydrochloric Acid
- Nitric Acid
- Sulphuric Acid
- Methanol
- Toluene
- MTO
- Xylene
- MEK
- IPA
- Acetone
- Ethyl Acetate
- Other PESO solvents
- Non-PESO solvents
- Laboratory chemicals
- Hazardous and poisonous chemicals
7. Annual Maintenance Budget
- Maintain records of repair costs.
- Track spare consumption.
- Prepare annual maintenance budgets.
- Forecast spare requirements.
- Recommend cost-saving initiatives without compromising safety and reliability.
8. Project Execution & Infrastructure Development
- Support maintenance planning for warehouse expansion and process improvements.
- Prepare technical specifications for new equipment.
- Obtain a minimum of three vendor quotations.
- Prepare technical comparisons and recommendations for management approval.
- Coordinate installation, commissioning, and performance testing.
- Complete projects within approved timelines and budgets.
9. Training & Competency Development
Conduct training for:
- New Maintenance Engineers
- ITI Fitters
- Mechanical Technicians
- Electrical Technicians
- Warehouse Operators
- Safety Engineers
- Filling Machine Operators
- Forklift Operators
Training shall include:
- Preventive Maintenance
- Breakdown Maintenance
- Critical Spare Management
- Equipment Inspection
- Safe Chemical Handling using appropriate equipment and acessories
- Lockout/Tagout (LOTO)
- Permit to Work
- Flameproof Equipment Maintenance
- Static Electricity Control
- Spill Prevention
- Emergency Shutdown Procedures
- Safe Maintenance in Hazardous Areas
10. Documentation & Records
Maintain and periodically review:
- Preventive Maintenance Register
- Breakdown Register
- AMC Register
- Calibration Register
- Equipment History Cards
- Critical Spare Register
- Utility Consumption Records
- Maintenance Cost Records
- Inspection Reports
- Statutory Certificates
- Service Reports
- Root Cause Analysis (RCA)
- Corrective and Preventive Action (CAPA) Reports
- JSA for every Non Routine activities .
11. Daily, Weekly, Monthly, Quarterly, Half yearly and Yearly Reviews
- Conduct weekly maintenance review meetings with the Maintenance Engineer and Safety Team.
- Review preventive maintenance compliance every Saturday.
- Monitor equipment downtime and Mean Time between Failures (MTBF).
- Track maintenance KPIs and statutory compliance.
- Review incident investigations related to equipment failures and implement corrective actions.
- Internally testing the Earth pits resistivity and connectivity checking reporting and taking immediate measures to resolve the corrupted Earth pits and accessories.
- Building stability & Equipment Integrity
- Painting of the fire hydrant pipe lines, accessories and Pumps.
- Solar AMC and condition Monitoring
- Water, Waste Water (STP & ETP) ,Power Generation & Utilisation and reduction processes.
- Man power requirement & Vendor supports